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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/160,775 filed Mar. 17, 2009, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of solar energy collector systems, and more particularly, to parabolic trough solar collectors.
BACKGROUND OF THE INVENTION
[0003] There are a variety of solar energy collector systems available for converting solar energy into other forms of energy that can be more readily used or stored. These systems typically employ solar collectors that collect solar radiation and convert it into a more useable form of energy, such as heat.
[0004] Solar collectors of the flat plate type have been used in low energy applications such as heating water, generating low pressure steam, supplementing air conditioning and heating systems, and the like. Flat plate collectors do not focus the sun's radiation and have limited applicability.
[0005] Another type of collector is generically called a concentrating collector. These collectors focus or concentrate the sun's radiation energy in a particular area. Concentrating collectors can be designed to operate at high temperatures with reasonable flow rates, thus substantially increasing the versatility of systems incorporating these collectors over systems employing flat plate collectors.
[0006] One type of concentrating collector is the parabolic trough collector. This type of collector uses an elongated reflective trough having a parabolic cross-section to concentrate the sun's radiation along a longitudinal focal line extending through the focal points of the parabolic elements of the trough. A conduit can be positioned along this longitudinal focal line and a heat transfer liquid can be circulated through the conduit, where it will be heated by the sun's energy. Satisfactory flow rates at high temperatures can be obtained from these collectors.
[0007] With the assistance of a tracking system, parabolic trough collectors can become very efficient as they follow the movement of the sun. U.S. Pat. No. 6,886,339 discloses a solar power collection system comprising parabolic trough collectors that operate with a positioning system that provides movement about a single axis of rotation. A controller drives a motor to pivot the parabolic trough collectors about the longitudinal focal line. However, because of the need for such a tracking system, parabolic trough collectors have typically relied on complicated and expensive rotating assemblies to position the parabolic trough collectors directly toward the sun as the sun travels from east to west during the day. Consequently, there is a need for a solar energy collector system that does not rely on complicated and expensive rotating assemblies to position the parabolic trough collectors directly toward the sun.
[0008] Another problem associated with solar energy collector systems is with respect to the conduit positioned along the focal line. A small focal point is desired to maximize the efficiency of the collectors. However, this typically requires regular adjustments of the reflecting surfaces. A tradeoff is to use a larger focal point to collect more energy, but this reduces efficiency since a larger volume of liquid is to be heated. Consequently, there is also a need to improve the efficiency of the conduit for solar energy collector systems.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing background, it is therefore an object of the present invention to provide a straightforward solar energy collector system that is also efficient.
[0010] This and other objects, advantages and features in accordance with the present invention are provided by a solar energy collector system comprising at least one base, and at least one parabolic trough collector carried by the at least one base for reflecting sunlight to a longitudinal focal line. The parabolic trough collector may comprise a center section horizontally positioned with respect to ground, and opposing end sections adjacent the center section. Each end section may be angled towards the ground.
[0011] The parabolic trough collector and the base may remain stationary when reflecting sunlight to the longitudinal focal line. An advantage of a stationary solar energy collector system is that the parabolic trough collectors do not need to be rotated as the sun travels from east to west during the day since a section thereof is always pointed toward the sun.
[0012] The solar energy collector system may further comprise at least one tilting device coupled to each base for adjusting a latitudinal angle of the parabolic trough collector with respect to the ground. This advantageously compensates for the seasonal rotation of the sun.
[0013] The solar energy collector system may further comprise a conduit positioned along the longitudinal focal line to receive the reflected sunlight. The conduit is to circulate a heat transfer liquid therethrough to be heated by the reflected sunlight.
[0014] The conduit may comprise a center section horizontally positioned with respect to the ground, and opposing end sections adjacent the center section. Each end section may be angled towards the ground. In other words, a profile of the conduit corresponds to a profile of the parabolic trough collector.
[0015] The conduit may comprise an inner tube and a spaced apart outer tube, with the heat transfer liquid to be circulated between the inner and outer tubes. By circulating the heat transfer liquid between the inner and outer tubes, a larger focal point is advantageously obtained with a reduced volume of the heat transfer liquid.
[0016] The inner and outer tubes may be U-shaped. The conduit may further comprise a conduit cover covering exposed upper portions of the U-shaped inner and outer tubes to seal off the heat transfer liquid. The conduit cover may also cover the inner tube between the exposed portions of the U-shaped inner tube. The conduit cover may comprise a clear material, and the inner and outer tubes may each comprise an opaque coating.
[0017] The parabolic trough collector and the base may be formed as a monolithic unit. The parabolic trough collector and the base may comprise a thermoplastic material and/or a thermosetting material. This significantly reduces setup, shipping and maintenance costs typically associated with a parabolic trough solar collector panel that is rotated to track the sun.
[0018] The solar energy collector system may comprise a plurality of bases adjacent one another. Likewise, there may be a plurality of parabolic trough collectors adjacent one another. Each base is carried by a respective parabolic trough collector having a conduit positioned along the longitudinal focal line. The conduit may further comprise a respective interconnecting section for connecting adjacent conduits together. In addition, the adjacent parabolic trough collectors may be coupled together.
[0019] Another aspect is directed to a solar energy collector system comprising at least one base, at least one collector carried by the at least one base for reflecting sunlight to a longitudinal focal line, and a conduit positioned along the longitudinal focal line to receive the reflected sunlight. The conduit may comprise an inner tube, and an outer tube spaced apart from the inner tube. A heat transfer liquid is to be circulated between the inner and outer tubes. An advantage of the conduit associated with a basic collector is that a larger focal point is advantageously obtained with a reduced volume of the heat transfer liquid since the heat transfer liquid circulates between the inner and outer tubes.
[0020] Yet another aspect is directed to a method for collecting solar energy using a solar energy collector system as described above. The method may comprise providing at least one base, and at least one parabolic trough collector carried by the at least one base. The at least one parabolic trough collector comprises a center section horizontally positioned with respect to ground, and opposing end sections adjacent the center section, with each end section angled towards the ground. The method may further comprise using the at least one parabolic trough collector for reflecting sunlight to a longitudinal focal line. A conduit is positioned along the longitudinal focal line to receive the reflected sunlight, and a heat transfer liquid is circulated through the conduit to be heated by the reflected sunlight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of a stationary parabolic solar power system in accordance with the present invention.
[0022] FIG. 2 is a perspective side view of a single parabolic trough collector in accordance with the present invention.
[0023] FIG. 3 is a side view of the parabolic trough collector illustrated in FIG. 2 .
[0024] FIG. 4 is an end view of the parabolic trough collector illustrated in FIG. 2 .
[0025] FIG. 5 is a perspective side view of a single parabolic trough collector with a tilting device associated therewith to compensate for the seasonal rotation of the sun in accordance with the present invention.
[0026] FIG. 6 is a perspective view of another embodiment of the stationary parabolic solar power system illustrated in FIG. 1 .
[0027] FIG. 7 is a partial perspective side view of the parabolic trough collector and a conduit positioned thereabove in accordance with the present invention.
[0028] FIG. 8 is a partial perspective side view of the conduit illustrated in FIG. 7 .
[0029] FIG. 9 is a flowchart illustrating a method for collecting solar energy using a solar energy collector system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.
[0031] Referring initially to FIG. 1 , a stationary parabolic solar power system 10 comprises a plurality of spaced apart side-by-side parabolic trough collectors 12 , and a conduit 14 associated therewith. Each parabolic trough collector 12 is shaped so that a section thereof is always pointed toward the sun. An advantage of the stationary parabolic solar power system 10 is that the parabolic trough collectors 12 do not need to be rotated as the sun travels from east to west during the day since a section thereof is always pointed toward the sun.
[0032] Referring now to FIGS. 2-6 , each parabolic trough collector 12 includes a center section 22 and a pair of angled end sections 24 , 26 . One of the angled end sections 24 is pointed toward the sun in the morning as the sun rises, whereas the other end section 26 is pointed toward the sun in the afternoon as the sun sets. Each end section 24 , 26 may be angled within a range of 25 to 65 degrees with respect to the ground. The illustrated end sections 24 , 26 are shown at 45 degrees with a curved transition to the center section 22 . The center section 22 is flat so that it is pointed toward the sun when the sun is more directly overhead.
[0033] The center section 22 and the pair of angled end sections 24 , 26 are coupled to a base 30 . The base may also be referred to as a cradle. The base 30 is bolted to the ground and holds the parabolic trough collector 12 in place. Since there are no moving parts, each parabolic trough collector 12 may be formed as one piece with its base 30 . This advantageously increases manufacturing efficiency.
[0034] Each parabolic trough collector 12 may be formed out of a molding material comprising a thermoplastic material or a thermosetting material, as readily appreciated by those skilled in the art. The molding material may be based on a polymer or elastomer. The polymers may also be fiber-reinforced.
[0035] In forming each parabolic trough collector 12 , a STF Sheetless ThermoForming™ process may be used to deliver a dynamically controlled layer of material directly to a mold as it is extruded. This process is a fast and cost-effective way to mold large thermoformed products with a one-step operation directly from an extruder.
[0036] Since each parabolic trough collector 12 is stationary, and may be formed as one piece with the base 30 , this significantly reduces setup, shipping and maintenance costs typically associated with a parabolic trough solar collector panel that is rotated to track the sun.
[0037] The dimensions of a parabolic trough collector 12 may be 8 feet wide, 15 feet long, and 8 feet tall. Of course, the parabolic trough collector 12 may be formed in other dimension depending on the intended application. Even though the illustrated parabolic trough collectors 12 are spaced apart in FIG. 1 , they may be positioned so that there is no space between, as illustrated in FIG. 6 . Moreover, the sides of the parabolic trough collectors 12 may be configured so that they have interlocking sides. In lieu of interlocking sides, clips or clamps may be used to couple together an adjacent pair of parabolic trough collectors 12 .
[0038] Each parabolic trough collector 12 has a reflective surface for reflecting sunlight to a longitudinal focal line. A reflective film or coating is on the reflective surface. The coating may be a reflective paint, for example. The use of mirrors is avoided, which would significantly add to the weight of the parabolic trough collector 12 .
[0039] Tilting devices 33 may be carried by each base 30 to adjust a latitudinal angle of the parabolic trough collector 12 with respect to the ground. As illustrated, one side of the base 30 is tilted to increase the surface area of the parabolic trough collector 12 as the sun moves during its seasonal rotation. In other words, the parabolic trough collector 12 is rotated in a north-south direction.
[0040] The tilting devices 33 may be jackscrews, for example. Rotation of the parabolic trough collector 12 throughout the year may be within plus/minus 10 degrees, for example. Although the illustrated base 30 has a pair of tilting devices 33 associated therewith, the actual number will vary depending on the configuration of the base.
[0041] A controller 35 is connected to the tilting devices 33 for control thereof so that each base 30 is incrementally adjusted to provide the desired rotation, as readily appreciated by those skilled in the art. One controller 35 may control the tilting devices 33 for a plurality of bases 30 making up the stationary parabolic solar power system 10 .
[0042] The conduit 14 will now be discussed in greater detail. Although the conduit 14 is discussed with respect to the parabolic trough collectors 12 , the conduit 14 can be applied other types of solar energy collector systems, as readily appreciated by those skilled in the art. In other words, the illustrated conduit 14 associated with parabolic trough collectors 12 is for illustration purposes, and this is not to be viewed as limiting.
[0043] The conduit 14 comprises spaced apart parallel sections 16 positioned along the longitudinal focal line of a parabolic trough collector 12 . Interconnecting sections 18 are coupled to the parallel sections 16 . A heat transfer liquid (i.e., a fluid) is circulated through the conduit 14 , where it will be heated by the sun's energy.
[0044] As best illustrated by the partial perspective views in FIGS. 7 and 8 , the parallel sections 16 of the conduit 14 comprise an inner tube or pipe 40 and an outer tube or pipe 42 , wherein the heat transfer liquid is circulated between the inner and outer tubes. By limiting the heat transfer liquid to within the inner and outer tubes 40 and 42 , the volume of fluid to be heated is reduced. However, the outer tube 42 provides a larger focal point for collecting the sunlight.
[0045] As readily appreciated by those skilled in the art, the volume of a tube is equal to πΓ 2 times the length L of the tube. A larger diameter tube has a larger focal point, which makes it easier to collect the solar energy for heating the heat transfer liquid. However, this requires a larger volume of heat transfer liquid to be heated which in turn reduces efficiency of the solar power system 10 .
[0046] A smaller diameter tube has a smaller focal point, which means that a smaller volume of heat transfer liquid is to be heated. However, a smaller diameter tube typically requires periodic adjustments so that the tube is properly aligned with respect to the longitudinal focal lines of the parabolic trough collectors 12 for collecting the solar energy.
[0047] By circulating the heat transfer liquid between the inner and outer tube 42 and 44 , a larger focal point is advantageously obtained with a reduced volume of heat transfer liquid. Both the inner and outer tube 42 and 44 may have an opaque coating.
[0048] Another distinctive feature of the parallel sections 16 of the conduit 14 is that it has a U-shape or half-circle shape. In otherwords, the uppermost or top half of each parallel section 16 has been removed. This advantageously reduces the volume of the heat transfer liquid to be heated. A conduit cover 50 is attached to the exposed inner and outer tube 42 and 44 to seal off the heat transfer liquid as well as the inner surfaces of the inner tube 40 . The conduit cover 50 may be clear in order to create a green house effect by letting sunlight in but trapping the heat from escaping.
[0049] The interconnecting sections 18 coupled to the parallel sections 16 do not need the inner/outer tube configuration as in the parallel sections. Instead, the interconnecting sections 18 comprise a single tube or pipe for circulating the heat transfer liquid to or from the parallel sections 16 . The interconnecting sections 18 may also be insulated.
[0050] Another aspect is directed to a method for collecting solar energy using a solar energy collector system 10 as described above. Referring now to the flowchart 100 illustrated in FIG. 9 , from the start (Block 102 ), the method comprises providing at least one base 30 , and at least one parabolic trough collector 12 carried by the at least one base at Block 104 . The at least one parabolic trough collector 12 comprises a center section 22 horizontally positioned with respect to ground, and opposing end sections 24 , 26 adjacent the center section, with each end section angled towards the ground. The method further comprises at Block 106 using the at least one parabolic trough collector 12 for reflecting sunlight to a longitudinal focal line. A conduit 16 is positioned along the longitudinal focal line to receive the reflected sunlight at Block 108 . A heat transfer liquid is circulated through the conduit 16 to be heated by the reflected sunlight at Block 110 . The method ends at Block 112 .
[0051] Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. | An apparatus includes a sample chamber constructed according to a design certified by the Department of Transportation for transporting fluids at a first pressure P 1. A cylindrical sample compartment exists within the sample chamber. The sample compartment is designed to withstand the pressure P 1. The cylindrical sample compartment has a cylindrical inner surface with a radius r and a height h. A hollow cylindrical sleeve is secured to the cylindrical inner surface of the sample compartment and has a wall of thickness t. The sample chamber is capable of transporting fluids at a second pressure P 2. P 2 is higher than P 1. |
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DISCLOSURE
1. Field of the Invention
The invention is in the field of removing metal alkaryl sulfonates from a hydrocarbon solution (e.g. a crude oil).
2. General Background
Aqueous solutions containing metal alkaryl sulfonates are used in the recovery of petroleum (e.g. crude oil) from subterranean formations. After separation of the aqueous solution and the crude oil often a substantial amount (e.g. 100-1000 parts per million) remains in the crude oil. The metal alkaryl sulfonate must be removed from the crude oil before the crude oil is refined since the presence thereof causes many problems in the refinery, e.g. corrosion and water problems.
I have discovered an effective way of removing metal alkaryl sulfonates from crude oil and other hydrocarbons.
BRIEF SUMMARY OF THE INVENTION
Briefly stated, the present invention is directed to a method of removing metal alkaryl sulfonates from a hydrocarbon solution, wherein said method comprises:
(a) contacting the hydrocarbon solution containing a metal alkaryl sulfonate with an aqueous basic solution containing an effective amount of a "recovery" surfactant,
(b) forming a hydrocarbon phase and an aqueous phase containing methyl alkaryl sulfonate, and
(c) separating the hydrocarbon phase and the aqueous phase.
The recovery surfactant is described in the detailed description.
In one aspect, step (a) of the present invention can be conducted by adding to the hydrocarbon solution containing metal alkaryl sulfonate, water, basic compound, and recovery surfactant in any order.
DETAILED DESCRIPTION
My method is suitable for removing from hydrocarbons metal alkaryl sulfonates represented by the following formula ##STR1## wherein A=hydrogen or a C 1 -C 4 alkyl group
m=1 or 2 when A is alkyl
R=C 9 -C 18 alkyl group
n=1 or 2
M=alkali metal, preferably sodium
when A is hydrogen, m=1
when A is alkyl the maximum number of carbon atoms in A(m) is 4, and
the total number of carbon atoms in A(m) and R is in the range of 12 to 22, preferably 12 to 18.
The preferred sulfonate is a sodium mono- or dialkyl benzene sulfonate wherein the alkyl group contains from 9 to 18 carbon atoms. The most preferred sulfonate is a sodium monoalkylbenzene sulfonate wherein the alkyl group contains 12 to 18 carbon atoms.
The metal alkaryl sulfonate is usually present in a crude oil. However, my process is applicable to liquid hydrocarbons, either pure or mixtures thereof, containing from 6 to 18 carbon atoms. The hydrocarbons can be straight-chain or branched-chain. In order to be liquid it is necessary that the hydrocarbon containing higher carbon atoms (e.g. above C 12 ) contain branched-chain materials. With mixtures of hydrocarbons containing higher carbon atoms it is necessary that a larger amount of branched-chain hydrocarbons be present.
Preferably, my process uses an aqueous solution which is (a) basic and (b) contains an effective amount of a "recovery" surfactant. The term basic refers to an aqueous solution having a pH in the range of 7.1 to 14, preferably 9 to 12. In order that the aqueous solution have the required pH usually it is necessary to add a small amount of basic material to the solution. Example of suitable basic material include alkali metal hydroxides and carbonates. Sodium hydroxide is particularly suitable. Knowing that the aqueous solution should have a pH of 7.1 to 14 any person skilled in the art can readily add the required amount.
As indicated previously, my process can be conducted by adding the water, basic compound and recovery surfactant separately to the hydrocarbon solution containing metal alkaryl sulfonate.
The amount of water used, based on the amount of hydrocarbon, suitably is in the range of 0.5:1 to 10:1, preferably 1:1 to 5:1 on a weight basis.
The term "recovery" surfactant is used to describe the material which is used in the aqueous solution in combination with the required amount of basic material. Examples of suitable types of "recovery" surfactants include the following:
(a) ethoxylated alcohols
(b) ethoxylated alkylphenols
(c) ethoxylated alcohol sulfates
(d) polyoxyethylene-polyoxypropylene block polymers, and
(e) ethoxylated polypropylene glycols.
The ethoxylated alcohols which are used in my invention are represented by one of the following formulae
RO(CH.sub.2 CH.sub.2 O).sub.n H (A)
wherein R is an alkyl group containing from 10 to 20, preferably 12 to 18, carbon atoms and n is a number in the range of about 5 to about 40, preferably about 10 to about 25. Linear alkyl groups are particularly suitable. While more than 40 moles of ethylene oxide may possibly be used, materials containing this amount are not particularly better and are not readily available. ##STR2## wherein R is an alkyl group, preferably linear, containing 10 to 20, preferably 12 to 18, carbon atoms, m is a number in the range of 1 to 32, preferably 6 to 30, and n is a number in the range of 2 to 30, preferably 4 to 20.
Suitable ethoxylated alkyl phenols are mono- or dialkyls, wherein each alkyl group contains from about 8 to 12 carbon atoms, and which contain from about 20 to about 100 ethoxy groups, preferably from about 30 to about 70 ethoxy groups. The preferred ethoxylated alkyl phenol is a monoalkylphenol containing 8 to 10 carbon atoms in the alkyl group.
Suitable ethoxylated alcohol sulfates are represented by the following structural formula
[CH.sub.3 (CH.sub.2).sub.x CH.sub.2 (OCH.sub.2 CH.sub.2).sub.n OSO.sub.3 ]M
wherein x is an integer in the range of about 8 to about 20, preferably from about 10 to about 16, n is a number in the range of about 1 to about 50, preferably about 2 to about 30, more preferably about 3 to about 12, and M is NH 4 or Na, but preferably is sodium.
The alcohol moiety of the ethoxylated alcohol sulfate can be an even or odd number or a mixture thereof. Preferably, the alcohol moiety is an even number. Also, preferably, the alcohol moiety contains 12 to 18 carbon atoms.
Polyoxyethylene-polyoxypropylene block polymers which are used in my invention are represented by one of the following formulae: ##STR3## wherein a and c are numbers in the range of 1 to 15, preferably in the range of 2 to 10, with the sum of a and c being in the range of 2 to 30, preferably 4 to 20, and b is a number in the range of 1 to 32, preferably 6 to 30 ##STR4## wherein a and c are numbers in the range of 1 to 16, preferably 3 to about 15, with the sum of a and c being in the range of 2 to 32, preferably 6 to 30, and b is a number in the range of 2 to 30, preferably 4 to 20.
Suitable ethoxylated polypropylene glycols are those containing from about 10 to about 60 weight percent ethylene oxide and having a molecular weight in the range of about 1300 to about 2900. The preferred ethoxylated polypropylene glycols are those containing from about 20 to about 50 weight percent ethylene oxide and having a molecular weight in the range of about 1500 to about 2500.
The amount of recovery surfactant in the aqueous solution suitably is in the range of about 10 to about 10,000 parts per million by weight based on the hydrocarbon. On the same basis the preferred amount of recovery surfactant is in the range of about 50 to about 500 parts per million by weight.
In conducting my process as admixture is formed of the hydrocarbon and the basic aqueous solution containing the recovery surfactant. (As indicated hereinbefore the water, basic compound and recovery surfactant can be added separately.) The admixture preferably is heated to a temperature in the range of about 100° F. to about 200° F. The admixture is agitated sufficiently to allow contact between the hydrocarbon and aqueous solution. The admixture is then allowed to stratify, forming an aqueous layer and a hydrocarbon layer. The layers are then separated. The aqueous layer contains basic material, recovery surfactant and a part of the metal alkaryl sulfonate.
My process usually provides better than a 40 weight percent recovery of the sulfonate from the hydrocarbon. It is readily apparent that using a multi-stage adaptation of my process could result in recovering substantially all of the sulfonate present in the hydrocarbon. For example, assuming a 50 percent recovery, a five-stage process would recover better than 96 percent of the sulfonate.
In order to illustrate the nature of the present invention still more clearly the following examples will be given. It is to be understood, however, that the invention is not to be limited to the specific conditions or details set forth in these examples except insofar as such limitations are specified in the appended claims.
EXAMPLES 1-5
These examples are both illustrative and comparative.
Materials Used
Sulfonate--a sodium monoalkylbenzene sulfonate having an equivalent weight of 334 (52 weight percent active ingredient)
Hydrocarbon--Goodwin crude oil from Cat Canyon Field, Santa Maria, California
Water--Synthetic "hard" water containing 5000 ppm total hardness
Sodium Hydroxide--reagent grade
Recovery Surfactants
"A"--sodium salt of a sulfated ethoxylate derived from a C 12 -C 18 linear primary alcohol blend and containing 9.25 moles of ethylene oxide (20 percent active ingredient)
"B"--an ethoxylated octylphenol containing 30 moles of ethylene oxide per mole of octylphenol (70 percent active ingredient)
"C"--an ethoxylated octylphenol containing 70 moles of ethylene oxide per mole of octylphenol (100 percent active ingredient)
Five solutions were prepared containing the following materials.
______________________________________Example 1 sodium monoalkylbenzene sulfonate 0.114 g water added to 300 gramsExample 2 sodium monoalkylbenzene sulfonate 0.057 g recovery surfactant "C" 0.03 g water added to 300 gramsExample 3 sodium monoalkylbenzene sulfonate 0.057 g recovery surfactant "B" 0.02 g recovery surfactant "C" 0.015 g water added to 300 gramsExample 4 sodium monoalkylbenzene sulfonate 0.057 g recovery surfactant "C" 0.03 g sodium hydroxide (10 percent active solution) 1.2 g water added to 300 gramsExample 5 Sodium monoalkylbenzene sulfonate 0.057 g Recovery surfactant "A" 0.136 g Sodium Hydroxide added to 300 grams______________________________________
Procedure
The solutions of each of the examples were divided into two portions. One portion was saved for sulfonate analysis and the other portion was contacted with an equal weight of the Goodwin crude oil at 170° F. The admixture of the solution and crude oil were shaken in a sealed container after which they were transferred to centrifuge tubes where they were allowed to cool at room temperature. Then they were centrifuged at about 2200 rpm for one half hour. This produced an oil layer and a water layer. The water portion was removed and weighed.
The original solution for each example and the recovered water solution from the crude oil/water emulsions were analyzed for sulfonate content using the standard Methylene Blue Test. The results of the tests are summarized in Table I.
TABLE I______________________________________ Sulfonate Sulfonate Sul- Analysis of Analysis on fonateEx- Solution Composition Water Recov- Re-ample of Examples of ered from coveredNo. (ppm) Emulsion Emulsion (ppm) (%)______________________________________1 210 Solution of 61 22.1 Example 1 (50 g) Crude Oil (50 g)2 111 Solution of 0 0 Example 2 (50 g) Crude Oil (50 g)3 115 Solution of 0 0 Example 3 (50 g) Crude Oil (50 g)4 111 Solution of 61 55 Example 4 (50 g) Crude Oil (50 g)5 160 Solution of 92 58 Example 5 (50 g) Crude Oil (50 g)______________________________________
EXAMPLES 6 AND 7
These examples are both illustrative and comparative concerning my invention.
The materials used were the same as in Examples 1-5, except the monoalkylbenzene sulfonate was 27 percent active.
Two solutions were prepared comprising 50 grams of Goodwin lease crude and 0.019 gram of a 27 percent monoalkylbenzene sulfonate (net amount of sulfonate=5.13 mg.)
A solution was prepared comprising 50 g of synthetic water and 5 mg of recovery surfactant "C".
A second solution was prepared comprising 50 g of synthetic water, 5 mg of recovery surfactant "C" and 20 mg of sodium hydroxide.
EXAMPLE 6
The following were added to a reaction vessel:
(a) solution containing crude plus monoalkylbenzene sulfonate, and
(b) solution containing water plus recovery surfactant "C".
The admixture was heated to 170°-200° F. (this is because the crude was quite viscous). It was then agitated by shaking. After allowing the resulting emulsion to cool it was centrifuged at 2,000 rpm for 45 minutes. An oil phase and a water phase were formed. The water phase was 42 grams which contained 40 ppm of sulfonate (methylene blue titration). Thus there was recovered 1.68 mg of sulfonate or about 33 percent of the original amount.
EXAMPLE 7
The following were added to a reaction vessel:
(a) solution containing crude plus monoalkylbenzene solfonate, and
(b) solution containing water plus recovery surfactant "C" plus sodium hydroxide.
The procedure used was the same as in Example 6. The recovered water phase amounted to 42 grams which contained 50 ppm of sulfonate (methylene blue titration). Thus there was recovered 2.1 mg of sulfonate or about 41 percent of the original amount.
With regard to the examples, Examples 1-5 illustrate the following. The use of a combination of recovery surfactant and basic compound shift the partition coefficient of alkaryl sulfonates in a water/hydrocarbon mixture. The result is an increased amount of sulfonate in the water phase.
Examples 6 and 7 show that the use of a combination of basic compound and recovery surfactant provides an improvement in the removal of alkaryl sulfonates from a hydrocarbon.
Thus, having described the invention in detail, it will be understood by those skilled in the art that certain variations and modifications may be made without departing from the spirit and scope of the invention as defined herein and in the appended claims. | A method of removing metal alkaryl sulfonates from a hydrocarbon solution is disclosed. Briefly, the method comprises (a) contacting the hydrocarbon solution containing metal alkaryl sulfonates with an aqueous basic solution containing a "recovery" surfactant, (b) forming a hydrocarbon phase and an aqueous phase containing metal alkaryl sulfonates and (c) separating the hydrocarbon phase and the aqueous phase. |
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FIELD OF THE INVENTION
The present invention relates to a drilling fluid additive to provide enhanced fluid loss properties, enhanced wall cake thickness, and enhanced bore hole stability to the drilling fluid.
BACKGROUND OF THE INVENTION
In drilling wells for the purpose of producing oil or gas from subterranean deposits, a fluid known as drilling mud is used to perform several functions necessary to successfully complete each well. This drilling fluid or mud performs many functions such as lubricating the drill string, cleaning the bore hole, and exerting sufficient pressure to the sides of the bore hole to prevent the entrance of liquids or gases into the bore hole from the formation being penetrated.
The drilling fluid must have a low fluid loss to prevent excessive loss of fluid into the formation by depositing an impervious filter cake on the sides of the bore hole. The thickness of the filter cake is usually directly proportional to the volume of fluid loss. Therefore, the lower the fluid loss the thinner the filter cake. Maintaining the diameter of the bore hole being drilled is critical to a successful operation. If the fluid loss is high, then the wall cake will be thick and therefore, the desired diameter of the well bore will be reduced.
Fluid loss additives most commonly used to control the fluid loss and also the wall cake thickness are bentonite clays, polymers, lignites, and surfactants. Gilsonite, a native asphalt occurring in vein deposits below the surface of the ground, greatly reduces fluid loss and wall cake thickness when properly incorporated with any water based drilling fluid.
Gilsonite is an asphaltic material that is found in Utah and Colorado. Gilsonite and other asphaltic-type materials penetrate the shale pore spaces as the drill bit penetrates the formation. It is assumed that a plastic-flow mechanism will allow the asphaltite to extend into the pores of the shale, thus, reducing fluid loss or mud invasion with a tendency to bond the shale and prevent sloughing. Asphaltite plates out on the bore hole to thereby reduce fluid loss.
However, asphaltite is by nature extremely hydrophobic and will not readily mix with water or water based drilling fluids. Thus, it is difficult to use asphaltite as an effective drilling fluid additive.
Attempts have been made to make asphaltite-based products more compatible with the drilling fluid. However, none of these attempts has been fully successful.
Moreover, in typical drilling mud systems, the asphaltic material is packaged in fifty pound bags and dumped into the mud hopper on the rig in amounts equaling from 1 to 50 pounds per barrel of mud. Since the asphaltic material is extremely hydrophobic, a surfactant is then added to the mud system in amounts of 0.5 to 10 per cent by volume to make the asphaltite disperse or become water wet. However, this process is extremely expensive because the surfactant might be used up on other solid materials in the mud system, such as, barite, bentonite, and drilled solids.
Furthermore, the above mentioned process is very expensive because it does not allow the asphaltite enough retention time with the aqueous phase of the drilling fluid to become dispersed or broken up into individual particles. Therefore, much of the material is lost over the rig shaker after the initial or first circulation through the well bore. Rig shakers can now be operated with shaker screens as fine as 250 mesh with 80-100 mesh being standard. With the above methods of adding asphaltite products dry to the drilling fluid, a conservative estimate of at least 10% and up to 90% of the asphaltite product is screened out and lost over the rig shaker after the first circulation.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a new and improved method of applying asphaltite based products to the drilling fluid to thereby drastically reduce the screening of the asphaltite out of the drilling fluid as the drilling fluid passes through the rig shaker.
In fact, the instant invention will allow 90% of the asphaltite based material to pass through a 200 mesh shaker screen and 99% through a 120 mesh screen. This reduced screening allows the asphaltite based material to remain in the drilling fluid system indefinitely and creates a more economical and environmentally safe method of achieving the benefits of the asphaltite.
Another object of the present invention is to provide an asphaltite dispersion which provides an improved particle size distribution of the asphaltite products.
A further object of this invention is to provide a method of adding the asphaltite product to the drilling fluid in such a manner that the person adding the product will not be subjected to the fine dust while adding the product in a dry form through the mud hopper on the drilling rig.
A still further object is to improve the lubricating properties of the drilling fluid.
A still further object is to improve the rheology properties of the drilling fluid.
The present invention accordingly provides a process for the manufacture of a water based drilling fluid additive. The process comprises the steps of:
(a) mixing hydrophobic asphaltite and either a surfactant or a dispersant and
(b) shearing the mixture of step (a) under a sufficiently high mechanical shear for a sufficient time to convert the hydrophobic asphaltite into hydrophilic asphaltite.
The present invention also provides a water based drilling fluid additive prepared according to the above process.
The present invention further provides a water based drilling fluid comprising water and a water based drilling fluid additive as prepared above.
The present invention still further provides a process for enhancing the properties of a drilling fluid during the drilling of the well, by combining and circulating with a water based drilling mud, an additive as described above. The additive is mixed with the drilling mud in an amount to sufficiently reduce fluid loss and wall cake thickness.
The present invention still further provides a process of drilling a well with a rotary bit which comprises forming a bore hole with the bit while circulating a drilling mud through the bore hole. The drilling mud comprises an additive as described above and the additive is mixed with the drilling mud in an amount to sufficiently reduce fluid loss and wall cake thickness.
The process of the present invention offers a superior method of pre-dispersing and therefore wetting the surface area of the individual asphaltite, such as gilsonite, with a surfactant, emulsifier, or dispersant prior to adding the product to the drilling fluid. This process provides for a more even particle size distribution of the colloidal size particles as well as particles in the 1 to 200 micron size.
Additionally, the present invention overcomes the "fish-eye" condition that occurs when fine gilsonite particles are added to the drilling fluid. The fish-eye condition of the product is the balling up of many ultra-fine particles which might be partially water wet on the outside but still dry in the center of the ball. The fish-eye gilsonite particle is then screened out of the drilling fluid by the rig shakers.
These and other objects, features and advantages of the present invention will be made more apparent from the following description of the preferred embodiments.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the presently preferred embodiments of the invention.
In accordance with the present invention of manufacturing a water based drilling fluid additive, hydrophobic asphaltite is mixed with a surfactant or dispersant. This mixture is then sheared under a sufficiently high mechanical shear for a sufficient time to convert the hydrophobic asphaltite into hydrophilic asphaltite.
As a result, the surface area of asphaltite, such as gilsonite, is wetted and hydrophilic. This allows the gilsonite or asphaltite product to remain dispersed and separated into individual particles which stack or plate out on the side of the well bore to reduce fluid loss. These finely dispersed, surface coated particles act as excellent plugging agents for improved fluid loss control.
In the present invention, the asphaltite particles are in a state of dispersion having an average particle size much finer than their original size due to the shearing action in the environment of the surfactant or dispersant. The asphaltite particles become dispersed into much finer particles which expose more surface area. This surface area is then exposed to the surfactant which converts the hydrophobic asphaltite particle into a hydrophilic asphaltite particle. The asphaltite product thereby readily mixes and disperses with any water based drilling fluid.
Any inherently hydrophobic asphaltic material can be used in the present invention. A high grade mined pulverized gilsonite is preferred.
Surfactants of the present invention can be selected from, for example, ethoxylated phenols, alcohols, glycols, or fatty acid type materials. A preferred surfactant is ethoxylated glycol. Dispersants of the present invention can be selected from, for example, potassium hydroxide, sodium hydroxide, or lignitic type materials. The surfactants and dispersants are either liquid or solid but are preferably liquid.
The mixture of the asphaltite and the surfactant or dispersant are subjected to an extremely high mechanical shear to impart hydrophilic properties to the asphaltite. The mixture should perferably be subjected to a shear of at least 1700 rpms for at least 60 minutes.
A typical method of shearing the liquid mixture is by using a high speed mechanical disperser such as a ROTOSTAT® 200XP-200, manufactured and sold by Admix, Inc. of Londonderry, N.H., USA.
Optionally, the mixture obtained after the shearing process may be adjusted to a pH of about 8 before the mixture is added to the drilling mud. The pH adjustment is a means to further disperse the solids of the invention in the liquid phase.
The asphaltite is preferably used in an amount of about from 5% to 90% by weight of the additive mixture. About 50% by weight of the asphaltite in the additive mixture is especially preferred.
If a surfactant is employed, the surfactant is preferably used in an amount of about from 5% to 90% by weight of the additive mixture. About 35% by weight of the surfactant in the additive mixture is especially preferred.
If a dispersant is employed, the dispersant is preferably used in an amount of about from 1% to 50% by weight of the additive mixture. About 10% by weight of the dispersant in the additive mixture is especially preferred.
The additive mixture comprising the asphaltite and either a surfactant or a dispersant is mixed with the drilling mud in an amount to sufficiently reduce fluid loss and wall cake thickness. The additive mixture is preferably used in from about 1/2% to about 30% by volume of the drilling mud. The additive mixture is more preferably used in from about 2% to about 5% by volume of the drilling mud.
The asphaltite additive can also include other components that are inherently hydrophobic prior to the shearing step.
The asphaltite additive can be utilized in drilling fluids while drilling oil wells, gas, wells, mineral wells, water wells, or any other earth boring operation.
The specific examples below will enable the invention to be better understood. However, they are given merely by way of guidance and do not imply any limitations.
EXAMPLE 1
Improved high pressure and temperature fluid loss and improved low pressure fluid loss
The fluids in Table 1 below were circulated through a 100 mesh screen 25 times and then tests were run on the fluids in accordance with Table 1.
TABLE 1______________________________________ 2% by Percent 2% byBase Volume dry Re- Volume PercentMud Gilsonite duction Invention Reduction______________________________________100 psi 5.4 4.4 19% 1.8 67%fluid loss(ml)500 psi 29.5 21.2 28% 11.0 63%fluid loss@ 300°(ml)______________________________________
Approximately 95% of the present invention additive remained in the drilling fluid after 25 circulations as opposed to 44% of the dry product. These calculations were made by collecting the solid product trapped on the 100 mesh screen, drying the same and then weighing the dry sample.
EXAMPLE 2
Decrease in the filter cake thickness
TABLE 2______________________________________ PERCENT BASE 2% INVENTION REDUCTION______________________________________100 psi 2.4 1.8 25%fluid loss(ml)cake thickness 2/32 1/32 50%(inches)500 psi 22.5 11.0 50%fluid loss@ 300°(ml)500 psi 6/32 3/32 50%cake thickness(inches)______________________________________
This invention reduced the size of the filter cakes. The uniform individual particle size distribution provided better compaction medium which restricts the flow of liquids from the drilling fluid.
EXAMPLE 3
Improved lubricity of the drilling fluid
TABLE 3__________________________________________________________________________PLATE BASE 1% 2%PRESSURE MUD INVENTION PERCENT INVENTION PERCENT(lbs) (amperes) (amperes) REDUCTION (amperes) REDUCTION__________________________________________________________________________100 14 12 14% 10 29%200 26 22 15% 20 23%300 35 32 9% 26 26%400 44 39 11% 32 27%500 60 43 28% 38 37%600 SEIZURE 60 DID NOT SEIZE 49 DID NOT SEIZE__________________________________________________________________________
The lubricity here refers to the lubricity characteristics of the drilling fluid in contact with the drill stem and bore hole walls. The drilling fluid lubricity was measured by the ability of the drilling fluid to reduce the coefficient of friction between two surfaces with the drilling fluid between the surfaces. The present invention reduced lubricity because it formed a film between the surfaces while minimizing wall cake build up.
EXAMPLE 4
Improved flow properties of the drilling fluid
The following results in Table 4 were achieved with the use of a montmorilinite and a water slurry.
TABLE 4______________________________________BASEFLUID 1% INVENTION______________________________________600 RPM 37 600 RPM 16300 RPM 30 300 RPM 10200 RPM 28 200 RPM 8100 RPM 24 100 RPM 56 RPM 17 6 RPM 13 RPM 15 3 RPM 1 PV 7 PV 6 YP 23 YP 4 GELS 15/38 GELS 1/4______________________________________BASEFLUID 1% INVENTION 2% INVENTION______________________________________16.8 ppg Low Lime MudPV 37 PV 39 PV 40YP 14 YP 10 YP 8GELS 2/8 GELS 2/6 GELS 1/510.5 Seawater LignosulfonatePV 17 PV 18 PV 19YP 14 YP 10 YP 8GELS 3/8 GELS 2/6 GELS 1/4______________________________________ PV = plastic viscosity YP = yield point GELS = gel strength
Thus, the invention also shows an added benefit of thinning drilling fluids.
Additionally, in the present invention, by depositing a thin impermeable filter cake on the well bore, water sensitive shale is stabilized. This invention provides individual gilsonite particles which plug off microfractures in the drilled formation to shut-off intrusion of the fluid into the formation. This invention therefore decreases the amount of capillary attractive forces present in the microfractures of the well bore.
It would be apparent to those skilled in the art that various modifications and variations can be made in the present invention without deviating from the scope or spirit of the invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided that these come within the scope of the following claims or their equivalents. | A process for the manufacture of a water based drilling fluid additive comprising the steps of:
(a) premixing hydrophobic asphaltite and either a surfactant or a dispersant and
(b) shearing the mixture of step (a) under a sufficiently high mechanical shear for a sufficient time to convert the hydrophobic asphaltite into hydrophilic asphaltite. This invention is also directed to a water based drilling fluid additive prepared according to the above process and the use of the additive in a water based drilling fluid. |
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CLAIM OF PRIORITY
This Application is a continuation under 35 U.S.C. §120 of earlier filed U.S. Non-Provisional application Ser. No. 13/430,584, filed Mar. 26, 2012, by Susanna Lee, which claimed priority to U.S. Non-Provisional application Ser. No. 13/225,259, filed Sep. 2, 2011, which claimed priority under 35 U.S.C. §119(e) from earlier filed U.S. Provisional Application Ser. No. 61/381,382, filed Sep. 9, 2010, by Susanna Lee, all of which are incorporated herein by reference.
BACKGROUND
1. Field of the Invention
The current disclosure relates to faucet attachments generally and specifically to faucet attachments used to enable people to effectively gain access to water that would otherwise be beyond their arm reach.
2. Background
When children are young it is common for parents to assist their children in reaching water faucets. Like adults, children need to wash their hands, gain access to drinking water, or access tap water for countless other reasons. Unlike adults, children have a shorter arm reach which can interfere with the usage of faucets that are generally designed for adult use.
Some methods to solve this problem that have been used include direct parental assistance and the use of foot stools. There are distinct disadvantages to these methods. Adults sometimes are unable or unavailable to assist children, and foot stools require large amounts of floor space.
The problem is not limited to young children. People with disabilities, the elderly, people with dwarfism, people with arthritis or back pain, or other adults may find it difficult to reach the normal water-flow of a faucet. Users may also desire to alter the water-flow from a faucet to more easily water plants, fill a pet's water dish, or for many other reasons.
The solution to this problem is a device that can attach to a faucet and physically bring the water-flow from a faucet closer to the user rather than the user having to come closer to the water-flow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an embodiment of a faucet attachment device.
FIG. 2 depicts an exploded view a faucet attachment device, showing the underside of a trough member and a cross section of an attachment member.
FIG. 3 depicts an embodiment of a faucet attachment device without a faucet.
FIG. 4 depicts the back side of an embodiment of an attachment member.
FIG. 5 depicts an embodiment of a trough member where one portion of the trough member is made from more flexible material than the rest of the trough member.
FIG. 6 depicts an alternate embodiment of a faucet attachment device.
FIG. 7 depicts an embodiment of an extendable trough member
FIG. 8 depicts an embodiment of a trough member with protrusions.
FIG. 9 depicts an embodiment of an attachment member.
FIG. 10 depicts a top-down view of an embodiment of an attachment member.
FIG. 11 depicts an embodiment of a faucet attachment device that is secured to a faucet.
FIG. 12 depicts an alternate embodiment of a faucet attachment device that is secured to a faucet in an alternate way.
FIG. 13 depicts an embodiment of a faucet attachment device with decorative features.
FIG. 14 depicts an embodiment of a faucet attachment device with a removable faceplate.
FIG. 15 depicts an embodiment of a faucet attachment device with a temperature sensor, a temperature display, and a power source.
FIG. 16 depicts a circuit with a temperature sensor, a temperature display, and a power source.
DETAILED DESCRIPTION
FIG. 1 depicts an embodiment of a faucet attachment device 100 . The faucet attachment device 100 can comprise a trough member 102 coupled with an attachment member 104 . The trough member 102 can comprise a channel 110 and channel walls 116 118 running along the longitudinal edges of the channel 110 . The channel 110 can be partially open. The channel 110 can comprise an entrance 112 at one end, and an exit 114 at the opposing end. The entrance 112 can be narrowly formed or broadly formed depending on the desired application. The exit 114 can also be narrowly formed or broadly formed depending on the desired application. Some embodiments can comprise a tapered channel 110 . The tapering of the channel 110 can occur in either direction from the entrance 112 to the exit 114 . By way of a non-limiting example, in some embodiments the channel 110 can be tapered from a broadly formed entrance 112 toward a narrowly formed exit 114 . The channel 110 and the trough 102 can be any desired length.
In some embodiments, the channel walls 116 118 can be extensions of the channel 110 along the edges of the channel 100 , and can have a variety of shapes and sizes. In the embodiment shown in FIG. 1 , the channel walls 116 118 can be curved extensions of the channel 110 , such that a transverse cross section of the channel 110 and the channel walls 116 118 can be substantially a “U” shape. In alternate embodiments, the channel walls 116 118 can be separate components that can be coupled with the channel with glue, adhesives, tape, cement, screws, bolts, rivets, anchors, clips, brads, staples, or any other known or desired affixing mechanism. The channel walls can be straight, curved, wavy, thick, thin, flat, short, tall, or have any other desired characteristic. In some embodiments, the trough member 102 can be made of polypropylene, polyethylene, polyurethane, thermoplastic rubber, bamboo, recycled plastic, metal, or any other material or combination of materials that provides the desired strength, flexibility, durability, weight, water resistance, or other desired physical characteristic.
The attachment member 104 can comprise an attachment opening 106 . The attachment opening 106 can be configured to engage a faucet 108 . In some embodiments, the attachment opening 106 can be substantially the size of a transverse cross-section of a faucet arm. In alternate embodiments, the attachment opening 106 can be circular, semi-circular, square, oval, wider horizontally than vertically, or have any other size or shape. In some embodiments, the attachment member 104 can be made of polypropylene, polyethylene, polyurethane, thermoplastic rubber, bamboo, recycled plastic, metal, or any other material or combination of materials that provides the desired strength, flexibility, durability, weight, water resistance, or other desired physical characteristic. In some embodiments the attachment member 104 can be primarily comprised of one material. In alternate embodiments, the attachment member 104 can be comprised of a different, more flexible, material in the area surrounding the attachment opening 106 . In some embodiments, the entire attachment member 104 can be made of a flexible material, such that a user can apply pressure to the sides of the attachment member 104 and can thereby widen the attachment opening 106 such that a faucet 108 can pass through the attachment opening 106 .
FIG. 2 depicts the underside of the trough member 102 and a cross section of the attachment member 104 . In some embodiments, the attachment member 104 can comprise a slit 120 . The slit 120 can be formed in the shape of a transverse cross section of the trough member 102 , such that the entrance 112 of the trough member 102 can slide into the slit 120 in the attachment member 104 . The trough member 102 can comprise bumps or ridges 122 extending from the top or bottom sides of the entrance 112 . The slit 120 can comprise depressions 124 along the inside of the slit 120 . In operation, the entrance 112 of the trough member 102 can be inserted into the slit 120 . The depressions 124 inside the slit 120 can engage the bumps or ridges 122 of the trough member 102 . The interaction of the bumps or ridges 122 and the depressions 124 can create friction between the trough member 102 and the attachment member 104 and can keep the two members coupled. Alternatively, in some embodiments, the attachment member 104 can be permanently coupled with the trough member 102 via glue, adhesives, tape, cement, screws, bolts, rivets, anchors, clips, brads, staples, or any other known or desired affixing mechanism. In some embodiments, the attachment member 104 can be removably coupled with the trough member 102 by snaps, loops, hooks, clips, interlocking parts, pins, bands, screws, brads, buttons, or any other known or desired affixing mechanism. In still other embodiments, the attachment member 104 can be part of the same unitary body as the trough member 102 , such that they are not separate components.
In operation, the embodiment of the faucet attachment device 100 depicted in FIG. 1 can engage a faucet 108 by passing the faucet 108 through the attachment opening 106 of the attachment member 104 , such that the faucet 108 can be frictionally coupled with the attachment member 104 . The attachment member 104 can be adjusted to engage the faucet 108 in such a position that the trough member 102 can be positioned below the faucet 108 . When the faucet 108 is operated, water flowing from the faucet 108 can strike the trough member 102 at the entrance 112 . The water can be diverted from its natural course to instead flow along the channel 110 . The channel walls 116 118 can prevent the water from spilling over the edges of the channel 110 . The water can leave the channel 110 at the exit 114 and flow along a course more easily accessible to a user.
FIG. 3 depicts the embodiment shown in FIG. 1 without a faucet. In the embodiment shown in FIG. 3 , the attachment member 104 can comprise an extension piece 126 that extends into the attachment opening 106 . The extension piece 126 can have a variety of sizes and shapes, and can extend into the attachment opening 126 from any desired direction or angle. The extension piece 126 can be used to provide additional support to the attachment member 104 , to provide a tighter fit when the attachment opening 106 engages a faucet, to prevent water from spilling backwards along the channel 110 or behind the device, or for any other known or desired reason.
FIG. 4 depicts the back side of an embodiment of the attachment member 104 . In some embodiments, the attachment member 104 can comprise at least one structural support 128 coupled with the attachment member 104 . The at least one structural support 128 can be housed within the attachment member 104 , or coupled with any portion of the exterior of the attachment member 104 . The at least one structural support 128 can be an extension, ridge, bar, pole, bump, or any other known support component. In some embodiments, the at least one structural support 128 can be made of the same material that the attachment member 104 comprises. In alternate embodiments, the at least one structural support 128 can be made of a harder or more rigid version of the same material that the attachment member 104 comprises. In still other embodiments, the at least one structural support 128 can be made of a different material or combination of materials than the attachment member 104 comprises, such as polypropylene, polyethylene, polyurethane, thermoplastic rubber, bamboo, recycled plastic, metal, or any other material or combination of materials that provides the desired strength, flexibility, durability, weight, water resistance, or other desired physical characteristic. In some embodiments, the at least one structural support 128 can be an extension of the attachment member 104 such that the structural support 128 and the attachment member 104 are one unitary body. By way of a non-limiting example, the at least one structural support 128 can be molded into the back side of the attachment member 104 . In alternate embodiments, the at least one structural support 128 can be a separate component coupled with the attachment member 104 through adhesives, screws, snaps, interlocking parts, fitting the edges of the structural support 128 into holes or grooves within the attachment member 104 , or any other known or desired affixing mechanism. In some embodiments, at least one structural support 128 can be coupled at an angle with at least one other structural support 128 , at any point along any of the structural supports 128 . By way of a non-limiting example, in the embodiment shown in FIG. 4 , one structural support 128 is coupled with the attachment member 104 in a horizontal position below the attachment opening 106 and the extension piece 126 , and two other structural supports 128 extend vertically downward from the horizontal support 128 to the bottom of the attachment member 104 .
FIG. 5 depicts an embodiment of a trough member 502 in which one portion of the trough member 502 can be made from more flexible material than the rest of the trough member 502 . The trough member 502 can be substantially similar to the trough member 102 shown in FIG. 1 , and can comprise a channel 510 , an entrance 512 , an exit 514 , and channel walls 516 518 . The trough member 502 can have a variety of shapes and sizes. The trough member 502 can be made of polypropylene, polyethylene, polyurethane, thermoplastic rubber, bamboo, recycled plastic, metal, or any other material or combination of materials that provides the desired strength, flexibility, durability, weight, water resistance, or other desired physical characteristic. In some embodiments, the trough member 502 can be made of different materials with different flexibilities, such that some parts of the trough member 502 can have different flexibilities than other parts of the trough member 502 . By way of a non-limiting example, in the embodiments shown in FIG. 5 , the exit 514 can be made of a more flexible material than the rest of the trough member 502 , such that the exit 514 can droop when liquid flows over it. In some embodiments, the channel 510 can be substantially linear from the entrance 512 to the exit 514 . In alternate embodiments, the channel can droop, rise, swing left, swing right, have waves, have curves, have ridges, or have any other functional form known, convenient, or desired.
FIG. 6 depicts an alternate embodiment of a faucet attachment device 600 . The faucet attachment device 600 can comprise a trough member 602 coupled with an attachment member 604 . The attachment member can comprise an attachment opening 606 . The attachment member 604 can be one unitary component, or it can be coupled with a removable piece 630 . In some embodiments, the removable piece 630 can be removably coupled with the attachment member 604 via snaps, loops, hooks, clips, interlocking parts, pins, bands, screws, brads, buttons, or any other known or desired attachment mechanism. In alternate embodiments, the removable piece 630 can be coupled with the attachment member 604 by a hinge 632 located at a connection point 634 or any other desired location. In some embodiments, the removable piece 630 can extend across a gap within the attachment member 604 such that the removable piece 630 can form a part of the edge of an attachment opening 606 when the removable piece 630 is coupled with the attachment member 604 .
In operation, the removable piece 630 can be removed from the attachment member 604 . In alternate embodiments, the removable piece can be rotated away from the attachment member 604 via a hinge 632 at connection point 532 . The attachment member 604 can be positioned underneath a faucet arm, such that the trough member 602 is below the faucet. The removable piece 630 can be placed on top of the faucet arm and coupled with the attachment member 604 at connection point 634 via snaps, loops, hooks, clips, interlocking parts, pins, bands, screws, brads, buttons, or any other known or desired attachment mechanism.
FIG. 7 depicts an embodiment of a trough member 702 that can be comprised of at least two trough pieces 736 . In some embodiments, the at least two trough pieces 736 can interact with one another to extend the trough member 702 to a desired length. In alternate embodiments, the at least two trough pieces 736 can interact with one another to retract the trough member 702 to a desired length. In some embodiments, the at least two trough pieces 736 can interact with each other to extend or retract the trough member 702 to a preset intermediate length between a fully extended position and a fully retracted position, or to any desired intermediate length between a fully extended position and a fully retracted position. The at least two trough pieces 736 can comprise grooves 738 and groove inserts 740 . The groove inserts 740 of one trough piece 736 can slide inside the grooves 738 of an adjacent trough piece 736 . In some embodiments, the trough pieces 736 can comprise hollow cavities 742 , such that one trough piece 736 can slide along the grooves 738 and retract into, or extend from, the hollow cavity 742 of an adjacent trough piece 736 . In alternate embodiments, the at least two trough pieces 736 can interact by having trough pieces of different sizes engaged inside one another in a telescoping configuration, by interlocked sliding arms, or by any other known or desired extension or retraction method.
FIG. 8 depicts an embodiment of a trough member 802 . The trough member 802 can be substantially similar to the trough member 102 shown in FIG. 1 , and can comprise a channel 810 , an entrance 812 , an exit 814 , and channel walls 816 818 . The trough member 802 can also comprise one or more protrusions 844 . In the embodiment shown in FIG. 8 , one or more protrusions 844 can be located on the outwardly facing sides of the channel walls 816 818 . In alternate embodiments, one or more protrusions 844 may be located on the inwardly facing sides of the channel walls 816 818 , at the tops of the channel walls 816 818 , near the entrance 812 , or at any other location desired on the trough member 802 . The protrusions 844 can take a variety of forms, and can have a variety of shapes and sizes. In some embodiments, the protrusions 844 can be a button, resemble body parts such as ears, or take any other size or shape. The protrusions 844 can be made of polypropylene, polyethylene, polyurethane, thermoplastic rubber, bamboo, recycled plastic, metal, or any other material or combination of materials that provides the desired strength, flexibility, durability, weight, water resistance, or other desired physical characteristic. In some embodiments, the protrusions 844 can be more or less flexible than the rest of the overall structure.
FIG. 9 depicts an embodiment of an attachment member 904 . The attachment member 904 can comprise at least one end portion 946 , at least one open area 948 , and at least one faucet interaction region 950 . The open areas 948 can be apertures located within the end portions 946 . In some embodiments, one end portion 946 can be connected to another end portion 946 by at least one faucet interaction region 950 . In some embodiments, the end portions 946 can be removable from the faucet interaction regions 950 . The at least one faucet interaction region 950 can be one or more straps, bands, or any other mechanism capable of interacting with a faucet. The end portions 946 and the faucet interaction regions 950 can be made of polypropylene, polyethylene, polyurethane, thermoplastic rubber, bamboo, recycled plastic, metal, or any other material or combination of materials that provides the desired strength, flexibility, durability, weight, water resistance, or other desired physical characteristic. The end portions 946 can be made of a different material than the faucet interaction regions 950 . In some embodiments, the at least one faucet interaction region 950 can be made of a more flexible or stretchable material than the material used for the end portions 946 .
In the embodiment shown in FIG. 9 , two end portions 946 are connected by two faucet interaction regions 950 . The open areas 948 can be configured to engage protrusions similar to the protrusions 844 shown in FIG. 8 , thereby coupling the attachment member 904 to a trough member similar to the trough member 802 shown in FIG. 8 . The open areas 948 can have a variety of sizes and shapes. In some embodiments, the open areas 948 can be circular, rectangular, triangular, semi-circular, or have any other known or desired shape. In some embodiments, an open area 948 can be substantially the same size as a cross section of a protrusion 844 such that the open area 948 can engage the protrusion 844 snugly. In alternate embodiments, an open area 948 can be larger than the cross section of a protrusion 844 , such that the open area 948 can be easily engaged around or removed from the protrusion 844 . In some embodiments that have a plurality of open areas 948 , the open areas 948 can be the same size and shape, or have different sizes or shapes as desired.
FIG. 10 depicts a top-down view of an embodiment of an attachment member 1004 . The attachment member 1004 can comprise two end portions 1046 , an open area 1048 located within each end portion 1046 , and at least one faucet interaction region 1050 . The faucet interaction regions 1050 can be one or more straps, bands, or any other mechanism capable of interacting with a faucet. In the embodiment shown in FIG. 10 , there can be more than one faucet interaction region 1050 located behind each other so that only one is visible from the top-down viewpoint shown. The end portions 1046 can be coupled with the at least one faucet interaction region 1050 at one or more joints 1052 located at each end of each faucet attachment region 1050 . The joints 1052 can comprise a hinge, a ball and socket configuration, rotatably interlocking pieces, or any other mechanism that allows the end portions 1046 to rotate independently of the at least one faucet interaction region 1050 while remaining connected, such that the attachment member 1004 can have a tri-axial configuration. In operation, each end portion 1046 can be rotated to an angle suitable for the open area 1048 on the end portion 1046 to engage a protrusion such as protrusion 844 shown in FIG. 8 . The at least one faucet interaction region 1050 can be rotated to an angle suitable for it to secure around a faucet. All three components can be oriented at different angles as needed. In some embodiments, the joint 1052 can lock the three components into position after they are rotated to the desired angles. The joint 1052 can lock the components into position by having a hinge with a pin, a clip, interlocking pieces that snap into place at certain angles, or any other known or desired mechanism for locking a joint.
FIG. 11 depicts an embodiment of a faucet attachment device 1100 that is secured to a faucet 1108 . The faucet attachment device 1100 can comprise a trough member 1102 with at least one protrusion 1144 , and an attachment member 1104 with at least one faucet interaction region 1150 . In some embodiments, the faucet attachment device 1100 can be secured to the faucet 1108 by wrapping the at least one faucet interaction region 1150 above the faucet 1108 and connecting the attachment member 1104 to the at least one protrusion 1144 such that the trough member 1102 hangs below the faucet 1108 .
FIG. 12 depicts an alternate embodiment of a faucet attachment device 1200 that is secured to a faucet 1208 in a different way. The faucet attachment device 1200 can comprise a trough member 1202 with at least one protrusion 1244 , and an attachment member 1204 with at least two faucet interaction regions 1250 . In some embodiments, the faucet attachment device 1200 can be secured to the faucet 1208 by wrapping one of the faucet interaction regions 1250 above the faucet 1208 , wrapping another one of the faucet interaction regions 1250 below the faucet 1208 , and connecting the attachment member 1204 to the at least one protrusion 1244 such that the trough member 1202 hangs below the faucet 1208 . In alternate embodiments, the at least one faucet interaction regions 1140 can be looped around the faucet 1208 , spun to create a helix form that the faucet 1208 can pass through, or manipulated in any other fashion desirable to secure the overall faucet attachment device 1200 to a faucet 1208 .
FIG. 13 depicts an embodiment of a faucet attachment device 1300 having decorative features. The faucet attachment device 1300 can comprise a trough member 1302 , an attachment member 1304 , and an attachment opening 1306 . In some embodiments, the decorative features can be permanently formed parts of the faucet attachment device 1300 . In alternate embodiments, the decorative features can be removed from the faucet attachment device 1300 and interchanged with other decorative features as desired. In the embodiment shown in FIG. 13 , the decorative features include eyes 1354 and feathers 1356 located on the attachment member 1304 . In some embodiments, the attachment opening 1306 can be formed into the shape of a mouth, nose, or any other desirable feature. Some embodiments can include decorative features intended to make the faucet attachment device resemble an animal, such as a duck, cow, chicken, pig, or any other animal. Other embodiments can include decorative features intended make the faucet attachment device resemble cartoon characters, vehicles, plants, or any other desired design. In some embodiments, decorative features can include any other body part or facial characteristic, such as ears, noses, hair or any other desired characteristic. Decorative features are not limited to representations of facial features or body parts, and can include various color schemes, patterns, or any other desired design.
FIG. 14 depicts an embodiment of a faucet attachment device 1400 that can comprise a removable faceplate 1458 . The faucet attachment device 1400 can be substantially the same as the faucet attachment device 1300 shown in FIG. 13 , and can comprise a trough member 1402 , an attachment member 1404 , and an attachment opening 1406 . The removable faceplate 1458 can be decorated with a design. Various embodiments of the removable faceplates 1458 can feature pictures of faces, pictures of scenery, graphic designs, artwork, or any other desirable design. In some embodiments, the removable faceplate 1458 can be coupled with the faucet attachment device 1400 by fitting connection components 1460 into corresponding holes 1462 in the attachment member 1404 . In alternate embodiments, the removable faceplate 1458 can be coupled with the faucet attachment device 1400 by using snaps or hooks, sliding it into grooves within the trough member 1402 , by placing it into a windowed pocket coupled to the faucet attachment device 1400 , by attaching it to areas similar to the protrusions 724 shown in FIG. 8 , or by any other known or desired attachment mechanism. The removable faceplate 1458 can comprise a faceplate opening 1464 that can correspond with the attachment opening 1406 . In operation, a faucet arm can pass through both the attachment opening 1406 and the faceplate opening 1464 . In some embodiments, the structure of the removable faceplate 1458 can provide support to the attachment member 1404 when the faucet attachment device 1400 is connected to a faucet.
FIG. 15 depicts an embodiment of a faucet attachment device 1500 that can comprise a temperature sensor 1566 and a temperature display 1568 . The faucet attachment device 1500 can be substantially the same as the faucet attachment device 100 shown in FIG. 1 , and can comprise a trough member 1502 , an attachment member 1504 , and an attachment opening 1506 . The faucet attachment device 1500 can also comprise a power source 1570 configured to supply power to the temperature sensor 1566 and the temperature display 1568 in circuit. The power source 1570 can provide power to the temperature sensor 1566 and the temperature display 1568 . The power source 1570 can be a battery, a generator, a hydroelectric generator, a plug attached to an electrical outlet, or any other known or desired mechanism for providing power to a circuit. In some embodiments, the power source can comprise a switch to turn the power source on or off.
The temperature sensor 1566 can be located on or within the trough member 1502 , or anywhere else on the faucet attachment device 1500 . The temperature sensor 1566 can be a thermistor, thermocouple, resistive thermal device, or any other known or desired temperature sensor. The temperature display 1568 can be in the form of an LCD screen, LED lights, or any other known or desired display. In operation, the temperature sensor 1566 can measure the temperature of the water flowing down the channel of the trough member 1502 , and the water's temperature can be displayed to the user on the temperature display 1568 . In various embodiments the temperature can be displayed in terms of Fahrenheit or Celsius degrees, icons or colors indicating that the water is generally hot or cold, or any other known or desired method of indicating a temperature. The temperature display 1568 can be located anywhere on the faucet attachment device 1500 . In some embodiments, the temperature display 1568 can be integrated with decorative features that can be present on the device. For example, the eyes 1354 shown in FIG. 13 can include LED lights that glow red when the water is hot and green when the water is cold, thereby indicating when the water flowing from the device is safe for a user to touch. In alternate embodiments, the faucet attachment device 1500 may not have a temperature display 1568 that operates visually, but can indicate the water temperature to the user by broadcasting audio signals through a speaker, or through any other known or desired mechanism for indicating information. In still other embodiments, the temperature sensor 1566 can comprise a heat-sensitive material that changes color or appearance when exposed to heat, such that the temperature sensor 1566 can indicate a temperature to a user directly without a separate temperature display or a power source. The heat-sensitive material can be a thermochromatic or thermochromic coating, such as an ink, a paint, or a dye, applied to all or a portion of the trough member 1502 , a thermal paper, a thermochromic polymer, or any other known material that changes appearance when exposed to heat.
FIG. 16 depicts a circuit 1672 comprising the power source 1570 coupled with the temperature sensor 1566 and the temperature display 1568 shown in FIG. 15 . The circuit 1672 can transmit power between the components. In some embodiments, the circuit 1672 can transmit signals between the components. In some embodiments, the signals can include data transmissions, such as data transmissions regarding the temperature measured by the temperature sensor, the power level within the circuit, whether to display temperature in Fahrenheit or Celsius degrees, or any other type of data desired.
In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense. | A device and method for delivering water to a person who is unable to reach household or other types of water dispensing faucets. In some embodiments, the device comprises a trough for delivering the liquid and an attachment member for attaching the trough to a faucet. |
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FIELD OF THE INVENTION
[0001] The present invention relates to a method of building a structure and also to a method to strengthening, or reducing the deflection of, a built structure.
[0002] The invention has been primarily developed for use in relation to steel portal frame structures and will be described hereinafter with reference to this application. However, the invention is not limited to this field of use and is also applicable for other structural and architectural works.
BACKGROUND OF THE INVENTION
[0003] When designing a structure or building, consideration must be given to, amongst others requirements, the requirements of strength, deflection and dynamics. It is common for additional material to be required in a structure to satisfy deflection requirements, when compared to the material required to satisfy strength requirements. The additional material increases material and construction costs and can also adversely affect the building's dynamic response (particularly to earthquakes) and also requires a corresponding increase in the building's foundations.
[0004] It is important that the amount of materials used in building structures is minimised from a cost and environmental standpoint. It is an object of the present invention to reduce the material required in a building whilst still satisfying deflection criteria.
SUMMARY OF THE INVENTION
[0005] Accordingly, in a first aspect, the present invention provides a method of building a structure, the method including the steps of:
[0006] 1. fabricating a generally longitudinal, steel sub-structure of the structure with a cable retainer attached to, or forming part of, the sub-structure and that extends substantially longitudinally therealong;
[0007] 2. assembling the sub-structure into a structure;
[0008] 3. inserting a cable into the cable retainer;
[0009] 4. after step 2, applying a tensile force to the cable, relative to the cable retainer; and
[0010] 5. after step 4, bonding the cable to the cable retainer.
[0011] In a second aspect, the present invention provides a method of building a structure, the method including the steps of:
[0012] 1. fabricating a generally longitudinal, steel sub-structure of the structure with a cable retainer attached to, or forming part of, the sub-structure and that extends substantially longitudinally therealong;
[0013] 2. inserting cable into the cable retainer;
[0014] 3. after step 2, applying a tensile force to the cable, relative to the cable retainer; and
[0015] 4. after step 3, bonding the cable to the cable retainer; and
[0016] 5. assembling the sub-structure into a structure.
[0017] In a third aspect, the present invention provides a method of strengthening, or reducing the deflection of, a built structure, the method including the steps of:
[0018] 1. attaching a cable retainer to a generally longitudinal, steel sub-structure of the structure with the cable retainer extending substantially longitudinally therealong;
[0019] 2. inserting cable into the cable retainer;
[0020] 3. applying a tensile force to the cable, relative to the cable retainer; and
[0021] 4. after step 3, bonding the cable to the cable retainer.
[0022] The cable retainers are adapted to follow the tensile line of resistance the sub-structure is subjected when loaded during use.
[0023] Preferably, the method includes assembling at least two sub-structures into a structure.
[0024] Preferably also, the method includes inserting at least two cables into the cable retainer.
[0025] The cable is preferably bonded to the cable retainer by any one of the following: welding, gluing (including grouting, most preferably with cementitous grout), or by expanding the cable retainer relative to the cable or shrinking the cable relative to the cable retainer (for example by heating the cable retainer and/or by cooling the cable and thereafter allowing them to shrink and/or expand into engagement with one another) prior to inserting the cable into the cable retainer.
[0026] The tensile force is preferably applied to the cable by jacking.
[0027] The structure is preferably a steel portal frame structure, more preferably produced from I or T section beams or from tubular truss assemblies.
[0028] When the sub-structure is in the form of an I or T section beam, the cable retainer are attached to the web of the beam and, most preferably, passes through the flange of the beam. When the sub-structure is a truss assembly, the cable retainer is in the form of one of the tubular members integral with the truss.
[0029] The sub-structure is preferably utilised in the centre span of the structure. However, the sub-structure can also be used in the columns or walls of the structure.
[0030] In one form, the cable retainer extends within the boundaries of its associated sub-structure. In another form, the cable retainer is attached to the sub-structure external the boundaries of sub-structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
[0032] FIGS. 1 to 11 are each schematic cross-sectional drawings of structures utilising an embodiment of the invention;
[0033] FIG. 12 is an exploded view of the sub-structures comprising the structure shown in FIG. 11 ;
[0034] FIG. 13 is a cross-sectional end view of an embodiment of an I beam suitable for use in the structures shown in earlier drawings;
[0035] FIG. 14 is a cross-sectional end view of another embodiment of an I beam suitable for use in the structures shown in earlier drawings;
[0036] FIG. 15 is a cross-sectional end view of a further embodiment of a rectangular beam suitable for use in the structures shown in earlier drawings; and
[0037] FIG. 16 is a cross-sectional end view of an embodiment of a truss assembly suitable for use in the structures shown in earlier drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] FIG. 1 shows a steel portal frame structure 20 formed from a centre span 22 , two columns 24 and two foundations 26 . Each half of the centre span 22 and each of the columns 24 represent a sub-structure of the steel portal frame structure 20 .
[0039] The centre span 22 has a first cable retainer 28 attached thereto, by welding in the regions 30 and via the struts 32 in the region 34 . Each of the columns 24 also have cable retainers 36 attached thereto by welding.
[0040] Cables, represented by double headed arrows 38 and 40 , are passed through the cable retainers 28 and 36 respectively. The cables 38 , 40 are tensioned relative to the cable retainers 28 , 36 respectively then bonded to the cable retainers 28 , 36 respectively, prior to releasing the tension in the cables. The tensioning, bonding and releasing steps shall be described in more detail below.
[0041] The cable retainers 28 , 36 extend generally along the longitudinal direction of their associated centre span (sub-structure) 22 or column (sub-structure) 24 . More particularly, the cable retainers 28 , 36 are positioned to follow the tensile line of resistance of their associated sub-structure when the structure 20 is subjected to its intended load during use.
[0042] For example, the steel portal frame structure 20 shown in FIG. 1 is designed to be subject to a downward and horizontal load/use and the cable retainers 28 , 36 are thus oriented as shown to best resist deflection caused by that load.
[0043] The resulting structure is able to better resist deflection under its designed load conditions as the tension applied to the cables relative to their associated sub-structure stores strain energy in the resulting sub-structure. Accordingly, as forces are applied to structure, the counter strain stored in the sub-structure resists the application of that load.
[0044] The resulting structure can, within certain boundaries, accept load with reduced strain and thus has an increased load carrying capacity for a given deflection. A 50-100% reduction in deflection can result compared to a similar sized existing structure.
[0045] The steel portal frame structures shown in FIGS. 2-12 each have their components and sub-structures identified with like reference numerals to those used in FIG. 1 . However, in each structure, the cable retainers follow a different path compared the columns and centre span so as to suit differing load conditions.
[0046] The structure 50 shown in FIG. 2 is designed to resist upward and horizontal load conditions/usage.
[0047] The structure 60 shown in FIG. 3 is designed to resist downward and horizontal load conditions/usage.
[0048] The structure 70 shown in FIG. 4 is designed to resist upward and horizontal load conditions/usage.
[0049] The structure 80 shown in FIG. 5 is designed to resist upward and horizontal load conditions/usage.
[0050] The structure 90 shown in FIG. 6 is designed to resist downward and horizontal load conditions/usage.
[0051] The structure 100 shown in FIG. 7 is designed to resist upward and horizontal load conditions/usage.
[0052] The structure 110 shown in FIG. 8 is designed to resist downward and horizontal load conditions/usage.
[0053] The structure 120 shown in FIG. 9 is designed to resist upward and horizontal load conditions/usage.
[0054] The structure 130 shown in FIG. 10 is designed to resist downward and horizontal load conditions/usage.
[0055] The structure 140 shown in FIG. 11 is designed to resist upward and horizontal load conditions/usage.
[0056] FIG. 12 shows the various sub-structures that comprise the structure 140 shown in FIG. 11 . As shown, the centre span 22 is formed from three sub-structures 22 a, 22 b and 22 c. The structure 140 is preferably built by assembling all of the sub-structures into the final form shown in FIG. 11 , inserting cables through the cable retainers, jacking the cables into a state of tension, bonding the cables to the cable retainers (for example with cementitous grout) and then releasing the jacking load on the cables.
[0057] As an alternative, one or more of the sub-structures can be assembled and tensioned according to the method described above, and then subsequently attached to the sub-structures. For example, the centre span sub-structure can be assembled on the ground and, after tensioned cables have been bonded thereto, be raised into its final position and connected to the column sub-structures.
[0058] As a further alternative, cable retainers can be added to a pre-existing structure, or a new structure built without them, which are then tensioned and bonded in the manner described above. This finds particular application in improving the strength and/or deflection performance of an existing built structure or structure whose design is complete.
[0059] FIGS. 13 and 14 show examples of cable retainers 28 , 36 , in the form of steel tubes, being attached to beams 150 and 152 , for example by welding, which are suitable for use in the previously described structures (for example, those structures shown in FIGS. 1 to 6 ).
[0060] FIG. 15 shows an alternative beam 154 in which the cable retainer 28 , 36 is in the form of an opening or hole or channel through the beam which is suitable for use in a previously described structure (for example, the structure shown in FIG. 10 ).
[0061] FIG. 16 shows an example of cable retainers 28 , 36 , in the form of steel tubes, being part of a truss assembly 156 , which is suitable for use in the previously described structures (for example, those structures shown in FIGS. 7 to 10 ).
[0062] The structures described above can be designed to meet strength and dynamic requirements, whilst reducing the need to increase the material added to the structure to satisfy deflection requirements. The embodiments described previously advantageously enable the span of a structure to be increased whilst using the same amount of materials to thus provide a larger structure for the same material cost. Conversely, a structure with a like span to an existing structure can be produced using a reduced amount of materials. The structures described above are also lighter and cheaper than existing comparable structures, particularly when foundation saving are taken into account.
[0063] Although the invention has been described with reference to specific embodiments, it would be appreciated by those skilled in the art that the invention can be embodied in many other forms. For example, the cable retainers can be of any shape and any number of cables can be inserted therein. | A method of building a structure, the method including the steps of: 1. fabricating a generally longitudinal, steel sub-structure of the structure with a cable retainer attached to, or forming part of, the substructure and that extends substantially longitudinally therealong; 2. assembling the sub-structure into a structure; 3. inserting a cable into the cable retainer; 4. after step 2, applying a tensile force to the cable relative to the cable retainer; and 5. after step 4, bonding the cable to the cable retainer. |
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This application is a continuation-in-part of application Ser. No. 229,437, Filed Apr. 7, 1988, now abandoned, which, in turn, is a continuation-in-part of application Ser. No. 59,430, filed Jun. 8, 1987, now abandoned.
This invention concerns a hinge, suitable for use in a variety of applications. The design and construction of the hinge allow it to join two members, while being itself completely hidden, and permit a very close fit between the members when in its initial position. When the hinge is folded open, its exposed portions provide an unobtrusive and aesthetically pleasing design.
In one of its embodiments, the hinge can be used in a folding table and leaf arrangement. The hinge is constructed to be exceptionally strong, to support weight placed on the extended leaf of the table. In the extended position, the hinge is completely invisible and thus provides an unbroken table-top surface.
The hinge may also be modified for use in a variety of cabinet doors. These embodiments are of light construction, but retain all the durability and features of the table hinge.
BACKGROUND OF THE INVENTION
The present invention belongs to the family of hinges used to join two members, of wood or a honeycomb material for example, in a variety of applications. More particularly, this invention relates to hidden hinges having multiple pivotal axes.
The original concept of a folding hinge is by no means a new one. Many varieties of such devices exist and are common knowledge to the general public.
There are also numerous hinges that pivot around more than a single axis, pivot through an arc of at least 180°, or may be constructed so as to be hidden in some position. The present invention, however, provides a hinge capable of performing all of these functions in a practical and aesthetic manner, not found in previous hinges.
U.S. Pat. No. 2,236,400, issued to Follmer, discloses a hinge with two axes of pivot. The hinge is completely visible, however, when it is mounted in the face of the table-top it is designed for use with.
U.S. Pat. No. 1,735,696, issued to Ridley, discloses a hidden hinge, that makes use of a link to join its two axes of pivot. The patent discloses no means to insure that the members in which the hinge is mounted will not contact one another and bind the hinge's motion.
The hinges of the prior art suffer from the fact that they cannot be truly hidden, and still perform their intended function, without risking damage to the members in which they are mounted. In order to assure that these hinges can pivot without causing the edges of the members to come into contact and bind, there must be a sizable gap between the members, and that makes the connecting link visible. In addition, the hinges of the prior art have an even greater tendency to bind if the direction of motion is changed part way through the hinge's rotation.
It would be advantageous to provide a hinge which could be completely hidden in its initial position, and yet allow the members it joins to move in a smooth and reliable manner, regardless of the direction of motion, while being unobtrusive and aesthetically pleasing in its folded position.
It is the object of the present invention to provide a hinge that will be truly hidden in its initial position.
A further object is to provide a hinge which will facilitate a fit between the joined members that is so close as to be virtually unbroken, i.e. with only a very narrow gap between the members.
A further object is to provide a hinge which can pivot through its arc of travel in one easy, smooth motion, and not bind or allow the edges of the members to come into contact with one another and be damaged.
A further object is to provide a hinge which will be unobtrusive and aesthetically pleasing when folded completely open.
Other objects and advantages of the present invention will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the assembled hinge of the first embodiment.
FIG. 2 is an isometric view of the same hinge as in FIG. 1, but disassembled.
FIG. 3 is a cross-sectional view of the hinge depicted FIG. 1, taken along the line 3--3 in FIG. 1, but also showing with broken lines the outline of a table top and leaf to which the hinge is mounted.
FIG. 4 depicts the same mounted hinge as FIG. 3, but in a cross-sectional view taken along the line 4--4 in FIG. 1.
FIG. 5 is an enlarged view of the hinge as depicted in FIG. 3, but with the table leaf folded halfway back.
FIG. 6 depicts the same hinge as in FIG. 5, but with the table leaf completely inverted.
FIG. 7 is an isometric view of the assembled hinge of the second embodiment.
FIG. 8 is an isometric view of the second embodiment hinge in its disassembled state.
FIG. 9 is an isometric view of a third embodiment hinge in its disassembled state.
FIG. 10 is an enlarged cross-sectional view of the hinge depicted in FIG. 9, assembled and in the leaf-extended position, with the table top and leaf shown by broken lines.
FIG. 11 shows the same hinge as in FIG. 10, but with the leaf folded halfway back.
FIG. 12 shows the same hinge as in FIG. 10, but with the table leaf nearly completely inverted.
FIG. 13 is a cross-sectional view, taken along the line 11--11 in FIG. 9, but also showing mounting screws and, in broken lines, the leaf to which the mounting plate is attached.
FIG. 14 is an isometric view of the assembled flush-mount hinge, showing in broken lines the outline of the member in which the loose plate is mounted.
FIG. 15 is an isometric view of the same hinge as in FIG. 14, but disassembled.
FIG. 16 is an enlarged, cross-sectional view of the mounted hinge of FIG. 14, taken along the line 5--5, with the door folded halfway open.
FIG. 17 depicts the same hinge as FIG. 16, but with the door folded completely open.
FIG. 18 is an isometric view of the 90° hinge, partly disassembled.
FIG. 19 shows the first step in the mounting process of the hinge of FIG. 18, which is a cross-sectional view of the stationary stile.
FIG. 20 depicts the stile of FIG. 19, but with the trenches cut for the mounting of an extension mount.
FIG. 21 shows the stile of FIG. 20 with the extension mount in place.
FIG. 22 is an exploded view of the stile with extension mount, hinge, and mounting screw and pin.
FIG. 23 shows the completed 90° hinge assembly.
FIG. 24 shows an orthogonal view of the mounted hinge from the front, with the cap removed and the facing of the door "peeled back".
SUMMARY OF THE INVENTION
The present invention provides a hinge constructed of two mounting plates and a substantially U-shaped center link which connects the axes of pivot of the two plates. The link and plates contain stop mechanisms which determine their respective limits of pivot. In addition, the hinge contains a means for restraining the rotation of only one of the mounting plates around its corresponding link arm to insure a pattern of motion that is always consistent, and allows for the hinge to be mounted with a very narrow gap between the members being joined. The hinge of the present invention can be variably constructed to conform to a number of alternative uses.
DETAILED DESCRIPTION
Table Hinge
The first embodiment of this invention concerns a hinge for a fold-up table leaf. More particularly, it relates to a hinge that provides strong horizontal support for the extended leaf, without being visible. Also, the hinge permits a very close fit between the stationary table top and the leaf when in the extended position.
Fold-up table leaves that are unsupported by a leg when placed in the extended position are found in a variety of applications, including passenger vehicles and hotel rooms. In executive jet aircraft, for instance, built-in card tables often are equipped with fold-up leaves to permit easier access to the seats at the table. The hinges for these table leaves have to be exceptionally strong, in order to support any weight placed on the extended leaf. Also, it is desirable that the hinges not interrupt the top surface of the table when in the extended position, in other words, that the hinges be invisible when the leaf is down. This is for both practical and aesthetic reasons.
The hinge of the present invention satisfies both of these objectives. It is comprised of a mounting plate that attaches to the edge of a stationary table top, a substantially U-shaped link that is pivotally attached near the end of one of its arms to the mounting plate, and another mounting plate that is pivotally attached to the second arm of the link, and to which plate the fold-up leaf is attached.
For purposes of the following discussion, the two mounting plates will be referred to as a "first" mounting plate and a "second" mounting plate. It should be understood, however, that either plate can be mounted to the table top or to the fold-up leaf.
Each mounting plate has a front surface and a rear surface. The rear surface is the surface that faces the edge of the table top or leaf when the hinge is mounted. The front surface of each mounting plate includes a pair of bracket members. The U-shaped link has a base and two substantially parallel arms. In one embodiment each of the arms of the link is pivotally attached near its end to one of the pairs of these bracket members. Each arm of the link preferably is thick enough (measured in the direction perpendicular to the U-shaped plane of the link) that it touches both of the bracket members to which it is attached. The axis of rotation of the attachment between each mounting plate and the arm of the link preferably will be substantially parallel to that plate's rear surface and perpendicular to the U-shaped plane of the link. The hinge is constructed so that the link and the first mounting plate are pivotable between a first limit, in which the arms of the link are substantially parallel to the rear surface of the first mounting plate, and a second limit that is at least about 90° of arc away from the first limit.
Similarly, the axis of rotation of the attachment of the second link arm to the bracket members of the second plate preferably is substantially parallel to that plate's rear surface and perpendicular to the U-shaped plane of the link. The construction of the hinge is such that the link and second plate are pivotable between a first limit, in which the plate's rear surface preferably is substantially parallel to the arms of the link, and a second limit that is approximately 90° of arc away from the first limit.
When both mounting plates and the link are at their first limits of pivot, the table leaf will be in the extended (i.e., unfolded or "down") position. When both plates and the link are at their second limits of pivot, the table leaf will be in the folded (i.e., inverted or "up") position.
The hinge will include means for increasing the inertial resistance between the first mounting plate and the U-shaped link, so as to partially restrain the link and the first mounting plate from being swung apart when they are at their first limit of pivot. The hinge includes no such means, however, between the link and the second mounting plate. In other words, the second mounting plate and the link are able to freely swing away from their first limit of pivot, but the first mounting plate and the link resist swinging apart when at their first limit of pivot. In this way, when the table leaf is in the extended position and force is applied to fold it up, that force will first cause the link and second plate to swing apart by approximately 90° (so that the leaf is standing straight up) and then, after that motion is completed, will cause the link and first mounting plate to swing apart until the inverted leaf comes to rest on top of the table. This partial restraining feature assures that the leaf will swing wide and not hit the table top.
Normally, a pair of hinges will be used. The first mounting plate, with the preferred restraining feature (what we might call the "tight" plate), can be attached either to the table or to the leaf. Both hinges must be mounted the same way, however. In other words, the tight plates of both hinges must be aligned on the same side, either both attached to the table top or attached to the fold-up leaf.
To provide the first limit of pivot between the first mounting plate and the link, it is preferred that the plate and link be so dimensioned that the first arm of the link abuts the front surface of the first plate when the plate and link are at their first limit of pivot. This abutment halts further movement between the first plate and the link.
To provide the first limit of pivot between the link and the second mounting plate, it is preferred that the front surface of at least one of the two mounting plates include a protruding stop member that abuts the front surface of the other mounting plate when the link and the two mounting plates are at their first limits of pivot, i.e., in the leaf extended position. Ideally, the front surface of each of the two mounting plates will include a protruding stop member and those members will be so positioned that they abut one another when the link and the two plates are at their lower limits of pivot. It is preferred that these protruding stop members be located low on the mounting plates, i.e., near the base of the link when in the leaf extended position.
The first limit of pivot between the second mounting plate and the link can be provided by so dimensioning those parts that the second arm of the link abuts the front surface of the second plate when the plate and link are at their first limit of pivot, e.g., when the leaf is fully extended. This abutment feature may be used in addition to, or in place of, the use of one or two protruding stop members.
The second limit of pivot between the second mounting plate and the link preferably is provided by the combination of (a) a protruding member carried either by one of the brackets of the plate or by the second link arm and (b) a corresponding recess in the surface of the attached bracket or link arm, in which recess the protruding member rides when the link and second plate are pivoted. The recess must have an end wall which the protruding member abuts when the second mounting plate reaches its second limit of pivot. The protruding member can be provided by a variety of elements, for example either a removable pin or a lug that is integral with the bracket or link. I have found more strength to be provided by a lug that is integral with one of the brackets on the mounting plate. An optional, additional pin or lug can be used on the other bracket for further increased strength.
The hinge may optionally also include means for providing a second limit of pivot between the link and the first mounting plate that is approximately 90° to 100° of arc away from the first limit of pivot for those two parts. The same combination of a protruding member (carried either by one of the brackets or by the first link arm) and a corresponding recess in the surface of the bracket or link arm may be used to provide this second limit of pivot.
Each of the two mounting plates in the hinge of this invention preferably contains at least one screw hole located on each side of the link. These are for mounting the hinge. The axes of the screw holes should be substantially perpendicular to the plate's rear surface.
The preferred means of partially restraining the link and the first mounting plate from swinging apart when they are at their first limit of pivot is provided by a coil spring mounted on the axis of the first link arm, one end of the coil exerting torque on the mounting plate, the other end of the coil exerting an opposite torque on the link arm, urging the plate and the link toward their first limit of pivot.
In the preferred embodiment, one end of the coil lies in a notch cut in the first mounting plate, preferably near the center of the plate. The opposite end of the coil spring is inserted into a hole in the first link arm.
Use of the resistance spring provides inertial resistance to the motion of the link arm and first mounting plate from their first limit of pivot. That resistance can be overcome by manual force, however, and the first plate and arm moved to their second limit of pivot. Once at their second limit of pivot, the weight of the table leaf will be adequate to prevent the spring from automatically returning the plate and arm to their first limit of pivot; it will require manual force to do so. The spring insures that the first pivoting motion will always be at the second mounting plate; when the extended table leaf is folded up and when the folded-up leaf is swung down, the first pivoting motion will be at the first mounting plate. This order will be the same regardless of whether the "tight" side of the hinge is mounted to the table top or to the leaf. This order of hinge motion insures that the edges of the table, and of the leaf, will never come into contact with one another or bind in any way, even if the direction of motion is abruptly changed while the leaf is being swung up or swung down.
Another method of partially restraining the link and the first mounting plate from swinging apart when they are at their first limit of pivot is provided by the distance between the bracket members on the first mounting plate being made slightly less than the thickness of the first link arm, so that, in order to assemble the hinge, the link arm must be forced into the space between the brackets. This will cause the brackets to exert a constant clamping pressure against the link. After numerous cycles of use, the pressure exerted by the brackets against the link naturally will lessen. In this embodiment of the present invention, however, the following means can be provided for restoring the original tight fit.
The rear surface of the first mounting plate may be made so that it is slightly bowed inward. This is with reference to the direction parallel to the axis of rotation of the link. When the first plate is mounted to the straight edge of the table top or leaf, a shim may be placed behind the plate, centered between the two bracket members, in order to cause the plate to bow a little bit more when the mounting screws are tightened. The shim should not be so thick, however, as to cause all of the clamping pressure against the first arm of the link to be released. Later, when the joint has worn loose, the shim may be removed, thereby restoring the clamping pressure.
Preferably, a third screw hole will be provided in the first mounting plate, between the two bracket members. If the joint becomes loose a second time, a screw can be inserted in that middle hole to draw the center of the plate back further, until it is flush against the table or leaf edge. This will slightly bend the brackets toward one another, and once again restore the clamping pressure against the first arm of the link.
Obviously, in the preferred embodiment incorporating the coil spring, the first mounting plate need not be bowed, but a third screw hole may still be provided for additional mounting strength.
The hinge of the present invention is designed to be mounted in routed-out recesses in the edges of the table top and leaf. The recesses need not break through either the top or bottom surfaces of the table top or leaf. When the leaf is extended, this gives both of those surfaces a smooth appearance, interrupted only by a narrow, even gap between the table top and the leaf. The hinge is invisible, folded away inside the recesses, or pockets, in the two opposed edges. The structure of the hinge allows the leaf to be mounted so close to the table top that, in the extended position, the top and the leaf present a continuous writing surface.
The U-shaped design of the center link gives the hinge of the present invention a nice smooth appearance when it is in the folded-up position. Steel hinges of the prior art, lacking such an appearance, often have had to be plated with brass, chromium, gold, or silver to satisfy aesthetic demands.
If desired, however, the hinge of the present invention also can be metal plated. To facilitate the plating operation, it is preferred that the portions of each arm of the link that ride against the adjacent bracket members be raised land areas, machined to the desired finished tolerance. The height of the rise should be at least as great as the intended thickness of the plating. In this manner, the land areas can be chemically or physically masked during the plating operation, to prevent the link from becoming thicker in that area. Most, if not all, of the land area will be hidden from view in the assembled hinge, so the fact that it is not plated will not be noticeable.
Cabinet Hinge
Other embodiments of the present invention are intended for use with door and stile assemblages, useful for mounting cabinet doors. These embodiments are of lighter weight construction, but contain essentially the same features of the table leaf hinge. The cabinet versions allow a door either to be flush-mounted, so as to be coplanar with the stile when the door is closed, or mounted perpendicular to the stile. The "flush-mount" hinge contains mounting plates that are directly analogous to the table leaf hinge mounting plates. In the "90°" version, however, one of the mounting plates is designed to allow the hinge to be most easily and securely mounted to provide a 90° angle between the plane of the stile and the plane of the flat surface of the door, when the door is in the closed position. Both the flush-mount and 90° hinges will be described in further detail below.
In general, the cabinet hinge is comprised of a mounting plate that attaches to the edge of a stationary stile upon which a cabinet door is to be mounted, a substantially U-shaped link that is pivotally attached near the end of one of its arms to the mounting plate, and another mounting plate that is pivotally attached to the opposite arm of the link, and to which plate the cabinet door is attached.
For purposes of the following discussion, the two mounting plates will be referred to as a "first" mounting plate and a "second" mounting plate. The first mounting plates of both the flush-mount and 90° versions are essentially the same. The flush-mount hinge has a second mounting plate which is substantially similar to the first. In the 90° version, however, the second mounting plate is different from the first. It should be understood that for the flush-mount hinge, either plate can be mounted to the stile or to the door. In the 90° hinge, it is preferred that the second mounting plate be mounted in the stile.
Each mounting plate of the flush-mount hinge has a front surface and a rear surface. The rear surface is the surface that faces the edge of the stile or door when the hinge is mounted. In the 90° hinge, however, the front and rear surfaces of the second mounting plate are substantially perpendicular to the edge of the stile. For both versions, the front surface of each mounting plate includes a pair of bracket members. The U-shaped link has a base and two substantially parallel arms. Each of the arms of the link is pivotally attached near its end to one of the pairs of these bracket members. Each arm of the link preferably is thick enough (measured in the direction perpendicular to the U-shaped plane of the link) that it touches both of the bracket members to which it is attached. The axis of rotation of the attachment between each mounting plate and the arm of the link preferably is substantially parallel to that plate's rear surface and perpendicular to the U-shaped plane of the link. The hinge is constructed so that the link and the first mounting plate are pivotable between a first limit, in which the arms of the link are substantially parallel to the rear surface of the first mounting plate, and a second limit that is at least about 90° of arc away from the first limit.
Similarly, the axis of rotation of the attachment of the second link arm to the bracket members of the second plate preferably is substantially parallel to that plate's rear surface and perpendicular to the U-shaped plane of the link. The construction of the hinge is such that the link and second plate are pivotable between a first limit, in which the plate's rear surface is substantially parallel to the arms of the link, and a second limit that is approximately 90° of arc away from the first limit.
When both mounting plates and the link are at their first limits of pivot, the cabinet door will be in its closed position. When both plates and the link are at their second limits of pivot, the door will be open, and folded back approximately 180°.
The hinge will include means for increasing the inertial resistance between the first mounting plate and the U-shaped link, so as to partially restrain the link and the first mounting plate from being swung apart when they are at their first limit of pivot. The hinge includes no such means, however, between the link and the second mounting plate. In other words, the second mounting plate and the link are able to freely swing away from their first limit of pivot, but the first mounting plate and the link resist swinging apart when at their first limit of pivot. In this way, when the door is closed and force is applied to open it, that force will first cause the link and second plate to swing apart by approximately 90° (so that the flat plane of the door is perpendicular to the stile in the flush-mount version, or parallel to the stile in the 90° hinge) and then, after that motion is completed, will cause the link and first mounting plate to swing apart until the door is swung completely open. This partial restraining feature assures that the door will swing wide and not hit the edge of the stile.
Normally, a pair of hinges will be used. In the flush-mount hinge, the first mounting plate, with the preferred restraining feature (what we might call the "tight" plate), can be attached either to the door or to the stile. Both hinges must be mounted the same way. In other words, the tight plates of both hinges must be aligned on the same side, either both attached to the door or both attached to the stationary stile. In using the 90° hinge it is preferred that the tight plate be mounted in the door and the second plate be mounted in the stile. Again, both hinges must be mounted with the same orientation.
The limits of pivot are provided for in the same manner for the flush-mount and 90° hinges. To provide the first limit of pivot between the first mounting plate and the link, it is preferred that the plate and link be so dimensioned that the first arm of the link abuts the front surface of the first plate when the plate and link are at their first limit of pivot. This abutment halts further movement between the first plate and the link.
The first limit of pivot between the second mounting plate and the link also can be provided by so dimensioning those parts that the second arm of the link abuts the front surface of the second plate when the plate and link are at their first limit pivot, e.g., when the door is closed.
The second limit of pivot between the second mounting plate and the link preferably is provided by the combination of (a) a protruding member carried by one of the brackets of the plate and (b) a corresponding recess in the surface of the link arm, in which recess the protruding member rides when the link and second plate are pivoted. The recess must have an end wall which the protruding member abuts when the second mounting plate reaches its second limit of pivot. The protruding member can be provided by a variety of elements, for example either a removable pin or a lug that is integral with the bracket or link. I have found more strength to be provided by a lug that is integral with one of the brackets on the mounting plate. An optional, additional pin or lug can be used on the other bracket for further increased strength.
The hinge may optionally also include means for providing a second limit of pivot between the link and the first mounting plate that is approximately 90° to 100° of arc away from the first limit of pivot for those two parts. The same combination of a protruding member carried by one of the brackets and a corresponding recess in the surface of the link arm may be used to provide this second limit of pivot.
Each of the two mounting plates in the flush-mount embodiment of this invention preferably contains at least one screw hole located on each side of the link. These are for mounting the hinge. The axes of the screw holes should be substantially perpendicular to the plate's rear surface. Each of the plates of the flush-mount hinge, and the first plate of the 90° hinge, preferably contain similar screw holes. These plates are preferably mounted by being screwed directly into the edge of the member to which the plate is to be attached. The second plate of the 90° hinge must be mounted differently in order to more easily achieve the right-angle orientation of the door mount.
The second mounting plate of the 90° hinge preferably contains a female-threaded screw hole and a smooth pin hole. These holes are preferably located side-by-side on the plate, and at a lower level than the level of the base of the link arm when the plate is at its first limit of pivot. In this embodiment, the second mounting plate is mated to an extension mount which may be held (for example by glue) in a routed-out pocket in the edge of the stationary stile. The plate preferably is attached to the extension mount through the use of a machine screw screwed into the plate's threaded hole. The plate's smooth hole is fitted over a pin on the extension mount to keep the hinge from rotating around the axis of the mounting screw. When mounted, the hinge joins the stile and door so as to form a 90° angle between the plane of the stile and the plane of the flat surface of the cabinet door, when the door is in the closed position. This hinge can be mounted so as to allow the door to swing in either direction (i.e., left or right, relative to the stile). Other methods of joining the second plate to the extension mount, and a variety of such mounts, will be apparent to those skilled in the art of door-stile arrangements.
The preferred means of partially restraining the link and the first mounting plate from swinging apart when they are at their first limit of pivot is the same for all versions of the hinge of the present invention--namely, the aforementioned coil spring mounted on the axis of the first link arm, one end of the spring exerting torque on the mounting plate, the other end of the spring exerting an opposite torque on the link arm, urging the link and the plate toward their first limit of pivot.
The cabinet hinges of the present invention are designed to be mounted in routed-out recesses in the edges of the stile and door. The recesses need not break through either the top or bottom surfaces of the stile or door. When the door is closed, this gives both of those surfaces a smooth appearance, interrupted only by a narrow, even gap between the stile and the door. The hinge is invisible, folded away inside the recesses, or pockets, in the two opposed edges.
The U-shaped design of the center link is the same in the cabinet version as in the table-leaf version and gives the hinge the same smooth appearance when it is in the folded-open position. Again, to facilitate plating of the hinge, it is preferred that the portions of each arm of the link that ride against the adjacent bracket members be raised land areas, machined to the desired finished tolerance, the height of the rise being at least as great as the intended thickness of the plating.
This invention will be better understood in all its described embodiments by studying the drawings accompanying this specification. Referring to the drawings, FIGS. 1-6 depict one embodiment of the table leaf hinge of the present invention, FIGS. 7 and 8 depict a second embodiment having an alternate restraining means, and FIGS. 9-13 depict a slightly different third embodiment of the table hinge. FIGS. 14-17 depict the first embodiment or flush-mount version of the cabinet hinge, and FIGS. 18-24 depict the 90° angle cabinet hinge and details of its mounting.
In the hinge of FIGS. 1-6 first or "fixed" mounting plate 10 is attached by screws 11 to stationary table top 12. Second or "pivoting" mounting plate 13 is attached by screws 14 to fold-up table leaf 15. Left arm 20 of U-shaped link 16 is attached to bracket members 17 and 18 of the fixed mounting plate 10 by pivot pin 19, which is mounted in hole 37. The distance between bracket members 17 and 18 is the same as the thickness of link arm 20. This prevents looseness in the hinge, but allows arm 20 to pivot freely about pivot pin 19, without any substantial interference from bracket members 17 and 18. Bracket members 25 and 26 of pivoting mounting plate 13 are attached to arm 21 of link 16 by pivot pin 22, which is mounted in hole 23. Brackets 25 and 26 carry lugs 27a and 27b that are integral with the mounting plate. Fixed mounting plate 10 similarly has lugs 28a and 28b protruding from brackets 17 and 18. The right arm 21 of link 16 is held in place by spring 9. One end of spring 9 is inserted in hole 8 in arm 21 of link 16. The opposite end of spring 9 rides in notch 7 in mounting plate 13.
The action of the hinge during the folding up of table leaf 15 can be seen by comparing FIGS. 3, 5, and 6. As seen in FIG. 5, upward force on leaf 15 causes link 16 to pivot on pin 19 until recess 30a and 30b in arm 20 come to rest against lugs 28a and 28b of bracket member 17 and 18. In this position leaf 15 is pointing straight up. Additional counterclockwise force on leaf 15 causes the flexing of spring 9, thus permitting plate 13 to pivot around pin 22. As illustrated in FIG. 6, this motion of plate 13 continues until lugs 27a and 27b on brackets 25 and 26 abut against recess 29a and 29b in arm 21. By this time leaf 15 is fully inverted and is folded back over table top 12.
As seen in FIGS. 1, 3, and 4, when leaf 15 is in its fully extended position, coplanar with table top 12, it is prevented from dropping below horizontal by the abutment of feet 31 and 32, respectively, of mounting plates 10 and 13. Also working to hold the leaf 15 level is the abutment of link arm 21 against front wall surface 34 that extends between brackets 25 and 26 of pivoting mounting plate 13. Similarly, link arm 20 comes to rest against front wall surface 35 of fixed mounting plate 10. Preferably, feet 31 and 32 will meet when leaf 15 is still slightly above horizontal, e.g., about 2° above. Then, when any substantial weight is rested on leaf 15, the leaf can bend slightly downward without dipping below horizontal.
Link 16 has raised land areas 38 and 39 around its pivot pin holes 40 and 41. Although barely perceptible in the drawings, that feature is repeated on the opposite side of the link.
FIGS. 7 and 8 represent the second embodiment of the table leaf hinge. In this embodiment, the resistance of the "tight" plate 113 of the hinge is provided by the pinching action of the brackets 125 and 126 on the arm 121 of the link 116. In this version of the hinge only single lugs 127 and 128 that are integral with brackets 117 and 125 on each side of the link arm are used. The use of a single lug on each bracket allows for a hinge to be created with less material and machining, for applications that do not require the strength provided by the extra lugs.
This embodiment, though having a different restraining means, in this case the pinching action of brackets 125 and 126, follows the motion of the preferred embodiment shown in the description of FIGS. 5 and 6 above. The difference in this second embodiment is that in order to move from the position shown in FIG. 5 to that shown in FIG. 6, the additional counterclockwise force is added to get brackets 125 and 126 to release arm 121 and allow plate 113 to rotate around pin 122.
In the hinge of FIGS. 9-13, fixed mounting plate 213 is equipped with a stop pin 228 mounted in hole 236 of bracket 226. Unlike the embodiment of FIGS. 1-6 or 7-8, in this version of the hinge no protrusion from bracket or link arm is used to establish a second limit of pivot for the pivoting mounting plate 210. Instead, its second limit of pivot (when unmounted) would be the position at which the two mounting plates would contact one another. In other words, it is not necessary that the second limit of pivot between the link and the first mounting plate in the hinge of this invention be precisely at or near 90° of arc away from the first limit of pivot. It is only necessary that it be at least about 90° of arc away.
Arm 220 of link 216 is attached to pivoting mounting plate 210 by pivot pin 219, which is mounted in hole 237 in brackets 217 and 218. Arm 221 of link 216 is attached to brackets 225 and 226 of fixed plate 213 by pivot pin 222, which is mounted in hole 223. Link 216 has raised land areas 239 and 240 around pivot pin holes 241 and 242. Corresponding land areas (barely perceptible in the drawings) are on the opposite side of link 216 as well.
Stop pin 228 protrudes from bracket 226 and rides in curved recess 229 in link arm 221. As seen in FIG. 11, as table leaf 212 is lifted, link 216 rotates counterclockwise about pivot pin 222 until the end wall of recess 229 in link arm 221 abuts against the protruding end of stop pin 228. Plate 210 is temporarily restrained from pivoting about pin 219 by the pinching action of brackets 217 and 218. As shown in FIG. 12, as more counterclockwise force is applied to leaf 212, the brackets 217 and 218 release arm 220 and allow plate 210 to rotate about pin 219 until leaf 212 comes to rest (not shown) against table top 215. As mentioned above, in this embodiment no protruding stop member is used with the pivoting mounting plate 210.
As can be seen in FIGS. 9 and 13, the rear surface 238 of fixed mounting plate 210 is slightly bowed or arched. If the clamping pressure against link arm 220 decreases over time to the point that the hinge no longer operates in the correct sequence--that is, link 215 pivots around pin 222 before mounting plate 210 pivots around pin 219--then the pressure can be increased by driving middle screw 214 further into the edge of table leaf 212. As shown in FIG. 13, this serves to draw brackets 217 and 218 closer together, and thus reestablish the clamping action against link arm 220.
FIGS. 14-17 depict the "flush-mount" cabinet door embodiment of the hinge of the present invention. These figures show the cabinet hinge in the same orientation as the hinge of the figures above, in order to more clearly show that the cabinet hinge contains the same features as the table leaf hinge. The cabinet door hinges will mount in a door and stile arrangement. This arrangement can be in any orientation of cabinet desired. For instance, a cabinet with a flush-mouthed door that opens vertically, or one that opens horizontally. The hinge and stile shown in FIGS. 14 and 15 lie flat so as to be in the same orientation as the figures showing the table leaf hinge.
In FIGS. 14 and 15, fixed mounting plate 310 is attached to stationary stile 312. Pivoting mounting plate 313 mounts in cabinet door 315. Left arm 320 of U-shaped link 316 is attached to bracket members 317 and 318 of fixed mounting plate 310 by pivot pin 319, which is mounted in holes 337 and 340. The distance between bracket members 317 and 318 is approximately the same as the thickness of link arm 320. This prevents looseness in the hinge, but allows arm 320 to pivot freely about pivot pin 319, without any substantial interference from bracket members 317 and 318. Bracket members 325 and 326 of pivoting mounting plate 313 are attached to arm 321 of link 316 by pivot pin 322, which is mounted in holes 323 and 341. Brackets 325 and 326 carry lugs 327 that are integral with the mounting plate. Fixed mounting plate 310 similarly has lugs 328 protruding from brackets 317 and 318. The right arm 321 of link 316 is held at its first limit of pivot by the resistance supplied by spring 309. One end of spring 309 is inserted in hole 308 in arm 321 of link 316. The opposite end of spring 309 rides in notch 307 in mounting plate 313.
The action of the hinge during the opening of the cabinet door is the same as that of the table leaf hinge and can be seen by comparing FIGS. 14, 16, and 17. As seen in FIG. 16, a pulling force on door 315 causes link 316 to pivot on pin 319 until the front surface 330 of link arm 320 comes to rest against lugs 328 of bracket members 317 and 318. In this position door 315 is pointing straight out, perpendicular to stile 312. Additional counterclockwise force on door 315 causes the flexing of spring 309, thus permitting plate 313 to pivot around pin 322. As illustrated in FIG. 17, this motion of plate 313 continues until lugs 327 on brackets 325 and 326 abut against the front surface 329 of link arm 321. By this time the door 315 is completely folded back in front of stationary stile 312.
Link 316 has raised land areas 338 and 339 around its pivot pin holes 340 and 341. This feature is repeated on the opposite side of the link (not shown).
FIG. 18 shows a partly disassembled view of the 90° cabinet door hinge. This hinge contains the salient features of the hinge shown in FIG. 14 and follows an order of motion as is indicated in FIGS. 16 and 17. In FIG. 18, pivoting mounting plate 413 is essentially the same as fixed mounting plate 313 of FIG. 14. Left arm 421 of U-shaped link 416 is attached to bracket members 425 and 426 of pivoting mounting plate 413 by pivot pin 422, which is mounted in hole 423. Plate 413 has resistance supplied by spring 409 to hold link 420 against plate 413, i.e., at the first limit of pivot. Bracket members 425 and 426 contain lugs 427 which are integral with mounting plate 413. When pivoting plate 413 is at its second limit of pivot, lugs 427 of plate 413 abut against front surface of link arm 421.
Arm 420 of link 416 is attached to bracket members 417 and 418 of fixed mounting plate 410 by pivot pin 419, which is mounted in holes 437 and 423. The distance between bracket members 417 and 418 is the same as the thickness of link arm 420. This prevents looseness in the hinge, but allows arm 420 to pivot freely about pin 419, without any substantial interference from bracket members 417 and 418. Fixed mounting plate 410 similarly has lugs 428 protruding from bracket members 417 and 418, which are integral with plate 410. Fixed mounting plate 410 has screw hole 450 and pin hole 451 to enable mounting plate 410 to be attached to extension mount 452 (shown in broken lines).
Reference now is made to FIGS. 19-24 which describe a method of mounting the 90° hinge of FIG. 18 in a stile and door arrangement in which the door, when closed, is perpendicular to the plane of the stile. FIGS. 19-23 depict a sequence of steps, illustrating the general mounting procedure. In order to see the hinge mount clearly, the view of these figures is oriented from above in a cross section of the door and stile. FIG. 24 is a view of the front of a cabinet door made of a honeycomb material, with part of the facing "peeled back" to show the mounted hinge.
FIG. 19 shows stile 510, with the initial mounting area 511 that is to be routed out. The view is taken along a cross-section of the stile in order to show in solid lines what would be hidden within the stile if viewed from its top end.
Once the initial mounting area 511 has been cut out, two narrow channels 512 and 513 are routed out deeper into the stile as shown in FIG. 20. Channel 512 and channel 513 are provided to hold the "legs" of extension mount 514.
FIG. 21 shows extension mount 514 after it has been set in channels 512 and 513. Extension mount 514 is held in place by an adhesive, to form a strong bond with stile 510. Different adhesives may be used and may depend on the particular material of construction of the stile 510 and extension mount 514. Variations of materials and adhesives will be apparent to those skilled in the art of such mounting procedures. The cap 515 of extension mount 514 contains a pin hole 516, and a screw hole 517. These holes correspond to the mounting holes found in the second mounting plate of the 90° hinge.
FIG. 22 shows a partially exploded view of the 90° hinge as it is mated to extension mount 514. The hinge's second mounting plate 522 also contains a pin hole 518 and a screw hole 519. The second mounting plate 522 is aligned with cap 515 of extension mount 514 and secured with a machine screw 521 through holes 517 and 519. A straight pin 520 is inserted through holes 516 and 518 in order to keep mounting plate 522 from pivoting around the axis of screw holes 517 and 519. Straight pin 520 should be tight fitting to insure that it does not fall out. FIG. 22 also shows that the second mounting plate 522 is attached to the hinge's first mounting plate 523 by U-shaped center link 524.
FIG. 23 shows the complete hinge assembly mount. Once second mounting plate 522 has been mated to extension mount 514, first mounting plate 523 can then be mounted to a door 525. First mounting plate 523 is mounted as are the mounting plates of the flush-mount version of the hinge. Space is routed out in the edge of door 525, and plate 523 is simply screwed in place with flat head wood screws. Once door 525 has been mounted, a cap 526 is affixed to the edge of stile 510 in order to hide mounting plate 522 and extension mount 514. Cap 526 may be affixed with a proper adhesive and is of such thickness as to provide a flush surface with the outer face of door 525. If desired, the resulting empty space 527 behind second mounting plate 522 can be filled with a plug before cap 526 is glued in place, in order to strengthen the mount and provide further support for cap 526. Finally, the arrow shows the direction of motion in which door 525 will travel when it is opened.
FIG. 24 shows the mounted hinge assembly from an angle facing the front of the mounted door, with cap 526 removed and the face of door 525 peeled back to expose first mounting plate 523. This view shows more clearly the mounting arrangement of first plate 523, using wood screws 528, and its connection to link 524 and second plate 522. | The present invention provides a hinge construction of two mounting plates and a substantially U-shaped center link which connects the axes of pivot of the two plates. The link and plates contain stop mechanisms which determine their respective limits of pivot. In addition, the hinge contains a means for restraining the rotation of only one of the mounting plates around its corresponding link arm to insure a pattern of motion that is always consistent, and allows for the hinge to be mounted with a very narrow gap between the members being joined. The hinge of the present invention can be variably constructed to conform to a number of alternative uses. |
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This is a continuation-in-part of U.S. Provisional patent application Ser. No. 60/030,959, filed Nov. 15, 1996, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to concrete wall forms and, more particularly, to a waler system for concrete wall forms.
The construction of walls with poured concrete normally involves the use of a form system which includes a pair of spaced generally parallel wall forms. Each wall form is constructed with a plurality of aligned panels and the wall forms define a space between them in which the concrete is poured and allowed to cure. The forces tending to separate the wall forms under the tremendous liquid pressure of newly deposited concrete is resisted by a series of tie rods extending between the wall forms and located at the juncture between the adjacent panels of each wall form.
Typically, each panel of each wall form includes a plywood, metal or similar material panel portion reinforced on a back face thereof by flanges extending along the side, top and bottom edges of the panel. The flanges along the side edges of each panel are arranged vertically and are commonly referred to as "studs". The studs or flanges include a plurality of holes which, when aligned with the holes in the flange of the adjacent panel, provide an aperture through which a pin is typically inserted to connect the adjacent panels together and construct the wall form. Commonly, the pin includes a slot through which a wedge is inserted to further secure the assembly.
The displacement of the wall forms as a result of the pressure and forces exerted by the poured concrete is resisted by horizontally extending walers which extend transversely across a plurality of panels on the back side of the wall form. Walers of this type are commonly used to reinforce the wall form against the forces exerted by the concrete and to maintain respective panels in proper alignment to avoid unwanted displacement or wavering in the wall form resulting from misalignment of the respective panels with each other.
The prior art includes numerous waler designs for securing and attaching the waler beams to the back surface of the wall form panels. However, known waler systems typically do not allow for convenient and effective installation of the waler beams to provide a sturdy and effective reinforcement and alignment of the wall form panels. Further, typically the waler systems do not provide for convenient and user friendly attachment and removal of those systems from the wall form panels. Very often each wall form utilizes at least two waler beams including an upper and a lower horizontally extending waler beam. Furthermore, each waler beam requires a plurality of clamps for attachment to the wall form panels. Therefore, the installation and removal of the waler system on a single wall panel can include dozens or more attachment devices. Therefore, the installation and removal of the waler system during the construction of a poured concrete wall can prove to be very time consuming and burdensome for the worker.
Therefore, a need exists in the industry for a waler system which is convenient and easy to install and remove from the wall form panels while still effectively reinforcing the wall forms and maintaining the alignment of the respective panels.
SUMMARY OF THE INVENTION
These and other objectives of the invention have been attained by a waler system according to a presently preferred embodiment of the invention which includes a number of clamps for supporting and securing each waler beam to the back surface of the wall form. Each clamp according to a presently preferred embodiment of the invention includes a lower horizontal leg projecting rearwardly from the wall form panels. A tab projects from the terminal end of the lower leg of each clamp to be positioned between the flanges on the adjacent wall form panels. A hole is provided in the tab for alignment with the holes in the respective adjacent flanges of the panels so that a standard pin or other attachment mechanism can be inserted through the hole in the tab and the holes in the flanges to anchor the clamp to the wall form panels.
An upper leg of the clamp extends generally parallel to the back face of the wall form panels and perpendicular to the lower leg. The upper leg is movable relative to the lower leg and the wall form to and between a loading/unloading position and a clamping position. The clamp is generally L-shaped in the loading/unloading position and the upper leg is spaced farther from the wall form panels than when the clamp is in the clamping position so that the waler beam can be loaded onto the clamp to rest on the lower leg of each clamp without interference from the upper leg. After the waler beam is loaded and is resting on the lower leg of each of the associated clamps, the upper leg is moved into the clamping position so that a gripping pad on the inner face of the upper leg contacts the waler beam which is then clamped between the upper leg and the flanges of the wall form panels. The upper leg of each clamp translates downwardly and inwardly toward the flanges from the loading/unloading position to the clamping position.
After the concrete is poured and the wall is cured, each of the clamps are unclamped to release the waler beam prior to disassembly of the wall forms.
The upper leg is biased by a spring captured within the upper leg toward the loading/unloading position. The lower leg includes an arm which is housed within the shell configuration of the upper leg. The arm includes a pair of slots which capture a pair of pins extending between opposed side walls of the shell to guide the upper leg from the loading/unloading position to the clamping position and vice versa.
The waler system and clamps according to a presently preferred embodiment of this invention can be easily installed and disassembled by merely securing each of the clamps with the pin used to join the adjacent panels of the wall form. Once the clamps are installed on the wall form, the waler beam is placed on the horizontal leg of the associated clamps and the upper leg of each clamp is then forced downwardly into the clamping position by a blow with a hammer, mallet or the like on an upper impact head portion of each upper leg. For removal of the waler beam, an impact base at the base of each upper leg is struck with a mallet, hammer or the like to disengage the leg from the waler beam and translate the clamp into the loading/unloading position. The force required to translate the clamp from clamping position to the loading/unloading position is less than the force required for the opposite operation because the upper leg is spring biased toward the loading/unloading position. Therefore, the installation of the waler system according to a presently preferred embodiment of the invention can be accomplished easily and effectively by the workers to provide a sturdy and effective alignment mechanism for the wall form panels.
BRIEF DESCRIPTION OF THE DRAWINGS
The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a portion of a wall form and waler system according to a presently preferred embodiment of the invention;
FIG. 2 is a cross-sectional view of a waler clamp in the loading/unloading position secured to the wall form; and
FIG. 3 is a view similar to FIG. 2 with the waler clamp in the clamping position securing the waler beam to the wall form.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a presently preferred embodiment of a waler system 10 according to this invention is shown. The waler system 10 includes a number of clamps 12 each of which is attached at the juncture between adjacent panels 14 forming a wall form 16. Each panel 14 includes a planar panel portion 18 and a flange 20 projecting rearwardly from the panel portion 18 along spaced side edges thereof. Each flange 20 includes a plurality of holes 22 (FIGS. 2 and 3) which are aligned with the respective holes 22 in the adjacent panel 14. It will be appreciated by one of ordinary skill in the art that the wall form 16 shown in FIG. 1 is used in conjunction with a similar configured wall form 16 to define a space therebetween into which concrete (not shown) is poured and allowed to cure to form a poured concrete wall (not shown). Additionally, although a particular configuration is shown and described for each of the panels of the wall form, it will be appreciated that the waler system 10 according to this invention can be used on a variety of configurations of panels and wall form designs.
The waler system 10 further includes a waler beam 24 extending generally horizontally across a plurality of adjacent panels 14 forming the wall form 16. Preferably, as shown in FIG. 1, the waler system 10 includes an upper and a lower waler beam 24 to reinforce and align the panels 14 of the wall form 16. The upper and lower waler beams 24 and the associated clamps 12 for each beam 24 are identical to like components according to this invention with the exception of the position of the respective components. Therefore, the following description is directed to an exemplary clamp 12 and waler beam 24 and it will be appreciated by one of ordinary skill in the art to be applicable to the other associated components according to this invention.
The waler beam 24 according to the presently preferred embodiment of the invention is typically a 2×4 or 2×6 wooden or other material beam. The various sizes of the waler beam 24 can be accommodated with appropriately sized and configured clamps 12 according to this invention.
With reference to FIGS. 2 and 3, each of the clamps 12 includes an upper leg 26 which is generally parallel to and spaced from the flanges 20 on the wall form panels 14. Each clamp 12 also includes a lower leg 28 which is perpendicular to the upper leg 26 and the flanges 20. A tab 30 is formed on the terminal end of the lower leg 28 for insertion between the flanges 20 on the adjacent wall form panels 14. It will be appreciated that a notch or cut-out (not shown) may be provided in each of the flanges 20 to accommodate the tab 30 therebetween. A hole 32 is provided in the tab 30 which is sized and configured similar to the holes 22 in the flanges 20 so that the clamp 12 can be secured to the flanges 20 by aligning the hole 32 in the tab 30 with the holes 22 in the flanges 20 of the adjacent panels 14 a nd inserting a pin 34 therethrough. The pin 34 may include a slot (not shown) through which a wedge (not shown) can be inserted to securely anchor the pin 34 and join the adjacent flanges 20 and panels 14 together as is well known in the art.
The tab 30 , according to the presently preferred embodiment of the invention, is thinner than the lower leg 28 of the clamp 12 to which it is attached so that an inner portion of a peripheral rim 36 formed on the lower leg 28 is juxtaposed against an outer edge of the flange 20 in an abutting relationship. As a result, when the clamp 12 is secured to the flanges 20 as described herein and shown in FIGS. 2 and 3, the clamp 12 is prevented from rotating about the pin 34 relative to the flanges 20 due to the interaction of the inner portion of the rim 36 and the flange 20.
The lower leg 28 preferably includes a plurality of ribs 38 forming an interconnected pattern of rectangles or squares on the lower leg 28 to add strength thereto without significantly increasing the weight of the clamps 12. The upper surface of the lower leg 28 is generally flat and extends perpendicularly to the flanges 20 so that a generally rectangular shaped cross-section of the waler beam 24 can rest on the upper surface of the lower leg 28 as shown in FIG. 3.
An arm 40 projects outwardly and upwardly from the lower leg 28 and is covered by a shell 42 to form the upper leg 26 of the clamp 12. Preferably, the arm 40, lower leg 28 and tab 30 are all integrally formed from steel, aluminum or another metal or molded as an integral unit from glass filled nylon or another material. The arm 40 includes an upper and lower slot 44, 46 respectively, which are each formed by generally oval shaped rims 48 in the body of the arm 40. An upper tapered edge 50 of the arm 40 is formed for sliding contact with a similarly tapered internal rib 52 formed in the shell 42 of the upper leg 26. The shell 42 further includes a pair of spaced sidewalls 54 between which the arm 40 is sandwiched. A peripheral border 56 separates the sidewalls 54 of the shell 42 and extends lengthwise along the shell 42 along an outer surface thereof and upwardly around the top of the shell 42 and then downwardly along the top half of an inner portion of the shell 42. The tapered internal rib 52 of the shell 42 in cooperation with the border 56 forms a cavity 58 in which a spring 60 is housed between the sidewalls of the shell 42. The spring 60 is captured between the upper end of the border 56 of the shell 42 and the upper end of the arm 40 as shown in FIGS. 2 and 3 to bias the upper leg 26 upwardly into a loading/unloading position as shown in FIG. 2. The upper leg 26 translates relative to the lower leg 28 into a clamping position as shown in FIG. 3 and a pair of pins 62, each of which is captured in one of the slots 44 or 46 in the arm 40, in cooperation with the sliding upper tapered edge 50 of the arm 40 and the tapered internal rib 52, guides the upper leg 26 to and between the respective positions.
The base of the shell 42 includes an enlarged impact base 64 and likewise the upper end of the shell 42 can be reinforced to provide an impact head 66 for the purposes of which will be described herein below.
The inner surface of the upper leg 26 preferably includes a gripping pad 68 comprising a plurality of serrations or teeth to increase the gripping force with the waler beam 24 when the clamp 12 is in the clamping position of FIG. 3. Preferably, the shell 42 is molded from glass filled nylon, metal or another material and the pins 62 are advantageously enclosed in the shell 42 so that translation of the pins 62 within the slots 44, 46 cannot be fouled by concrete, dirt or other foreign matter.
Installation of the waler system 10 according to this invention is easily accomplished by securing a number of clamps 12 to the wall form 16. The clamps 12 are connected to the wall form 16 at the juncture between the adjacent panels 14 by inserting the pin 34 through the aligned holes 22 in the flanges 20 and through the hole 32 in the tab 30 on the lower leg 28 of the clamp 12. After the appropriate number of horizontally aligned clamps 12 is secured by pins 34 to the wall form 16, the waler beam 24 is placed on the upper surface of the lower leg 28 of each clamp 12 in the loading/unloading generally L-shaped configuration shown in FIG. 2. In the loading/unloading position the inner surface of the upper leg 26 is spaced from the waler beam 24 to provide for easy and efficient installation of the waler beam 24 on the clamps 12 without interference of the upper leg 26.
Each of the clamps 12 are then translated into the clamping position of FIG. 3 by forcing the shell 42 downwardly and inwardly as shown by arrows A and B of FIG. 2 so that the spring is compressed and that the griping pad 68 engages the outer surface of the waler beam 24 to thereby clamp the waler beam 24 against the flanges 20 of the wall form 16 and provide for reinforcement and alignment of the respective panels 14. Once each of the clamps 12 is translated into the clamping position of FIG. 3, the concrete is poured between the wall forms 16 and allowed to cure thereby forming the concrete wall.
Disassembly of the waler system 10 according to the present invention is easily accomplished by impacting the impact base 64 on the shell 42 of the upper leg 26 as shown by arrow C and thereby translating the shell 42 upwardly and outwardly in the direction of arrow D to disengage the gripping pad 68 from the waler beam 24. The force required to disengage the upper leg 26 of the clamp 12 from the waler beam 24 is assisted by the biasing force of the spring 60 urging the upper leg 26 upwardly and outwardly away from the beam 24. As the clamp 12 is transformed to and between the loading/unloading position of FIG. 2 and the clamping position of FIG. 3, the pins 62 translate within the slots 44, 46 and the tapered edge 50 of the arm 40 and the internal rib 52 of the shell 42 cooperate to guide and stabilize the movement of the upper leg 26.
It would be appreciated that the installation and disassembly of the waler system 10 can be easily accomplished by reconfiguring the clamps 12 to and between the loading/unloading position and the clamping position by a hammer, mallet or the like striking the impact base 64 or impact head 66 of the upper leg 26 as appropriate. Furthermore, the clamping force of the clamps 12 according to the presently preferred embodiment of the waler system 10 provides a sturdy and stable reinforcement and alignment of the panels 14 of the wall form 16 while still providing for convenient installation and disassembly.
From the above disclosure of the general principles of the present invention and the preceding detailed description of a preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof. | A waler system includes a number of clamps each of which has a lower leg including a tab with a hole therein which is secured to the wall form of a poured concrete wall system by a standard pin connection. An upper leg of the clamp translates between a loading/unloading position so that a waler beam can be installed easily and conveniently on the clamp attached to the wall form. Each of the clamps is then simply translated into the clamping position by forcing the upper leg downwardly and inwardly toward the beam and the wall form. After the concrete has been poured and the wall cured, the waler system can be disassembled by simply translating the upper leg of each clamp upwardly and outwardly to disengage the waler beam. The transformation is assisted by a spring captured within the upper leg of each clamp. |
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BACKGROUND OF THE INVENTION
The invention relates to means of enclosing a vehicle, such as an automobile, truck or the like, for the purpose of protecting it from the destructive elements of the environment, for example, moisture, acid rain, sunlight, dust and dirt.
The need for an enclosure such as claimed in this invention arises from the recent popularity and growth of the collector car market. There is an increasing need to shelter such collector cars, especially outdoors, since indoors garage space is becoming increasingly scarce and expensive to obtain. Numerous shelters and protective devices are presently used for protection of vehicles, including car covers, car tents, protective bags and enclosed trailers or buildings. A few types of car covers can acceptably protect the upper part of an automobile from rain and sunlight but they offer very limited protection for the lower parts of a vehicle, namely the wheels, chassis parts, rocker panels and bumpers, from splashing water, blowing snow and rising moisture from the ground. Further, a car cover will physically contact the painted surfaces of a vehicle, casing possible damage from abrasion. A car tent such as cited in J. F. Oliver, Collapsible Housing Structure, U.S. Pat. No. 2,798,501 (1957), can also protect an automobile from rain and sunlight but being of an open construction at the bottom, it cannot protect from rising ground moisture. Also, since a car tent is normally not ventilated, it has a tendency under certain temperature conditions to accumulate condensation on its inside walls which can cause water droplets to form and drip on the vehicle. The resulting high humidity conditions can cause severe corrosion damage to steel and chrome plated parts. Enclosed bags of flexible material are also known to exist for the storage of automobiles. Such bags are only intended for indoor use and are inconvenient to use since they are openable only from one end. Enclosed trailers or garages are generally relatively very expensive compared to this invention and are not easily disassembled, moved or transported. Although air supported structures have been heretofore utilized for the containment of vehicles; such structures have not been as ideally suited for the task of protection and preservation of vehicles as the protective enclosure claimed herein. Prior air supported structures have employed extensive means to anchor the perimeter of the structure to the ground or to a pre-fabricated base. Such anchors must necessarily bear heavy tension loads developed by upward air pressure on the roof of the structure and must therefore be of heavy construction and costly. Examples of such construction are shown in Malet, Inflatable Structure For Use As A Shelter, U.S. Pat. No. 4,567,696 (1986), FIGS. 4 and 5 and in W. W. Bird, Weather-Tight Enclosure System, U.S. Pat. No. 3,496,686 (1970) FIG. 5. In addition, methods must be employed to seal the perimeter of such air supported structures either to a special base member or to an underlying surface, increasing cost of manufacture further. This type of construction is shown in Hickey, U.S. Pat. No. 3,929,178 (1975) as well as Patents of Malet and W. W. Bird referenced above, wherein the perimeter of a cover part is being sealed to a base member. In contrast, the portable protective enclosure claimed herein does not require means for sealing nor anchoring its perimeter. Further, Hickey's Patent referenced above would not be as suitable as this invention for housing vehicles with fine paint finishes, since its flexible cover interior is not pressurized, and thus self supporting, but opposingly is drawn tightly in contact with the vehicle by means of suction applied to its interior, thereby possibly causing damage to the paint finish of the vehicle.
OBJECTS OF THE INVENTION
It is an object of this invention to overcome the disadvantages cited above and provide a protective enclosure for a vehicle which totally encloses the vehicle including the bottom surface to prevent evaporating moisture from the ground from causing corrosion damage to parts of the vehicle such as bare steel chassis parts and chrome plated parts.
It is a further object of this invention to provide a protective enclosure for a vehicle which is ventilated for nearly equalizing the temperature inside the enclosure compared with the temperature outside the enclosure, therefore minimizing condensation formation on the vehicle.
It is another object of this invention to provide a protective enclosure for a vehicle which eliminates, in an air supported structure, the need for expensive sealing methods between a base members and an upper cover member by providing a shell that continuously encircles the vehicle, including the bottom.
It is a further another object of this invention to provide a protective enclosure for a vehicle which under normal conditions remains free of the vehicle, preventing damage to painted surfaces of the vehicle from abrasion.
It is another object of this invention to provide a protective enclosure for a vehicle which is convenient to use and which allows rapid entry and exit along with the ability to store or transport the enclosure in a small space.
It is yet another object of this invention to provide a protective enclosure for a vehicle which, when in use is firmly held in place due to the weight of the vehicle resting upon it and therefore, does not need extensive anchoring techniques to attach it to the ground and is resistant to wind and other forces attempting to move it.
Further objects and advantages of the invention will become apparent from the following summary, specifications and drawings.
SUMMARY OF THE INVENTION
In accordance with the invention, an air supported enclosure is provided, fabricated of lightweight vinyl sheeting, which when inflated encloses a vehicle on all sides including the bottom. A slide fastener in the form of a zipper is provided on three sides of the enclosure for access to its interior. The zipper closure is protected from entry of moisture by an overflap of the vinyl material covering the fastener.
Located in the interior of the front part of the enclosure is a fan which functions to inflate and pressurize the enclosure. The pressure differential thus developed is sufficient to support the enclosure and stabilize it so that it remains unaffected by strong wind velocities. The fan also functions to ventilate the enclosure so the temperature within the enclosure remains nearly equal to the temperature outside the enclosure. The air inlet port of the fan is connected through an opening in the vinyl sheeting to an S shaped duct which at the other end connects to a filter housing containing a washable filter element to filter fine dust particles from the incoming air stream and a coarse screen to exclude larger dirt particles, falling leaves, bugs, snowflakes and the like. Due to the configuration of the S shaped duct, the filter housing is located in a relatvely high position and in an inverted manner to place the open end of the housing facing down. This prevents entry of water and keeps the air intake port free of snow accumulations.
A supporting frame, fabricated preferentially of round steel tubing, rests on the vinyl sheeting at the bottom surface of the enclosure and encircles the vehicle. Supports, made of sheet metal rest loosely on the supporting frame and extend under at least four wheels of the enclosed vehicle, placing the full weight of the vehicle on the supporting frame. This holds the bottom of the enclosure firmly on the ground and directs the vinyl sheeting away from the vehicle. The frame is fabricated in sections attached by connectors which enable it to be disassembled and transported or stored conveniently. The vinyl sheeting can be folded around the fan assembly to create a small transportable package.
Although one particular embodiment of this invention is shown, it is understood that many different sizes, shapes and configurations of the invention may be fabricated within the scope of the claim set forth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left front partial cut-away view of the inflated enclosure also showing the filter housing and duct.
FIG. 2 is a left rear view of the inflated enclosure showing the zipper closure and overflap.
FIG. 3 is a detail sectional view of the zipper closure and weather protective overflap taken along lines 3--3 of FIG. 2.
FIG. 4 is a top view of the enclosure prior to inflation with the slide fasteners open and the top portion of the flexible sheeting rolled up.
FIG. 5 is a close-up view of the front wheel of a vehicle resting upon a support member which engages the supporting frame of the enclosure.
FIG. 6 shows a cross sectional view of the filter housing.
FIG. 7 is a view from the interior of the enclosure showing the ventilator fan and duct.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the figures, in FIG. 1 a flexible sheeting 1 preferably made of lightweight, watertight, reinforced vinyl material, encloses totally within it a vehicle 2, such as an automobile. The sheeting 1 comprises a rectangular top portion 3, a rectangular bottom portion 4 and essentially bread-loaf shaped sides 5 joined by sewing or electronic welding technique to form a completely watertight enclosure surrounding the vehicle on all sides, including bottom.
A closure means, preferably a heavy duty zipper 6 extending on two sides 5 and rear 7 allows when opened access to the interior of the enclosure. An overlapping strip of sheeting material 8 covers the zipper 6 so that water entry is not possible.
Located within the front part of the enclosure 9 a ventilating fan 10 is mounted on a bracket 11 and situated so that its air intake port faces an opening in the enclosure sheeting having a fitting 12 connecting to a flexible ducting 13 leading to a filter housing 14. Referring to FIGS. 6 and 7, when the motor 15 driving the impeller of ventilating fan 10 is electrically energized, air is drawn in through a screen 16, enters the filter housing 14, flows through filter 17, duct 13, and is discharged by the fan 10 into the interior of the enclosure causing it to become inflated. Once inflated and an equilibrium condition is attained, the airflow is of such magnitude that it equals the leakage through small openings in the enclosure and through the zipper 6 which is designed to leak an amount of air sufficient to ventilate the enclosure. The fan 10 is sized to develop pressure against this fixed airflow to keep the enclosure firmly inflated. In this equilibrium condition the flexible sheeting 1 assumes a semicircular shape in cross section. The fan 10 is mounted on the bracket 11 whose lower edge is attached to frame 19 by clamps 20. Clamps 20 allow the bracket 11 to pivot about frame 19 to adjust its position to conform to the position of the flexible sheeting 1 when inflated. Included on bracket 11 is an electrical inlet box 22 containing means for connecting to a source of electrical current, and an electrical outlet box 23 containing means for connecting an extension cord to power additional enclosures or other accessories. The S shaped flexible duct 13 is connected, as in FIG. 1, to the filter housing 14 and fitting 12 by hose clamps 24 and is retained in an upright position by strap 25 attached to the sheeting material. The relatively high position of the filter housing 14 with its open end with screen 16 (FIG. 6) facing in a downward direction prevents entry of water and snow into the enclosure.
As in FIG. 1, the perimeter of the enclosure is retained firmly on the ground by the weight of the vehicle 2 bearing on the support members 18 and supporting frame 19. Since the enclosure is self-supporting, it is completely free of the vehicle 2 at all points and under normal operating conditions cannot scratch or otherwise injure the finish of the vehicle. Further, since the enclosure assumes a semi-rigid airfoil-like shape, it is stable under windy outdoor conditions. The supporting frame 19 consists of several sections of circular steel tubing rigidly held together by screw-lock type connectors 20 which allow the frame to be quickly disassembled and stored or transported. As in FIG. 4, the frame sections at each end of the enclosure pass through pockets 21 formed by an additional thickness of the sheeting material. This locates the frame 19 precisely in the enclosure. The wheels 26 (FIG. 5) of the vehicle 2 rest upon support members 18 incorporating tabs 27 which engage frame 19 and hold frame 19 firmly against the inflation pressure which tends to lift the frame from the ground. As in FIG. 1, support members 18 can be adjustably positioned fore and aft along frame 19 corresponding to the wheelbase and length of the vehicle. As in FIG. 5, the front support members 18 contain a raised section 28 which functions as a stop when the vehicle is driven onto the enclosure.
To place a vehicle into the enclosure the sheeting material is spread out and positioned as shown in FIG. 4 with the sides 5 laying folded on each side and the top portion 3 rolled up at the forward end. The frame 19 is placed on the bottom sheeting 4 and connected using connectors 20. The support members 18 are then positioned according to the size of the vehicle 2 and the vehicle 2 is driven onto the enclosure with the front of the vehicle 2 toward fan 10 until the front wheels contact stop 28. The top portion 3 of the enclosure is rolled over the vehicle 2 and the slide fasteners 6 closed. The fan motor 15 is then energized causing the enclosure to inflate to its operating configuration. | An air supported enclosure for the protection of a vehicle from the harmful effects of the outdoor environment comprising a flexible sheeting totally surrounding but not touching the vehicle. Access into the enclosure is gained by a slide fastener which extends around three sides of the enclosure. The enclosure is ventilated to minimize temperature differentials between its interior and its exterior therefore also minimizing the formation of condensation in its interior. |
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FIELD OF THE INVENTION
This invention is related generally to prevention of erosion and promotion of seed germination in soil, and more particularly, to installation of erosion blankets to prevent erosion and promote seed germination.
BACKGROUND OF THE INVENTION
Erosion blankets are used throughout the world to stabilize soil before seed germinates and/or small plant plugs cover the ground. Erosion blankets are used for a variety of reasons, such as stabilizing large areas along highways, stabilizing areas around detention/retention ponds, establishing fine quality lawns for commercial and residential properties and restoring prairies. Erosion blankets are typically provided in rolls of 65 to 100 yard rolls, depending upon the type of blanket. The most widely used blankets are made of straw and wood fiber. Typically, erosion blankets of every type are installed by hand.
Erosion blankets are typically utilized to keep the soil and seed from eroding away during and after precipitation. In addition to preventing erosion, such blankets retain moisture in the soil under the blanket for a much longer period of time. The extended presence of moisture enables the seed to germinate much more quickly than without blanket cover.
In addition, erosion blankets retard weed growth when grass seed is planted in the late spring and early summer months. Due to the consistent shade that is provided by the erosion blanket the vast majority of noxious weed seed will not germinate.
In the landscaping industry, two alternative products are often used to encourage seed germination. These products are straw mulch and hydro mulch, both of which are typically mechanically blown or dropped onto the soil. However, bales of straw which are broken apart and spread on the soil as straw mulch can blow away which leads to mixed results. Hydro mulch, a paper component with seed and fertilizer mixed in slurry of water, helps the seed germinate but does not control erosion. Furthermore, hydro mulch is a poor medium to keep moisture in the soil during critical dry times of the growing season. While straw mulch and hydro mulch are less effective than erosion blankets, their use is popular due to their lower associated costs, especially the labor costs involved in installing the mulch on the soil.
Erosion blankets are typically installed after a site has been fine graded (soil prepared for seed) and seeded. The seed may be broadcast or installed using a mechanical seeder. For use with small plant plugs, the erosion blanket is installed and the plant plugs are manually planted into the blanket. In either use, after the erosion blanket has been laid on the ground, stakes must be manually driven through the blanket into the ground to keep the blanket in correct position. The stakes are typically six inches long and must be driven deep enough such that they are flush with the erosion blanket so that mowers do not strike them. The manual operations dealing with the installation of stakes significantly increase the cost of installing an erosion blanket and often lead landscapers to use the less labor-intensive products mentioned above for reasons involving both time and costs.
Therefore, there is a continuing significant need in the field of erosion prevention and seed germination promotion for improvements related to the installation of erosion blankets and for more efficient installation thereof. An improved device and method achieving these goals would lead to better erosion protection and, therefore, higher quality lawns and prairies, as well as cleaner lakes, creeks, streams, rivers and oceans.
OBJECTS OF THE INVENTION
It is an object of the invention to provide an improved device which efficiently installs erosion blankets.
Another object of the invention is to provide an erosion blanket installation device which is simple in structure and operation in order to facilitate effective installation.
Another object of the invention is to provide an erosion blanket installation device which mechanically drives stakes into the ground to hold the blanket in position.
Another object of the invention is to provide an erosion blanket installation device which mechanically drives staples into the ground to hold the blanket in position.
Another object of the invention is to provide an erosion blanket installation device which simultaneously unrolls and pins to the ground the erosion blanket.
Another object of the invention is to provide a method of mechanically installing an erosion blanket on the ground.
Still another object of the invention is to provide a method of installing an erosion blanket on the ground which minimizes the need for manual operations during installation.
Still another object of the invention is to provide an easy penetration point in the ground for the insertion of a stake which automatically pins an erosion blanket to the ground.
Yet another object of the invention is to provide a method of automatically pinning an erosion blanket to the ground during installation.
These and other objects of the invention will be apparent from the following descriptions and from the drawings.
SUMMARY OF THE INVENTION
This invention is an improved method and device for efficiently and effectively installing erosion blankets on ground surfaces. The invention represents a significant advance over the state of the art by providing a novel device, which allows for an automatic method of installation which is heretofore unknown in the art.
The erosion blanket installation device is able to install a 500 yard roll of a straw erosion blanket on the ground while securing the blanket in place until the turf or vegetation naturally stabilizes the ground soil via a staple or a pneumatically driven stake which enters a 5″-6″ furrow.
The device for installing an erosion blanket, i.e., laying and securing the blanket along a pathway on the ground, is comprised of a vehicle frame, an axle arm connected with respect to the vehicle frame and engaging an axle around which the blanket roll is sleeved, at least one staple or stake gun connected with respect to the frame and at least one staple or stake cartridge connected with respect to the gun for supplying staples or stakes to pin the blanket to the ground.
The erosion blanket is rolled so that it may be sleeved around the blanket axle before use of the device. The blanket is positioned in the vehicle frame by sliding the roll around the blanket axle. As the device is propelled along the pathway the blanket is unwound from the roll and is placed on the ground. The device preferably includes a blanket guide roller for which directs the blanket to the ground upon unwinding. The gun pins the blanket in position by driving a staple or stake through it into the ground.
For use with a stake gun, rather than a staple gun, the device also preferably includes at least one furrow blade connected with respect to the frame. Preferably three furrow blades are supported by a furrow bar which is connected to a hydraulic cylinder which urges the blades into the ground. The blades furrow the ground during movement of the device and are urged to stay in position by their arcuate shape.
The preferable device includes at least one hitch connection point connected with respect to the frame. The hitch connection points are designed to connect to a hitch of a tractor or other vehicle which is able to tow the device. There are preferably three hitch connection points to provide sufficient connection to the towing vehicle.
The preferable device further includes an air compressor which is connected to each gun for forcing staples or stakes through the blanket into the ground. An air compressor is connected to each gun via a compressor hose and allows for pneumatic pinning of the blanket.
It is also preferred that the device include a retractable arm which is connected with respect to the frame. The retractable arm is movable between an open position which allows the roll to be loaded by sliding over the blanket axle and a closed position in which the retractable arm engages the free end of the blanket axle to hold the roll in place. A spring-loaded retractable-arm pin is connected with respect to the frame and pivotably supports the retractable arm with respect to the frame. A retractable-arm brace connects the retractable-arm pin to the frame. In use, the retractable arm is pivoted so that the erosion blanket may be positioned within the vehicle. After the blanket roll is in position within the device, the retractable arm is pivoted so that the second end of the blanket axle may engage the retractable arm to hold the roll in place.
In another preferred embodiment the device includes at least one compression wheel for pressing the blanket against the ground as the blanket unwinds. The compression wheel is supported by a compression-wheel frame. The compression-wheel frame preferably supports each gun and staple or stake cartridge as well.
The novel method of installing erosion blankets on ground surfaces comprises (a) propelling a blanket-laying device along a pathway, (b) rotating the roll of the erosion blanket supported in the device such that the blanket unwinds and is positioned on the surface along the pathway; and (c) in conjunction with the rotating step, mechanically pinning the blanket to the ground.
It is preferred that the rotating and pinning steps are performed simultaneously. The rotating and pinning steps are also preferably performed continuously until the roll expires. Furthermore, the rotating step is preferably performed in conjunction with, and as a result of, the propelling step. That is, the propelling of the device causes the roll to rotate and unwind. In the novel method, the blanket is preferably initially anchored to the ground surface by manually driving staples or stakes through the blanket into the yard. However, alternate embodiments of the invention allow for the blanket to be anchored to the ground without any manual manipulation.
The preferred method includes the step of pressing the blanket to the surface as it unwinds from the roll to allow for effective surface coverage. Such step is preferably performed by compression wheels, and more preferably by at least 3 axially-spaced compression wheels, e.g., one wheel pressing the left side of the blanket, one wheel pressing the middle of the blanket, and one wheel pressing the right side of the blanket.
The preferred method also includes the step of furrowing the surface before the pinning step. Such a step is preferably performed by at least 3 blades which are aligned with the means for mechanically pinning the blanket to the ground.
The device is preferably propelled along the pathway at at least about 3 miles per hour (mph). A tractor or similar vehicle can be connected to the device via a hitch in order to tow the device at the proper velocity. It is preferred that the erosion blanket is installed on the surface at a rate of at least about 400 yards every 3 minutes, or 400 feet/minute. Even more preferably, the erosion blanket is installed on the surface at a rate of at least about 500 yards every 3 minutes, or 500 feet/minute.
The pinning step is preferably performed using staples or stakes. Such staples or stakes are preferably biodegradable. The staples or stakes are preferably forced through the blanket into the ground by an air compressor included in the vehicle. As discussed above, the air compressor is connected to a gun which fires the staples or stakes into the ground. The gun is connected to a staple or stake cartridge which supplies the staples or stakes.
It is preferable that the number of staples or stakes held by the device be proportional to the length of the roll. Upon expiration of the roll positioned in the device, the preferred method includes the steps of loading staples or stakes and another roll of the blanket with respect to the device; propelling the device along a pathway; rotating the roll such that the blanket unwinds and is positioned on the surface along the pathway; and in conjunction with the rotating step, mechanically pinning the blanket to the ground.
The step of loading staples or stakes and another roll is preferably accomplished in less than about 15 minutes. The preferred method uses blanket rolls which are 500 yards long and at least 15,000 yards of blanket are installed in 8 hours.
An alternate method of installing an erosion blanket along a pathway on a ground surface comprises providing a roll of an erosion blanket; supporting the roll in a device; propelling the device in a direction along a pathway; and unwinding the roll so that the blanket covers the pathway, the device automatically pinning the blanket to the ground surface as it unrolls.
The preferred alternate method further comprises the step of pressing the blanket to the surface as it unwinds to allow for effective surface coverage. Such a step is preferably performed by compression wheels, and more preferably by at least 3 axially-spaced compression wheels.
The preferred alternate embodiment also comprises the step of furrowing the surface simultaneous with the propelling step. The furrowing step is preferably performed by at least 3 blades
The pinning step is preferably performed using staples or stakes. The staples and stakes are preferably biodegradable and are forced through the blanket into the ground by an air compressor included in, or connected to, the device.
In the preferred alternate method, the erosion blanket is installed on the surface at a rate of at least about 400 feet/minute. More preferably, the erosion blanket is installed on the surface at a rate of about 500 feet/minute.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of the erosion-blanket-laying device in accordance with the invention.
FIG. 2 is a rear view of the erosion-blanket-laying device in accordance with the invention.
FIG. 3 is a view from the right side of the erosion-blanket-laying device in accordance with the invention.
FIG. 4 is a view from the left side of the erosion-blanket-laying device in accordance with the invention.
FIG. 5 is a overhead plan view of the erosion-blanket-laying device in accordance with the invention.
FIG. 6 is a detailed view of the compression wheel, gun and cartridge in accordance with the invention.
FIG. 7 is a detailed view of the compression wheel in accordance with the invention.
FIG. 8 is a detailed view of typical stakes for use with the erosion-blanket-laying device in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a front view of the erosion-blanket-laying device 10 in accordance with the invention. Device 10 includes a frame 20 which comprises five frame supports (two external frame supports 20 a , 20 e and three internal frame supports 20 b , 20 c , 20 d ) which, as seen in FIGS. 3 and 4, extend horizontally from the front before arcing downwardly toward the rear of device 10 . Frame supports 20 a , 20 b , 20 c , 20 d , 20 e are connected by front frame crossbars 30 a , 30 b and rear crossbars 30 c , 30 d . Each frame support and crossbar is preferably 2″ by 2″ steel framing (hollow square framing with a thickness of ¼″). Alternatively, each frame support and crossbar is 90-degree angle bar. Preferably, the frame supports and crossbars are 1018 Cold Roll steel.
Connected to front frame crossbars 30 a , 30 b is a vertical stabilizer frame 24 comprising five vertical stabilizer bars 24 a , 24 b , 24 c , 24 d , 24 e . Vertical stabilizer bars 24 are preferably flat pieces which are 4″ wide, ½″ thick and 1′11″ to 2′ long. Lower end 25 b of vertical stabilizer bar 24 b is connected to hitch-connection point 35 b . Upper portion 23 c of vertical stabilizer bar 24 c is connected to hitch-connection point 35 c . Lower end 25 d of vertical stabilizer bar 24 d is connected to hitch-connection point 35 d . The three hitch connection points 35 provide for connection of device 10 to a tractor or other towing vehicle. Such a vehicle preferably has a category 2, three-point hitch and at least a 100 hp engine. All connections between frame supports 20 , cross bars 30 and hitch-connection points 35 are weldings.
As seen in FIG. 3, fixed axle arm 26 is welded to a rear portion of external frame support 20 a and extends forward. Axle arm is preferably 2″ by 2″ steel framing. Axle arm 26 includes a connection point for erosion blanket axle 92 . Preferably, blanket axle 92 is welded to axle arm 26 at distal end 92 a of blanket axle. Erosion blanket 90 (shown in FIGS. 3 and 4) is wound into a roll so it can be slipped onto blanket axle 92 when being positioned in device 10 . Blanket axle 92 is preferably made of lightweight polished steel with ⅜″ thick wall. Blanket axle preferably has a diameter of 3½″ and a length of about 6′7″. Blanket axle 92 must have sufficient strength to hold a 500 yard blanket roll which has an approximate mass of 150 lbs.
As seen in FIG. 4, retractable arm 27 is connected to external frame support 20 e through retractable arm pivot 28 so that retractable arm 27 may swing about pivot 28 . Retractable arm 27 is preferably constructed from flat bar steel. The lower end of retractable arm 27 has an opening provide for connection to the proximal end 92 b of blanket axle 92 . Pressure clips (not shown) are provided at the opening to hold the connection to blanket axle 92 in place. Such pressure clips can be opened manually in order to disconnect blanket axle 92 from retractable arm 27 .
Retractable-arm brace 29 is connected to frame support 20 e . Provided on retractable-arm brace 29 is a connection point for spring-loaded retractable-arm lock 31 . Retractable-arm lock 31 is preferably a spring-loaded pin which passes through retractable arm 27 and retractable-arm brace 29 to prevent retractable arm 27 from pivoting about retractable-arm pivot 28 . In order to load a roll of erosion blanket 90 , retractable-arm lock 31 is removed from retractable arm 27 and retractable arm 27 is pivoted about retractable-arm pivot 28 so that the lower end of retractable arm 27 is moved toward frame support 20 e . Retractable arm 27 may be suspended in the blanket loading position by connection to pin hole 32 . Erosion blanket 90 is positioned within the opening created by slipping blanket 90 over blanket axle 92 after retractable arm is pivoted out of the way. Then retractable arm 27 is pivoted back to its original locked position and proximal end 92 b of blanket axle 92 is connected to the lower end of retractable arm 27 . Retractable-arm lock 31 is reconnected to retractable arm 27 and retractable-arm brace 29 to lock blanket 90 in position.
Compression wheels 70 are connected with respect to the lower end of interior frame supports 20 b , 20 c , 20 d . Such connection is preferably through a spring-mounted piston-like arrangement (shown in FIG. 6) for reasons discussed below. Compression wheels 70 are preferably composite cement rollers epoxied with a textured rubber coating and have lengths of 9″ and diameters of 6″. The composite cement is preferably formed from poured concrete and fiberglass fibers which add strength and durability. The rubber surface is preferably ½″ thick. Wheels 70 preferably weigh about 18.5 lbs each. Compression wheels 70 rotate about compression-wheel axles 71 which pass through forked wheel brackets 72 . Compression-wheel axles are preferably of the ball bearing type.
As shown in FIG. 7, wheel brackets 72 upwardly terminate in hollow bracket shafts 73 which house springs 74 with lengths of 12″ and diameters of ¾″. Bracket shafts 73 are preferably 1⅜″ by 1⅜″ and are received within the interior frame supports 20 b , 20 c , 20 d . Springs 74 extend out of bracket shafts 73 and engage spring stops 21 which are positioned within interior frame supports 20 b , 20 c , 20 d . Thus compression wheels 70 are urged downward from frame supports 20 b , 20 c , 20 d . This configuration allows wheels 70 to support the weight of the device (approximately 1200 lbs.) while absorbing the vibrations encountered when the device is propelled along a pathway on the ground.
Mounted to the rear side 72 a of each wheel bracket 72 is a gun 60 . The mounting arrangement is preferably designed to allow for gun 60 to be easily removed from and reattached to wheel brackets 72 . Preferably, each gun 60 is connected to each wheel bracket 72 with self-locking nuts. Each gun 60 has an outer hard metal casing with an airtight finish to prevent dust and water from entering the internal motor.
Each gun 60 is powered by air compressor 40 which is secured to the top of center frame support 20 c (as seen in FIG. 5 ). Air compressor 40 is preferably comprised of a 2½ gallon steel tank with various air valves. The tank is pressurized by a compressor motor which is powered by a power take-off 45 from the tractor or other towing vehicle. Device 10 preferably includes a female power take-off fitting for connection to a male power take-off at the rear of the towing vehicle. Air-compressor hoses 41 extend from air compressor 40 and lead to guns 60 . Air compressor 40 has a preferred operating pressure of between about 75 and 115 psi. Such pressure is sufficient to force staples or stakes 61 through blanket 90 and into the ground.
Before use, the air compressor is turned on and each pneumatic gun 60 is calibrated for a predetermined tractor speed and the number of staples or stakes to be installed per yard.
Cartridge 62 is connected to gun 60 to provide staples or stakes 61 for pinning blanket 90 to the ground. For use with stakes, each cartridge 62 holds approximately 170 stakes. By firing a stake every 3 feet, 170 stakes are used for 510 feet of erosion blanket. Therefore, three cartridges 62 are loaded into each gun 60 to provide enough stakes for a 500 yard roll of erosion blanket. Stakes 60 are preferably biodegradable and breakdown in the environment after about 6 months. Each stake 60 is preferably 6 inches long.
Guide chamber 63 (best shown in FIG. 5) allows stakes 61 to be forwarded to gun 60 and set into position for “hammer,” one at a time, from the roll of stakes in cylindrical cartridge 62 . Hammer mechanism 64 shoots stakes 61 into the ground one at a time when triggered by trigger wire 65 .
Trigger wire 65 extends from hammer mechanism 64 to a position 2.87″ from each wheel axle 71 . Trigger wire 65 monitors each wheel 70 and triggers each hammer mechanism 64 every two revolutions of each wheel 70 (approximately every 3′ the device travels). The middle trigger wire (connected to middle gun 60 c ) is preferably offset from the outer trigger wires (connected to outer guns 60 b , 60 d ) by 1½ so that staples or stakes 60 are fired into blanket 90 in a pattern which more strongly secures blanket 90 to the ground.
Blanket guide roller 80 (FIGS. 3 and 4) is connected with respect to axle arm 26 and exterior frame support 20 e . Guide roller 80 rotates about roller axle 81 which connects to roller bracket 82 and axle arm 26 through greased ball bearing fittings. Guide roller 80 preferably is lightweight steel with a ⅜″ thick steel wall cylinder with a ¼″ thick textured rubber surface covering. Roller axle 81 is preferably a 1″ ball bearing axle. Roller bracket 82 is connected to exterior frame support 20 e . When blanket 90 unwinds, it is directed between guide roller 80 and frame supports 20 b , 20 c , 20 d . Blanket 90 is then directed downward to compression wheels 70 where blanket 90 is positioned on the ground surface.
Furrow bar 50 is pivotally mounted with respect to exterior frame supports 20 a , 20 e (shown in FIGS. 3 and 4) and supports three furrow blades 55 . (shown in FIGS. 1 and 2 ). Each furrow blade 55 is aligned with a compression wheel 70 and gun 60 . Each furrow blade 55 is preferably formed from A-36 Steel or a chromium based hardened steel. The blades 55 must be durable and replaceable in case of breakage. Each blade 55 is preferably 9″ long and curved forward so that it digs into the ground during the forward motion of device 10 .
Furrow bar 50 is preferably primarily 1″ by 1″ steel with ends which are ¾″ diameter cylindrical steel to allow for pivoting with respect to device 10 . Furrow bar 50 is pivotally attached to exterior frame supports 20 a , 20 e (shown in FIG. 5 ). Furrow bar 50 is not attached to wheel bracket 72 . A 1″ by 1″ by 4″ piece of steel is welded at the end of furrow bar 50 to attach to a commercially available hydraulic cylinder 58 with a steel eye bracket. The upper end of hydraulic cylinder 58 is connected to axle arm 26 with another steel eye bracket. Hydraulic hose 59 extends from the upper end of cylinder 58 and leads to a hitch connection point. A hydraulic control lever is positioned near the driver's seat in the tractor (not shown) so that the driver may activate the cylinder to raise or lower furrow bar 50 and, thus, furrow blades 55 .
The total weight of the preferred device (including a 500 yard blanket roll) is approximately 1250 lbs. The total weight of the alternative device which uses 90 degree angle steel is approximately 975 lbs.
In order to begin use of the erosion blanket installation device, an erosion blanket roll must first be loaded into the device. The end of the blanket roll is threaded over the guide roller and under the compression wheels and is then manually stapled or staked into place by hand. This is done to ensure that the end of the roll stays in place and the roll unwinds properly as the device is towed forward. The tractor driver will lower the furrow blades via the hydraulic control lever mounted near the driver's seat. The blades cause the device to rise about 6″ from the ground. Then the driver will engage the power take-off which powers the air compressor.
For use with stakes, a furrow blade preferably readies the ground for penetration. Once the tractor begins towing the device at the predetermined speed, the furrow blades will immediately dig into the ground to a depth of 5″ to 6″ and the device will be lowered onto the spring-loaded compression wheels. Because blanket 90 is positioned between wheels 70 and the ground, blanket 90 will unroll. At the same time, three guns 60 will fire stakes 62 through blanket 90 into the furrows in the ground. Stakes 62 lock in the ground and anchor the blanket in place until turf or vegetation grows through blanket 90 and naturally stabilizes the ground.
When the roll expires, another blanket roll is installed in the device and the cartridges are refilled. The end of the new roll is again manually stapled or staked and the process is repeated.
Use of the novel device with a tractor connected via a three-point hitch allows an erosion blanket to be installed and stapled or staked in place with 3 rows of staples or stakes. A 500 yard erosion blanket roll can be installed and sufficient staples or stakes can be reloaded in the device in 15 minutes. Such a device allows two people to install a 500 yard roll in the device. For use with stakes, the device preferably creates 3 rows of 6″ deep furrows into which the 6″ biodegradable stakes are driven by a pneumatic gun. Such furrows are created by 9″ curved blades connected to the bottom of the device. Furrows are not necessary for use with staples.
Thus, it should be apparent that there has been provided, in accordance with the present invention, a novel device for efficiently and effectively installing erosion blankets on ground surfaces that fully satisfies the objectives and advantages set forth above.
Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. | An improved device and method for mechanically installing erosion blankets on a ground surface. The device holds a roll of an erosion blanket and provides that the blanket unwind when the device is propelled forward. Upon unwinding, the device positions the blanket on the ground and pins the blanket in position using staples, stakes or the like. Preferred embodiments of the device provide for furrowing of the ground before installation of the blanket. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Ser. No. 60/514,946 filed Oct. 3, 2002, the entire disclosure of which is incorporated herein by reference and U.S. Ser. No. 60/514,883 filed Oct. 27, 2003, the entire contents of which is incorporated herein by reference.
BACKGROUND
[0002] In the hydrocarbon exploration and recovery arts it is often desirable to employ valves in the downhole environment to control the migration of fluids. In some cases these valves include a closure member that is positionable across a flow area of a tubing string to shut in the wellbore below the closure member. Such valves are often called safety valves. Tubing retrievable safety valve(s) (TRSV) are commercially available from Baker Oil Tools, Houston, Tex., under part number H826103110. These valves have been extensively and reliably employed all over the world. Due to harsh conditions downhole however, all downhole components have limited life spans. When a TRSV fails to operate at optimum, cost associated with profitable hydrocarbon recovery can rise. In such cases, it is desirable to lock the original TRSV open and provide for communication with, and thus control over, a wireline run safety valve to be installed to assume the function of the original TRSV. Devices configured to provide such communication are known to the art but each has drawbacks. Advancements in the art are always beneficial and well received.
SUMMARY
[0003] Disclosed herein is a communication and lock open device. The device includes a lock open portion including a latch configured to engage a shifting profile on a closure member of a safety valve. The device further includes a communication portion configured to rotationally align a cutter with a non-annular hydraulic bore in the safety valve and axially cut into the hydraulic bore with the cutter.
[0004] Further disclosed herein is a selective collet which includes a sleeve having one or more fingers, at least one of the fingers having an attachment feature and an upset extending radially outwardly of the sleeve. The sleeve further includes a latch hold down engageable with a latch to prevent engagement thereof with another structure.
[0005] Also disclosed herein is a tubing retrievable safety valve that includes a housing, a flow tube mounted at the housing, a closure member mounted at the housing by a selectively shearable thread, the closure member operable responsive to the flow tube, a biasing member in operable communication with the flow tube, and a hydraulic control fluid in pressurizable communication with the flow tube.
[0006] Also disclosed herein is a method for replacing the function of a tubing retrievable safety valve while employing an original control line including running a communication and lock open tool in a wellbore, locating the tool in a tubing retrievable safety valve and shearing a thread in the tubing retrievable safety valve to render longitudinally moveable a closure member of the tubing retrievable safety valve. The method further includes shifting the closure member to lock the member in an open position, orienting a cutter and longitudinally establishing fluid communication with a piston bore of the tubing retrievable safety valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0008] FIGS. 1 A-C are a cross-sectional view of a TRSV modified slightly from the commercial embodiment identified in the background section of this application;
[0009] FIGS. 2 A-G, 3 A-G, 4 A-G, 5 A-G, 6 A-G, 7 A-G, 8 A-G, 9 A-G, 10 A-G and 11 A-G, are all extended view of one embodiment of the communication and lockout device in progressive actuation positions;
[0010] FIG. 12 is an enlarged view of tab 110 to illustrate the chisel edge; and
[0011] FIGS. 13-16 illustrate alternate components for certain components illustrated in FIGS. 2 A-G to FIGS. 11 A-G.
DETAILED DESCRIPTION
[0012] Referring to FIGS. 1 A-C, one of skill in the art should recognize most of the components of the TRSV 10 illustrated. These are not discussed specifically herein other than incidentally to the discussion of the communication and lock open tool and with respect to features of the TRSV that are themselves new. Components of the illustrated TRSV that are distinct from the commercially available TRSV and do represent a portion of the invention includes a thread 12 and a profile 14 . Thread 12 is not visibly changed from the prior art TRSV but is indeed modified. Thread 12 is in one embodiment, constructed as a narrow cross-section thread (about ½ thickness of standard square thread profile for example). The thread may be made from an alloy such as nickel alloy and may be annealed to a specified yield strength (lower than mating parts). Further, in some applications, sections of the thread are removed (milled from substantially to completely through from inside dimension to outside dimension) to achieve the desired shear value. Any shear valve can be obtained. This also accommodates the disassembly of the tool to allow removal of the sheared part. Upon shearing, the flapper (closure member) 16 is longitudinally moveable relative to the TRSV housing 11 . By shifting (moving) the flapper relative to housing 11 , to a location where part of the flapper is behind a lock tab 18 in the TRSV 10 . The flapper 16 is no longer closeable and is thus locked open. It is noted that the shear strength of the thread 12 is selected to be equivalent in strength to any and all of the other commercial components of the flapper assembly. This prevents unintended shearing and related problems.
[0013] As noted above, another new addition to the commercial TRSV is profile 14 . The profile itself is relevant to the function described herein and not what supports that profile. In the illustrated embodiment, profile 14 is occasioned by a sleeve 104 , but it could easily be an integral portion of housing 11 of TRSV 10 , if desired. The purpose of profile 14 is to orient an alignment device such as an alignment collet, which orients a cutter, which is part of the communication and lock open tool discussed further hereunder. Profile 14 ensures that the cutter will create communication by cutting into a non-annular hydraulic chamber comprising a piston bore 20 (hydraulic chamber) of the original TRSV 10 . It will be appreciated by one of ordinary skill in the art that original piston bore 20 is fluidly connected to a control line 22 , commonly hydraulic, that is in operable communication with a control location, which may be remote, and may be a surface location. By cutting into piston bore 20 , the communication medium employed by piston bore 20 (e.g., hydraulic fluid) is available at an inside dimension of the TRSV 10 and therefore available to communicate with an after-installed replacement valve such as a wireline retrievable safety valve (WRSV). Such communication with the after-installed valve means that the after-installed valve is controllable from the original remote or surface location using the original control line 22 .
[0014] Referring to FIGS. 2 A-G, the communication and lock open device 30 described herein is illustrated disposed at an inside dimension of the TRSV 10 in a non-actuated condition, having been run there on a suitable string (not shown) due to a desire to replace the function of TRSV 10 . Device 30 comprises many components that cooperate with one another and move relative to one another in a predetermined sequence wherein components, for example, at an uphole end of device 30 and a more downhole portion of device 30 may actuate simultaneously or in sequence. For clarity, the interconnection of the various components is described first, with operation of those components only alluded to where such allusion provides for better understanding. A detailed description of the operation of device 30 follows this initial component description. In connection with the component description, reference, to FIGS. 2 A-G is largely sufficient without reference to other figures. It is pointed out however that due to movement of the tool, some figures may make viewing some components easier. Components are numbered in each of the drawings to avoid any ambiguity. Reference to other of the drawings may be helpful.
[0015] Beginning at the uphole end of the device 30 (at the left of the drawings) a fishing neck 32 is in communication with an upper shaft sleeve 34 . Fishing neck 32 also includes at a downhole end thereof a spring washer 36 for decreasing impact force when the tool is fully stroked. Fishing neck 32 is threadedly connected to upper shaft 38 at thread 40 . Upper shaft 38 , at a downhole end thereof is threadedly connected to shaft 42 at thread 44 . In order to prevent the unintentional unmating of thread 44 , one or more set screw(s) 46 are employed in one embodiment. On an outside dimension of upper shaft 38 , near thread 44 (which is on an inside dimension of the upper shaft), is dog recess 48 having beveled edges 50 . Edges 50 communicate with beveled edges 52 on dogs 54 . Dogs 54 communicate with upper latch mandrel 56 . Upper latch mandrel 56 further includes an upper C-ring 58 and extends in a downhole direction to one or more shear screw(s) 60 . Shear screw(s) 60 , releasably affix upper latch mandrel 56 to upper latch collet 62 which is threadedly connected to upper latch extension 64 through thread 66 and set screws 68 . Upper latch extension 64 includes on its inside dimension, a recess (or plurality of recesses) 70 to receive a portion of dogs 54 during actuation of the device 30 .
[0016] Upper latch collet 62 extends in a downhole direction to culminate at collet profile 72 , which is configured to engage a lock profile 74 in the TRSV 10 . It will be appreciated that lock profile 74 includes a shoulder 76 that provides a no-go when combined with shoulder 78 on collet profile 72 . In one embodiment, the shoulders are reverse cut to hold without support for a position of the operation. Collet profile 72 is supported in engaged condition with lock profile 74 by latch support 80 when the device 30 is actuated. Support is provided by surface 82 of latch support 80 . It will be appreciated that approach ramp 84 assists in allowing movement of latch support 80 to the support position under collet profile 72 .
[0017] Device 30 may be run selectively or non-selectively with respect to the action of upper latch collet 62 . This is occasioned by selective collet 81 having an upset 83 , a collet attachment 85 and latch collet hold down 87 . Attachment 85 communicates with recess 91 in latch mandrel 56 in one of two ways. One way is that attachment 85 is engaged with recess 91 ab initio and the tool is not in selective engagement mode. The second is that attachment 85 is not engaged with recess 91 . In this configuration, latch collet hold down 87 is in communication with the upper latch collet 62 urging collet profile 72 inwardly, which prevents engagement thereof with TRSV profile 74 . This configuration would be employed when several TRSVs are in the well, and one deeper than the first is targeted. In the selective mode, the upset 83 is employed to release the collet 62 at the appropriate depth. Since the seal bore in the TRSV is the smallest internal dimension, the upset will catch on it. If it catches on it in an upward movement, the selective collet 81 is moved out of communication with profile 72 and will allow profile 72 to engage the TRSV profile 74 . Thus, in use, the device 30 is run to a location just downhole of the target TRSV and then pulled back to selectively engage with that TRSV. Upon actuation of the selective collet 81 , the attachment 85 engages recess 91 to prevent later interference of selective collet 81 with the operation of latch collet 56 .
[0018] Latch support 80 is driven, through shear screw(s) 86 , by upper latch mandrel 56 . Once latch support 80 is in the desired location, angle surface 88 will shoulder on bevel 90 . Subsequent downhole force on upper latch mandrel 56 will shear screw(s) 86 .
[0019] A downhole end 92 of upper latch mandrel 56 is inter-engaged with guide 94 (numbered in two places to make extent of component clear). Guide 94 provides support and articulation to cutter retainer 96 and cutter dog 98 . Cutter dog 98 includes a bumper 99 to limit radial movement in the illustrated embodiment. Cutter dog 98 is configured to rotate to an aligned position with the non-annular hydraulic piston bore 20 , up to about 180° (in one embodiment) while extending cutter blade 100 to a position commensurate with a larger diametral dimension than an outer dimension of device 30 and having a position aligned with and uphole of piston bore 20 in TRSV 10 . Cutter dog 98 is configured to cut into piston bore 20 with axial only (as illustrated) or axial and radial movement together (with manipulation of the timing of interaction of the relevant components) coincident axially downward movement of components of device 30 including upper latch mandrel 56 and associated components moveable therewith as discussed hereinabove and detailed hereinbelow.
[0020] The movement of cutter dog 98 is caused by profile 102 in a sleeve 104 disposed at an inside dimension of TRSV 10 through alignment collet 108 which includes alignment tab 110 . Alignment collet 108 is urged outwardly to follow profile 102 by mandrel 112 , which includes frustoconical sections 114 and 116 . The two angled frustocones are provided to urge the cutter dog into the cutting position. Two angles are provided as opposed to one for clearance between guide 94 and mandrel 112 to increase initial radial cutter movement, and to ensure radial movement is complete prior to cutting into the bore 20 . Mandrel 112 is maintained in position while alignment collet 108 is urged downhole to effect the wedging outward of alignment collet 108 . Maintenance of mandrel 112 in place is effected by an uphole end thereof where mandrel 112 is threadably engaged with latch support 80 at thread 118 , and set screw(s) 120 . Thus mandrel 112 is hung from latch support 80 . It is noted that sleeve 104 further includes a slot 106 to positively locate alignment tab 110 .
[0021] Movement of alignment collet 108 causes movement of guide 94 through alignment collet slides 122 in grooves 124 of guide 94 .
[0022] A downhole end of guide 94 is axially slidably mounted at cap screw(s) 126 through a downhole end of alignment collet 108 to a collar 128 , which slides on mandrel 112 and functions to centralize the collet 108 and guide 94 . Guide 94 further includes slot(s) 127 to cooperate with cap screw(s) 126 .
[0023] Mandrel 112 extends downhole for a distance in one embodiment of about 27 inches to accommodate the length of the flow tube and power spring in the TRSV. A downhole end of mandrel 112 is threadedly connected to inner sleeve 134 through thread 130 and set screw(s) 132 . Inner sleeve 134 attaches at a downhole end thereof via shear screw(s) 146 to outer sleeve 148 . Outer sleeve 148 is attached at a downhole end thereof to lower latch mandrel 150 through thread 152 and set screw(s) 154 . Within mandrel 112 , shaft 42 extends downhole beyond the downhole end of mandrel 112 to terminate by threaded connection 136 and set screw(s) 138 to slide 140 . Slide 140 is slidingly received in inner sleeve 134 . Mounted within inner sleeve 134 is spring pin 142 and downhole end 144 of slide 140 . At an inner dimension of slide 140 is lower shaft 156 , which is shear screwed 158 to slide 140 at 144 . Spring pin 142 slides with slide 140 at recesses 145 . Lower shaft 156 continues downhole through lower latch mandrel 150 to a dimensionally enlarged downhole terminus having angled surfaces 160 , and 164 which function to urge lower latch collet 162 outwardly at an appropriate time in the actuation sequence described hereunder to engage surface 163 with TRSV shifting profile 165 . Surfaces 160 and 164 define a single angled surface interrupted by a machining groove utilized in manufacture of the devices to simplify the same with respect to room for machining.
[0024] Threadedly connected to lower shaft 156 via thread 166 and set screw(s) 168 is lower shaft extension 170 . Lower shaft extension 170 is disposed within mandrel extension 172 which itself is connected via cap screw(s) 174 to lower latch mandrel 150 . Outwardly disposed at the mandrel extension 172 is dog support 174 . Dog support 174 includes a profiled uphole section 176 having uphole and downhole facing angled surfaces 178 , 180 . Surfaces 178 , 180 function to actuate locating dogs 182 . Actuation of dogs 182 occurs when profile 176 is moved uphole or downhole of dog pivot point(s) 184 . Dogs 182 themselves include an uphole actuation surface 186 and a downhole retraction surface 188 whose interaction with profile 176 services to actuate the dogs and retract the dogs, respectively. A C-ring 190 is disposed around dog support 174 . The C-ring interacts with grooves 192 and 194 to maintain actuation and retraction positions of dog support 174 subsequent to sufficient actuation force to move the support to the desired position by collapsing the C-ring over rib 196 . A snap ring 195 is also set around mandrel extension 172 to move dog support 174 upon downward movement of other components, whose movement will be clear from the operation discussion hereunder. Grooves 192 and 194 are provided in a dog housing 197 . Dog housing 197 is connected to cap 198 by thread 200 . Cap 198 is further connected by thread 202 and set screw(s) 204 to lower shaft extension 170 . Further, cap 198 includes an o-ring 206 .
[0000] Operation
[0025] The communication and lock open tool has been described from an uphole end to a downhole end and with light reference to the interplay of components. In this section applicant will describe the complete operation of the device with reference to all of the figures of the application. It will be appreciated that this device is to be run in the hole to a TRSV 10 having the features described herein as unique over prior art TRSVs. Referring to FIGS. 2 A-G, the tool is in a run-in position, no actuation having been started. Referring to FIGS. 3 A-G actuation has begun in that the collet profile 72 has naturally snapped outwardly into lock profile 74 with a TRSV 10 . In the illustrated embodiment the selective collet 81 has not been employed and is thus shown as of run-in engaged at attachment 85 with recess 91 . It is noted that due to the reverse cut of shoulder 78 on the collet profile 72 and shoulder 76 of the lock profile 74 of TRSV 10 the tool in this position can and does hold some weight. The weight that is held by the reverse cut is sufficient to allow angle 50 of upper shaft 38 to bear against dogs 54 causing the dogs 54 and the upper latch mandrel 56 to move downhole. Such movement of course will cause shear screw(s) 60 to shear under that load. The load provided to shear shear screw(s) 60 is only present until dogs 54 move radially outwardly into recess 70 of upper latch extension 64 . Upon dogs 54 moving into recess 70 , angle 50 no longer bears upon dogs 54 and therefore the load is removed. At this point, the dogs 54 and upper latch mandrel 56 simply sit in the position illustrated in FIG. 3D until further actuated as described hereunder. Upper shaft 38 and components thereabove, and indeed components therebelow, which are discussed hereunder, continue to move downhole. It will be noted that latch support 80 will move under collet profile 72 at the same time that dogs 54 snap into recess 70 . Once the latch support 80 is properly positioned under collet profile 72 the communication and lockout device is indeed locked into the TRSV 10 and will not move from that position until collet profile 72 is unsupported by latch support 80 .
[0026] Simultaneously, with the support of collet profile 72 , shaft 42 continues to move downhole causing slide 140 to move downhole with spring pin 142 , lower shaft 156 , lower shaft extension 170 , cap 198 , dog housing 197 and dogs 182 . It will be noted that mandrel extension 172 does not move downhole and that because of snap ring 125 at a downhole end of mandrel extension 172 , dog support 174 cannot move downhole with dog housing 197 . Because dog support 174 cannot move downhole, the profiled uphole section 176 of dog support 174 is urged into contact with actuation surface 186 of dogs 182 uphole of pivot 184 causing the dogs to move outwardly. The outward movement of the dogs has two functions, firstly to open flapper 16 fully so that it may move behind tab 18 in TRSV 10 when thread 12 is sheared and secondly to locate and hold weight on shoulder 185 of dogs 182 in communication with shoulder 183 of TRSV 10 . Helping to maintain the dogs in the desired position is C-ring 190 , which moves over rib 196 into recess 194 from its original retraction position of recess 192 .
[0027] With the locating dogs 182 in the located position, components 156 , 170 , 198 , 197 and 182 can no longer move downhole. Thus, further movement of slide 140 in a downhole direction causes shearing of shear screw(s) 158 that previously connected slide 140 to lower shaft 156 and allowing slide areas 145 to slide past spring pin 142 until downhole end 144 of slide 140 contacts lower latch mandrel 150 . Downward movement of lower latch mandrel 150 causes lower latch collet 162 to move outwardly on surfaces 160 and 164 thereby increasing its diametral dimension until surface 163 engages shifting profile 165 within TRSV 10 . Simultaneously, lower latch mandrel 150 through cap screws 174 causes mandrel extension 172 as well as lower latch collet 162 to move further downhole. Upon this movement and referring to FIGS. 3F and 4F directly, the thread 12 is sheared causing flapper 16 to move behind tab 18 to lock open the flapper 16 . As noted above, mandrel extension 172 is also moving downhole simultaneously. That downhole movement without other effect is limited by shoulder 173 which will contact shoulder 175 of dog support 174 . Upon contact between shoulders 173 and 175 , C-ring 190 is moved from recess 194 back into recess 192 causing profiled uphole section 176 of dog support 174 to interact with the retraction surface 188 of dogs 182 thereby causing dogs 182 to disengage from TRSV shoulder 183 and retract to their pre-actuation position. At the same time that dogs 182 retract, the lower latch collet 162 reaches a downhole facing surface 167 of lower shaft 156 which allows lower latch collet 162 to snap back into its pre-actuation dimension but in a different position downhole of surface 167 . This movement disengages the lower end of the tool from the TRSV and concludes the lock open operation. The fact that the lock open operation has been concluded is signaled to an operator by a drop of the tool approximately eight inches once dogs 182 and collet 162 are disengaged from TRSV 10 . The positions of the components of the tool following the approximately eight-inch drop are illustrated in FIGS. 4A-4G .
[0028] With the lock out operation concluded, it is time to create communication with the old piston bore 20 such that a new wireline retrievable safety valve can be installed and operated from the original control line 22 . With the tool in the position indicated in FIGS. 4A and 4B , one will note that upper shaft sleeve 34 has come into contact with dogs 54 thereby reloading those dogs which were unloaded at the beginning of the lock open operation by moving into recess 70 . Referring to FIG. 6 , with the further downhole movement of uphole components 32 , 36 , 34 , 38 , one will appreciate that dogs 54 have been urged downhole thereby urging upper latch mandrel 56 downhole as well. This movement loads shear screw(s) 86 and shears them at a selected load causing guide 94 to begin moving downhole, which itself urges alignment collet 108 downhole. It should be noted at this point that the urging of alignment collet 108 downhole does not occur from the uphole edge of alignment collet 108 at alignment tab 110 but rather occurs at short collet ends 109 which are visible in broken lines to show location in each of the drawings but are also shown deflected in broken lines in FIGS. 8D, 9D and 10 D to illustrate how they function relative to mandrel 112 . It is apparent herefrom that the short collet fingers are urged inwardly through the combined action of angle 95 and mandrel neck down 113 .
[0029] As the alignment collet 108 moves downhole it will move outwardly in a recess area 111 of the original TRSV 10 such that alignment tab 110 will land on alignment profile 14 . In order to make the drawings most clearly illustrate the movement of the device, the alignment tab has been originally illustrated in a position 180 degrees off from its final desired aligned position. It will be understood that the alignment profile 14 occurs around the perimeter of the TRSV, such as a mule shoe, so that regardless of the orientation of the communication and lock open device upon initial run-in the alignment tab 110 will be picked up by some portion of the alignment profile 14 and will thereby be rotated into alignment to allow for the cutting device to create the communication desired. Also noted is that normally device 30 is not used until a sufficient time has passed from original well completion that it is likely scale has built up on surfaces downhole. Because of this likely condition, it is desirable to provide a chisel-like cutting edge on tool tab 110 to cut through the scale allowing the tab to follow profile 14 as intended. A schematic view of the chisel-like cutting feature is illustrated as numeral 208 in FIG. 12 .
[0030] Referring to FIGS. 7C and 7D the device has now rotated the alignment collet 108 and thereby the guide 94 into the appropriate position. In the appropriate aligned position, cutter dog 98 and cutter 100 are positioned longitudinally uphole of the piston bore 20 of original TRSV 10 . Further downhole movement of upper shaft 38 and related components causes the upper latch mandrel 56 , the guide 94 and cutter dog 98 with cutter 100 to continue to move downhole into contact with mandrel 112 frustoconical sections 114 and 116 to position the cutter to open a communication channel with the piston bore 20 . Once the cutter is positioned correctly the purpose of slot 127 becomes apparent. At this point in the procedure the alignment collet 108 has been rotated and dropped into its retaining slot in the TRSV 10 and can no longer move downhole, yet the cutter 100 is still uphole of the piston bore 20 . Further downhole movement of upper latch mandrel 56 and related components as set forth hereinabove cause the cutter 100 to move longitudinally downhole onto frustocones 114 and 116 and into piston bore 20 of TRSV 10 , cutting a path into piston bore 20 and thereby opening communication to the inside dimension of TRSV 10 from the original control line surface or other remote location. In order for the movement of guide 94 downhole to allow the cutter to enter piston bore 20 guide 94 must be able to move relative to alignment collet 108 . Slots 127 allow for such movement. FIG. 8D illustrates the cutter inside the space of piston bore 20 . At this point and referring to FIG. 9 the tool is to be withdrawn from the downhole environment thus making way for a later run WRSV or other replacement valve or tool. Upon the beginning of the uphole pull on fishing neck 32 , upper shaft 38 moves upwardly within upper latch mandrel 56 until a bottom end angle 48 of upper shaft 38 picks up on ring 58 such that the upper shaft 38 can pull upper latch mandrel 70 uphole. Further, the cutter dog is unsupported from the frustocones 114 , 116 and brought back into its original unactuated position by cutter retainer 96 . This is illustrated in FIGS. 9, 10 and 11 . As the fishing neck reaches full extension, the upper latch mandrel 56 moves back to its original position where its shoulder on upper latch extension 64 and guide 94 comes back into contact with latch support 80 . Further pulling uphole unsupports collet profile 72 so that it is collapsible and therefore disengagable from TRSV 10 and the tool is withdrawn from the hole.
[0031] Further to the foregoing discussion of a first embodiment of the control system communication and lock open tool there are several components that can be replaced with alternatives. The alternative components may be individually substituted for those described above, may be substituted in groups or may all collectively be substituted for like components as described above.
[0032] In one alternate component the cutter dog 98 represented in FIG. 2C is modified to slide upon the outside dimension of the mandrel 112 . Cutter dog 98 a (see FIG. 13 ) is formed to include slide area 400 , which has an angle calculated to match an outside dimension of the mandrel 112 relative to the angle of the cutter. This area 400 slides upon the outside dimension of mandrel 112 during use. The arrangement provides for greater stability of the cutter dog 98 a, as a greater percentage of the surface area of the dog remains supported throughout its motion. This may be beneficial in some applications. In other respects the tool operates as above described.
[0033] In another alternate component, the lower shaft 156 introduced in FIG. 2E is modified and illustrated in FIG. 14 as lower shaft 156 a. A set of segments 404 are located such that they engage a recess 402 while remaining in contact with slide 140 at interface 406 . Segments 404 are maintained in the engaged position by the inside dimension of inner sleeve 134 . A relief 407 is provided in the inside dimension of inner sleeve 134 a to allow the segments 404 to move outwardly and disengage recess 402 in lower shaft 156 a. Once disengaged, the operation of the device is as disclosed hereinabove.
[0000] This alternate construction allows the tool to sustain an impact load on the lower shaft while the tool is being run downhole without premature shearing of the shear screws 158 .
[0034] Yet another component, referring to FIG. 15 , modifies lower shaft 156 and lower shaft extension 170 as those components are illustrated in FIG. 2F . As above described, and illustrated in FIG. 2F , lower shaft 156 is threadedly attached to lower shaft extension 170 . Set screws 168 are also employed to prevent relative rotation of the two parts. Illustrated in FIG. 15 , the lower shaft and lower shaft extension are replaced by an extended lower shaft 408 . Shaft 408 includes a collet support 410 , which is attached to shaft 408 by shear members 412 . Collet support 410 provides the angle that was previously provided by surfaces 160 and 164 in FIG. 2F . Therefore it will be appreciated that the purpose of collet support 410 is too urge lower latch collet 162 outwardly at an appropriate time in the operation of the device. As noted above, collet support 410 is attached to shaft 408 by shear members 412 such as shear screws and therefore can be detached from shaft 408 if desired by placing a load of sufficient predetermined magnitude on the shear screws to shear them. This is of importance when and if the tool encounters an impediment to the proper expansion of the latch into its intended groove. Such may occur due to, inter alia, debris or mislocation problems. In such situation it is possible for the tool as described in FIG. 2F to become stuck. The modification detailed in FIG. 15 resolves that potential by allowing the device to continue to function by shearing the screws 412 , allowing the extended lower shaft 408 to move relative to the collet support 410 .
[0035] In a final alternate component of that hereinbefore described, and referring to FIG. 16 , the cap 198 of FIG. 2G is modified to exist in two parts: a cap mount 414 and a cap head 416 . Cap mount 414 is mounted to lower shaft extension 170 or extended lower shaft 408 depending upon which embodiment is utilized. For purposes of discussing the FIG. 16 view, shaft 408 is illustrated with the understanding that either shaft could be used. The mounting is at thread 418 and setscrews 420 ensure prevention of relative motion between these parts. Cap mount 414 retains thread 200 from the previously described embodiment, illustrated in FIG. 3G . The cap mount 414 is attached cap head 416 . As illustrated cap head 416 is fastened utilizing thread 422 . Cap head 416 includes fluid bypass openings 424 to reduce fluid resistance while running the tool. Also noted is that the cap head may be constructed of brass or other softer material to alleviate seal bore damage as the tool is run in the hole.
[0036] It is to be understood that any one component, any group of components or all of these alternate components may be employed with the tool as described earlier in this application.
[0037] While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | Disclosed herein is a communication and lock open device which includes a lock open portion including a latch configured to engage a shifting profile on a closure member of a safety valve. Further included is a communication portion configured to rotationally align a cutter with a non-annular hydraulic bore in the safety valve and axially cut into the hydraulic bore with the cutter. Also disclosed is a method for replacing the function of a safety valve while employing an original control line including running a communication and lock open tool in a wellbore, locating the tool in a tubing retrievable safety valve and shearing a thread in the valve to render moveable a closure member of the tubing retrievable safety valve. The method includes shifting the closure member to lock the member in an open position, orienting a cutter and establishing fluid communication with a bore of the valve. |
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FIELD OF INVENTION
[0001] The present invention relates to a prefabricated system incorporating a complete mechanical and utility unit that can operate as a stand alone “closed system” with the possibility of elements being added on at the time of construction or at a later date.
BACKGROUND
[0002] Traditional construction practices for constructing a building are not efficient and wasteful of time of skilled labor, materials and future resources to operate. One of the major expenditures of the overall cost of any project is skilled labor (e.g. Electricians, Plumbers, etc.). The skilled labor is also required to work at the job site which is not efficient in many ways. Two examples of this are: the skilled labor is required to travel to and from the site and the skilled labor must relocate all of their equipment throughout the project as the work is completed.
[0003] The common solution to this problem has been to prefabricate Modular buildings in part or whole. Current prefabrication techniques can be classified in those two groups but both have drawbacks. Whole fabricated buildings are difficult to transport to the site and erect. Partially fabricated units are not complete and must be assembled often resulting in double the amount of structure (walls, slabs, etc.). Attaching said units also require a great amount of on site skilled labor to assemble the mechanical systems. The resultant joints between the units leave a potential for failure. These prefabricated buildings or modules provide limited design flexibility, allowing few configurations and not recognizing specific site or design conditions.
[0004] In current building techniques incorporation of the mechanical systems into the building can require unnecessary time, for example the electrician may be required to come to the site before the foundation pour to place electrical conduit. by limiting the required integration of the mechanical system into the other building materials it would greatly increase efficiency and reduce costs.
[0005] Often storage space is limited and difficult to secure on a construction site. Prefabrication offers a solution by not requiring raw materials to be stored on site waiting to be installed.
[0006] The idea of a grouping plumbing and mechanical walls creating a service core is not a novel idea, but rather it is a fundamental principle in the vertical organization of architecture. One solution proposed by past inventions have created prefabricated systems that can be stacked or assembled to create this service core, but the connections and structural intersections make these systems difficult to use in the field requiring special knowledge for installation and construction. These connections are also a possible point of failure in the systems.
[0007] Therefore devising building techniques that reduce skilled labor and increase efficiency are desired.
SUMMARY OF THE INVENTION
[0008] I have discovered a novel construction system that would be a complete prefabricated mechanical and utility unit, herein referred to as “the unit”. The system would include all mechanical and utility systems for the building to operate. The Unit utilizes the most efficient method of building (prefabrication) for the most expensive part of construction (Mechanical & Utility Systems).
[0009] The system is comprised of multiple walls and floor diaphragms that provides structure while housing the mechanical & utility systems.
[0010] These units could be assembled on an assembly line similar to techniques used to manufacture automobiles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of the complete prefabricated mechanical & utility system
[0012] FIG. 2 is a axonometric view of the unit, installed as possible use
[0013] FIG. 3 is a perspective view of the unit, installed as possible use
[0014] FIG. 4 is a perspective view of the unit, installed as possible use
[0015] FIG. 5 is a perspective view of the unit, looking up a ceiling cavity
[0016] FIG. 6 is a perspective view of the unit, installed as possible use
[0017] FIG. 7 is a perspective view of the unit, installed as possible use
[0018] FIG. 8 is a perspective view of the unit, installed as possible use
[0019] FIG. 9 is a perspective view of the embedded mechanical systems
[0020] FIG. 10 is a axonometric view of the foundation
[0021] FIG. 11 is a diagram of the possible delivery system
[0022] FIG. 12 is a longitudinal elevation of the unit
[0023] FIG. 13 is a section through the unit
[0024] FIG. 14 is the exterior elevation
[0025] FIG. 15 is the interior elevation
[0026] FIG. 16 is a plan view of the roof top
[0027] FIG. 17 is a plan view of the Foundation
[0028] FIG. 18 is a plan view of the unit
[0029] FIG. 19 is an example first floor plan using the unit
[0030] FIG. 20 is an example second floor plan using the unit
[0031] FIG. 21 is a plan view of an example hotel use
[0032] FIG. 22 is a plan view of possible configuration
[0033] FIG. 23 is a plan view of possible configuration
[0034] FIG. 24 is a plan view of possible configuration
[0035] FIG. 25 is a plan view of possible configuration
[0036] FIG. 26 is a plan view of possible configuration
DETAILED DESCRIPTION OF THE INVENTION
[0037] Embodiments of the invention can be used in the construction of buildings to reduce cost, improve efficiency, reduce construction time, and decrease a buildings operational costs. The unit is prefabricated at a factory and is of a transportable size. The unit is transported to a site that is prepared for the installation of the unit. The unit would preferably be fabricated in an assembly line method.
[0038] The prepared site would preferably have foundation and all utility inlets in place. A premade form is used to cast the foundation and with ensure proper placement of utility inlets while reducing the cost and waste of additional formwork when pouring the foundation.
[0039] The invention is a part or whole of the mechanical and utility systems for a building. Once installed and inlets have been attached the system is able to operate. Additional elements may be added at the site so that the unit can be customized to any situation. The ability to be customized makes the system extremely flexible and able to adapt to any situation, increasing its design flexibility.
[0040] The unit is built of traditional building materials so that no special knowledge is required to install, modify, or repair. Wood framing is shown in FIG. 1 but other materials may be used to satisfy structural or other limitations.
[0041] An advantage of prefabricating the mechanical system is that it can be inspected prior to installation. Problems can be addressed prior to the units being installed saving delays at the site. The units can also be tested in the factory prior to shipment ensuring high standard of quality. The automation system is pre-programmed at the factory reducing the site work of the automation technician.
[0042] The units contain all the meters to monitor and control all the services. External digital readouts can be placed anywhere on the exterior of the building as required by the utility services. The unit otherwise would be able to connect to the utility companies to report usages though wireless or data lines. Two way communication would be possible allowing the utility to communicate and control parts of the system as known in the art.
[0043] STRUCTURE—The vertical structural members ( 1 ) shows the frame of the unit to be of typical construction materials. The rim joist ( 2 ) shows the edge beam parallel to the long wall, thus creating a cavity between the edge beam and the longitudinal wall. The edge beam is able to support adjacent floor members. The structural sheathing ( 3 ) will allow the unit to remain rigid during transportation and may provide lateral resistance in the completed building. A pressure treated sill ( 4 ) or similar material that would allow the unit to be placed directly on the concrete foundation. Anchoring hardware ( 5 ) such as hold-downs that would securely fasten the unit to the foundation.
[0044] WEATHERPROOFING—The roof top waterproofing pan ( 8 ) is a one piece liner made of a durable impervious material such as plastic that lines the rooftop parapet area to waterproof it, and is connected to the scupper ( 9 ) that is incorporated into the Liner allowing water to exit the rooftop mechanical area. An overflow scupper ( 10 ) located at a higher elevation allows water to escape if the main scupper becomes obstructed. All weatherproofing connectors and flashing may be also manufactured to ensure quality of construction.
[0045] WATER—The water supply is connected at the water meter ( 15 ) which is monitored by the automation system. All of the water supplied to the unit is filtered at the water treatment module ( 16 ). The potable water is then either sent into the cold water supply line ( 14 ) or sent to the tankless water heater ( 19 ). The hot water line ( 13 ) is supplied by the tankless water heater ( 19 ). The hot and cold water lines service all the fixtures in the unit and have additional connections to service other fixtures.
[0046] WASTE LINES—The washer drain ( 6 ) is installed at a location that is ready for immediate use and is connected to grey waste line ( 11 ). An overflow pan ( 7 ) made out of metal or plastic prevents water leakage incase the washer fails and is connected to the grey waste line ( 11 ). The shower/tub drain ( 21 ) is placed in location for immediate use and is connected to the grey water line ( 11 ). The Solid waste line ( 12 ) is installed in the unit that connects the Sewer lateral to the plumbing fixtures that can not produce grey water easily such as the toilets drain ( 22 ), kitchen sink ( 23 ), and dishwasher. The waste line vent ( 20 ) is connected to the grey waste line ( 11 ) and the solid waste line ( 12 ) to vent them through the parapet of the unit.
[0047] GAS LINES—All required inlets and outlets are installed for all gas appliances. The gas line ( 24 ) is connected at the Gas meter ( 25 ) which is controlled through the automation system. The gas line connects the equipment on the roof top such as the water heater ( 19 ), heat pump ( 26 ), and generator ( 34 ). The gas line is also connected to the clothes dryer ( 50 ) and to the stove connector line ( 54 ).
[0048] HVAC—The airconditioner/heatpump ( 26 ) is controlled by the automation system. The intake/exhaust grill ( 28 ) is made to resemble a traditional chimney cap. The thermostat ( 29 ) is controlled by the automation system.
[0049] ELECTRICAL—The electrical supply is connected at the electrical meter ( 30 ) which is controlled by the automation system. Conduit ( 33 ) connects the meter ( 30 ) to the Electrical panel ( 31 ). The use of conduit and the properties of its material could reduce the amount of EMF (Electrical Magnetic Fields) exposure to the user of the unit. The electrical panel ( 31 ) is connected to and controlled by the automation system ( 32 ). The generator ( 34 ) provides backup power if electrical service is interrupted. Lighting ( 35 ) is preinstalled in the unit. Electrical conduit ( 33 ) is located at the edge beam ( 2 ) that is connected to the electrical panel ( 31 ). This allows additional electrical fixtures to be placed outside the unit and the wires can be fed to the panel.
[0050] AUTOMATION SYSTEM—Automation Systems are known in the art but are currently expensive to install. The systems abilities are able to be expanded upon by incorporating it into a prefabricated system. The Unit does not require the use of an automation system but by using an automation system it eliminates the need for certain elements. Such elements are light switches, rather than skilled labor required to install the lights outside the unit, the lighting fixtures just need to be plugged into the automation system.
[0051] PRE-INSTALLED ELEMENTS—Elements are included in the system that allow future systems to be installed, but any of these additional items could be incorporated into the unit if desired. Such elements are a power converter ( 37 ) pre-installed so that photovoltaic panels can be mounted on the building and plugged into the unit. A solar water heater junction box ( 39 ) is also installed so that solar water heaters can be mounted on the building and plugged into the unit. A grey water holding tank ( 17 ) would store grey water to be used at the site where potable water is not required. A hydronic pump ( 18 ) would provide required pressure to transport grey water from element ( 17 ) to outlet. An air handler ( 27 ) that can be placed at any location in the project works in conjunction with the compressor/heatpump ( 26 ) so all heating and cooling requirements can be met. Added photovoltaic panels ( 36 ) can be connected “plugged in” to power converter ( 37 ). Solar water heaters ( 38 ) connect to solar water heater junction box ( 39 ).
[0052] VENTING—Venting for all the equipment is installed in the unit terminating at the vent cap ( 43 ). Using the said ventcap reduces the amount of roof penetrations of the adjacent building reducing the chance of waterproofing failure, reducing the time of the roof installation and reduces the amount of trade coordination. The laundry dryer duct ( 40 ) is connected to the vent cap ( 43 ) and is ready for connection to the dryer. The Laundry make up air ( 56 ) is provided so that make up air is not required by additional means required for gas appliances. The Laundry make up air ( 56 ) may use means to reduces air humidity such as pressurization to increase the efficiency of said dryer. The bathroom duct and fan ( 41 ) is installed, connected to the vent cap ( 43 ) and ready for use to meet required codes for ventelation of the said bathroom. The hood duct ( 44 ) is installed and connected to the vent cap ( 43 ) and is operable when connected to the Hood ( 45 ). The tankless water heater ( 19 ) is equipped a exhaust vent ( 46 ) and an intake air vent ( 47 ). The refrigerator vent ( 48 ) is provided to either exhaust the heat generated by the refrigerator coils or use the exhaust heat to assisting the tankless water heater ( 19 ) or the air conditioner/heatpump ( 26 ) and is controlled by the automation system. The rooftop mechanical area may be equipped with ventilation as required by specific mechanical units. All or any of the ventilation ducts may be equipped with mechanical means of improving efficiency (i.e. fans)
[0053] SHOWER/TUB DRYER—The shower/tub dryer ( 50 ) is a element that provides force air from the room that it is located or outside air that is used to dry said area reducing humidity limiting the growth of mold and fungus. The shower/tub dryer is controlled by the automation system and may turn on or off when required to reduce moisture levels as required and is connected to the vent cap ( 43 ) via shower/tub duct vent ( 49 ).
[0054] DETECTORS—Detectors and sensors are placed throughout the unit to monitor for system or building failures. The gas detector ( 60 ) is located near the appliances that use gas or along parts of the unit that gas might accumulate. The water detector ( 57 ) are located along the floor and in the under floor vault, installed to monitor if sink/tub overflows, washer malfunctions or if a pipe in the walls rupture. A water sensor is also located in the roof equipment area to warn if the scuppers are blocked and the roof pan is filling with water. Fire detectors are provide including a Co 2 ( 58 ) detector and smoke detector ( 59 ). Security detectors ( 61 ) are ready for installation at typical locations i.e. (doors, windows). All detectors are controlled by the automation system. The automation system has the ability to shut off services (i.e. gas, water), turn on fans to vent (i.e. gas), to signal audible, visual, mechanical alarms or notify third party services such as the fire department, police department, a security company, etc.
[0055] ENERGY CONSERVATION—By combining all of the mechanical systems together it will be possible to greatly conserve energy by reclaiming “lost” energy by using heat transfer devices. In typical construction heat expelled from mechanical devices (i.e. clothes dyer, oven, refrigerator, or heatpumps) is considered “lost”. In the unit the excess heat would be collected though heat transfer devices known in the art and used by the unit to preheat or precool water or air to conserve energy. A geothermal tank system ( 63 ) is also incorporated as the automation system will use the ground temperature in combination with any of the other devices to conserve energy by cooling water, air, or mechanical coils to improve their efficiency. Exterior temperature coils are mounted on the exterior of the unit which allows the automation system to use extreme exterior temperature in hot or cold climates to assist in providing heating or cooling for any of the incorporated devices, increasing the efficiency of the unit as a whole.
[0056] The lifespan of all mechanical equipment is limited and dated. New technology will make old units obsolete. The ability to update a buildings entire mechanical system would allow the remaining building to be reused and preserved. The unit could be installed in such a manor that it is not an integral part of the structure allowing it to be removed and replaced with a new unit. The old unit could then be recycled.
[0057] A common problem with new or alternative building techniques is that it is difficult to incorporate the mechanical systems, at least the trades may provide resistance by increasing fees due to unknowns and unfamiliar conditions. By self containing the mechanical and utility systems it allows the use of alternative building techniques and materials. (i.e. straw bale, adobe, foam block)
DETAILED DESCRIPTION OF THE DRAWINGS
[0058] FIG. 2 , FIG. 3 , FIG. 4 , FIG. 6 , FIG. 7 , and FIG. 8 show the unit installed with other elements. Element ( 45 ) shows the location of a hood for a stove. Element ( 52 ) shows the hotwater line installed on site connecting the unit to the kitchen sink. Element ( 53 ) is the cold waterline installed on site connecting the unit to the kitchen sink. Element ( 54 ) is the gas line installed onsite connecting the unit to the gas appliances. Element ( 55 ) is the Ventilation duct connecting Element ( 45 ) to the Unit
[0059] FIG. 5 is a perspective view looking at the ceiling cavity of the unit. Element ( 42 ) is a fan unit connected to element ( 41 ) to ( 43 ). Element ( 50 ) is a dryer for the shower/tub.
[0060] FIG. 10 is an axonometric view of the prepared foundation. The foundation can be used with slab or raised floor construction. The formwork ( 51 ) can be reused or made in mass such as plastic formwork. This would allow proper installation of site connections, structural and utility by precut holes and markings as required. The formwork may be removed to use again or left in place.
[0061] The obvious method of transportation for multiple units would be on a flatbed truck and craned into place. This method is preferred if multiple units are to be installed but FIG. 11 is a diagram of a possible alternative delivery system that would allow for a single unit to be transported and erected without the use of a crane. The trailer ( 62 ) could be towed behind any vehicle and brought to the site. Said trailer would have the ability to tilt up the unit while aligning it with the foundation using human or mechanical means.
VARIATIONS
[0062] Multiple variations are possible for the unit. Certain configurations may be more applicable than others depending on the intended use or specific site/project conditions. The unit may be a single story or multiple stories. The dimensions of the unit may very maintaining the unit is transportable. The unit could be constructed out of any construction material. The unit can be double loaded (as shown) or single loaded (example: the plumbing wall is the exterior wall). The unit may or may not structurally support the adjacent structure. The services can be located above, below or within the unit. The unit could also incorporate any mechanical or utility service, not only the specific ones described in this document.
[0063] The unit may control any data, utility, or service. Items such as cable, Ethernet, dsl, phone, satellite, wireless data, detectors, monitoing equipment, etc. shall be apart of this document.
[0064] An example of a variation of the unit is one with no plumbing on the exterior wall and the mechanical equipment underneath the unit may be more efficient in colder climates. The pipes could freeze in an exterior wall and the other mechanical equipment would provide enough heat output to keep the mechanical vault from freezing.
[0065] Another variation is a unit that allows other units or other systems to be serviced by the Unit acting as a hub or core to the overall system.
[0066] The unit may also be used in the construction of milti-residential, hospitality and in healthcare projects due to the repetition of mechanical and utility systems. For hospitality the front desk could control the rooms systems from the front desk. For the healthcare application the nurses station could monitor all of the incorporated medical equipment.
[0067] The unit may be used for emergency housing for organizations such as FEMA. A single story simplified version of the unit that does not incorporate such elements as the automation system. Appliances and fixtures would be installed and ready for use. The structure would be made out of a material that could resist exposure to weather. The smaller size of this unit would allow for many more to be loaded on a transportation vehicle. This variation would allow for quick and efficient mechanical and utility support for emergency shelter. After the emergency use is no longer required the same units could be made available for reconstructing destroyed permanent housing. | A complete prefabricated mechanical and utility unit for residential or commercial use that includes all utilities and mechanics for servicing the adjacent uses. Once attached to utility supply lines the invention does not require work from skilled labor to operate. The unit has the ability to support satellite services as required. |
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part (CIP) application of application Ser. No. 08/335,123 to Hsieh entitled "A Circuit Arrangement for a Sanitary Apparatus" that was filed in the U.S. Patent and Trademark Office on Nov. 7, 1994, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a circuit arrangement for a sanitary apparatus, and particularly to an electronic circuit for controlling sanitary fittings in a non-contacting manner.
RELATED PRIOR ARTS
U.S. Pat. No. 5,251,872, entitled Automatic Cleaner for Male Urinal discloses a device adapted for automatically cleaning a male urinal. The device includes a pyroelectric sensor for detecting the proximity of the human body, an infrared ray emitting circuit for emitting infrared rays to a human body, and an infrared ray receiving circuit detecting infrared rays reflected by the human body. The device disclosed in U.S. Pat. No. 5,251,872 does not directly take advantage of the pyroelectric sensor to activate the circuits thereof and additionally applies an infrared ray emitting circuit and an infrared ray receiving circuit which obviously increases the cost of the device and additionally consumes a significant power supplied by a battery.
U.S. Pat. No. 4,941,219, entitled Body Heat Responsive Valve Control Apparatus relates to a low battery energized passive detection system responsive to radiated body heat for operating fluid flow valves. The disclosed apparatus applies a pyroelectric detector for detecting the presence of body heat within a defined detection field and producing an output signal in response to the detection and a plurality of operational amplifiers for performing the functions of comparing and amplifying. Due to the utilization of valves and operational amplifiers, this apparatus will have a slower response to the variation of the fluid flow and this apparatus is also easily influenced by the variation of the supplied power. Further, as this apparatus uses operational amplifiers, it will consume a lot of power and the battery will not be efficiently used.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a circuit arrangement which prevents automated faucet from wasting water and decreases the risk of electric shock.
Another object of the present invention is to provide a circuit arrangement which allows the automated faucet to be installed conveniently without the interconnection to an alternating current power.
According to the present invention, an electronic circuit includes a pyroelectric sensing circuit for detecting the approach of hands of a user, a microprocessor for analyzing a signal from the pyroelectric sensing circuit and outputting a signal to a driving circuit, a voltage source for supplying the power required by the electronic circuit, an oscillator for providing a signal to the driving circuit and the microprocessor, and a manual operative circuit is connected to the driving circuit for activating the driving circuit.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the circuit arrangement of the present invention;
FIG. 2 is a circuit diagram of the present invention; and
FIG. 3 is a diagram showing operation waveforms of a respective signal in a microprocessor of FIG. 1 and a corresponding digital sequence for the signal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a pyroelectric sensing circuit 20 detects the presence of body heat within a defined detection field, the pyroelectric sensing circuit 20 then sends a signal to a microprocessor 10, the microprocessor 10 will analyze the signal from the pyroelectric sensing circuit, if the signal received by the microprocessor 10 is judged as a result of body heat, the microprocessor 10 will send a triggering signal to a driving circuit 70 which then outputs a signal to actuate a motor-operated control valve in a faucet. A manual activating circuit 40 is connected to the driving circuit 70 for activation thereof when required. An oscillator 30 is connected to the microprocessor 10 for providing an oscillating signal thereto. The oscillator 30 is further connected the driving circuit 70 for providing an oscillating signal thereto. A power circuit 50 is provided for supplying the power needed by this circuit.
As shown in FIG. 2, a pyroelectric sensing circuit 20 is composed of a pyroelectric sensor 21 and a plurality of electronic components for detecting the proximity of the human body. An output of the pyroelectric sensing circuit 20 is connected to a microprocessor 10. An output of the microprocessor 10 is connected to an emitter of a transistor 31. An oscillator 30 composed of two NAND gates, a capacitor and two resistors for outputting an oscillating signal is connected to a base of the transistor 31.
A collector of the transistor 31 is connected to a driving circuit 70 composed of two flip-flops 71,72, two transistors 73, 74, a motor-operated control valve 75, and an ON/OFF switch 751. The collector of the transistor 31 is connected to a clock input of the flip-flop 71. A non-inverted output of the flip-flop 71 is connected to a base of the transistor 73 via a normally closed contact of the ON/OFF switch 751. The ON/OFF switch 751 is controlled by the motor-operated control valve 75 and they are connected by a method within the skill of those skilled in the art which causes the ON/OFF switch 751 to activate in a sequence as later mentioned. An inverted output of the flip-flop 71 is connected to a normally open contact of the ON/OFF switch 751.
The motor-operated control valve 75 is connected to a collector of the transistor 73. The non-inverted output of the flip-flop 71 is further connected to a clock input of the flip-flop 72, the inverted output of the flip-flop 72 is connected to a clear terminal of the flip-flop 71 via the transistor 74 for clearing the states of the flip-flop 71.
If the presence of a body heat is detected by the pyroelectric sensing circuit 20, the output of the microprocessor 10 will send a trigger signal of low voltage (e.g. ground potential) to the emitter of the transistor 31. The transistor 31 then outputs a square wave signal having a same frequency as that of the oscillating signal from the oscillator 30 to the clock input of the flip-flop 71 which causes the non-inverted output of the flip-flop 71 to become high, then the transistor 73 is turned on, the motor-operated control valve 75 will start to open. When the valve is at a fully open position, the ON/OFF switch 751 will be actuated, the transistor 73 will be turned off, the motor-operated control valve 75 will be stopped. Thus, the water will continuously flow.
When the hands of the user leave the detection field, the output of the microprocessor 10 will be high, the square wave signal input to the flip-flop 71 is stopped. The inverted output of the flip-flop 71 will become high, then the transistor 73 and the motor-operated control valve 75 are activated and the valve 75 will start to close. If the motor-operated control valve 75 is at fully closed position, the ON/OFF switch 751 is actuated and returns to its initial state. The water flow is stopped.
A manual activating circuit 40 is composed of a NAND gate 42 with two inputs, a capacitor 43, a resistor 44, and a toggling switch 41. A first input of the NAND gate 42 is connected to the base of the transistor 31 and a second input is connected to a positive voltage source V+ via the toggling switch 41. The output of the NAND gate 42 is connected to the clock input of the flip-flop 71 via a diode 45. The capacitor 43 and the resistor 44 are connected between the second input of the NAND gate 42 and the ground for composing a delay function such as ten seconds, that is, the driving circuit 70 will be activated for ten seconds after which the circuit will be disconnected.
As shown in the FIG. 2, a power circuit 50 is composed of a plurality of battery cells 60 connected in series, two transistors in a Darlington connection, a Zener diode, two capacitors, and a resistor for supplying a positive voltage V+ as mentioned above.
Referring to FIG. 3A, an output signal of the pyroelectric sensing circuit 20 is shown. This output signal is then transmitted into the microprocessor 10 for further processing. In FIG. 3A, a pulse P1 corresponds to a pulse which has detected a presence of body heat of a user and a pulse P2 corresponds to a pulse which does not detect the presence of the body heat. The signal as shown in FIG. 3A is then sampled and held with a sampling frequency of 400 Hz to derive a resultant signal as shown in FIG. 3B. The sampled and held signal shown in FIG. 3B is then compared with a predetermined reference level Vref (shown in a dashed line), then the waveform having a greater level than the reference level Vref is output, thus, a resultant signal is shown in FIG. 3C which has a corresponding binary sequence as shown in FIG. 3D. The microprocessor 10 then reads the sequence in bytes (eight bits) and executes an exclusive OR operation between two sequential bytes (i.e., a current byte and a preceding byte) to determine whether the pyroelectric sensing circuit 20 detects the presence of the body heat in a detection field. If the resultant byte has three or more "1" bits (includes three "1" bits), the microprocessor 10 will regard as a logic signal of "High" (referred to "H"). If the resultant byte has only two "1" bits or less, the microprocessor 10 will deem the resultant signal as a logic signal of "Low" (Referred to "L"). If the logic "H" signals do not continuously appear, i.e., only appear for 20 milliseconds, the signals received by the pyroelectric sensing circuit 20 will be judged as environmental noises and the motor 75 in FIG. 2 will not be activated. If the logic signal remains "H" for at least 40 milliseconds, the triggering signal will be output to the driving circuit 70 to activate the motor 75.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. | A circuit arrangement for controlling a sanitary device in a non-contact manner includes a pyroelectric sensing circuit for detecting a temperature in a predetermined location and outputting a signal, a microprocessor for receiving a signal from the pyroelectric sensing circuit and outputting a triggering signal when the signal received by the microprocessor is judged as a result of body heat, a driving circuit for receiving the triggering signal and actuating a motor-operated control valve. |
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a divisional application of the earlier filed co-pending patent application Ser. No. 387,969, entitled SWIMMING POOL PLAY PEN, filed Aug. 13, 1973 now U.S. Pat. No. 3,874,005 issued Apr. 1, 1975, entitled "Child's Safety Playpen For Use in Water."
BACKGROUND OF THE INVENTION
The present invention pertains to those arts concerned with an infant's playpen. More particularly, the present invention provides a unique playpen for use in water, both for the protection of young children as well as for their amusement.
In attending a small child or an infant in a swimming pool or the water, there is a constant threat of the child drowning for many different reasons. This problem magnifies itself when the attendant of the child is also engaged in swimming. Should the attendant stray into deeper water, the child may attempt to follow the attendant into the deeper water since such would be a natural act of a child. On such situations, it is convenient to be able to take the child into deeper waters whereby both the attendant and the child can simultaneously enjoy the water.
There are numerous non-sinkable or buoyant devices sold today for supporting children in the water whereby they need not be constantly held in an attendant's hands. Typical of such devices are those as disclosed in U.S. Pat. Nos. 1,764,852; 2,562,080; 2,946,068; 3,074,084; and 3,161,897. A common problem of such devices is that children quite often are able to move about too freely whereby they either crawl or fall out of the devices. In any event, since the child is not restrained therein and if the child separates himself in some manner or means, he will be exposed to drowning.
The present invention overcomes these and other related prior art problems by providing a playpen adaptable for use in a swimming pool or water whereby the depth of water within the playpen can be easily regulated without very much effort. As is well known, playpen structures similar in structure to those used in the present invention are relatively light weight and portable, and can be manually moved about.
Among the advantages and features of the present invention is the fact that it is virtually impossible for a child to become separated from the present playpen and be placed in the jeopardy of drowning. These and other unique advantages and features of the present invention will become evident in light of the following detailed description of the preferred embodiments of the present invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 in the drawings is a side elevational view of one preferred embodiment of the present invention.
FIG. 2 in the drawings depicts a plan view of the embodiment of FIG. 1 with a partial cutaway portion showing certain details of the bottom support of the present playpen.
FIG. 3 in the drawings depicts another preferred embodiment of the present invention with a partial cutaway portion showing certain details of the flotation collar which supports the playpen in a body of water.
FIG. 4 of the drawings is an isolated plan view of adjustable means for varying the elevation of the playpen bottom.
FIG. 5 is an isolated sectional view of the adjustable support means of FIG. 4 taken along the section line 5--5.
FIG. 6 in the drawing depicts a plan view of the floatation collar shown encircling the playpen embodiment of FIG. 3.
FIG. 7 represents a side elevation view of the collar shown in plan of FIG. 6.
FIG. 8 in the drawing depicts a cross-sectional elevation view taken diagonally across one corner of the floatation collar along the line 8--8 of FIG. 6 of the drawings.
FIG. 9 in the drawing illustrates an isometric view of support means for supporting an umbrella upon the playpen bottom which is shown in a partial cut-away portion.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2 in the drawings, the preferred embodiment of the present playpen 10 illustrated therein is shown as being adapted for resting upon the bottom 11 of swimming pool. For simplicity of design as well as ease of manufacture and maintenance, the structural support members which together form the basic structural skeleton or support frame of the present device are preferably tubular members constructed of a rust resistant material, such as aluminum, chromium plated steel or galvanized steel so as to be water compatible. The vertically oriented members 12, 13, 14 and 15 are spaced apart in an operable relationship so as to preferably define a square floor plan. The top ends of these members in turn are connected together by the top cross members 16, 17, 18, and 19 which are preferably rigidly affixed to their respective vertical stanchions by suitable means, such as by welding or the like.
The stanchions 12, 13, 14, and 15 are also connected together along their bottom portion by the lower cross support members 20 as shown in FIG. 1 of the drawings. The drawings illustrate only a side elevation view of the lower cross support members 20 and hence, those members connecting the stanchions 12 and 13, 13 and 14, and 14 and 15 are not illustrated. The lower cross support members 20 are also suitably affixed to their respective stanchions, such as by welding.
The present playpen 10 is provided with the platform support member means 21 for supporting an infant within the enclosure defined by the stanchions 12, 13, 14, and 15 and the top cross support members 16, 17, 18, and 19 which form playpen wall enclosure means. The platform 21 is preferably a foraminous rigid member, being provided with the holes 37, capable of supporting an infant of average weight and age for which the present playpen would be designed as desired. As illustrated, particularly in FIG. 2, the holes 37 are located across the width and bredth of the playpen 21. Use of a foraminous platform also reduces the weight of that member which is especially designed when employing heavier materials of construction, such as galvanized steel.
The platform 21 is constructed and arranged relative to its supporting superstructure whereby its elevation can be raised or lowered by variable support means. This is accomplished by provision of the adjustable toggle support pin means 22 which, as shown in FIG. 5 of the drawings, are operably designed to bayonnet within selected ones of the series of support holes 23 provided in each of the respective stanchions 12, 13, 14, and 15 as shown in detail in FIG. 5. As can be seen in the figures, the support holes 23 extend along a substantial length of the stanchions.
The toggle support pin 22 further comprises the eyelet portion 24 which is designed such that an operator can readily grab the pin for removal and insertion within the holes 23. The eyelet portion 24 is connected to the elongated shank portion 25 which is of a diameter such that it will fit snugly without interference within the holes 23. The toggle pin 22 is also provided with the toggle retainer member 26 which is pivotably connected to the shank portion 25 of the pin 22 by virtue of a connecting pin 27. The shank portion 25 is provided with a vertical slot traversing its end wherein the toggle retainer 26 is suspended by virtue of the pin 27.
The support platform 21 is preferably provided with the groove 28 in each of its corners adapted to mate with the outer peripheral surface of a respective support stantion as shown in FIG. 4 of the drawings illustrated with regard, for instance, to the stanchion 14. Each corner of the platform 21 is also preferably provided with the pin retaining collar 29 which is affixed to the bottom of the support 21 at each of its corners. The collars 29 are oriented as shown in FIG. 4 of the drawings such that the toggle support pin 22 can by bayonneted through a hole 23 provided in the stanchion 14 as well as through the collar 29 to thereby safely secure each corner of the platform 21 to its respective support stanchion. In such an operation, the pin 22 is first arranged whereby the toggle retainer 26 is positioned essentially parallel to that of the shank portion 25 which is accomplished by supporting the pin 22 such that the plane defined by its bottom portion 24 is essentially parallel to the ground. After insertion of the pin through the respective hole 23 and the collar 29, it is then twisted 90° whereby the toggle retainer member 26 pivots downward due to gravity and assumes a position essentially perpendicular to the longitudinal axis of the shank portion 25. This provides a means of safety for preventing the pin 22 from vibrating or being accidentally knocked out of the collar 29 which would allow the platform 21 to drop lower in the water endangering the life of the infant within the enclosure.
The superstructure defined by the stanchion 12, 13, 14 and 15, and the connecting cross members 16, 17, 18, 19 and 20 are covered with the foraminous material 38 which is preferrably rust resistant and thereby water compatible to thereby withstand the environment, and can be made of materials such as a nylon mesh, galvanized wiring, or the like. The material 38 is stretched over the vertical sides of the superstructure so as to define an enclosed column or walled enclosure wherein the elevation of the foraminous platform 21 can be regulated as desired. The holes 23 are positioned between the top cross supports 16, 17, 18, and 19 and the lower cross supports 20 over which the mesh 38 expands so that the child 31 is confined regardless of the elevation at which the platform 21 is set. The number of the holes 23 and the spacing of the cross support members can be varied a substantial amount as desired, primarily depending upon the depth of water in which the present playpen is to be utilized which would be generally within a water depth of 3 to 4 feet. In any event, taking into consideration these design parameters, the depth of the water level 30 to which the infant 31 is immersed can be easily controlled depending upon the capabilities of the infant to handle himself in water.
In the embodiment of FIGS. 1 and 2 of the drawings, the present playpen 10 is rigidly affixed to the support stand 32. The stand 32 further comprise a swivel-mounted foot member 33 which in turn is operably connected to the sleeve portion 34. The sleeve member 34 is of a diameter sufficient to receive the lower portion of the respective stanchion which accordingly telescopes therein. The lower portion of each of these stanchions 12, 13, 14 and 15 are also provided with a series of holes or apertures 35, as well as the sleeve portion 34 of stanchion 32, the holes in both of these members being spaced apart such that they are in alignment when the members are operably fitted together. The toggle support pins 36, similar to the toggle pins 22, are provided for attaching the stand 32 to a respective support stanchion. This is operably accomplished in a manner functionally equivalent to the manner by which the pins 22 support the platform 21 in operable position, with however, the pins 36 being of shorter length. By virtue of the fact that the foot members 33 are swivelmounted, the present playpen 10 can be readily mounted upon the inclined surface 11, the differences in elevations between the pair of stanchion 12 and 13, and 14 and 15 being taken into consideration by adjusting the depth of penetration of the bottom portion of the respective stanchion within the sleeve member 34 of a given stand 32, for example, as illustrated in the side elevational view of FIG. 1.
FIG. 3 of the drawings illustrates another preferred embodiment of the present invention whereby the playpen 10 can be readily relocated and/or floated at random in a pool without the necessity of it having to be supported upon the floor of the pool. This is accomplished by a provision of the floatation collar 40 which can comprise any suitable buoyant means, such as a hollow container, expanded cellular polystyrene, or the like. As shown in FIG. 6 of the drawings, the floatation collar 40 is of a shape sufficient to fit around and preferably encircle the present playpen 10.
As shown in FIGS. 3, 6 and 7, in regard to the preferred floatation collar design depicted therein, the collar 40 is provided with the sleeve members or bushings 41 which telescopes through the collar 40 along a diagonal center line (see FIG. 6), being mounted essentially an equal distance along its height as shown in FIG. 7. The structural relationship is more clearly illustrated in FIG. 8 (which is a sectional elevation view taken from the line 8--8 of FIG. 6) which shows the sleeve support member 41 extending through the expanding cellular polystyrene floatation collar 40 by virtue of the hole 42 being provided therethrough.
The preferred collar design shown in FIG. 3, 6 and 7 of the drawings can be attached in any convenient manner to the playpen 10 such as, for example, by virtue of the toggle support pins 43 (FIG. 3). The support pins 43 are identical in structure to that of the pin 22 and 36, except however, being of sufficient length to completely bayonnet through the aperture 44 of the collar bushing 41 and through the respective corner stanchion by virtue of the holes 45 provided therein, the pins 43 being designed to accomplish the same safety aspects of the pins 22 and 36. The support stanchions 12, 13, 14 and 15 are preferably provided with a multitude of the holes 45 whereby the elevation of the collar 40 can be selected to achieve the operating conditions designed by the user. For example, the playpen can be made to sit at its maximum height out of the water by locating the platform 21 at its lowermost position and the depth of water within the playpen selected and fixed by virtue of adjusting the elevation of the floatation collar 40. Conversely, the playpen can be allowed to float at its lowest level by locating the floatation collar at its maximum height via adjustment with the pins 43, and the depth of water within the playpen can be determined by adjusting the elevation of the platform 21. This adjustable relationship between the platform 21 level and floatation collar 40 provides, among other things, a means for controlling the depth of the corner stanchions so as to prevent their contact with the floor 11 of the pool.
The present swimming pool playpen means 10 can be conveniently provided with the umbrella support stanchion 46, as illustrated in FIG. 3 of the drawings in combination with the umbrella phantom-lined 47 and in more detail in FIG. 9 of the drawings. Referring to the latter figure, the umbrella stand 46 further comprises the sleeve portion 48 which is adapted to receive the support shaft 49 of the umbrella 47 which bayonnets therein. The support sleeve 48 in turn is rigidly affixed to the flange 50 which is supported upon and bolted to the support platform 21 by virtue of the bolt holes 51 provided in the flange 50, the bolts 52 then projecting therethrough and through the holes 53 provided in the platform 21, rigidly bolting the umbrella stand 46 of the platform 21 by virtue of the wingnuts 54.
It will be apparent to one skilled in the art that various modifications and/or changes in the basic design of the present invention can be made without departing from its true scope and spirit. For example, the present playpen means need not be made of a square design, but rather can be circular, or for that matter, of any shape. Moreover, the tubular superstructure described supra need not be employed, but rather, an integral structure may be employed, that is, various members, including the foraminous sides of the present playpen can be cast in one single structure. Moreover, the expanded cellular polystyrene floatation collar need not be formed in a continuous member, but rather, can be formed in separate components and operably affixed to the playpen at any convenient point of attachment, for example, beneath the platform 21.
It will also be appreciated by one skilled in the art that the materials of the construction of the present playpen as described in detail above can also be varied without departing from the basic objectives of the present invention. For example, the floatation collar need not be fabricated from expanded cellular polystyrene, but rather, could be a hollow tank or similar structure. Moreover, the structural components of the present invention can be made not only of rust resistant steel, but various plastic materials, such as polyvinyl chloride, or the like can be employed. The mesh or enclosure screen when not made integral with the present playpen, can be any suitable material other than nylon, for example a polyester, or the like. Accordingly, not wishing to be bound by the specific details of the above described structure and materials for construction, but rather, what is considered as the full scope and spirit of the present invention as set forth in the appended claims. | The present invention pertains to a novel swimming pool playpen means comprising a foraminous enclosure adapted for suspension in a body of water such that its bottom portion can be operably positioned a pre-determined relatively shallow depth beneath the surface of the water. One preferred embodiment includes adjustable support means for resting the playpen upon the water bottom and another preferred embodiment is directed to flotation means operably connected to the playpen for suspending it within a body of water and whereby it can be conveniently relocated with very little effort. The enclosure portion of the present swimming pool playpen is preferably constructed of a rigid tubular frame over which a foraminous material is mounted. |
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FIELD OF THE INVENTION
[0001] This invention relates generally to the manual collection of unsavory materials, and more particularly to manual material collection bags.
BACKGROUND OF THE INVENTION
[0002] The present invention provides an economical, efficient, convenient and simple protective and cleansing means for the manual collection of unsavory material, its disposal, and the personal cleansing of the collector after collection.
[0003] The invention addresses the collection of odious, foul, repulsive, repellant, vile, disgusting, offensive, unpleasant, or otherwise unsavory material that the material collector does not desire to directly contact, and, if direct contact should occur, be cleansed of the material. It particularly addresses the collection of unsanitary and unhygienic material that presents the opportunity to contaminate or infect the collector with bacteria, viruses, germs, or a transmittable illness or disease. The invention especially addresses concerns related to the collection of pet waste, e.g. pet feces.
[0004] The collection of unsanitary and unhygienic material is of concern in the pet industry which encompasses both dogs and cats, dog owners that number in the millions, and professional dog walkers. Legislation in many areas has mandated the collection and proper disposal of pet waste in public and private areas. The collection and disposal of pet waste inherently involves issues and needs relating to cleanliness, personal hygiene and environmental awareness.
[0005] Other areas of material collection to which the present invention is suited are where contamination of the material to be collected is of concern, such as forensic evidence. Also, the present invention is suited to the collection of material by a person who may have a transmittable illness or disease.
[0006] Prior means for the collection of unsanitary and unhygienic material include, for instance, that described in U.S. Pat. No. 6,273,481 issued to Columbo, et al. This patent discloses a canine pet waste recovery and disposal kit that consists of an outer packaging about a flexible, re-sealable bag that loosely contains an absorbent towel, a pre-moistened towelette, and a dog treat. The user of the kit opens the outer packaging and then the resealable bag; removes the towel, towelette and treat from the bag; collects the waste with the towel; and drops the towel and waste in the bag. The user then wipes his or her hands with the towelette. This kit, however, requires the removal of the outer packaging, then removal of the towelette from the bag and placing it elsewhere before collecting the waste and, thus, presents the risk that the towelette may become lost or become contaminated with the waste.
[0007] A drawback to the recovery and disposal kit described in the Columbo patent is the many steps required in handling the unsanitary and unhygienic material and disposing of the material within the bag. The outer packaging of the kit is opened, the re-sealable bag is opened, the contained items are removed and placed elsewhere, a towel is used to collect the waste material, the waste material and towel are placed in the bag, the cleansing packet is located where it was placed after removal from the bag and retrieved for use, the hand is cleaned with the towelette, the used towelette and its packet are placed back within the bag, and the bag is resealed and disposed of. The many steps involved in handling this type of kit are cumbersome and can lead to contact with the unsanitary and unhygienic material. Further, the Columbo patent does not describe the presence of a means of sanitizing.
[0008] Currently, there apparently is no item on the market that provides convenient and simple manual collection of unsavory material with protection and cleansing means for the collector; none for the collection of unsanitary and unhygienic material; or, most particularly, for providing for personal hygiene in connection with the collection and disposal of pet waste.
[0009] Thus, there is a need for a convenient and simple means for the collection of unsavory (particularly unsanitary and unhygienic) material that does not expose the collector to potential contamination (or the material to contamination from the collector) while keeping a cleansing towelette from possible contamination yet readily available for the collector's hygiene.
[0010] The present invention addresses this need for a simple and convenient means for manually collecting unsavory material that protects the collector from contact with the material and also provides a readily available and non-contaminated cleansing means to the collector.
[0011] A second object of the present invention is to provide a self-contained collection bag kit for the collection of unsavory (in particular unsanitary and unhygienic) material and for personal hygiene in the collection process.
[0012] A further object is to provide a collection bag kit that affords protection and premoistened cleansing means to a person collecting unsavory material.
[0013] Another object of the present invention is to provide a collection bag kit that is environmentally friendly by means of producing the invention with materials that are biodegradable or compostable.
[0014] Yet another object of the present invention is to provide a collection bag kit that has a reversible bag container that protects the person collecting the material and an internally attached cleansing towelette from possible contact and contamination and then, after collection, presents the towelette for ready use by the collector.
SUMMARY OF THE INVENTION
[0015] The present invention is a manual material collection bag kit comprising a disposable, reversible and flexible bag container with a mouth opening, and a cleansing towelette removably attached to an inside surface of the bag container.
[0016] Attachment of a cleansing towelette to an inside surface of the bag container provides protection for the cleansing towelette, minimizing the risk of it contacting and being contaminated with the material being collected, or being misplaced, and for it to be conveniently accessible to the user.
[0017] The manual material collection bag kit is designed such that the user thereof inserts his or hand through the mouth opening into the bag container to substantially cover the hand. The user retrieves the material to be collected with the covered hand. The outer surface of the bag container contacts the material thus protecting the user's hand from direct contact with the material as the user collects it with their hand inside the bag container.
[0018] After collecting the material with the hand inside the bag container, the user, with his or other hand, grasps the open edges of the bag container, and pulls the bag down and around the hand holding the collected material, thereby reversing and turning the bag container inside out. When the bag container is inverted, the collected material is contained in the bag. And the users hand is on the outside.
[0019] The cleansing towelette being attached to an inner surface of the bag container is protected from contact and contamination with the collected material during the collection process. Once the bag container is turned inside out, the attached cleansing towelette is on the outside of the bag, exposed and conveniently accessible for removal and use.
[0020] Thus, the present invention provides an economical, efficient and sanitary means for the manual collection of unsavory material, (particularly unsanitary and unhygienic material), its disposal, and the subsequent cleansing of the person collecting the material.
[0021] The manual material collection bag kit of the present invention may be made of biodegradable or compostable material. Thus, the present invention may be made and used environmentally responsibly.
[0022] Typical uses for the invention include the collection and disposal of material that the collector considers odious, foul, repulsive, repellant, vile, disgusting, offensive, unpleasant, or otherwise unsavory material that the collector does not desire to contact, and particularly unsanitary and unhygienic material, such as pet waste (e.g. pet feces), material from pet body locations (mouth, anus, feet, etc.), human waste (e.g. human feces), rotted fruit and other food crops, items covered in dirt or soiled, fish, road kill-dead animals, spoiled food, dung, litter, trash, and garbage, dead birds, rodents, compost, dropped food, and any type of spent-mutilated-fungus laden item.
[0023] In addition, the present invention may be utilized in other areas of material collection where contamination of the material by the collector is of concern and personal hygiene after collection is complete is desired. Such additional uses include the collection of forensic evidence, as an example, and the collection of material by a person that has a transmittable disease or illness.
[0024] For a better understanding of the present invention, together with other and further embodiments, reference is made to the following description taken in conjunction with the Figures, the scope of which is set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a schematic of an embodiment of the invention comprising a bag container having attached to an inside surface a sanitizing wipe.
[0026] FIG. 2 is a sectional view of the embodiment taken along line 9 - 9 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0027] In preparing the preferred embodiments of the present invention, various alternatives may be used to facilitate the objectives of the invention. These embodiments are presented to aid in an understanding of the invention and are not intended to, and should not be construed to, limit the invention in any way. All alternatives, modifications and equivalents that may become obvious to those of ordinary skill upon a reading of the present disclosure are included within the spirit and scope of the present invention.
[0028] Further, this disclosure is not a primer on processes or materials for making bag containers, towelettes, packets, or manual collection bag kits; basic concepts known to those skilled in the art have not been set forth in detail. Readers are referred to appropriate and available texts for further details on these subjects.
[0029] Briefly stated, the manual material collection bag kit of the present invention comprises a disposable, reversible, flexible bag container along with a cleansing towelette that is removably attached to an inside surface of the bag container.
[0030] A particular preferred embodiment that illustrates the invention is diagrammed by FIGS. 1 and 2 . The collection kit of this embodiment includes a generally rectangular flexible bag container 1 which has removably attached to an inside surface 2 a generally rectangular packet 3 with its outer edges 4 and 4 a pressured sealed to the inside surface 2 of the bag container. The packet 3 contains a sanitizing wipe 5 with antimicrobial solution. The bag container 1 has a mouth opening 6 that is sealed with an adhesive 7 . Opposite the mouth opening is the bottom edge 8 of the bag container. FIG. 2 further shows the attachment of the outer edges 4 and 4 a of packet 3 , containing the sanitizing wipe 5 , to an inside surface 2 of the bag container 1 .
[0031] To collect material using the collection kit diagrammed by FIGS. 1 and 2 , the user opens the bag container, inserts his or hand into the bag through the mouth opening. With the bag container substantially covering the hand, the user retrieves the material to be collected (e.g. pet waste). The outer surface of the bag contacts the material thus protecting the user's hand from direct contact with the material as the user collects it with their hand inside the bag. After collecting the material with the hand inside the bag container, the user, with his or her other hand, grasps the edges of the bag about the mouth opening, and pulls the bag down and around the hand holding the collected material, thereby inverting, or reversing, the bag container, turning it inside out. When the bag container is inverted, the collected material is encompassed in what is now the inside of the bag container and the hand is on the outside. The attached cleansing towelette or wipe is also now on the outside of the bag container, exposed and accessible for retrieval and use. After using the sanitizing wipe, the user may place it in the bag container with the collected material, and dispose of the bag containing the collected material and used towelette or wipe.
[0032] Having illustrated the present invention by describing a specific preferred embodiment with reference to the drawings, various alternate illustrative embodiments are now described.
[0033] The disposable bag container employed in the present invention has a mouth opening. The mouth opening is of sufficient size to permit the intended user to insert a hand into the bag container. The mouth opening may be initially sealed or open. Opposite the mouth opening is the bottom edge or side of the collection bag container.
[0034] The bag container is disposable. The bag container is reversible, or invertible, such that it may be turned inside out to encompass collected material. The bag container also is flexible to facilitate the grasping, picking up, and collection of material.
[0035] The disposal bag container employed in the present invention may be of standard construction, with the exception that a cleansing towelette is removably attached to an inside surface of the bag. The bag container may be made of any suitable flexible material. Generally, the material will be a film sheet. It is preferable that the material be moisture proof and odor impermeable. Such materials include polymer blend plastic material, particularly polyethylene or polypropylene.
[0036] For environmental reasons, it is preferred that the bag container be made of material that is biodegradable; more preferably, a material that is compostable. A biodegradable material is any material made of a bio-base (such as corn, wheat, potatoes, etc.) which, when disposed of after use, will be decomposed completely by micro-organisms generally present in the earth into carbon dioxide, water and biomass. Preferably, the biodegradable material meets one or more of the definitions set forth in The European Norm EN13432, Japanese Greenpla Standard and the American Society for Testing and Materials ( ASTM International ) D6400-99 standards.
[0037] A compostable material is a material that will biodegrade in, or otherwise become part of, usable compost (e.g., soil-conditioning material) in a safe or timely manner in an appropriate composting program.
[0038] Biodegradable and compostable bags and bag material that are suitable in the manufacture of the present invention include those available from Biocorp, Inc., Becker, Minn.; BIOgroupUSA, Jacksonville, Fla.; and BioBag International, Askim, Norway. These materials employ Mater-Bi™ materials which are a family of biodegradable thermoplastic materials manufactured by Novamont SpA, Novara, Italy.
[0039] The bag container should be large enough to substantially cover the intended user's hand, and may be manufactured in a variety of sizes to accommodate different hand sizes. The bag may be of generally rectangular shape, mitten shaped, gloved shaped, or a similar shape. A preferred bag container is a bag of generally rectangular shape, made of a flexible material that is also resistant to tearing, and large enough to cover the user's hand at least to the wrist (e.g. approximately 25.40 centimeters (10 inches) wide×38.10 centimeters (15 inches) long).
[0040] The bag container may also have a folded or pleated bottom side that spreads apart to more easily accommodate the user's hand. The sides of the bag container may be similarly folded or pleated.
[0041] The bag container also may have sleeves located inside and along the bottom side for the user to insert a thumb, finger, fingers, or a combination thereof.
[0042] The bag container also may have excess material near the opening to help grasp and pull to invert the bag container while grasping and holding the collected material.
[0043] The bag container has a mouth opening that initially may be sealed completely or be left open. It is preferred that the bag container be initially sealed. If completely sealed, means are provided for the user to readily open the bag container. Any ready open sealing means of any suitable mechanical (including heat or pressure sealing, and laser transmission welding) or adhesive type may be employed.
[0044] For ease of manufacture, preferred is an adhesive seal. Preferred adhesive seals include seals employing glue, tape, an UV curable adhesive material, or a methacrylate, acrylic, polyurethane, cyanocrylate or similar compound specifically formulated for bonding. Particularly preferred ready open seal means include a perforation along an adhesive seal that can be grasped and pulled in a side-to-opposite side manner in order to open the mouth.
[0045] Other suitable ready open seals include those commonly used on plastic sandwich or storage bags, such as a mechanical method type of a zipper seal (a raised ridge on one inner side that fits inside a groove on an opposite inner side), a slider zipper (that uses the same raised ridge and inside groove, but seals by sliding a tab down the length of the opening), or a twist tie.
[0046] To prevent spillage or leakage of material collected or the release of odor from the bag container before its disposal, a means for sealing or resealing the collection bag container once the collected material is inside the inverted bag is preferably provided. If the bag container is initially provided sealed, the resealing means may be the same, different or integral with the initial sealing means. Such means include those described above as well as a mechanical zipper seal of double formation such that it is operable to seal the bag container before use then, when the bag container is inverted to encompass the unsavory material, to reseal the bag container. A double formation sealing means is disclosed, for example, in U.S. Pat. No. 4,808,175, issued to Hansen, the disclosure of which is herein incorporated by reference. A drawstring or handle ties, such as are commonly used on kitchen trash bags, also may be employed. A twist tie for sealing the bag container after collecting material may be included if the design deems so for closure.
[0047] Other suitable seals include a pull away tape attached on the outside of the bag container which, when the bag is inverted, would be located on the inside near the mouth opening of the bag container. At this point, the tape covering would be pulled away exposing the adhesive tape, and the sides of the bag container near the mouth opening could then be pressed together to re-seal the bag container.
[0048] In the present invention, a cleansing towelette, or wipe, is removably attached to an inside surface of the disposable bag container. More than one towelette may be included. If more than one towelette is included, it may be attached to the same or a different inside surface of the bag container. The cleansing towelette is preferably pre-moistened with a wet cleanser, such as water; more preferably with a sanitizing or antimicrobial solution or gel.
[0049] The cleansing towelette, or wipe, may be made of standard construction and of standard material, including paper, cloth, and non-woven fabric comprised of synthetic fibers or natural fibers, and foamed material. The towelette may be a single ply or multiply sheet, or sponge like. Preferably for environmental reasons, the towelette or wipe (and its associated packet, if any) is made of biodegradable or compostable material. If the towelette is pre-moistened, it should be made of material that is absorbent of the cleanser, solution or gel employed to pre-moisten it.
[0050] The cleansing towelette or wipe maybe any type that is generally available. It is preferred that the towelette or wipe be individual sealed in its own packet container. If it is not sealed in its own packet container, and the cleansing towelette is pre-moistened, then the bag container preferably is sealed to prevent moisture loss.
[0051] The material for the packet, if the cleansing wipe is pre-moistened, should be moisture proof, and preferably odor impermeable. The same or different materials as used to make the collection bag may be used, if suitable.
[0052] Any sealing means of any suitable type may be employed to seal the cleansing towelette or wipe in the packet. The seal can be by means of heat or pressure sealing, or laser transmission sealing, or adhesive once the cleansing wipe in is inside the packet. Preferably, the packet is readily openable by tearing or by providing a ready open seal.
[0053] The towelette, or wipe, may be unscented or scented with any desired scent such as lemon, lavender, citrus, coconut, cherry, strawberry, and other pleasant natural scents.
[0054] The cleansing wipe packet may be removably attached to an inside surface of the bag container by means of heat or pressure sealing, or laser transmission sealing the outer edges of the packet to the bag container, or by means of the packet having an adhesive on the outside of the packet and the packet being adhered to the bag container.
[0055] In embodiments of the present invention where the cleansing towelette or wipe is not within a packet, or other enclosure separate from the bag container, it may be removably attached directly to an inside surface of the bag container by any suitable means. Such suitable means include placing a cleansing towelette pre-moistened with a wet cleanser directly against an inside surface of the bag container. When the surface of the pre-moistened towelette and the inside surface of the bag container are in direct contact, moisture from the towelette is trapped between the two surfaces, binding the two surfaces together. In this embodiment, the bag container is completely sealed and moisture proof to prevent moisture loss. If the moisture between the pre-moistened towelette and the inside surface of the bag container should evaporate or otherwise escape, the surface to surface adhesion would fail and the towelette would no longer be attached to an inner surface of the bag container.
[0056] Another preferred means of removably attaching the cleansing towelette or wipe to an inside surface of the bag container is to provide a pocket for it inside the bag container. A pocket may be formed by placing the cleansing towelette, or a packet containing the towelette, against an inside surface of the bag container material, laying a sheet of the bag material on top of the cleansing towelette or packet, and then heat or pressure sealing, or laser transmission sealing the bag materials together. A perforation may be provided for tear-away access to the cleansing wipe or packet once the bag container is inverted and the pocket is accessible for removing the cleansing towelette. The provision of a pocket may also be accomplished by using an adhesive to adhere the bag material sheet to the inside surface of the bag container.
[0057] Other items may be included in the collection bag kit depending on its intended function. For example, if the collection kit is intended to collect dog waste, a chewable dog treat or a packet of grooming oil (e.g. an animal skin and coat food supplement oil) may be included. An environmental friendly non-hazardous pet toy, that may make a noise, may also be included. To protect an included item from possible contact with the material being collected and possible misplacement, and to have it readily accessible, it is preferred that the item (or items) is removably attached to an inside surface of the bag container. If the bag container has more than one inside surface, the additional item may be removably attached to the same inside surface to which the towelette is attached or a different inside surface. Attachment of any additional item may be by any suitable means, including those means suitable for removably attaching a towelette to the inside surface of the bag container. As with the bag container and cleansing towelette, it is preferred that all included items are made of biodegradable or compostable material.
[0058] Having thus described and exemplified the invention with a certain degree of particularity, it should be appreciated that the following claims are not to be so limited but are to be afforded a scope commensurate with the wording of each element of the claim and equivalents thereof. | A manual material bag collection kit comprising a disposable bag container and a cleansing towelette removably attached on an inside surface of the bag, that is useful for the collection of unsavory material and the cleansing of the collector, and designed such that the collector inserts a hand into the collection bag, collects the material, reverses the collection bag to encompass the collected material, and removes the attached towelette for cleansing. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation of U.S. application Ser. No. 10/536,615, filed May 26, 2005, which is the National Stage of International Application No. PCT/AU03/01596, filed Dec. 1, 2003, which claims the benefit of Australian Application Serial No. AU 2002953027, filed Nov. 29, 2002; and is a Continuation-in-Part of U.S. application Ser. No. 10/276,547, filed Nov. 14, 2002 and now U.S. Pat. No. 6,964,183, which is the National Stage of International Application No. PCT/AU01/00579, filed May 18, 2001, which claims the benefit of Australian Application No. PQ7576, filed May 18, 2000.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a dual lock apparatus, and in particular, to a dual lock apparatus that has at least two independent means of acting on a lock whereby operation of the two locking means is controlled by an improved clutch mechanism.
2. Background Information
In a previous patent by the same applicant (PCT/AU01/00579 entitled ‘A Dual Lock Apparatus’), whose contents are expressly incorporated by reference herein, there was disclosed a locking apparatus having at least two independent means of acting on a lock. Although the apparatus as described in the aforementioned patent has been found to function satisfactorily, an improved clutch mechanism which allows the two locking mechanisms to function independently has been developed and is the subject of the present application.
There are numerous types of locks in existence today that are used to secure various devices. One of the more common uses of locks is in relation to doors. Typically door locks have a bolt that can be extended from a locking mechanism so as to engage a doorframe or furniture with the bolts being driven by the use of a unique or slave key. There have also been developed locks that are not only operable by the use of the slave key but also a master key, allowing the master key holder, for example, to operate all doors in a pre-defined area whilst the slave key holders are limited to being able to operate specific doors only. This however requires the master key and the slave key to be of the same type thus potentially compromising security.
There have also been developed electromechanical locks that use an electric motor to drive the bolt. The difficulty with these types of arrangements is that if the electric motor was for whatever reason inoperable, the door may be left either in the unlocked or locked state and may require disassembly to be fixed.
Further still, the difficulty with some existing locks is that although the door may be unlocked, that is it may be opened, the bolt still engages a portion of the door frame and further manual operation of the bolt by the use of a handle is required to be able to open the door. On the other hand, if the bolt was to be retracted fully, then the door may swing freely, also an undesirable effect.
It is an object of the present invention to propose a locking apparatus that overcomes at least some of the abovementioned problems or provides the public with a useful alternative.
Although the present specification discusses doors in particular it is to be understood that the present invention is not intended to be limited to doors and may equally well be used to provide a locking apparatus in relation to other devices such as safes and gates to name but two.
SUMMARY OF THE INVENTION
In one form of the invention there is proposed a dual lock apparatus of the type including a lock moveable between a first position whereby said lock extends outwardly from said apparatus and a second position whereby said lock is contained within said apparatus said apparatus including:
a slider movable between a first position and a second position and including a first end associated with said lock such that movement of the slider causes corresponding movement of the lock, and a second end associated with a first locking means and a second locking means whereby independent operation of said first and second locking means is controlled by a clutch mechanism;
said clutch mechanism including an aperture which extends through said slider and a piston movable between at least a first and second position within said slider aperture;
said second locking means including a member movable between a first and a second position said member including an outwardly biased locking member adapted to engage said slider aperture to thereby mechanically connect said second locking means with said slider to thereby effect movement of said slider upon movement of said member;
said first locking means including a rotatable cam such that when rotated said cam acts against said piston to thereby move said piston from said first position to said second position to thereby mechanically connect said first locking means with said slider to thereby effect movement of said slider.
Preferably said first locking means disengages said second locking means.
This allows independent operation of said first locking means with respect to said second locking means.
The above provides the advantage that if the second locking means is one that may be exposed to potential failure, the first locking means ensures that there is a safeguard in that the lock can always be operated even if the secondary locking means has ceased to function.
Advantageously at least one of said locking means is electrically driven. Advantageously said first locking means is a key activated locking means whilst said second locking means is an electromechanical locking means.
Preferably both said first and second locking means are key activated.
A particularly apt use of this invention is in the case where the electromechanical locking means is controlled by remote activation of an electric motor. If for whatever reason the electric motor were to fail, such as a power failure, then the primary locking mechanism that is operated for example by a key may be used to unlock or lock the lock.
Advantageously when said slider interacts with said locking bolt so as to move it into said first position, said slider resists withdrawal of said locking bolt.
In a further form of the invention there is proposed a dual lock apparatus of the type including a locking bolt moveable between a first position extending outwardly from said apparatus to engage with an external restraining means and a second position to be contained within said casing said apparatus including:
a slider adapted to interact with said locking bolt so as to move it into said first or second position said slider including at one end an aperture extending perpendicularly to the direction of motion of said slider said aperture adapted to house a slider abutment member;
said slider abutment member being moveable between a first position whereby a surface of said member is flush with a surface of said slider and a second position whereby said surface of said member is housed within said aperture;
a carriage associated with said slider said carriage including an abutment surface said carriage further being moveable between a first position wherein said slider is located in said slider second position, and a second position thereby urging said slider into said slider first position;
a first locking means having a rotatable cam means such that when rotated in a first direction so as to act against said carriage abutment surface urges said carriage into said carriage second position and said abutment member into said first position to thereby urge the slider towards its first position and thereby outwardly extend said bolt and when said cam is rotated in an opposite direction it acts to thereby urge the slider towards its second position to thereby inwardly retract said bolt;
a second locking means adapted to be activated independent of said first locking means including a rack associated with said slider and movable between a first position whereby said bolt is inwardly retracted and a second position whereby said bolt is outwardly extended, said member including an outwardly biased pin housed within a rack cavity and movable between a first and a second position, in said first position said pin engaging with said slider aperture to thereby effectively mechanically couple said second locking means to said slider and thus the bolt and in said second position said pin forced into said cavity whereby said slider may freely move to thereby effectively decouple said second locking means from the slider, this occurring when said slider abutment member is in said member first position.
Preferably when said cam discontinues urging of said carriage, a biasing member acts upon said pin to return it to said first position upon alignment of said pin and said slider aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several implementations or embodiments of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings,
FIG. 1 is a top view of the internal components of a lock in an unlocked configuration and including the lock slider body of the present invention;
FIG. 2 is a top view of the internal components of the lock of FIG. 1 in a locked configuration using a secondary locking mechanism, more specifically, an electric motor and rack system;
FIG. 3 is an exploded perspective view of the different components of the lock of FIG. 1 ;
FIG. 4 is an alternate exploded perspective view of the different components of the lock of FIG. 1 ;
FIG. 5 is a cross-sectional view of the main component of the lock of FIG. 1 whereby the secondary locking mechanism is used to lock the bolt;
FIG. 6 is a cross-sectional view of the main component of the lock of FIG. 1 whereby a primary locking mechanism (a key operated cam) disengages the secondary locking mechanism;
FIG. 7 is a cross-sectional view of the lock as in FIG. 6 whereby the primary locking mechanism is used to lock the bolt subsequent to disengagement of the secondary locking mechanism;
FIG. 8 is a cross-sectional view of the main components of the lock of FIG. 1 whereby the lock is in its fully locked state using the primary locking mechanism; and
FIG. 9 is a cross-sectional view of the main components of the lock of FIG. 1 whereby the lock is in its fully unlocked state using the primary locking mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts.
The present invention relates to locks and in particular to locks that are used for hollow winged aluminium doors and the like. It may also be adapted to be used on other type of doors such as sliding doors. It is not intended to limit the invention to any particular type of lock or door.
Shown in FIGS. 1 and 2 is a dual lock 10 in accordance with the present invention, FIG. 1 illustrating the lock 10 in its unlocked state and FIG. 2 showing the lock 10 in its locked state. FIGS. 1 and 2 illustrate the use of a secondary locking mechanism, generally indicated at 99 , that is, the use of an electric motor 100 to lock or unlock the lock 10 and which will be described hereinbelow. The primary locking mechanism, which is slightly more complex, will also be described.
A casing 12 is adapted to slidingly support a locking bolt 14 said bolt 14 being biased outwardly from said casing 12 by the use of a spring (not shown). The bolt 14 includes a sunken shoulder 16 at one side of the bolt rear end, said shoulder supporting an annular projection 18 . The bolt 14 is adapted to slide generally in a perpendicular axis 20 to the longitudinal axis 22 of the casing 12 . A lock case 24 limits the outward movement of said bolt.
A slider 26 is adapted to slide along the longitudinal direction 22 within the casing 12 and includes a first longitudinal slit 28 engaging a screw 30 , the screw 30 providing holding support for the lock 10 .
The slider 26 includes a second slit 32 extending at an inclined direction to both the perpendicular and the longitudinal axis 20 and 22 respectively. Slit 32 engages projection 18 of the shoulder 16 . One can thus appreciate that when the slider is moved towards the bolt, the inclination of the slit 32 causes the bolt 14 to be extended outwardly from said casing 12 . Conversely, when the slider 26 is moved in a direction away from the bolt 14 , the slit 32 acting on the shoulder projection 18 urges the bolt 14 to be withdrawn into the casing 12 . When locked, the slider 26 is maintained through use of a biasing member 34 , which may be indexed with a recess in the lid (not shown), for example.
The slider 26 may further include a shoulder 36 adapted to abut against face 38 in the casing 12 to act as a dead stop for the slider motion.
The end of the slit 32 where the bolt is caused to extend out of said casing includes a hooked portion 40 where the slit extends in a longitudinal direction parallel to the casing and thus perpendicular to the movement of the bolt. This has the advantage that when the projection 18 is located within the hooked location 40 , the slider effectively deadbolts the bolt. That is, if the bolt experiences an inward force, the edge 42 of the hooked portion 40 of the slit 32 engages the projection 18 and prevents the bolt 14 from moving into the casing 12 . To keep the projection steady within the hooked portion the slit may include a slight annular recess (not shown).
It is the slider 26 that provides the motion for the movement of the bolt 14 into and outward of the casing 12 . To enable the slider 26 to be movable by both the primary (key) and secondary (electric motor) locking mechanisms requires a clutch mechanism that is now described.
The secondary locking means includes a rack 44 that is adapted to engage the slider 26 . The rack 44 includes at one end splines 46 that are driven by a gear 48 rotatably driven by a shaft 102 extending from the electric motor 100 . The other end of the rack includes a generally oval-shaped cavity 50 which extends only partially therethrough. An outwardly biased pin 52 is positioned within the cavity 50 such that in its rest position, it extends beyond 53 of the rack 44 . The pin 52 contains a recess for housing the biasing member which in this case is a spring 54 . These parts of the lock can be seen more clearly in the exploded views of FIGS. 3-4 .
The slider 26 further includes an arm 56 with an aperture 58 extending therethrough. The aperture 58 is generally of the same shape as cavity 50 in rack 44 . Housed within aperture 58 is a cap 60 including a tapered shoulder 62 terminating into a head 64 . It should therefore be apparent that when aperture 58 and cavity 50 are coaxially aligned, pin 52 will be pushed through aperture 58 and abut the lower surface of cap 60 . Arm 56 includes a recess 67 to allow for movement corresponding with the primary locking mechanism which will be later explained.
Further included is a carriage 68 . Carriage 68 includes a carriage pocket 70 and carriage aperture 72 extending therethrough. A lock barrel or cylinder 74 rotatably fixed to the casing 12 includes a cam 76 that upon rotation of the key barrel is correspondingly rotated. The cam 76 is adapted to be housed within carriage aperture 72 and during the locking and unlocking processes, the cam 76 correspondingly follows the movement of the carriage 68 . It is during this process that recess 67 is required to allow for the cam rotation. Carriage 68 is shiftable along slider 26 to the extent provided by a locking cavity 78 on arm position. As there is no force provided by cam 76 , the cap 60 remains in the central position of the pocket 70 thereby allowing pin 52 to constantly abut surface 88 . Then, on operation of the electric motor to unlock the bolt 14 , the pin 52 acts on surface 90 of slider aperture 58 to shift the slider 26 in the opposite direction.
One can thus appreciate that the above operation, in using a secondary locking mechanism, is capable of locking and unlocking the lock 10 independent of the primary locking mechanism, that being operative use of the cam 76 .
FIGS. 6-9 illustrate the primary locking mechanism which involves the use of a key being inserted into the key barrel and rotated, thereby rotating cam 76 . More specifically, FIG. 6 illustrates the way the primary locking mechanism may function while the secondary locking mechanism is disengaged, FIG. 7 illustrates a continuation of this same locking action, while FIGS. 8 and 9 illustrate the fully locked and fully unlocked configurations of the lock 10 respectively.
Those skilled in the art would appreciate that when cam 76 is rotated in order to lock the lock 10 , it is caused to abut surface 92 of carriage aperture 72 . Therefore, carriage 68 is forced to longitudinally shift relative to the slider 26 . As can be seen in FIG. 6 , this action causes tapered surface 82 of carriage pocket 70 to push against tapered shoulder 62 of cap 60 . Cap 60 is forced into its carriage frame and the tapered surfaces continue to slide until the side of head 64 of cap 60 abuts with surface 94 of pocket 70 . This action not only causes pin 52 to be forced into cavity 50 due to the force applied by cap 60 , but also provides for a mechanical connection between the cam 76 and the slider 26 to thereby shift the slider 26 with further rotation of the cam 76 . Essentially, connection between the slider 26 and rack 44 is broken due to the resulting shear plane between rack and slider while connection between slider 26 and cam 76 is achieved.
With continued rotation of the cam 76 , the bolt is drawn into the extended and deadlocked position. It is to be understood that the deadlocked configuration of the bolt 14 is not achieved through the primary locking mechanism but rather through pocket 40 . If the primary locking mechanism did involve its own deadlocking feature, unlocking the bolt 14 using the secondary locking mechanism would not be possible. It should therefore be clear that the present invention provides for two independent means of locking and unlocking bolt 14 .
When unlocking lock 10 , which is to drive bolt 14 within the casing 12 , the key is obviously rotated in the opposite direction. Therefore, cam 76 is forced to abut with surface 96 of carriage aperture 72 thereby causing carriage 68 to shift in the opposite direction as described above, with the cap 64 forced to abut the opposite surface of carriage pocket 70 .
In the situation where the bolt has been unlocked using the primary locking mechanism and is required to be locked once again using the secondary locking mechanism, the electric motor when operated will drive the rack until the rack cavity 50 is coaxially aligned once again with slider aperture 58 such that spring 54 forces pin 52 back into abutment with cap 60 such that the slider 26 and rack 44 are now re-coupled for the electric motor to drive the lock.
One can thus appreciate how the present invention may be used to unlock a lock that has been locked by an electric motor that is still in the locked position. This is advantageous where the electric lock is to be overridden or where it has broken down. Use of the primary locking mechanism thus allows the lock to still operate even where the electric motor can no longer function.
It is to be understood that once the secondary locking mechanism has been disengaged, it remains motionless due to the gearing of the electric motor. Essentially, gearing back movement is prevented and thereby allows sufficient force to be applied to the slider to overcome tension that may be acting on the slider due to pin 52 which remains outwardly biased.
In a further aspect of the invention, the actions of the electric motor may well be governed by the use of a microprocessor in electrical connection with both the electrical motor and an arrangement of micro-switches which sense whether the slider is in a locked or unlocked position. The primary function of the processor is to process information gained from the micro-switches and to correspondingly operate the electric motor. One advantage to such a system over existing systems is that there is no longer the requirement for operating the motor for a predetermined amount of time to ensure that locking or unlocking has taken place and considerable battery power consumed in the process.
If under any circumstances the lock should fail to lock, the processor will realize that the lock is neither in a locked or unlocked state and sound an audible alarm to inform the user that the lock has not been successfully locked.
Further, the apparatus may well include a remote access means such as an infrared receiver such that locking and unlocking of the lock may be achieved from a remote location using a transmitting means. Further still, the apparatus may include an interrogation means so that a user may determine whether the bolt is in a locked or an unlocked position some distance away.
In some circumstances, a further bolt system may be engaged simultaneously with the dual lock of the present invention whereby the apparatus is in mechanical connection with one or more further bolts used to lock or unlock the door whereby the slider 28 is in mechanical connection with the bolts.
So as to keep the door from freely swinging when in the unlocked position, the lock mechanism may include a spring-loaded latch (not shown) being outwardly biased by a biasing means (not shown).
It is to be understood that other secondary driving means may equally well be employed. The rack may be acted upon by use of a manually operated crank (not shown).
In general the term deadlocking is intended to mean that when the lock is deadbolted, that the slider is effectively prevented from any slidable motion.
The above description generally referred to the slider being movable by a key activating the primary locking mechanism and an electric servomotor driving the secondary locking mechanism. It may equally well be, however, that the secondary locking mechanism is also activated by the use of a solenoid. However the electric motor provides much higher torques required especially where the lock arrangement includes multiple bolts such as additional upper and lower bolts. Even further still the secondary locking mechanism may also include a key activated lock accessible from one or both sides of the lock case or other types of simple non-secure actuators.
The present invention may also equally well be adapted for use on existing doors by the use of simple but effective adaptive pieces.
Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus.
In any claims that follow and in the summary of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprising” is used in the sense of “including”, i.e. the features specified may be associated with further features in various embodiments of the invention. | The present invention relates to a dual lock apparatus ( 10 ) of the type including a locking bolt ( 14 ) moveable between a first locked position and a second unlocked position said bolt movement corresponding with longitudinal movement of a slider ( 26 ) said apparatus including a first and a second locking means adapted to operate independently of one another. The first locking means ( 74 ) includes a rotatable cam ( 76 ) such that when rotated said cam acts against a moveable piston to thereby move said piston from a first position to a second position in which the second locking means becomes disengaged from said slider and further rotation of the cam urges longitudinal movement of the slider. The second locking means includes an electric motor in geared connection to a member ( 44 ) moveable between a first position and second position corresponding with the locked and unlocked positions of the bolt said member including an outwardly biased pin ( 52 ) adapted to engage the piston cylinder ( 58 ) and urge said piston into said piston first position to thereby mechanically connect the second locking means with the slider. The locking means can therefore operate independently of one another. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to application No. 61/812,044 filed on Apr. 15, 2013, which is currently pending. The patent application identified above is incorporated herein by reference in its entirety to provide continuity of disclosure.
FIELD OF THE INVENTION
This application relates to a skylight window having a substantially trapezoidal or ellipsoid shape to form a dormer when installed on a conventional pitched roof.
BACKGROUND OF THE INVENTION
Skylight windows are widely used in day lighting design in residential and commercial buildings to provide natural light through a roof of a structure. Conventional skylights normally have a perimeter frame that is rectangular with one or more pane of glass mounted within the frame and lay parallel to a pitched roof. Such conventional skylights have a drawback in that the collection of light is limited by the placement of the sky light on a side or exposure of a pitched roof in relation to the placement of the sun during the day. In addition, conventional flat skylights do not provide additional space in attic rooms wherein the ceiling is also the roof. Regarding dormers, conventional dormers do provide additional space in attic rooms. However, conventional dormers are even more limited with the collection of natural light in relation to the position of the sun and the side of a structure on which the conventional dormer is located on.
Therefore, a need exists for a skylight window having a plurality of translucent or transparent panels configured to create a trapezoidal shape in relation to a pitched roof, thereby creating a skylight window that is capable of collecting a greater amount of natural light than a conventional skylight while also providing addition space like a conventional dormer.
The relevant prior art includes the following references:
Pat. No.
Inventor
Issue/Publication Date
(U.S. Patent References)
3,844,087
Schultz et al.
Oct. 29, 1974
4,114,331
Sukolics
Sep. 19, 1978
4,548,006
Roberts, Sr.
Oct. 22, 1985
4,577,619
Howe, Jr.
Mar. 25, 1986
4,672,774
Rasmussen
Jun. 16, 1987
4,665,964
Zommers
May 19, 1987
4,823,525
Roberts et al.
Apr. 25, 1989
4,917,167
Voss et al.
Apr. 17, 1990
5,094,040
Bunka
Mar. 10, 1992
D336,527
Cole
Jun. 15, 1993
5,596,848
Lynch
Jan. 28, 1997
5,913,785
Moller et al.
Jun. 22, 1999
D432,667
Moller
Oct. 24, 2000
6,138,738
Moller et al.
Oct. 31, 2000
D582,054
Moller et al.
Dec. 2, 2008
D582,055
Moller et al.
Dec. 2, 2008
D617,007
Kjaergaard et al.
Jun. 1, 2010
D617,008
Kjaergaard et al.
Jun. 1, 2010
(Foreign Patent References)
EP0702769
Abraham et al.
Jan. 21, 1998
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a skylight window having a plurality of translucent or transparent panels configured to create a trapezoidal shape in relation to a pitched roof, thereby creating a skylight window that is capable of collecting a greater amount of natural light than a conventional skylight while also providing additional space of a conventional dormer.
An additional object of the present invention is to provide a skylight window having a plurality of translucent or transparent panels configured to create an elliptically curved shape in relation to a pitched roof, thereby creating a skylight window that is capable of collecting a greater amount of natural light than a conventional skylight while also providing additional space of a conventional dormer
The present invention fulfills the above and other objects by providing a trapezoidal skylight window dormer having four transparent and/or translucent panels made of glass, plastic or equivalent material and configured into a pitched, trapezoidal skylight with an angled, trapezoidal window to form a dormer type structure which can be installed on a conventionally framed, pitched roof of a structure. A pitch of a roof on which the present invention is being installed is preferably greater than 6:12 and less than 12:12.
The four panels forming the trapezoidal skylight window dormer of the present invention are triangular shaped with two of the panels being upper panels having identical shapes and forming a roof or upper surface of the trapezoidal skylight window dormer and two lower front panels, also having identical shapes that are angled in relation to each other, forming window or front surface. The panels are assembled in a framework, made of rigid material, such as metal, wood and so forth, and sealed in the framework to provide structural integrity and weather tightness. A lower free edge of the skylight window dormer is secured to a base frame which in turn is fitted and secured to a host roof. The junction of the skylight window dormer base and host roof is preferably flashed to provide a weather tight seal and trim, such as a metal trim, installed over the flashing to complete the installation. The interior portion of the skylight window dormer and ceiling may then be finished with conventional materials, such as wood trim.
Alternatively, the present invention fulfills the above and other objects by providing an elliptically curved skylight window dormer of two transparent and/or translucent panels, constructed from glass, plastic and so forth, configured to integrate a pitched, elliptically curved skylight with an similarly curved window to form a dormer type structure which can be installed on a conventionally framed, pitched roof of a structure. A pitch of a roof on which the present invention is being installed is preferably greater than 6:12 and less than 12:12.
The two panels forming the elliptically curved skylight window dormer of the present invention are elliptically shaped with an upper panel, having an elliptical curved shaped, forming a roof or upper surface of the elliptically curved skylight window dormer and a front panel, also having an elliptical curved shaped, forming window or front surface. The panels are assembled in a framework, made of rigid material, such as metal, wood and so forth, and sealed in the framework to provide structural integrity and weather tightness. A lower free edge of the skylight window dormer is secured to a base frame which in turn is fitted and secured to a host roof. The junction of the skylight window dormer base and host roof is preferably flashed to provide a weather tight seal and trim, such as a metal trim, installed over the flashing to complete the installation. The interior portion of the skylight window dormer and ceiling may then be finished with conventional materials, such as wood trim.
The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the following detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following detailed description, reference will be made to the attached drawings in which:
FIG. 1 is an angled skylight window dormer installed on a pitched host roof having an angled slope;
FIG. 2 is a side view of a skylight window dormer of the present invention;
FIG. 3 is a top view of a skylight window dormer of the present invention;
FIG. 4 is an opposing side view to FIG. 1 of a skylight window dormer of the present invention;
FIG. 5 is a perspective top view of a skylight window dormer of the present invention;
FIG. 6 is front view of a skylight window dormer of the present invention;
FIG. 7 is a cross section along lines A-A of FIG. 5 ;
FIG. 8 is a cross section along lines C-C of FIG. 2 ;
FIG. 9 is a cross section along lines B-B of FIG. 5 ;
FIG. 10 is a top view of an upper panel of the present invention;
FIG. 11 is a front view of a front panel of the present invention;
FIG. 12 is a plan for developing the present invention from a flat plastic sheet showing the angles required to create a monolithic three dimensional assembly from the flat plastic sheet material;
FIG. 13 is a detail view of a typical panel to host roof assembly;
FIG. 14 is a detail view of a typical panel to panel connector;
FIG. 15 is a detail view of a typical panel to panel connector cut along line A-A of FIG. 14 and inverted to form an angled connector;
FIG. 16 is an elliptical skylight window dormer installed on a pitched host roof having an angled slope;
FIG. 17 is a side view of a skylight window dormer of the present invention;
FIG. 18 is a top view of a skylight window dormer of the present invention;
FIG. 19 is an opposing side view to FIG. 17 of a skylight window dormer of the present invention;
FIG. 20 is a perspective top view of a skylight window dormer of the present invention;
FIG. 21 is front view of a skylight window dormer of the present invention;
FIG. 22 is a cross section along lines C-C of FIG. 17 ;
FIG. 23 is a cross section along lines A-A of FIG. 19 ;
FIG. 24 is a cross section along lines B-B of FIG. 19 ;
FIG. 25 is a front window plan for developing the present invention from a flat plastic sheet showing the angles required to create a monolithic three dimensional assembly from the flat plastic sheet material;
FIG. 26 is an upper window plan for developing the present invention from a flat plastic sheet showing the angles required to create a monolithic three dimensional assembly from the flat plastic sheet material;
FIG. 27 is an exploded detail view of connector plates for connecting panels during pre unit assembly;
FIG. 28 is a detail view of connector plates for connecting panels clamped together during unit assembly;
FIG. 29 is a detail view of connector plates for connecting panels clamped together and covered during post unit assembly;
FIG. 30 is a side view of a skylight window dormer installed on a pitched host roof having an angled slope;
FIG. 31 is a detail view of a typical panel to host roof assembly;
FIG. 32 is a cross section along lines C-C of FIG. 30 ;
FIG. 33 is a cross section along lines D-D of FIG. 32 ;
FIG. 34 is a cross section along lines E-E of FIG. 32 ; and
FIG. 35 is a cross section along lines F-F of FIG. 32 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of describing the preferred embodiment, the terminology used in reference to the numbered components in the drawings is as follows:
1 . skylight window dormer, generally 2 . pitched host roof 3 . upper panel 4 . front edge of upper panel 5 . rear edge of upper panel 6 . upper edge of upper panel 7 . roof window 8 . upper central axis 9 . front panel 10 . front edge of front panel 11 . upper edge of front panel 12 . lower edge of front panel 13 . vertical window 14 . front central axis 15 . sill 16 . cover 17 . flashing 18 . host roof/wall/framing 19 . shim 20 . connector 21 . flange 22 . cut line 23 . spline 24 . connector plate 25 . clamp
With reference to FIG. 1-11 , the skylight window dormer 1 comprises two upper panels 3 having substantially identical triangular shapes. Each upper panel 3 comprises a front edge 4 , a rear edge 5 and an upper edge 6 . Said two upper panels 3 are joined along said upper edges 6 to form a roof window 7 having an upper central axis 8 . Said rear edges 5 of said two upper panels 3 have a slope that is substantially equal to a slope of the pitched host roof 2 when the skylight window dormer 1 is installed on the pitched host roof 2 and the rear edges 5 of said two upper panels 3 are joined to the pitched host roof 2 . Two front panels 9 , having substantially identical triangular shapes, each comprise a front edge 10 , an upper edge 11 and a lower edge 12 . Said two front panels 9 are joined along said front edges 10 to form a vertical window 13 having a front central axis 14 . Said lower edges 12 of said two front panels 9 have a slope that is substantially equal to the slope of the pitched host roof 2 when the skylight window dormer 1 is installed on the pitched host roof 2 and the lower edges 12 of said two front panels 9 are joined to the pitched host roof 2 . Said upper edges 11 of said two front panels 9 are joined to said front edges 4 of said two upper panels 3 to form a substantially trapezoidal-shaped skylight window dormer 1 with said central axis 8 and front axis 14 meeting to form a substantially ninety degree angle.
Upper panels of the skylight window dormer are identical isosceles triangles joined at a base and inverted to form two upper surfaces at a horizontal ridge line located along a center line of the skylight window dormer. The upper panels are sloped to match an angle of a host roof angle (α) or some other roof angle (β), preferably between 26 degrees and 45 degrees. The horizontal ridge line extends from the host roof to the upper vertical corner of the skylight window creating length (L) of the skylight window dormer.
Front panels 9 are also identical isosceles triangles joined at their base and rotated 90 degrees to form a vertical window and a vertical corner at a front edge of the skylight window dormer that runs where the two front panels abut against each other. The front panels intersect at an angle (2γ) which is a function of the width (W) and length (L) of the skylight window dormer. The front panels extend from the host roof to a corner line of the skylight window dormer where upper edges of the front panels abut front edges of the upper panels, thereby creating the height (H) of the skylight window dormer window.
The width of the skylight window dormer (W) is a function of the upper panel roof angle (β) in relation to the height (H) of the skylight window dormer. Either height (H) OR length (L) of the skylight window dormer is selected to suit the desired size and the remaining parameter is determined by the host roof slope (s)=H/L.
Horizontal roof ridge line and vertical window corner line of the skylight window dormer are orthogonal. Roof assembly and window assembly of the skylight window dormer intersect in a plane sloped (α) degrees from horizontal.
The equal sides of all isosceles triangles are the same dimension (f). Fully assembled, the four panels of the skylight window dormer intersect such that all lower edges of the panels are all in the same plane which is integrated into the plane or pitch of the host roof by a base assembly.
The form of the skylight window dormer is an oblique tetrahedron with a rhombus or diamond shaped base.
The following are formulas and an examples for constructing and installing a skylight window dormer of the present invention on a pitched roof or other sloped surface.
a = select to suit
tan α = host roof slope
b = a tan α
tan β = b/d
c = a (1 + tan 2 α) 1/2
tan δ = d/c
d = select to suit
sin δ = d/f
e = d (1 + tan 2 β) 1/2
tan γ = d/a
f = (c 2 + d 2 ) 1/2
tan ρ = tanα/sinδ
g = a (1 + tan 2 γ) 1/2
tan φ = 1/(tanα sin δ)
Host Roof Slope = rise/run
tan λ 1 = 1/tanφ = tanα sinδ
tan λ 2 = 1/tan ρ = sinδ/tan α
EXAMPLE 1
a = 6.00
tan α = .5833
α = 30.24
b = 6.00 × .5833 = 3.50
tan β = 3.50/6.00 = .5833
β = 30.24
c = 6.00(1 + .5833 2 ) 1/2 = 6.95
tanδ = 6.00/6.95 = .8633
δ = 40.80
d = 6.00
sin δ = 6.00/9.18 = .6536
δ = 40.80
e = 6.00(1 + .5833 2 ) 1/2 = 6.95
tan γ = 6.00/6.00 = 1.000
γ = 45.00
f = (48.30 + 36.00) 1/2 = 9.18
tan ρ = .5833/.6536 = .8924
ρ = 41.75
g = 6.00(1 + 1.000 2 ) 1/2 = 8.48
tan φ = 1/(.5833)(.6536) =
φ = 69.13
2.623
Host Roof Slope = 7:12
tan λ 1 = .5833 × .6536 = .3812
λ 1 = 20.87
tan λ 2 = .6536/.5833 = 1.1205
λ 2 = 48.25
EXAMPLE 2
a = 6.00
tan α = .5833
α = 30.24
b = 6.00 × .5833 = 3.50
tan β = 3.50/3.50 = 1.000
β = 45.00
c = 6.00(1 + .5833 2 ) 1/2 = 6.95
tan δ = 3.50/6.95 = .5036
δ = 26.73
d = 3.50
sin δ = 3.50/7.78 = .4499
δ = 26.73
e = 3.50(1 + 1.000 2 ) 1/2 = 4.95
tan γ = .5833
γ = 30.24
f = (48.30 + 12.25) 1/2 = 7.78
tan ρ = .5833/.4499 = 1.2965
ρ = 52.36
g = 6.00(1 + .5835 2 ) 1/2 = 6.95
tan φ = 1/(.5833)(.4499) =
φ = 75.30
3.811
Host Roof Slope = 7:12
tan λ 1 = .5833 × .4499 = .2624
λ 1 = 14.70
tan λ 2 = .4499/.5833 = .7713
λ 2 = 37.64
EXAMPLE 3
a = 5.00
tan α = .5833
α = 30.24
b = 5.00 × .5833 = 2.92
tan β = 2.92/4.00 = .7300
β = 36.13
c = 5.00(1 + .5833 2 ) 1/2 = 5.79
tan δ = 4.00/5.79 = .6908
δ = 34.64
d = 4.00
sin δ = 4.00/7.04 = .5682
δ = 34.64
e = 4.00(1 + .7292 2 ) 1/2 = 4.95
tan γ = 4.00/5.00 = .8000
γ = 38.66
f = (33.52 + 16.00) 1/2 = 7.04
tan ρ = .5833/.5682 = 1.0266
ρ = 45.75
g = 5.00(1 + .8000 2 ) 1/2 = 6.41
tan φ = 1/.5833 × .5682 =
φ = 71.66
3.017
Host Roof Slope = 7:12
tan λ 1 = .5833 × .5682 = .3314
λ 1 = 18.34
tan λ 2 = .5682/.5833 = .9741
λ 2 = 44.25
Components or preferably insulated glass panels or equivalent plastic panels configured to suit the particular geometry discussed above with all edges protected and sealed by channels which are then bonded to the panels. All connectors, as illustrated in FIGS. 13-15 , may be custom configured and fabricated to attach panels to one another with a weather tight seal and trim. Four sills interconnect to form a base which is slightly smaller than a rough opening cut into a host roof to install the skylight window dormer. The rough opening is created by cutting roof rafters in the host roof and reframing to accommodate particular geometry of the skylight window dormer base. Interior angles of the rough opening depend on the geometry of the skylight window dormer base. Panels attached to the top of the base and the base itself may be secured to the framing of the host roof by conventional means. Then, flashing, shingles, trim and so forth are installed around the skylight window dormer to complete installation.
The skylight may be framed panels or a single monolithic piece formed or molded out of single piece of material and or have one or more edges fused or bonded together. For example, FIG. 12 illustrates a plan for developing the present invention from a flat plastic sheet showing the angles required to create a monolithic three dimensional assembly from the flat plastic sheet material.
With reference to FIG. 16-24 , an elliptical skylight window dormer 1 installed on a pitched host roof 2 having an angled slope is illustrated. The skylight window dormer 1 comprises an upper panel 3 having a substantially elliptically-curved shape. Said upper panel 3 comprises a front edge 4 and a rear edge 5 . Said upper panel forms a roof window. Said rear edge 5 of said upper panel 3 has a slope that is substantially equal to a slope of the pitched host roof 2 when the skylight window dormer 1 is installed on the pitched host roof 2 and the rear edge 5 of said upper panel 3 is joined to the pitched host roof 2 . A front panel 9 , having a substantially elliptically-curved shape comprises an upper edge 11 and a lower edge 12 . Said lower edge 12 of said front panel 9 has a slope that is substantially equal to the slope of the pitched host roof 2 when the skylight window dormer 1 is installed on the pitched host roof 2 and the lower edge 12 of said front panel 9 is joined to the pitched host roof 2 . Said upper edge 11 of said front panel 9 is joined to said front edge 4 of said upper panel 3 to form a substantially elliptically-curved skylight window dormer 1 with said front panel 9 and upper panel 3 meeting to form a substantially ninety degree angle.
Both the upper panel and front panel are created from glass or plastic sheets which are laid out geometrically so that they can be developed into elliptically curved panels about a first principal axis and symmetrically mitered panels about a second principal axis. All free edges and the common edges are identically shaped half ellipses.
The lower/free edge of the skylight window dormer is secured to an elliptically shaped curb or sill which is custom made to match the elliptically shaped bottom edge of the skylight window dormer. However, before the skylight window dormer is attached to this curb or sill, the curb or sill itself has to be integrated into a rectangular framed roof panel which in turn can be easily and conventionally integrated into a framed roof or wall structure.
The length L=(2a) or height H=(2b) of skylight window dormer is selected to suit. The remaining parameter is determined by host roof or wall slope (α). The width W=(2d) of the skylight window dormer is selected to suit. The length of skylight window dormer base 2c=2(a 2 +b 2 ) 1/2 .
The skylight panel is formed with an elliptical cross section at its midpoint. The equation for this ellipse is: (x/d) 2 +(y/b) 2 =1. The perimeter of the panel at its midpoint cross section is So=π[(d 2 +b 2 )/2] 1/2 The width of panel is (2a). Edges of the skylight panel are mitered at angle (α).
The window panel is formed with an elliptical cross section at its midpoint. The equation for this ellipse is: (x/d) 2 +(y/a) 2 =1. The perimeter of the panel at its midpoint cross section is So=π[(d 2 +a 2 )/2] 1/2 . The width of panel is (2b). Edges of the window panel are mitered at angle (π/2−α).
The shape of the common edge of both skylight and window panels and the shape of the cutout of the host roof or wall is defined by the following equation: (x/c) 2 +(y/d) 2 =1.
The skylight panel intersects the host roof or wall at angle (α) and window panel intersects same at angle (π/2−α). The centerline of skylight panel intersects the centerline of window panel at a right angle (π/2).
The following are formulas and an example for constructing and installing a skylight window dormer of the present invention on a pitched roof or other sloped surface.
a ≡ host roof or wall angle (given)
α = 30.24 degrees
tan α = a/b = host roof or wall slope (given)
tan α = a/b = 7/12 = .5833
a ≡ half length of SWD (select to suit)
a = 5.00
b ≡ half height of SWD = a tan α
b = 2.92
c ≡ half length of SWD base = (a 2 + b 2 ) 1/2 =
c = 5.79
a(1 + tan 2 α) 1/2
d = half width of SWD (select to suit)
d = 4.00
skylight ellipse: (x/d) 2 + (y/b) 2 = 1
(x/4.00) 2 + (y/2.92) 2 = 1
window ellipse: (x/d) 2 + (y/a) 2 = 1
(x/4.00) 2 + (y/5.00) 2 = 1
base/connector ellipse: (x/d) 2 + (y/c) 2 = 1
(x/4.00) 2 + (y/5.79) 2 = 1
perimeter of skylight panel @ midpoint:
so = 3.14(16.53/2) 1/2 = 11.06
so = π[(d 2 + b 2 )/2] 1/2
perimeter of window panel @ midpoint:
so = 3.14(41.00/2) 1/2 = 14.23
so = π[(d 2 + a 2 )/2] 1/2
Two elliptically shaped aluminum “horse shoes” which are fastened, sealed and bonded to the skylight and window panels respectively where they meet before these panels are assembled, as illustrated in FIG. 27 .
One aluminum cover attached over the connection between the skylight and window panels. Cover is scored in the middle and then bent from 0radians at the base to π/2 radians at the top to conform to the geometry of the intersecting skylight and window panels, as illustrated in FIG. 29 .
One continuous aluminum clip attached to the inside “flange” of the skylight window dormer connector plates which runs an elliptical course from the base on one side of the skylight window dormer to the base on the other side of the skylight window dormer, as illustrated in FIG. 28 .
Four T shaped aluminum extrusions which are formed to create the base of the skylight window dormer. Primary Forming of these extrusions creates the ellipse per the equation for the cutout in the host roof or wall. Secondary forming creates the proper flange angle required to receive mating edge of skylight window dormer, as illustrated in FIG. 31 .
Four L shaped aluminum extrusions which are formed to create the retainer of the skylight window dormer. Primary forming of these extrusions creates the ellipse per the equation for the cutout in the in the host roof or wall. Secondary forming creates the proper flange angle required to retain the exterior surface of the skylight window dormer in place, as illustrated in FIG. 31 .
Two insulated glass or equivalent plastic panels configured to suit a particular geometry with edges mitered to match squarely with each other and with the host roof or wall as illustrated in FIG. 31-35 .
Four triangular aluminum plates at the vertex of the skylight and window panels where they meet at the base of the skylight window dormer. These plates reinforce the connection between the skylight/window panels and the elliptically shaped extrusions at the midpoint of skylight window dormer base where all components are perpendicular to the host roof or wall.
One elliptically shaped wood sill or curb laminated or otherwise formed to suit the geometry of a particular skylight window dormer and the framing depth of the host roof or wall.
Host roof or wall is framed conventionally to accommodate the rectangular roof panel with the ellipsoid skylight window dormer completely installed therein. Secondary framing, sheathing and weather stripping to adapt the elliptically shaped sill or curb and ellipsoid skylight window dormer to conventional rectangular framing in the host roof or wall structure. Roofing shingles and trim to retrofit or complete the installation.
It is to be understood that while a preferred embodiment of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings. | A skylight window dormer for installation on a pitched roof or sloped surface. The skylight window dormer is constructed form a plurality of triangular shaped or elliptically curved panels joined to form a dormer type structure that provides panoramic viewing and additional headroom in tightly enclosed interior spaces. The skylight window dormer is installed using a similar method as conventional skylights and is, thus, combining the efficiency of installing a conventional skylight with the benefits of additional space provided by a conventional dormer. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/647,460, filed Dec. 29, 2006, which is a continuation of Ser. No. 11/193,623, filed Aug. 1, 2005, which is a continuation of U.S. patent application Ser. No. 10/635,679, filed Aug. 7, 2003, which claims priority benefit of U.S. Provisional Patent Application No. 60/401,781, filed Aug. 8, 2002. Each of the above-referenced applications is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention relates to composite screen or perforated surface and filtering membranes.
[0004] 2. Related Art
[0005] Various gutter anti-clogging devices are known in the art and some are described in issued patents.
[0006] In my patent U.S. Pat. No. 6,598,352, incorporated herein by reference, I disclose a filter configuration comprised of a debris repelling membrane, overlying a skeletal structure of ellipsoid rods spaced and resting on vertical planes that serve to break the forward flow of water and to channel water onto and through its integral perforated horizontal plane. Included herein is product literature for LEAFFILTER™, a gutter guard patterned after designs disclosed in U.S. Pat. No. 6,598,352. To date, LEAFFILTER™ has been noted to remain free enough of debris clogs and/or coatings of scum, oil, and pollutants so as to disallow gutter clogs in every known instance of it's installation onto rain gutter systems attached to at least eight thousand residential homes. The LEAFFILTER™ system, however, is costly to manufacture in comparison to other gutter guard systems.
[0007] U.S. Pat. No. 6,463,700 to Davis teaches a composite gutter guard, marketed as Sheer Flo®, comprising a polymer coated fiberglass mesh filter cloth overlying and sonic welded to an underlying perforated plane, disclosed in claims 1 and 4. Davis specifically teaches employment of a medium filter opening fiberglass mesh rather than a fine metal or polymer mesh cloth, disclosed in Column 1 lines 19-35. Such fiberglass mesh of medium openings can be shown to allow the lodging of pine needle tips and to be subject to water-proofing due to oil leaching from roofing shingles. This may cause permanent accumulation of debris upon the composite gutter guard and water-proofing may allow forward, rather than downward flow of water to occur. In instances of high ambient temperatures sonic welded fiberglass has been shown to break free of the underlying polymer plane and the composite gutter guard has been shown to warp and wave due to heat deformation. Davis teaches a mostly single planar composite gutter guard that allows much forward underflow of water to occur on the underside of the disclosed invention and such underflow acts to oppose downward flow of water through perforations.
[0008] U.S. Pat. No. 6,164,020 to Nitch teaches a gutter screen for preventing the accumulation of debris within a gutter. Nitch teaches a gutter screen that has a plurality of v-shaped bars positioned to run above and generally parallel to the gutter. Nitch teaches that the unique shape of the bars minimize the surface area of the underside of the screen decreases water tension on the underside of the screen and postulates that this decreases the ability of water to accumulate on the underside of the screen which promotes the pulling of water into the gutter, disclosed in Col. 2 lines 45 through 50. Such a device can be shown to eventually allow debris to accumulate within the spaces between v-shaped bars. Such a device can additionally be shown to allow the forward channeling of water to occur as an underflow from tip to tip of the downward most portion of the v-shaped bars due to their close spacing and lack of a length of downward extension that would provide a greater directed downward flow of water into the underlying gutter. This and other prior art do not recognize that water adhesion surfaces extending downward from a planar surface into a rain gutter in a height staggered manner or that are separated by a minimum of one inch provide greater siphoning action and are less likely to be overcome by a forward channeling of under flowing water on the underside of surfaces that receive water through perforations or open channels than is reliance on a lesser amount of water adhesion on the underside of perforated surfaces or screens with bottom most water dispersing areas that are closely spaced and follow mostly horizontally linear or follow a linear path that angles downward from the rear most portion of a gutter guard to the front lip of a rain gutter. Allowing for greater spacing of rods or fins or water channeling paths or staggering and/or extending the height of rods or fins so that they extend to a depth that the volume of water they channel downward overcomes by sheer weight and gravity an opposing underflow and continues a downward flow into an underlying gutter has not been found to be a simple matter of anticipation, or design choice by those skilled in the arts. Rather, it has proved to be unclaimed in disclosed prior art and untested in the field with the exception of the LEAFFILTER™ gutter guard which has proved to be very efficient at channeling water downward into a rain gutter while disallowing either the rain gutter or the gutter guard to clog or exhibit an overflow of water. Nitch teaches that fine screens allow for water run-off and are less capable of receiving water than other structural components such as bars or ribs, disclosed in Col. I lines 33-35. This and other prior art such as U.S. Pat. No. 6,463,700 to Davis do not recognize that fine screens can be shown to exhibit great water permeability and downward water channeling properties when contacting ovaled or angled edged surfaces resting on downward extending legs as is disclosed in U.S. Pat. No. 6,598,352 to Higginbotham, Col. 18 lines 26-67, Col. 19 lines 1-54.
[0009] U.S. Pat. No 5,755,061 to Chen teaches a rain cover that includes pairs of adjacent fins separated by a uniform traverse gap that significantly increases the return of water to the gutter by surface tension with the fm walls, disclosed in the ABSTRACT. As occurs with U.S. Pat. No. 6,164,020, copious amounts of roof runoff may negate the intended effect of water returning to the gutter allowing for forward flow of water past the gutter. The bottom terminal points of the fm walls Chen teaches exist in the same linear plane as do the bottom terminal points of the rods Nitch teaches in U.S. Pat. No. 6,164,020. This allows a forward underflow (beneath the topmost surface of a perforated or open channeled plane) of water to occur. In my U.S. Pat. No. 6,598,352 it is disclosed that such forward rather than downward flow of water has been shown to cease if downward extending planes or rods of varying heights, disallowing a linear channeling path for water to follow, and sufficiently spaced are employed beneath the top most surface of water receiving areas but the disclosed preferred embodiment has been shown costly to manufacture.
[0010] U.S. Pat. No. 5,557,891 to Albracht teaches a gutter protection system for preventing entrance of debris into a rain gutter. Albracht teaches a gutter protection system to include a single continuous two sided well with angled sides and perforated bottom shelf 9 into which rainwater will flow and empty into the rain gutter below. The well is of a depth, which is capable of receiving a filter mesh material. However, attempts to insert or cover such open channels of “reverse-curve” devices with filter meshes or cloths is known to prevent rainwater from entering the water receiving channels. This occurrence exists because of the tendency of such membranes, (unsupported by a proper skeletal structure), to channel water, by means of water adhesion along the interconnected paths existing in the filter membranes (and in the enclosures they may be contained by or in), past the intended water-receiving channel and to the ground. This occurrence also exists because of the tendency of filter mediums of any present known design or structure to quickly waterproof or clog when inserted into such channels creating even greater channeling of rainwater forward into a spill past an underlying rain gutter. Filtering of such open, recessed, channels existing in Albracht's invention as well as in U.S. Pat. No. 5,010,696, to Knittel, U.S. Pat. No. 2,672,832 to Goetz, U.S. Pat. Nos. 5,459,965 & 5,181,350 to Meckstroth, U.S. Pat. No. 5,491,998 to Hansen, U.S. Pat. No. 4,757,649 to Vahldieck and in similar “reverse-curved” inventions that rely on “reverse-curved” surfaces channeling water into an open channel have been known to disallow entrance of rainwater into the water-receiving channels. Albracht's as well as previous and succeeding similar inventions have therefore notably avoided the utilization of filter insertions. What may appear as a logical anticipation by such inventions at first glance, (inserting of a filter mesh or material into the channel), has been shown to be undesirable and ineffective across a broad spectrum of filtering materials: Employing insertable filters into such inventions has not been found to be a simple matter of anticipation, or design choice of filter medium by those skilled in the arts. Rather, it has proved to be an ineffective option, with any known filter medium, when attempted in the field. Such attempts, in the field, have demonstrated that the filter mediums will eventually require manual cleaning.
[0011] German Patent 5,905,961 teaches a gutter protection system for preventing the entrance of debris into a rain gutter. The German patent teaches a gutter protection system to include a single continuous two sided well 7 with angled sides and perforated bottom shelf which rainwater will flow and empty into the rain gutter below. The well is recessed beneath and between two solid lateral same plane shelves close to the front of the system for water passage near and nearly level with the front top lip of the gutter. The well is of a depth, which is capable of receiving a filter mesh material. However, for the reasons described in the preceding paragraphs, an ability to attach a medium to an invention, not specifically designed to utilize such a medium, may not result in an effective anticipation by an invention. Rather, the result may be a diminishing of the invention and its improvements as is the case in Albracht's U.S. Pat. No. 5,557,891, the German Patent, and similar inventions employing recessed wells or channels between adjoining planes or curvatures.
[0012] U.S. Pat. No. 5,595,027 to Vail teaches a continuous opening 24A between the two top shelves. Vail teaches a gutter protection system having a single continuous well 25, the well having a depth allowing insertion and retention of filter mesh material 26 (a top portion of the filler mesh material capable of being fully exposed at the holes). Vail does teach a gutter protection system designed to incorporate an insertable filter material into a recessed well. However, Vail notably names and intends the filter medium to be a tangled mesh fiberglass five times the thickness of the invention body. This type of filtration medium, also claimed in U.S. Pat. No. 4,841,686 to Rees, and in prior art currently marketed as FLO-FREE™ is known to trap and hold debris within itself which, by design, most filter mediums are intended to do, i.e.: trap and hold debris. Vail's invention does initially prevent some debris from entering an underlying rain gutter but gradually becomes ineffective at channeling water into a rain gutter due to the propensity of their claimed filter mediums to clog with debris. Though Vail's invention embodies an insertable filter, such filter is not readily accessible for cleaning when such cleaning is necessitated. The gutter cover must be removed and uplifted for cleaning and, the filter medium is not easily and readily inserted replaced into its longitudinal containing channel extending three or more feet. It is often noted, in the field, that these and similar inventions hold fast pine needles in great numbers which presents an unsightly appearance as well as create debris dams behind the upwardly extended and trapped pine needles. Such filter meshes and non-woven lofty fiber mesh materials, even when composed of finer micro-porous materials, additionally tend to clog and fill with oak tassels and other smaller organic debris because they are not resting, by design, on a skeletal structure that encourages greater water flow through its overlying filter membrane than exists when such filter meshes or membranes contact planar continuously-connected surfaces. Known filter mediums of larger openings tend to trap and hold debris. Known filter mediums smaller openings clog or “heal over” with pollen and dirt that becomes embedded and remains in the finer micro-porous filter mediums. There had not been found, as a matter of common knowledge or anticipation, an effective water-permeable, non-clogging “medium-of-choice” that can be chosen, in lieu of claimed or illustrated filter mediums in prior art, that is able to overcome the inherent tendencies of any known filter mediums to clog when applied to or inserted within the types of water receiving wells and channels noted in prior art until such a medium of inter connected centered threads was disclosed in my U.S. Pat. No. 6,598,352 Col. 22 lines 47-50. The present invention will employ such medium and utilize such in an embodiment less costly to manufacture while remaining effective.
[0013] Vail also discloses that filter mesh material 26 is recessed beneath a planar surface that utilizes perforations in the plane to direct water to the filter medium beneath. Such perforated planar surfaces as utilized by Vail, by Sweers U.S. Pat. No. 5,555,680, by Morin U.S. Pat. No. 5,842,311 and by similar prior art are known to only be partially effective at channeling water downward through the open apertures rather than forward across the body of the invention and to the ground. This occurs because of the principal of water adhesion: rainwater tends to flow around perforations as much as downward through them, and miss the rain gutter entirely. Also, in observing perforated planes such as utilized by Vail and similar inventions (where rainwater experiences its first contact with a perforated plane) it is apparent that they present much surface area impervious to downward water flow disallowing such inventions from receiving much of the rainwater contacting them.
[0014] A simple design choice or anticipation of multiplying the perforations can result in a weakened body subject to deformity when exposed to the weight of snow and/or debris or when, in the case of polymer bodies, exposed to summer temperatures and sunlight.
[0015] U.S. Pat. No. 5,406,754 to Cosby teaches a gutter guard comprising a fine screen supported by a structural stiffening matrix support that prevents the penetration of even fine debris from entering a gutter. When lesser amounts of water flow are present such a device will allow water flow through its combination of screens downward into the gutter. However, during heavy rainfall, roof runoff is known to simply travel over the top most surface of such a device past an underlying gutter rather that downward into the gutter. As with other devices aforementioned in preceding paragraphs, this may occur due to a forward moving underflow of water that can occur beneath the top most surface of nearly planar gutter guards that do not incorporate downward extending planes that break forward flow of water.
[0016] U.S. Pat. No. 4,841,686 to Rees teaches an improvement for rain gutters comprising a filter attachment, which is constructed to fit over the open end of a gutter. The filter attachment comprised an elongated screen to the underside of which is clamped a fibrous material such as fiberglass. Rees teaches in the Background of The Invention that many devices, such as slotted or perforated metal sheets, or screens of wire or other material, or plastic foam, have been used in prior art to cover the open tops of gutters to filter out foreign material. He states that success with such devices has been limited because small debris and pine needles still may enter through them into a rain gutter and clog its downspout opening and or lodge in and clog the devices themselves. Rees teaches that his use of a finer opening tangled fiberglass filter sandwiched between two lateral screens will eliminate such clogging of the device by smaller debris. However, in practice it is known that such devices as is disclosed by Rees are only partially effective at shedding debris while channeling rainwater into an underlying gutter. Shingle oil leaching off of certain roof coverings, pollen, dust, dirt, and other fine debris are known to “heal over” such devices clogging and/or effectively “water-proofing” them and necessitate the manual cleaning they seek to eliminate. (If not because of the larger debris, because of the fine debris and pollutants). Additionally, again as with other prior art that seeks to employ filter medium screening of debris; the filter medium utilized by Rees rests on an inter-connected planar surface which provides non-broken continuous paths over and under which water will flow, by means of water adhesion, to the front of a gutter and spill to the ground rather than drop downward into an underlying rain gutter. Whether filter medium is “sandwiched” between perforated planes or screens as in Rees' invention, or such filter medium exists below perforated planes or screens and is contained in a well or channel, water will tend to flow forward along continuous paths through cur as well as downward into an underlying rain gutter achieving less than desirable water-channeling into a rain gutter.
[0017] U.S. Pat. No 5,956,904 to Gentry teaches a first fine screen having mesh openings affixed to an underlying screen of larger openings. Both screens are elastically deformable to permit a user to compress the invention for insertion into a rain gutter. Gentry, as Rees, recognizes the inability of prior art to prevent entrance of finer debris into a rain gutter, and Gentry, as Rees, relies on a much finer screen mesh than is employed by prior art to achieve prevention of finer debris entrance into a rain gutter. In both the Gentry and Rees prior art, and their improvements over less effective filter mediums of previous prior art, it becomes apparent that anticipation of improved filter medium or configurations is not viewed as a matter of simple anticipation of prior art which has, or could, employ filter medium. It becomes apparent that improved filtering methods may be viewed as patentable unique inventions in and of themselves and not necessarily an anticipation or matter of design choice of a better filter medium or method being applied to or substituted within prior art that does or could employ filter medium. However, though Rees and Gentry did achieve finer filtration over filter medium utilized in prior art, their inventions also exhibit a tendency to channel water past an underlying gutter and/or to heal over with finer dirt, pollen, and other pollutants and clog thereby requiring manual cleaning. Additionally, when filter medium is applied to or rested upon planar perforated or screen meshed surfaces, there is a notable tendency for the underlying perforated plane or screen to channel water past the gutter where it will then spill to the ground. It has also been noted that prior art listed herein exhibits a tendency to allow filter cloth mediums to sag into the opening of their underlying supporting structures. To compensate for forward channeling of water, prior art embodies open apertures spaced too distantly, or allows the apertures themselves to encompass too large an area, thereby allowing the sagging of overlying filter membranes and cloths. Such sagging creates pockets wherein debris tends to settle and enmesh.
[0018] U.S. Pat. No. 3,855,132 to Dugan teaches a porous solid material which is installed in the gutter to form an upper barrier surface (against debris entrance into a rain gutter). Though Dugan anticipates that any debris gathered on the upper barrier surface will dry and blow away, that is not always the case with this or similar devices. In practice, such devices are known to “heal over” with pollen, oil, and other pollutants and effectively waterproof or clog the device rendering it ineffective in that they prevent both debris and water from entering a rain gutter. Pollen may actually cement debris to the top surface of such devices and fail to allow wash-off even after repeated rains. U.S. Pat. No. 4,949,514 to Weller sought to present more water receiving top surface of a similar solid porous device by undulating the top surface but, in fact, effectively created debris “traps” with the peak and valley undulation. As with other prior art, such devices may work effectively for a period of time but tend to eventually channel water past a rain gutter, due to eventual clogging of the device itself.
[0019] There are several commercial filtering products designed to prevent foreign matter buildup in gutters. For example the FLO-FREE™ gutter protection system sold by DCI of Clifton Heights, Pa. comprises a 0.75-inch thick nylon mesh material designed to fit within 5-inch K-type gutters to seal the gutters and downspout systems from debris and snow buildup. The FLO-FREE™ device fits over the hanging brackets of the gutters and one side extends to the bottom of the gutter to prevent the collapse into the gutter. However, as in other filtering attempts, shingle material and pine needles can become trapped in the coarse nylon mesh and must be periodically cleaned.
[0020] U.S. Pat. No. 6,134,843 to Tregear teaches a gutter device that has an elongated matting having a plurality of open cones arranged in transverse and longitudinal rows, the base of the cones defining a lower first plane and the apexes of the cones defining an upper second plane Col. 5 lines 16-25. Although the Tregear device overcomes the eventual trapping of larger debris within a filtering mesh composed of fabric sufficiently smooth to prevent the trapping of debris he notes in prior art, the Tregear device tends to eventually allow pollen, oil which may leach from asphalt shingles, oak tassels, and finer seeds and debris to coat and heal over a top-most matting screen it employs to disallow larger debris from becoming entangled in the larger aperatured filtering medium it covers. Filtering mediums (exhibiting tightly woven, knitted, or tangled mesh threads to achieve density or “smoothness”) disclosed in Tregear and other prior art have been unable to achieve imperviousness to waterproofing and clogging effects caused by a healing or pasting over of such surfaces by pollen, fine dirt, scum, oils, and air and water pollutants. Tregear indicates that filtered configurations such as a commercially available attic ventilation system known as Roll Vent® manufactured by Benjamin Obdyke, Inc. Warminster, Pa. is suitable, with modifications that accommodate its fitting into a rain gutter. However, such a device has been noted, even in its original intended application, to require cleaning (as do most attic screens and filters) to remove dust, dirt, and pollen that combine with moisture to form adhesive coatings that can scum or heal over such attic filters. Additionally, referring again to Tregear's device, a lower first plane tends to channel water toward the front lip of a rain gutter, rather than allowing it's free passage downward, and allow the feeding and spilling of water up and over the front lip of a rain gutter by means of water-adhesion channels created in the lower first plane.
[0021] Prior art has employed filter cloths over underlying mesh, screens, cones, longitudinal rods, however such prior art has eventually been realized as unable to prevent an eventual clogging of their finer filtering membranes by pollen, dirt, oak tassels, and finer debris. Such prior art has been noted to succumb to eventual clogging by the healing over of debris which adheres itself to surfaces when intermingled with organic oils, oily pollen, and shingle oil that act as an adhesive. The hoped for cleaning of leaves, pine needles, seed pods and other debris by water flow or wind, envisioned by Tregear and other prior art, is often not realized due to their adherence to surfaces by pollen, oils, pollutants, and silica dusts and water mists. The cleaning of adhesive oils, fine dirt, and particularly of the scum and paste formed by pollen and silica dust (common in many soil types) by flowing water or wind is almost never realized in prior art.
[0022] Prior art that has relied on reverse curved surfaces channeling water inside a rain gutter due to surface tension, of varied configurations and pluralities, arranged longitudinally, have been noted to lose their surface tension feature as pollen, oil, scum, eventually adhere to them. Additionally, multi-channeled embodiments of longitudinal reverse curve prior art have been noted to allow their water receiving channels to become packed with pine needles, oak tassels, other debris, and eventually clog disallowing the free passage of water into a rain gutter. Examples of such prior art are seen in various other commercially available products. In one such product, dirt and mildew build up on the bull-nose of the curve preventing water from entering the gutter. Other such products are similarly noted to lose their water-channeling properties due to dirt buildup. These commercial products state such, in literature to homeowners that advises them on the proper method of cleaning and maintaining their products.
[0023] None of theses above-described systems keep all debris out of a gutter system allowing water alone to enter, for an extended length of time. Some allow lodging and embedding of pine needles and other debris within their open water receiving areas causing them to channel water past a rain gutter. Others allow such debris to enter and clog a rain gutter's downspout opening. Still others, particularly those employing filter membranes, succumb to a paste and or scum-like healing over and clogging of their filtration membranes over time rendering them unable to channel water into a rain gutter. Pollen and silica dirt, particularly, are noted to cement even larger debris to the filter, screen, mesh, perforated opening, and/or reverse curved surfaces of prior art, adhering debris to prior art in a manner that was not envisioned.
SUMMARY
[0024] A filter assembly is provided that has a filtering screen and a skeletal structure, the skeletal structure being attached to the filtering screen. At least one of the filtering screen and the skeletal structure form a plurality of downward extending channels. The invention employs a filtering membrane and underlying skeletal support system applicable for disallowing small twigs, leaves, pine needles, pollen, and other debris larger than 100 microns from entering the gutter while directing rain water roof run off into an underlying rain gutter in the presence of such debris. The invention employs downward extending planes underside the filtering membrane and supporting skeletal structure that break the forward flow of water.
[0025] Unlike some prior art gutter guards which have a relatively fine-mesh polymer, fiberglass, or metal layer overlying a perforated panel that exhibits no downward water channeling planes, the gutter guard of the present invention includes a filtering screen integrally joined to a perforated expanded metal panel forming a lateral plane with downward extending water channeling paths. The absence of effective downward extending water channeling paths exhibited in prior art that employs filtering methods often allows for the forward channeling of water past rather than downward into an underlying rain gutter. Unlike prior art that does employ effective downward extending water channeling paths in a polymer body, notably LEAFFILTER™, the present invention has been demonstrated to achieve similar properties through a design more readily accomplished at lower cost of manufacture.
[0026] Accordingly, it is an object of the present invention to provide a gutter shield that permits drainage of water runoff into the gutter trench without debris becoming entrenched or embedded within the surface of the device itself and that employs a filtration membrane configuration that possesses sufficient self-cleaning properties that prevent the buildup of scum, oil, dirt, pollen, and pollutants that necessitate eventual manual cleaning as is almost always the case with prior art.
[0027] Another object of the present invention is to provide a gutter shield that redirects water and self-cleans as effectively as the LEAFFILTER™ gutter shield has been shown to do but do so at a lower cost of manufacture.
[0028] Another object of the present invention is to provide a gutter shield that will accept more water run-off into a five inch K-style rain gutter than such a gutter's downspout opening is able to drain before allowing the rain gutter to overflow (in instances where a single three-inch by five-inch downspout is installed to service 600 square feet of roofing surface).
[0029] Other objects will appear hereinafter.
[0030] It has now been discovered that the above and other objects of the present invention may be accomplished in the following manner. Specifically, the present invention provides a gutter screen for use with gutters having an elongated opening. Normally the gutters are attached to or suspended from a building.
[0031] An important feature of the present invention is to capture and redirect water flow across it's filtering membrane downward through the underlying skeletal support of expanded metal and into an underlying rain gutter as effectively as, and at a lower cost of manufacture, than does the LEAFFILTER™ gutter guard.
[0032] Another important feature of the present invention is to redirect downward flow of water rearward to the rear most portion of a rain gutter by means of angled walls comprising diamond shaped openings present in the underlying skeletal support of expanded metal whereby a forward underflow of water on the bottom surfaces of the gutter screen is greatly diminished.
[0033] The gutter shield device includes a first connecting plane of roll formed metal, a second filtering plane of roll formed metal and metallic or polymer cloth, and a third connecting plane of roll formed metal roll formed into an integral unit. The gutter shield device is adapted for being positioned in a longitudinally extending k-style gutter used for capturing rainwater runoff from roof structures.
[0034] According to another preferred embodiment of the invention, the first plane comprises an angled z-shaped connecting member for securing the gutter shield device to an inwardly extending flange of a k-style gutter to hold the gutter shield in place during use. According to another preferred embodiment of the invention, the first plane is fastened longitudinally along the first edge of the second plane by means of roll formed crimps. According to another preferred embodiment of the invention, the second plane comprises a combined fine filtering membrane with an underlying skeletal support of expanded metal support that may be assembled together as an integral unit.
[0035] According to another preferred embodiment of the invention, the filtering membrane has mesh openings not greater than 80 microns, top and bottom surfaces, first and second opposing edges, two opposing ends and an elongated axis extending between opposing ends. Adjacent the filtering membrane is the expanded metal support having diamond shaped openings, each wall of the opening angled downward at approximately 30 degrees, top and bottom surfaces, first and second opposing edges and two opposing ends.
[0036] According to another preferred embodiment of the invention, the first opposing edge of the expanded metal is fastened and crimped by means of roll forming to the first opposing edge of the filtering membrane to form a fast edge portion.
[0037] According to another preferred embodiment of the invention, the second opposing edge of the expanded metal is fastened and crimped by means of roll forming to the second opposing edge of the filtering membrane to form a second edge portion. The expanded metal support and filtering membrane, so joined as an integral plane, are then roll-formed to create two or more v-shaped downward extending longitudinal channels within the integral plane that transverse the length of the invention parallel to the first and second edge portions for redirecting water flow downward into the gutter.
[0038] According to another preferred embodiment of the invention, the third plane comprises a lateral connecting plane longitudinally fastened to the second edge of the second plane for securing the gutter shield device beneath the shingles of a roof. The first and third connecting planes provide a fastening method for securing the gutter shield device in place over a gutter.
[0039] In another embodiment, the third plane comprises a rear vertical leg fastened to and perpendicular to the second plane for resting on a gutter spike or gutter hangar for securing the gutter shield within the open lateral top of a rain gutter.
OBJECTS AND ADVANTAGES
[0040] Of the above described systems, the LEAFFILTER™ self cleaning gutter guard is known to have demonstrated an ability to, in almost every circumstance and over a period of years, prevent either a rain gutter or the gutter guard itself from clogging, or failing to direct water into a gutters downspout, due to debris lodging, or pollen or scum or oil accumulation. Of the remainder of the above described systems it has been noted that a buildup or coating of debris, pollutants, and oils either cause water adhesion properties to be lost or cause blockage of water receiving openings resulting in rain water roof run-off to flow past, rather than into, an underlying rain gutter.
[0041] An object of the present invention is to provide the above noted advantages, accomplished in the LEAFFILTER™ gutter guard, at a reduced cost to manufacturer and consumer. Additional objects of the present invention are to provide a gutter shield device that employs a fine filtration combination that is not subject to gumming or healing over by pollen, silica dust, oils, and other very fine debris, as well as to provide a filtration configuration and encompassing body that eliminates any forward channeling of rain water on surfaces or undersurfaces as is noted in prior art.
[0042] Another object of the present invention is to provide a filtration configuration that does not allow its filter cloth or membrane to sag and develop debris catching pockets. Another object of the present invention is to provide the noted advantages, accomplished in the LEAFFILTERT™ gutter guard, at a reduced cost to manufacturer and consumer. Another object of the present invention is to provide the above advantages in a readily roll-formed gutter guard that may be manufactured on-site, via mobile roll-forming machines, at residential locations allowing for custom fitting of different rain gutters present on residential homes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is a top view of a wire screen which is a component of the present invention.
[0044] FIG. 2 is a top view of a filter membrane which is a component of the present invention.
[0045] FIG. 3 is a top view of the filter membrane illustrating 3 applied adhesive strips.
[0046] FIG. 4 is a top view illustrating the filter membrane applied and resting on an underlying support screen of expanded metal, both being components of the present invention.
[0047] FIG. 5 is a top view of components of the present invention generally shown in FIG. 4 , that introduces two fastening sleeve components of the present invention.
[0048] FIG. 6 is a top view of components of the present invention illustrating an alternate embodiment of securing the filter membrane and underlying screen components of the present invention.
[0049] FIG. 7 is a top view of the present invention that illustrates a filter membrane of greater width than an underlying screen.
[0050] FIG. 8 is a top view of two components of the present invention merged by lapping a wider filtering membrane around lateral edges of an underlying screen and crimping both filter membrane and screen together along their respective lateral edges.
[0051] FIG. 9 is an exploded view of lateral edges of components of the present invention.
[0052] FIG. 10 is top view of components of the present invention generally shown in FIG. 4 .
[0053] FIG. 11 is an exploded view of a water directing channel component of the present invention.
[0054] FIG. 12 is an exploded view of a water directing channel component of the present invention exhibiting walls of the channel crimped together.
[0055] FIG. 13 is a top view of the present invention illustrating a rear attaching component.
[0056] FIG. 14 is an exploded view of the rear attaching component generally shown in FIG. 13 .
[0057] FIG. 15 is a top view of the present invention illustrating a rear attaching component unlike the rear attaching component shown in FIG. 13 .
[0058] FIG. 16 is an exploded view of the rear attaching component shown in FIG. 15 .
[0059] FIGS. 17 & 18 are top views of a preferred embodiment of the present invention.
[0060] FIG. 19 is a cross sectional view of an assembling line.
[0061] FIG. 20 is an exploded view of a roller component of the assembling line.
[0062] FIG. 21 is an exploded view of a tensioned roller component of the assembling line.
[0063] FIG. 22 is a cross sectional view of an assembling line generally shown in FIG. 20 .
[0064] FIG. 23 is a general pictorial view, partial in cross section, illustrating a gutter cover according to the present invention and installed above a conventional gutter adjacent to a conventional building.
[0065] FIG. 24 is a general pictorial view of the present invention generally shown in FIG. 23 , illustrating a different rear attaching member than is shown as employed by the present invention in FIG. 23 .
REFERENCE NUMERALS IN DRAWINGS
[0066] 1 Expanded metal screen
[0067] 1 a width of expanded metal screen
[0068] 2 downward extending channels
[0069] 2 a gap between walls of downward extending channels
[0070] 3 fine mesh membrane
[0071] 3 a width of fine mesh membrane
[0072] 4 glue strips
[0073] 5 sprayed liquid adhesive
[0074] 6 metal z-shaped sleeve
[0075] 7 metal u-shaped sleeve 8 crimps
[0076] 9 rear connecting sleeve
[0077] 10 width of top plane of rear connecting sleeve
[0078] 11 recessed channel
[0079] 12 opening
[0080] 13 gripping tooth
[0081] 14 width of recessed channel
[0082] 15 lower plane of rear connecting sleeve
[0083] 16 lower plane of rear connecting sleeve
[0084] 17 lower plane of rear connecting sleeve
[0085] 18 width of first segment of top plane of rear connecting sleeve
[0086] 19 width of second segment of top plane of rear connecting sleeve
[0087] 20 width of third segment of top plane of rear connecting sleeve
[0088] 21 top horizontal plane of rear connecting member
[0089] 22 top angled plane of rear connecting member
[0090] 23 vertical rear leg of rear connecting member
[0091] 24 height of lower segment of vertical rear leg of rear connecting member
[0092] 25 a - c decoiling cylinder
[0093] 26 rolling assembly cylinder
[0094] 26 a,b,c rolling assembly cylinders
[0095] 27 , 27 a - e shaping and crimping cylinders
[0096] 28 roofing shingles
[0097] 29 rain gutter
[0098] 30 front lip of k-style gutter
[0099] 31 subroof
[0100] 32 preferred embodiments of present invention
[0101] 33 fascia board
DETAILED DESCRIPTION
[0102] Referring now specifically to the drawings, in FIG. 1 a gutter screen (protector) is illustrated 1 with downward extending water receiving channels 2 . The preferred gauge of the gutter screen wire is approximately 0.035 to 0.055 inch, which is suitably thick to maintain it's shape and not deform or dip under load bearing weight of snow and ice. The preferred gauge of the gutter screen wire is also of a narrow enough diameter (0.035 to 0.055) to allow the screen 1 sufficient flexibility to be wrapped around a spindle 25 and later unrolled in a manufacturing process as illustrated in FIG. 19 .
[0103] Referring now to FIG. 1 the gutter screen 1 presents a horizontal surface which extrudes downward into channels 2 , which act to inhibit the forward flow of rainwater off a roof structure by means of their open-air areas 2 a, having no greater than ¼ inch width of open air, which interrupt or inhibit some amount of forward water flow. The forward flow of water is further inhibited by being encouraged to flow downward into an underlying gutter due to a downward flowing water path created by the water tension that exists on the wire surfaces of 1 and 2 as they extend downward into any underlying rain gutter. This is an improvement over gutter screens presented in prior art which tend to channel water forward along their single plane or near single plane wire structures, around open air space apertures present in the same plane of the screen, and past, rather than into, a rain gutter. The side walls of channels 2 are crimped closely together contacting each other creating a honey combed wall that has demonstrated an ability to channel greater volumes of water than a solid plane or fin of the same dimensions that would extend downward. Such fins or planes have been utilized in prior art.
[0104] The downward crimped extensions 2 occurring in the horizontal plane of screen 1 also offer an improvement over prior art that employs fine screen or mesh placed over a perforated undulating or wavy support skeleton: Such prior art exhibits lateral weakness, tending to concave, and also provides fewer contact points between fine screen mesh and larger underlying support screen allowing for sagging of the supported mesh to occur. It has also been observed that sequential “waves” or undulations separated by open air space, channel a lesser volume of water downward and allow more to channel forward than does the compressed or crimped channels 2 of the present invention. Prior art that employs waves or undulations as a supporting skeleton for an overlying finer mesh, if constructed of identical material as the present invention, incurs greater cost of manufacture, as more material is required for prior art to cover the same amount of open gutter the present invention would cover.
[0105] Referring now to FIG. 2 : a filtering membrane 3 is illustrated that is comprised of warp-knit or “junctured” (threads not crossing over and under each other but, rather, passing through or adjoining each other) metal or polymer threads that form a fabric or mesh with air space between threads of approximately <80 microns. This particular method of fabric or mesh construction prevents the smallest of debris from “catching” and then lodging in the membrane itself as is common with filter methods, cloth, and membranes presented in prior art. Testing has shown that filtering membranes and screens so constructed, and made to contact each other in as many points as possible, as illustrated in FIG. 10 , (with the points of contact being limited to no greater widths than 0.03 inches) exhibit great resistance to clogging or matting due to pollen, oil that leaches from shingles, and other pollutants that commonly coat prior art and eventually lead to the loss of water permeability and water adhesion. A particular test of the invention involved immersing the invention in 30 wt oil: within 10 seconds water permeability of the invention was regained. Prior art so tested: filters, perforated planes, fins, curved surfaces, tangled mesh, louvers, multi-channeled curved surfaces, filtering membranes over planar perforated surfaces, filtering membranes over undulating or wavy surfaces, demonstrated significant loss of water adhesion and siphoning abilities for hours and, in some instances, days.
[0106] As shown in FIG. 1 the screen 1 , can have diamond shaped water receiving openings 51 having angled metal walls 52 . The filtering membrane 3 can contact the top surface of the angled metal walls such that a point of contact forms angles greater than or less than 90 degrees between the bottom surface of the filtering membrane 3 and the top surface of the angled metal walls. The metal walls can be angled approximately 30-40 degrees whereby multi-angled redirection of forward water flow downward into the gutter is realized aiding siphoning and self-cleaning properties of the gutter screen. The metal walls can be angled downward and rearward from the forward longitudinal edge of the gutter screen whereby forward flow of water is further limited and redirected downward. The width of the diamond shaped water receiving openings 51 can be equal to or greater than ⅜ inch whereby water bridging paths across the water receiving openings and resulting forward flow of water is diminished.
[0107] Limiting the space between threads to approximately 80 microns, does allow sufficient water permeability, approximately 75%, to accommodate rainfall run-off if the threads are warp-knit or “junctured”. Tests have shown that when such cloth is tilted at angles greater than 20 degrees, forward flow of water begins and water permeability of the filtering cloth is significantly reduced. When, however, such cloth or membrane 3 is made to contact underlying planes that extend downward, additional surface tension is created at the points of contact and the siphoning ability of the filtering membrane is regained. When such downward extending planes are composed of porous sidewalls that contact each other, the siphoning ability of the filtering membrane is not only regained, but improved and water permeability (or the ability to siphon water downward through the membrane) of filtering membranes will increase and remain as high as 97% even when such membrane is tilted at angles of 50 degrees (referenced to a horizontal plane).
[0108] Referring to FIG. 3 , adhesive strips 4 are applied at each edge and at an approximate center location on the underside of filter membrane 3 . This process may be accomplished at a fabric mill at the time of cloth manufacture and is one method of affixing filtering membrane 3 to underlying screen 1 .
[0109] Referring to FIG. 4 liquefied adhesive paths 5 are sprayed or otherwise applied to the top surface of screen 1 where they then are made to contact the underside of filter membrane 3 as an alternate method (to adhesive strips) of affixing filter membrane 3 to underling screen 1 . The spraying would be accomplished at the site of the roll forming merger of membrane 3 to underlying screen 1 as is illustrated in FIG. 19 : spraying head 41 spraying liquefied adhesive 5 to the top surface of screen 1 .
[0110] Referring to FIG. 22 the filter membrane 3 wound on a spool 25 a, may be unwound and applied and pressed onto the top surface of gutter screen 1 , by tensioning roller bars 26 a, 26 b, and 26 c as is illustrated. The tensioning bars are intended to position the filter membrane 3 in place as the adhesive strips (or narrow paths of adhesive spray) temporarily secure the filter membrane to the gutter screen 1 allowing permanent securing sleeves 6 and 7 (supplied by decoiling cylinders 25 b, 25 c ) to be roll formed and crimped on to sides of filter screen 1 and membrane 3 by tooled dies 27 , 27 a, 27 b, 27 c, 27 d, & 27 e.
[0111] Referring to FIG. 4 it is illustrated that the adhesive strips or spray 5 , which join filter membrane 3 to screen 1 are not positioned over downward extending channels 2 . Doing so may create a “bridging effect” that would encourage forward water flow across the glue paths or strips rather than encourage the downward siphoning effect on water the channels 2 exhibit. The adhesive strips 4 do, however, act to impede the forward flow of water and when positioned away from channels 2 : The adhesive strips or spray paths 5 indirectly allow the downward extensions 2 to more effectively siphon water downward and into the rain gutter beneath by slowing the water flow entering the downward extensions as well as slowing the lesser amounts of water that falls through the remaining non-channeled portions of screen 1 .
[0112] This unique dual use of the adhesive strips or stray paths is an improvement over filtered gutter cover methods presented in prior art that tend to channel water by surface tension along single planed horizontal surfaces past the top opening of a rain gutter. This dual use of the adhesive strips or spray paths also offers an improvement over prior art that employs fine mesh over undulating or wavy support skeletons that may glue filtering mesh to the underlying skeleton along the top of undulations or waves, encouraging forward flow water paths and/or no glue paths whatsoever exist to inhibit forward water flow.
[0113] Referring to FIG. 5 , sleeve 6 is a metal or polymer “z” shaped length, approximately ½″ to 1″ in width, that will be crimped 8 onto the left edge of gutter screen 1 and filter membrane 3 permanently fastening them together as illustrated in FIG. 6 . Sleeve 6 of FIG. 5 provides a means of fastening the left (or forward facing) edge of the invention to the top lip of a K-style rain gutter. Sleeve 7 is a metal or polymer “u” or “v” shaped length approximately ½″ to 1″ in width that will be crimped 8 onto the rear (or right) edge of gutter screen 1 and filter membrane 3 permanently fastening them together.
[0114] The invention offers improvement over prior art in that the junctured or warp-knit construction of both screen 1 and membrane 2 , when joined and achieving as many points of contact as possible exhibits greater water permeability than has been seen in prior art employing fine filtration membrane or cloths whose thread pattern is not so constructed: The invention also offers improvement over prior art that employs filtering screens or cloths, in different embodiments, in that the present invention exposes greater surface area, per rear to forward lateral inch, of water permeable membrane (that is able to effectively direct water flow) to oncoming rain water roof run-off by means of the present invention's downward extensions 2 .
[0115] The invention, FIG. 6 , additionally offers improvement over prior inventions in that it demonstrates great resistance to residual organic buildup which has been demonstrated to clog, and render ineffective, prior art over time. The combination of the particular type of a “warp-knit” or “junctured” filtration cloth or fine mesh over a screen mesh or hardware cloth with diamond shaped openings (that also employs wires junctured together on an equal plane (rather than woven up and under one another) creates a stronger downward siphoning action than is exhibited in prior art that utilizes fine or medium filter membranes or cloth fastened over underlying screens or perforated surface. The strong siphoning action, downward water channeling, and water permeability of the invention is due, in part, to the myriad of “blocks” to forward water flow presented by warp knit or “junctured” mesh or cloth: each thread intersects or abuts another causing water flow to “brake”, then climb up and over a new thread, time and time again at each thread intersection, without being able to follow a more continuous and unobstructed flow path available with other threading methods such as under and over, or knotted thread weaving, or knitting, or non-woven lofty fiber methods. Gravity is then able to exhibit more force on any water, present on the invention, than does the momentum of forward water flow.
[0116] Referring to FIG. 19 , a spray jet 41 spraying a quick drying weak adhesive 5 onto the top surface of gutter screen 1 is shown as an alternative way of temporarily fastening and holding in place the filter cloth membrane 3 until sleeves 6 and 7 are crimped onto the edges of filter cloth membrane 3 and gutter screen 1 achieving a permanent fastening of the filter membrane to the gutter screen.
[0117] Referring to FIG. 7 , there is illustrated a filter membrane 3 slit to a width wider than the underlying skeleton 1 it will attach to.
[0118] Referring to FIG. 9 , it is illustrated that a metal wire cloth membrane of junctured or warp-knit construction, with thread per inch counts of 100 or more, is wrapped around and under a side edge of a supporting skeleton 1 . The wire cloth is then crimped 8 onto the underlying support screen. This method of securing a screening element to an underlying support structure offers an improvement over prior art in that such a securing method is easily accomplished, economical, and does not require a third additional fastening element or material.
[0119] Referring to FIGS. 10 , 11 , & 12 it is illustrated that membrane 3 a is roll formed down into channel 2 , (illustrated in the exploded view of FIG. 11 ). FIG. 12 illustrates that channel 2 is then crimped together so that membrane 3 and screen 1 contact each other within the well of channel 2 . This embodiment of channel 2 is another, less costly, method of achieving “downward extending legs”, disclosed in U.S. Pat. No. 6,598,352, column 13, lines 40-47, that break the forward flow of water and redirect water away from an overlying filtering membrane and also serves to further secure membrane 3 to underlying screen 1 . A downward curve of the combined screen 1 and membrane 3 is created at the top of each “leg” of channel 2 and is another, less costly, method of achieving “oval ellipses”, disclosed in U.S. Pat. No. 6,598,352, column 13, lines 47-51, that redirect water away from an overlying filtering membrane to underlying “downward extending legs”. This embodiment of channel 2 additionally creates a honey-combed porous plane that presents a great number of downward flow paths to water which is traveling the surface of an upper plane the channels 2 are connected to.
[0120] The greater number of flow paths presented by this honey-combed embodiment of channels 2 , over prior art that employs downward extending fins, or open air apertures in a singular plane, or curved surfaces, or singular filters, or filtering membranes over planar surfaces, or filtering membranes over undulating or wavy surfaces, offers improved siphoning ability and water re-direction into an underlying gutter.
[0121] Channel 2 should leave an open air space 2 a of no greater width than ⅛ inch. FIGS. 10 , 11 , & 12 demonstrate the preferred securing of membrane 3 a to underlying support skeleton 1 . The roll forming of 3 a down into channels 2 illustrates the most effective embodiment of channels 2 of the present invention: this embodiment best redirects water flow into an underlying gutter while presenting only minute areas, 2 a, where debris may tend to gather.
[0122] FIG. 13 and FIG. 15 illustrate two interchangeable rear attachments: 9 and 14 . The attachments have a forward securing configuration 13 , 15 , 16 , and 17 that allow the attachments to interchangeably clip onto main body 1 a. Rear attachment 9 may be utilized in instances where it may be advantageous to install the rear of the gutter cover onto, or sandwiched between, a roof membrane and underlying sub roof as is illustrated in FIG. 24 . Rear attachment 14 may be utilized in instances where it is desirable to allow the gutter cover to rest wholly inside the top open end of a rain gutter and not have any part of the gutter cover extend up onto a roof as is illustrated in FIG. 23 .
[0123] Referring to FIG. 14 it is illustrated that two indented channels 40 lie in plane 10 of rear channel 9 . These channels may serve to act as flex or adjusting points and to enable heating cables to be inserted into them, if desired.
[0124] Referring to FIG. 16 an exploded view of rear attachment 14 is seen. Plane 22 of rear attachment 14 can contact a fascia board and create a rear to forward tension to secure the present invention into the top open end of a rain gutter.
[0125] FIGS. 14 and 17 illustrate a preferred embodiment of the present invention:
[0126] A cloth filtering membrane 3 , with openings limited to no larger than 80 microns and of junctured or warp knit construction, is roll formed onto the top surface of supporting screen 1 and down into channels 2 and then roll formed around the lateral edges of support screen 1 and subsequently crimped in place near the later edges of supporting screen 1 and filtering membrane 3 , (as illustrated in FIG. 10 ). Channels 2 extend to lengths not less than ¾ inch and are crimped tightly together so that each side wall of the channels physically contact each other creating a micro-porous honey-combed downward extending plane. Testing has indicated that channels 2 begin to forward channel water on the underside of supporting screen 1 when their length is less than ¾ inch. A z-shaped roll-formed strip 6 is then crimped onto the forward lateral edge of the present invention: strip 6 will act to secure membrane 3 to underlying support skeleton 1 as well as serve to secure the gutter screen (the present invention) to the forward top lip of a k-style gutter. A choice of rear attachments 14 and 9 may then act to further secure membrane 3 to screen 1 . Additionally, the attachments allow the present invention 32 to act as a rain gutter screen that may be inserted wholly into the top of a rain gutter, resting on securing spikes or gutter hangars, and held in place by rear to forward tension (when 14 is chosen as the rear attachment) as is illustrated in FIG. 23 , or to serve as a gutter screen that allows for the insertion of it's rear attachment 9 beneath a roofing membrane or shingles to secure the present invention in place as is illustrated in FIG. 24 .
[0127] An improvement if offered over prior art in that the interchangeability of rear attachments 9 and 14 offer a configurable gutter cover that may be adjusted for installation in a wider array of circumstances existing in the field than is offered by prior art, which are known to be limited to the single choice of either “under the shingle” installation or to “wholly inside the gutter” installation.
Operation
[0128] Referring to FIGS. 23 and 24 , rain water will flow from a roof structure 28 onto the filtering membrane and screened plane 32 of the invention. The filtering membrane and screen combination 32 will redirect water flow downward into an underlying rain gutter. Testing has shown that 32 , absent channels 2 , is able to redirect approximately 50% of rainfall that contacts 32 when rainfalls of 3 to 5 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch. Testing further indicates that, when plane 32 incorporates channels 2 , the invention is able to redirect approximately 97% of rainfall into an underlying rain gutter (when rainfalls of 3-5 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch.) Testing of the invention, in it's preferred embodiment, indicate that the invention is capable of redirecting approximately 90% of rain fall into an underlying rain gutter when rainfalls of 8-10 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch. Significant water run-off or over shoot has been noted when the invention is installed on rain gutters that service roofs with pitches less than 3/12 and at “inside valleys” of hip valley roofs.
[0129] Debris, that may accompany rainfall runoff or that may, by other means, contact the invention will not lodge within or cling to plane 32 . Prior art commonly allows shingle grit, oak tassels, fir needles, and other small debris to enter a rain gutter or to become within the prior art itself. Testing has indicated the present invention makes this occurrence nearly impossible. Gravity or water adhesion may temporarily cause debris to rest on top of plane 32 , but it has been noted that water from roof run-off will travel beneath such debris and contact plane 32 and be directed into the underlying rain gutter 29 . Debris has been noted to rest or lodge on or within prior art and cause a bridging effect which channels water past the water receiving areas of prior art and onto the ground.
[0130] It has been noted that pollen has the capacity to “cement” debris to prior art, and to the present invention. Testing has shown that pollen may coat 32 but will wash through as soon as water from roof run-off contacts it. Testing has shown this is not the case with prior art: pollen tends to remain on prior art and require physical removal for restoration of water adhesion and/or permeability.
[0131] It is illustrated in FIG. 23 that the present invention may be inserted or snapped into the top open end of a rain gutter and remain in place by a rear to forward tension existing across plane 32 that is created by attachment 14 contacting fascia board 33 and z-shaped roll-formed strip 6 contacting the top upper lip 30 of a k-style gutter. Attachment 14 rests on an underlying hangar or spike and may be notched out to fit over them if necessary to maintain a constant level plane across sections of the invention as it is installed. Many building owners prefer that shingles or roof membranes not be lifted and disturbed due to the possible voiding of shingle warranties, and also prefer a gutter guard to install in a fashion that does not allow it to contact a building's sub roof: much prior art requires such installation.
[0132] Also, many homeowners find the appearance of a gutter guard covering the fast row of shingles on their home to be unattractive. In these instances, an installer in the field may snap attachment 14 onto the rear edge of plane 32 .
[0133] In some instances, a home or building owner may desire a “wholly inside the gutter” installation as is illustrated in FIG. 23 , but certain sections of a rain gutter may have shingles extending down into a gutter, or straps that extend from a subroof down into the gutter or onto it's top front lip, or the gutter may have a cable or other wire directly over it and passing thought the fascia board 33 it is attached to, or a drip edge may extend down into a gutter making the installation of a “wholly inside the gutter” gutter guard difficult or impossible. In these instances, an installer may opt to snap or place attachment 9 onto the rear lateral plane of 32 and continue installation with a matched product.
[0134] The invention will be manufactured in lengths that simply butt together at installation. Either rear attachment allows for quick installation and provides a gutter guard that ensures debris as small as 80 microns, or a grain of shingle grit, will not enter a gutter, and additionally ensures the gutter guard itself will remain water permeable and effective at channeling water into a rain gutter.
[0135] The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described. | A filter assembly includes a filtering screen having a top surface and a bottom surface. A skeletal structure is attached to the filtering screen and has a top surface and a bottom surface. The bottom surface of the filtering screen contacts the top surface of the skeletal structure. The skeletal structure forms a plurality of downward extending channels. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to hinges and more particularly, to a hinge, which uses a split retaining tube in a barrel to secure a pivot shaft, for allowing the pivot shaft to be rotated relative to the barrel and quickly positioned in the desired angle.
2. Description of the Related Art
A consumer electronic product with a lifting cover such as mobile computer, electronic dictionary, mobile video player, cell phone, etc., commonly uses a hinge to coupled the cover to the base member so that the cover can be opened from or closed on the base member. Therefore, the hinge also determines the quality level of the product. A good hinge allows positive positioning and does not cause noises during operation.
There is known a socket type hinge, which enables the pivot shaft to be positively positioned in the adjusted angular position. According to this design, the hinge comprises a female hinge member, which defines therein an axle hole, a male hinge member, which has a split shaft body positioned in the axle hole. The split shaft body of the male hinge member has two friction portions disposed in friction engagement with the peripheral wall of the axle hole of the female hinge member. However, this design of socket type hinge is not durable in use because the friction portions wear quickly with use.
Taiwan patent publication no. 313274, issued to the present inventor, discloses an improved structure of hinge for computer. According to this design, a springy adapter is provided between the male hinge member and the female hinge member to impart a friction resistance to the male hinge member, holding the male hinge member positively in the adjusted position. According to this design, the female hinge member must be processed to provide an inside annular step for securing the male hinge member in place. The processing of such an inside annular step is complicated, increasing the manufacturing time of the hinge.
SUMMARY OF THE INVENTION
The present invention has been accomplished under the circumstances in view. According to one aspect of the present invention, the hinge comprises a pivot shaft, a retaining split tube, and a barrel. The pivot shaft has a mounting portion for mounting, a shaft body, and a collar connected between the mounting portion and the shaft body. The shaft body has at least one annular locating groove extending around the periphery thereof. The barrel is capped on the shaft body of the pivot shaft and stopped against the collar of the pivot shaft, having an inside wall, a receiving open chamber surrounded by the inside wall for receiving the shaft body of the pivot shaft, and a mounting portion extended from one end thereof for mounting. The resilient retaining split tube is mounted in the receiving open chamber around the shaft body of the pivot shaft and forced by the inside wall of the barrel into friction with the periphery of the shaft body of the pivot shaft. The resilient retaining split tube has a plurality of angles respectively disposed in contact with the inside wall of the barrel, a plurality of planes respectively separated by the angles and disposed in contact with the periphery of the shaft body of the pivot shaft, a longitudinal crevice defined between two adjacent planes, and at least one retaining strip respectively protruded from the planes and engaged with the at least one annular locating groove of the shaft body of the pivot shaft to secure the pivot shaft to the retaining split tube and the barrel.
According to another aspect of the present invention, the mounting portion of the pivot shaft and the mounting portion of the barrel each have at least one mounting hole for mounting.
According to still another aspect of the present invention, the mounting portion of the pivot shaft and the mounting portion of the barrel each have at least one longitudinally extending plane.
According to still another aspect of the present invention, the number of the at least one annular locating groove of the pivot shaft is 1; the number of the at least one retaining strip of the split retaining tube is 2, and the two retaining strips are disposed at two sides relative to the longitudinal crevice and respectively engaged into the annular locating groove of the pivot shaft.
According to still another aspect of the present invention, the shaft body of the pivot shaft has a spiral grease groove extending around the periphery thereof for accommodating lubricating grease, and a chamfered end edge at the distal end remote from the collar.
According to still another aspect of the present invention, the split retaining tube has a relatively higher hardness than the barrel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a hinge according to the present invention.
FIG. 2 is a sectional assembly view of the hinge according to the present invention.
FIG. 3 is a cross-sectional view taken along line A-A of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1˜3 , a hinge in accordance with the present invention is shown comprised of a pivot shaft 1 , a retaining split tube 2 , and a barrel 3 .
The pivot shaft 1 has a mounting portion 11 disposed at one side for fastening to a body, for example, the cover member of a mobile electronic device, a shaft body 13 disposed at the other side for coupling to the retaining split tube 2 , a collar 12 connected between the mounting portion 11 and the shaft body 13 for stopping against the barrel 3 . The mounting portion 11 can be made in the shape of a flat bar, triangular prism, rectangular bar, or polygonal bar. Further, the mounting portion 11 can be made having mounting through holes for fastening to the cover member of a mobile electronic device with fastening members, for example, screws. The shaft body 13 has a chamfered front end 16 convenient for insertion into the retaining split tube 2 , an annular locating groove 14 extending around the periphery adjacent to the chamfered front end 16 , and a spiral grease groove 15 for receiving lubricating grease.
The retaining split tube 2 is a polygonal, for example, pentagonal split tube made of a metal spring plate, having a plurality of angles 21 and planes 22 alternatively arranged around the periphery, a longitudinal crevice 23 defined between two adjacent planes 22 and extending through two distal ends, and two retaining strips 24 respectively protruded from the two planes 22 at two sides of the longitudinal crevice 23 for engaging the annular locating groove 14 of the shaft body 13 of the pivot shaft 1 to secure the pivot shaft b 1 b to the inside of the retaining split tube 2 .
The barrel 3 has a barrel body 32 , a receiving open chamber 33 defined in the barrel body 32 and extending to one end of the barrel body 32 in communication with the atmosphere, and a mounting portion 31 extended from the other end of the barrel body 32 for fastening to, for example, the base member of the aforesaid mobile electronic device. The mounting portion 31 of the barrel 3 can be made in the shape of a flat bar, triangular prism, rectangular bar, or polygonal bar. Further, the mounting portion 31 can be made having mounting through holes for fastening to the base member of the mobile electronic device with fastening member, for example, screws. Further, the hardness of the retaining split tube 2 is relatively higher than the barrel 3 .
During installation, the retaining split tube 2 is attached to the shaft body 13 of the pivot shaft 1 to force the locating groove 14 of the pivot shaft 13 into engagement with the two retaining strips 24 of the retaining split tube 2 . Thereafter, the retaining split tube 2 is inserted with the pivot shaft 1 into the receiving open chamber 33 of the barrel 3 . At this time, the inside wall of the barrel 3 compresses the retaining split tube 2 radially inwards (because the diameter of the retaining split tube 2 is slightly greater than the inner diameter of the barrel body 32 of the barrel 3 , thereby keeping the retaining strips 24 in engagement with the annular locating groove 14 of the shaft body 13 of the pivot shaft 1 . When rotating the pivot shaft 1 , the inside wall of the barrel body 32 imparts a pressure to the angles 21 of the retaining split tube 2 , forcing the planes 22 in friction with the periphery of the shaft body 13 of the pivot shaft 1 . Therefore, the pivot shaft 1 is quickly positioned in position after disappearance of the external biasing force.
As indicated above, the invention provides a hinge, which is comprised of a pivot shaft, a retaining split tube, and a barrel. The retaining split tube is radially inwardly forced by the inside wall of the barrel against the periphery of the shaft body of the pivot shaft, thereby producing a friction resistance to hold the pivot shaft in position. Further, the split retaining tube has retaining strips engaged with the annular locating groove of the pivot shaft, preventing disconnection of the pivot shaft from the barrel. Further, the pivot shaft has a spiral grease groove spirally extending around the periphery of the shaft body of the pivot shaft for accommodating lubricating grease to lubricate the contact area between the pivot shaft and the split retaining tube.
Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. | A hinge includes a pivot shaft affixed to a first member, a barrel affixed to a second member, a polygonal retaining split tube mounted in the barrel around the shaft body of the pivot shaft and hooked on an annular locating groove at the shaft body of the pivot shaft and forced by the inside wall of the barrel in friction engagement with the periphery of the shaft body of the pivot shaft. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. Ser. No. 12/386,016 filed on Apr. 13, 2009; which is a continuation application of U.S. Ser. No. 11/880,000, filed on Jul. 19, 2007, which are incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates to a window covering that may be raised without the need to apply a force to either a control mechanism or the window covering itself as the window covering is opened. In particular, the present invention relates to a window covering having a control mechanism configured to exert an upward force on the shade element and bottom rail that is of sufficient magnitude to raise the shade element and bottom rail without additional force being applied by the user during raising.
BACKGROUND OF THE INVENTION
[0003] Window shades and coverings are found in many applications and used to regulate the amount of light entering a room, and to provide aesthetic appeal to a decor. Such window shades and coverings take many forms, including roller shades, Roman shades, Venetian blinds, and cellular shades. Conventional cellular or pleated shades utilize cord locks or a transmission mechanism to raise, lower and position the window covering in a desired position. With window coverings utilizing a cord lock, cords run up through the folded fabric, across the inside of a head rail and exit through a locking mechanism. Other cellular shades include a transmission mechanism and a continuous loop cord that is pulled by a user to raise and lower the window shade. Roman shades and Venetian blinds also tend to include raising cords that are secured to a lower bar or bottom rail.
[0004] There are some disadvantages to these designs. Cords present the potential hazard of a child getting caught in or strangled by the exposed control cord. Cords also tend to distract from the aesthetics of a window covering in that they extend along the face of the window covering and, when the window shade is opened, must either be wrapped on a hook or just left on the floor. With window coverings that utilize cord locks, the cords also experience substantial wear due to friction against surfaces as a result of raising and lowering of the window covering.
[0005] Other window coverings include common roller shades, which operate in the absence of a cord. These roller shades include a wound torsion-spring retraction mechanism in combination with a clutch or locking mechanism mounted with a roller onto which the shade is rolled and collected. In operation, a roller shade is pulled down by a user to a desired location, where it is locked in place by the clutch or locking mechanism. To unlock and release the shade so that it may be raised, the user typically pulls on a bottom rail of the shade, extending the shade sufficiently to disengage the internal clutch or locking mechanism within. When the clutch or locking mechanism is disengaged and the user releases the shade, the shade is retracted using the torsion-spring driven retraction mechanism. Known roller shades, however, are only operable with flat shade material which rolls up neatly into a confined location.
[0006] The mechanism utilized in such roller shades is not compatible with other window coverings, such as cellular shades, Venetian blinds, and Roman shades. As roller shades are raised, the amount of shade being lifted decreases such that a constant force torsional spring member is capable of applying the necessary winding or upward force throughout the opening range. By contrast, a similar lifting mechanism is typically unsuitable in cellular shades, Venetian blinds, and Roman shades. In these types of window coverings the material of the shade element is typically gathered by raising a bottom member, such as a bottom rail, and increasing amounts of weight are gathered on the bottom member as the window covering is raised. The reason for this is that the shade material or shade element increasingly stacks on the bottom rail as the bottom rail rises, which increases the load on the lifting mechanism.
[0007] In order to address this increasing weight, very strong torsional springs have been used to accommodate the maximum weight of the shade. One drawback to this approach, however, is that the rate at which the window covering is retracted may be too fast and uncontrolled. One attempt to address this problem is found in U.S. Pat. No. 6,666,252, issued to Welfonder. This patent teaches the use of a fluid brake to control the rate at which the raising cords are retracted throughout the raising process. Another approach that has been used is shown in U.S. Pat. No. 6,056,036, issued to Todd, which employs a mechanical friction member to continuously slow the rate of retraction. One problem with these approaches has been that the spring utilized exerts a force that makes it difficult for a user to overcome when attempting to lower the shade. Excessive pulling force by the user often results in damage to the window covering.
[0008] Alternatively, variable force springs have been used. Such variable force springs are substantially more complicated in use and manufacture.
[0009] Therefore, there is a need for a window covering raising mechanism for window coverings such as Venetian blinds, cellular shades and Roman shades that is self-raising and overcomes the foregoing problems.
SUMMARY OF THE INVENTION
[0010] The present invention relates to a self-raising window covering and a control mechanism for the window covering. In particular, the window covering is a self-raising window covering that includes a head rail, a shade element, such as a cellular panel, blind slats, or Roman shade material, a bottom rail, at least one raising cord operatively connected at a first end to the bottom rail, and a control mechanism. The head rail may define an elongated channel wherein the control mechanism is disposed therein. In some embodiments, the control mechanism includes a drive axle and a drive unit operatively connected with the drive axle. The drive unit, which may be a constant force spring, is adapted to provide a substantially constant rotational force on the drive axle.
[0011] At least one cord winding assembly is also provided in co-axial relation with the drive axle. Typically, the number of cord winding assemblies will be the same as the number of raising cords. However, in some instances, one cord winding assembly may be adapted to operate with multiple cords. The cord winding assembly includes at least one winding drum operatively connected to a second end of the raising cord and having a tapered portion. The cord winding assembly also includes a rotatable positioning member for moving the cord winding assembly laterally along the drive axle upon rotation of the positioning member. In a preferred embodiment, the positioning member is a threaded tubular member connected to the winding drum. The cord winding assembly is adapted to translate the rotational force on the drive axle to a raising force on the raising cord, wherein the raising force is greater than a total downward force exerted by the shade element and bottom rail throughout the range of opening and closing. In a preferred embodiment, the cord winding assembly is rotationally secured with the drive axle by a hub member adapted to engage the cord winding assembly and the drive axle. The hub member may be in a sliding relationship with the tapered portion of the cord winding assembly.
[0012] A clutch member or locking member is also operatively connected with the axle and adapted to releasably lock the drive axle in a desired position. In a preferred embodiment, the clutch member comprises a reciprocator disposed coaxially relative to the drive axle and movable between a released position and a locked position, and a spring member connected to the reciprocator and operable to either tighten or relax the hold of the reciprocator on the drive axle. The reciprocator is configured to cause the spring member to tighten on the drive axle in the locked position for blocking a rotation of the drive axle against the rotational force applied by the drive unit, and cause the spring member to relax the drive axle in the released position to permit a rotation of the drive axle under the rotational force applied by the drive unit
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view, partly in cutaway, of a preferred embodiment of a window covering according to the present invention;
[0014] FIG. 2 is an exploded perspective view of the single spring coil drive unit of FIG. 1 ;
[0015] FIG. 3 is a side elevational cross section view of the single spring coil drive unit of FIG. 1 ;
[0016] FIG. 4 is a side elevational cross section view of an alternative single spring coil drive unit;
[0017] FIG. 5 is a side elevational cross section view of a double spring drive unit;
[0018] FIG. 6 is a side elevational cross section view of an alternative double spring drive unit;
[0019] FIG. 7 is an exploded perspective view of the cord winding assembly shown in FIG. 1 ;
[0020] FIG. 8A is a front elevational view of the window covering of FIG. 1 in a closed position and with the head rail in cross section;
[0021] FIG. 8B is a front elevational view of the window covering of FIG. 1 in a partially open position and with the head rail in cross section;
[0022] FIG. 9A is a perspective view of a preferred clutch member when the window covering is in a fully raised position;
[0023] FIG. 9B is a cross sectional view of the clutch member of FIG. 9A ;
[0024] FIG. 10A is a perspective view of the clutch member of FIG. 9A as the user pulls down on the window covering;
[0025] FIG. 10B is a cross sectional view of the clutch member of FIG. 10A ;
[0026] FIG. 11A is a perspective view of the clutch member of FIG. 9A as the user releases the window covering;
[0027] FIG. 11B is a cross sectional view of the clutch member of FIG. 11A ;
[0028] FIG. 12A is a perspective view of the clutch member of FIG. 9A as the user pulls down on the window covering to release the clutch member;
[0029] FIG. 12B is a cross sectional view of the clutch member of FIG. 12A ;
[0030] FIG. 13A is a perspective view of the clutch member of FIG. 9A as the window covering self-raises;
[0031] FIG. 13B is a cross sectional view of the clutch member of FIG. 13A ;
[0032] FIG. 14 is a perspective view of an alternative embodiment of a window covering according to the present invention with a deceleration member;
[0033] FIG. 15A is a side elevational cross section view of the deceleration member of FIG. 14 disengaged from one cord winding assembly;
[0034] FIG. 15B is a side elevational cross section view of the deceleration member of FIG. 14 engaging one cord winding assembly; and
[0035] FIG. 15C is a side elevational cross section view of the deceleration member of FIG. 14 when the window covering is fully raised.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] The invention disclosed herein is susceptible to embodiment in many different forms. Shown in the drawings and described in detail hereinbelow are preferred embodiments of the present invention. The present disclosure, however, is only an exemplification of the principles and features of the invention, and does not limit the invention to the illustrated embodiments.
[0037] Referring to FIG. 1 , an embodiment of a self-raising window covering 10 according to the present invention is shown. A head rail 12 defining a channel is provided. A pair of drive units, such as spring units 14 and 16 are coaxially mounted about a drive axle 18 . Also mounted on drive axle 18 are cord winding assemblies 20 and 22 . Each of cord winding assemblies 20 and 22 includes a frustoconical winding drum 24 and 26 , and a threaded tubular member 32 and 34 , respectively. Raising cords 28 and 30 , which are shown as wound on winding drums 24 and 26 , are secured at an end to the winding drums 24 and 26 . In this embodiment, a clutch 36 is also provided and co-axially mounted on the drive axle 18 . Each of these components is discussed in greater detail below. Window covering 10 further includes a shade element, such as cellular shade material 38 and a bottom member, such as bottom rail 40 . The term “cord” as used may encompass a cord, strip, ribbon, string or any similar flexible elongated elements that are suitable for supporting the suspended shade element, and can be wound or unwound to deploy or retract the shade element. A relatively short length of cord 42 can also be provided so that the user can pull down the window covering and, as will be discussed in further detail, release the clutch so that the window covering will retract itself.
[0038] Referring to FIG. 2 , a preferred embodiment of the spring unit 14 is shown. The spring unit 14 comprises a spring casing 42 , a spring axle 44 , a constant force coil spring 46 and a cover 48 . The coil spring 46 and the spring axle 44 are secured within the casing 42 , which is closed by cover 48 . A first end 50 of the coil spring 46 is secured to the spring axle 44 , which is coaxially connected to the drive axle 18 ( FIG. 1 ). In this preferred embodiment, the coil spring is configured to provide sufficient rotational force to the drive axle 18 and winding drums 24 and 26 to raise the shade element and bottom rail. Other alternative embodiments of spring units are also possible, such as shown in FIGS. 3-6 .
[0039] For example, a suitable spring unit 114 shown in FIG. 3 may include a coiled spring member 146 having a first end secured with a first spring axle 142 that connects to the drive axle 18 shown in FIG. 1 , and a second end secured with a second spring axle 144 that is offset from the first spring axle 142 . The coiled spring 146 in a relaxed position may be initially wound around the second spring axle 144 . As the shade element is pulled downward, the coiled spring 146 may stretch out from the second spring axle 144 and progressively wind around the first spring axle 142 . This configuration of the spring unit 114 may be suitable when the used coiled spring 146 has a greater length to allow a longer deployment range of the shade element.
[0040] FIG. 4 illustrates another suitable spring unit 214 , which is similar to the embodiment shown in FIG. 3 except that the second end of the coiled spring does not connect to any second spring axle. Instead, the coiled spring 246 winds on itself at its second end, while the first end 252 of the coiled spring 246 connects to a single spring axle 218 connected to the drive axle 18 shown in FIG. 1 .
[0041] Still other suitable embodiments of spring units are shown in FIGS. 5 and 6 . In FIG. 5 , spring unit 314 includes an assembly of two coiled springs 346 and 348 that may be used to provide a greater raising force for the shade element. The first coiled spring 346 has its first end connected to a first spring axle 344 , and the second coiled spring 348 has its first end connected to a second spring axle 345 . The second end of the first coiled spring 346 and the second end of the second coiled spring 348 respectively connect to a third spring axle 318 located between the first and second spring axles 344 and 345 and connected to the drive axle 18 . As the shade element is pulled downward, the coiled springs 346 and 348 may respectively stretch out from the first and second spring axle 344 and 345 to progressively wind around the third spring axle 318 to apply an increased raising force on the drive axle 18 . In FIG. 6 , the shown embodiment is very similar to that shown in FIG. 5 except that the two coiled springs 446 and 448 that wind on the axle 418 connected to the drive axle do not connect with second spring axles. Although each of the embodiments shown utilizes a spring as the driving mechanism for the drive unit, it should be understood that any suitable mechanism for imparting a rotational force on the drive axle may be utilized.
[0042] Referring again to FIG. 1 , the rotational force exerted upon a drive axle 18 causes the cord winding assemblies 20 and 22 to rotate and translate for winding the cords 28 and 30 , which thereby raises the shade element 38 vertically toward the head rail 12 . Further details on a preferred embodiment of a cord winding assembly are provided with reference to FIG. 7 .
[0043] Cord winding assembly 20 is mounted co-axially with the drive axle 18 that passes through a fixed housing comprised of a frame 64 and upper cover 65 . The cord winding assembly 20 includes a winding drum 24 and a rotational positioning member, such as threaded tubular member 32 , fixedly connected at an end of the winding drum 24 . The cord winding assembly 20 is preferably mounted on the drive axle 18 via a hub member, such as adapter 60 that is configured to transmit rotational movement between the drive axle 18 and the cord winding assembly 20 while allowing a relative translation movement therebetween. In some embodiments, the adapter 60 may be coaxially mounted inside a central hole of the winding drum 24 , and include a through hole for mounting the drive axle 18 . To transfer rotational movement while permitting smooth relative translation between the winding drum 24 and the adapter 60 , a peripheral surface of the adapter 60 may be provided with radial portions that contact with ribs protruding radially inward from the surface of the central hole of the winding drum 24 . Further, the threaded tubular member 32 engages with toothed rollers 66 , which are rotatably mounted to frame 64 and bracket 68 fixedly secured in head rail 12 . Rotational movements thereby can be transferred between the drive axle 18 and the cord winding assembly 20 , while smooth relative translations with reduced frictions are permitted therebetween. In addition, the engagement via the adapter 60 and the threaded tubular member 32 allows an improved support of the load of the suspended components, e.g. shade element 38 and bottom rail 40 .
[0044] The winding drum 24 is tapered and is preferably frustoconical in shape, and may include striations or grooves to improve gripping of the cord 28 wound on the surface of the winding drum 24 . An end of the raising cord (not shown) is secured towards the larger diameter end 62 of the winding drum 24 . As the cord winding assembly 20 rotates and translates in a direction to wind the raising cord 28 , the raising cord is wrapped around increasingly narrower portions of the winding drum 24 .
[0045] Referring to FIGS. 8A and 8B , the raising operation of the window covering is shown. When the shade element 38 is fully deployed, as shown in FIG. 8A , the raising cord 28 is fully extended from a wider portion of the winding drum 24 . As the bottom rail 40 rises under the resilient force of the spring units 14 and 16 , as shown in FIG. 8 b , the threaded engagement between the threaded tubular member 32 and rollers 66 causes the rotating cord winding assembly 20 to move laterally within the head rail 12 , such that the raising cord winds along the winding drum 24 towards its narrower end.
[0046] Because the rising bottom rail 40 causes the shade element 38 to collapse and stack up thereon, the total weight being raised by the resilient force applied by spring units 14 and 16 thus increases. The load on the spring units is now described with reference to one of the spring units. The load on one spring unit 14 is derived with an adequate scale factor from a momentum M on the drive axle 18 that can be approximated by the product between the suspended weight W, including the weight of the bottom rail plus the amount of shade element 38 stacked thereon, and a winding radius R of the winding drum 24 . As the bottom rail 40 rises, W will increase, and R will decrease because the raising cord 28 winds on increasingly narrower portions of the tapered winding drum 24 that slide with reduced frictions owing to the adapter 60 and threaded tubular member 32 and adapter 60 . Accordingly, even though the suspended weight W increases, the load M on one spring unit 14 can be kept at a level that varies slightly and can be overcome by the constant force spring 46 ( FIG. 2 ) to fully raise the bottom rail 40 and shade element 38 . In order to lower the window covering, a user exerts an approximately constant pulling force regardless of the position in height of the window covering. With the cord winding assemblies 20 and 22 , spring units 14 and 16 of constant force thus can be suitably used to raise a suspended weight charge W that increases as it rises.
[0047] In some embodiments, such as the one depicted, the shade element itself may have an effect on the total downward force or suspended weight. For example, where the shade element is a cellular window covering, an inherent upward spring bias to the material may serve to decrease the total downward force. The total contribution of this spring bias varies depending on the degree to which the cellular window covering is extended.
[0048] As explained, as the window covering opens, the total weight suspended increases and the total raising force decreases. As such, the rate at which the window cover raises decreases as it nears a fully opened condition. Therefore, the shortcoming typically found in roller shade where the shade is retracted to quickly and violently avoided.
[0049] Referring again to FIG. 6 , the clutch member 36 is provided in order to lock the shade element 38 and bottom rail 40 in a desired position. Clutch member 36 is mounted coaxially with the drive axle 18 and is configured to unlock the drive axle 18 as the user pulls down the bottom rail 40 to stretch the shade element 38 , and to lock the drive axle 18 when the user releases the bottom rail 40 at the desired height. When the user pulls down slightly on the bottom rail again, the clutch disengages and allows the bottom rail 40 to be raised by the spring units 14 and 16 . Referring to FIGS. 9A and 9B , the clutch member 36 includes a casing 70 that has fixed protrusions 72 and 74 . A collar 76 rotating with the drive axle 18 is provided, which reciprocates axially along the drive axle 18 . A reciprocator 78 is co-axially mounted over collar 76 and is movable both rotatably and axially therewith. A spring 80 having a first end 82 and a second end 84 is provided between collar 76 and reciprocator 78 .
[0050] FIGS. 9A and 9B show the clutch when the window covering 10 is in a fully raised position. Spring 80 is in a relaxed condition with second end 84 in an abutting relationship with protrusion 74 . As shown in FIGS. 10A and 10B , when the user pulls on the bottom rail (not shown), a clockwise rotation (as shown) of the axle 18 and the collar 76 occurs and causes the second end 84 of the spring 80 to disengage from protrusion 74 . Spring 80 tightens on collar 76 such that rotation of the collar 76 is transmitted to reciprocator 78 via the contact between first end 82 of the spring 80 and reciprocator 78 , which brings reciprocator 78 into abutment with protrusion 72 . As the reciprocator 78 abuts against protrusion 72 , the spring 80 relaxes again and the drive axle 18 may continue to rotate as the user further pulls on the bottom rail. Referring to FIGS. 11A and 11B , as the user releases the bottom rail at a desired height, spring 80 tightens on collar 76 and the drive axle 18 , urged by the spring units 14 and 16 ( FIG. 1 ), rotates reciprocator 78 in a counterclockwise direction until it reaches a locking position where protrusion 72 abuts against a stop 79 on the reciprocator 78 . In this locking position, the spring 80 tightens to stop rotation of the drive axle 18 against the raising force exerted by spring units 14 and 16 . Referring to FIGS. 12A and 12B , as the user pulls down slightly on the bottom rail, the spring 80 tightens and a resulting clockwise rotation of the drive axle 18 and collar 76 causes the reciprocator 78 to disengage from the locking position to a release position. When the user releases the bottom rail as shown in FIGS. 13A and 13B , the spring units 14 and 16 cause the drive axle 18 to rotate in a counterclockwise direction to bring second end 84 of the spring 80 into engagement with protrusion 74 , and thereby loosening spring 80 , which permits drive axle 18 to continue rotating and fully opening the window covering.
[0051] An alternative embodiment of the window covering according to the present invention is shown in FIG. 14 . In most aspects, this embodiment is the same as the ones previously discussed. Window covering 510 includes a head rail 512 having a pair of spring units 514 and 516 mounted with a drive axle 518 . Cord winding assemblies 520 and 522 are also provided. Raising cords 528 and 530 pass through shade element 538 and are connected with bottom rail 540 . In addition, at least one deceleration member 550 is provided. Deceleration member 550 is engageable with one cord winding assembly 522 to slow down the rise of the bottom rail 540 as it approaches the head rail.
[0052] The preferred embodiment of the deceleration member 520 is shown in FIGS. 15A-15C . In the position of FIG. 15A , the cord winding assembly 522 is disengaged from the deceleration member 550 . As the cord winding assembly 522 winds the cord 526 , the cord winding assembly 522 also moves towards the deceleration member 550 . As the cord winding assembly 522 engages with a plate 552 of the deceleration member 550 as shown in FIG. 15B , the rotation of the cord winding assembly 522 causes the plate 552 to rotate. The plate 552 is connected to an axle sleeve 554 , which is in contact with a decelerating member, such as viscous oil liquid, contained inside a housing 556 . The sleeve 554 is configured to achieve a resistant contact with the decelerating member to decelerate the rotation of the cord winding assembly. For example, protrusions or fins may be provided on the axle sleeve 554 . The rate at which the bottom rail is raised by the spring units 514 and 516 is slowed as the bottom rail reaches the head rail so that the bottom rail more smoothly stops at a fully opened position.
[0053] The foregoing descriptions are to be taken as illustrative, but not limiting. Still other variants within the spirit and scope of the present invention will readily present themselves to those skilled in the art. | The present invention relates to a self-raising window covering and a control mechanism for the window covering. In particular, the window covering includes a drive unit, such as constant force spring, that is adapted to apply a substantially constant rotational force on the drive axle. A cord winding assembly is coaxially mounted on the drive axle, and includes at least one winding drum operatively connected to a second end of the raising cord and having a tapered portion, as well as a rotatable positioning member for moving the cord winding assembly laterally along the drive axle upon rotation of the positioning member. The cord winding assembly is adapted to translate the rotational force on the drive axle to a raising force on the raising cord, wherein the raising force is greater than a downward force exerted by the shade element and bottom rail throughout the range of opening and closing. A clutch member or locking member is also operatively connected with the axle and adapted to releasably lock the drive axle in a desired position. |
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This is a National Stage Entry of Application No. PCT/EP2008/060680 filed Aug. 14, 2008, filed in German, and the contents of which are incorporated herein by reference in their entirety.
FIELD OF AND BACKGROUND OF THE INVENTION
The invention relates to a device for mounting railroad tracks on a substructure and a railroad sleeper in the turnout area having this type of device as well as a fixed track for a section of railroad comprising carriers with this type of device.
Special rail mountings are required in the turnout area because, similar to a fixed track, no sleepers profiled on their upper side can be used. Such profiled sleepers would be useful since, on the one hand, they fix the axial position of the rail mounting in the longitudinal direction of the sleeper, and on the other, allow transverse forces to be introduced into the sleeper by means of corresponding profiling.
Both in the turnout area and on carriers of a fixed track the rails must be mounted on a substantially level subsurface. Moreover, one strives to be able to assemble rail mountings both in the turnout area and on a fixed track with the least possible complexity.
FIG. 4 shows the Vossloh 300w rail mounting system known from the prior art wherein a total of four mounting screws and corresponding plugs are used at each mounting point. Located on both sides of the rail 11 are angle guide plates 7 which are respectively held on the side facing away from the rail by a support angle 2 which is fixed by means of a sleeper screw 4 to a spring ring 3 . Here the sleeper screw 4 engages with a screw plug 1 . The angle guide plates 7 are used for the precise positioning of tensioning clamps 9 , the one on the right in FIG. 4 being shown in the pre-assembly position, and the one on the left being shown in the installed position. Every tensioning clamp is fixed to a washer by means of a further sleeper screw 10 and also engages with a screw plug 1 . Depending on the required spring compression values for the rail head an elastic intermediate plate 5 , a base plate 6 and a further plastic intermediate layer 8 can additionally be disposed between the rail foot and the concrete base layer 12 . With the mounting shown in FIG. 4 four plugs must be provided in the substructure for the four sleeper screws shown. For this reason the assembly of the rail mounting shown in FIG. 4 is very complex.
The rail mounting on a fixed track shown in FIG. 5 has a similar structure in some areas to the rail mounting shown in FIG. 4 , and so in the following one will only discuss the differences. In the example according to FIG. 5 , which corresponds to the Vossloh DFF 300-1 system rail mounting a base plate 13 is provided which can be connected securely to an intermediate plate 15 , e.g. is stuck to the latter. The unit comprising the base plate 13 and the intermediate plate 15 is screwed with the aid of mounting screws 16 through a bottom casting layer 17 into the base layer 18 of the fixed track, and is secured. With the aid of hook bolts 19 which are fitted in the base plate 13 the angle guide plates 7 and the tensioning clamps 9 are fastened, a fastening nut 14 being used on the threaded bolts of the hook bolt 19 in order to fix and tighten the tensioning screw.
The construction shown in FIG. 5 also requires increased assembly complexity since all four screws must be fixed at the assembly location, only the mounting screws 16 having to be fixed in the substructure, however.
OBJECTS AND SUMMARY OF THE INVENTION
One object of the invention is to provide a device for mounting railroad tracks on a substructure which has greater variability and is easy to assemble.
The device according to the invention for mounting railroad tracks on a substructure comprises two angle guide elements for each mounting point disposed on both sides of the rail foot, and one support element respectively on the side of each angle guide element facing away from the rail foot. Furthermore, a support unit disposed beneath the angle guide elements and support elements of the mounting point and two threaded bolts for tightening tensioning clamps are provided, the threaded bolts being arranged such that they extend through openings in the angle guide plates in the installed state.
In other words, the support unit disposed beneath the angle guide elements and support elements carries the whole rail mounting by on the one hand the support unit having dimensions such that it carries both the angle guide elements and support elements from the side of every angle guide element facing away from the rail foot, and also having two threaded bolts which in the installed state extend through openings in the angle guide plates and serve to mount and tighten tensioning clamps. In this way the device according to the invention can be pre-assembled on the rail or sleeper, and after placing onto the substructure in the form of a sleeper in the turnout area or a carrier of a fixed rail need only be connected to the substructure.
Preferably the tensioning clamps are substantially W-shaped, the central loop of which partially surrounds the shaft of the threaded bolts and comes to rest against the angle guide element. In addition to the good elastic properties due to the W-shape, an advantage of this type of tensioning clamp is that in the pre-assembled state the tensioning clamp is attached undetachably to the pre-assembly unit because the latter encompasses the threaded bolt with its central loop sufficiently tightly such that the latter can not detach itself.
Preferably the device further comprises two sleeper screws or bolt connections which respectively pass through one of the support elements and through a through-hole in the support unit. With the aid of these sleeper screws or bolt connections the whole assembly according to the invention can be mounted on a suitable substructure. No additional screws are needed which must either be anchored into the substructure according to the prior art shown in FIG. 4 , or which must be hooked on separately according to the prior art shown in FIG. 5 , and only secured in position after fixing under tension.
According to one preferred embodiment the support elements have a mounting contour, preferably a clip mechanism, which interacts with a complementarily formed attachment contour of the support unit in order to attach the support elements to the support unit in the pre-assembly position. This measure constitutes a simple alternative in order to also connect the support elements to the support unit in the pre-assembly position. Alternatively, however, the sleeper screw/bolt connection could also be configured such that it can e.g. be screwed into threads in the support unit and in this way the desired pre-assembly of the support elements can also be implemented. Preferably a clip mechanism can be provided which within the framework of pre-assembly requires a particularly small amount of complexity and also need only offer sufficient stability during the pre-assembly phase. Alternatively to a clip mechanism the mounting of the support elements on the support unit could also be realised by means of a mushroom contour.
Preferably the device further comprises projections on the support unit which in the installed position extend upwards and have locating surfaces for resting against counter surfaces of the support elements on the side of the respective support element facing away from the angle guide element. These types of projection can be in the form, for example, of one-piece ribs which are orientated in the longitudinal direction of the rail and serve to introduce transverse forces occurring via the rail foot and by interconnecting the angle guide element and the support element into the support unit and from there into the substructure. Therefore the projections replace the inclined shoulder region for bearing the angle guide elements provided with standard sleepers. Finally, the projections also serve to prevent unintentional turning of the support elements.
According to one preferred embodiment the threaded bolts are welded to the support unit. In this way, within the framework of the assembly there is already a smaller number of components to be assembled and in addition, when screwing on a fixing nut, the threaded bolt can be prevented from also turning relative to the support unit. Alternatively, it is also possible, however, to use the threaded bolts in the form of countersink screws which can be inserted into the support unit from the side facing away from the angle guide elements in the installed position. It is an advantage with conventional countersink screws that on the one hand they do not project over the lower side surface of the support unit, and on the other hand, due to their conically formed head, have a large friction surface in relation to the support unit which also helps to prevent undesired turning of the threaded bolts relative to the support unit.
The device according to the invention preferably further comprises at least one elastic intermediate layer between the angle guide elements, the at least one elastic intermediate layer serving to bear the rail. By appropriately selecting one or more elastic intermediate layers, and by appropriately selecting a material suitable for this on the one hand the required rail head spring compression can be guaranteed, but on the other hand electric insulation between the rail and the support unit is also established.
According to one preferred embodiment the device has, furthermore, a rigid pressure distribution plate, preferably made of metal or some other bend-resistant material, which can be attached onto the threaded bolts of the support unit and is configured and has dimensions such that it extends into open receiving spaces of the angle guide elements facing towards one another. In this way the load acting on the rail is distributed via the rail foot over a larger area than the dimensions of the rail foot, and so the loads are introduced more evenly and with smaller local surface pressures into the substructure.
Depending on the desired application it can be advantageous to provide the pressure distribution plate, as viewed in the longitudinal direction of the rail to be mounted, with a cross-section which is wedge-shaped, at least in some areas. This measure serves to set specific rail cants.
In connection with this it is advantageous to level out the rail cant by the two angle guide elements of a mounting point having different heights. In this way, purely by choosing a wedge-shaped pressure distribution plate and by choosing angle guide elements adapted to the latter while using standard elements otherwise a desired rail cant can be established.
According to one preferred embodiment the device has, furthermore, an elastic intermediate plate between the pressure distribution plate and the support unit.
Further adaptability in relation to the precise track gauge consists either of using angle guide elements with different dimensions between the rail foot and the support elements, or providing a spacer plate between an angle guide element and the adjacent support element on one side or on both sides of the rail. These measures serve to enable precise adaptation of the track gauge.
Preferably the receiving space provided in the angle guide elements is formed by an open U profile in the pre-assembly position, and the clear height of this receiving space is greater than the overall thickness of the elastic intermediate layer and the rigid pressure distribution plate. This facilitates not only assembly, but ensures that the forces from the tensioning clamps acting on the angle guide elements are introduced by direct contact between the angle guide elements and the support unit into the support unit.
The device according to the invention can be used both on railroad sleepers in the turnout area and on carriers of a fixed track, and offers considerable advantages to the effect that the mounting system can be pre-assembled on the rail or point without a sleeper.
BRIEF DESCRIPTION OF THE FIGURES
In the following the invention will be described, purely as an example, by means of the attached figures which show as follows:
FIG. 1 an exploded view of the device according to the invention on a substructure;
FIG. 2 the rail mounting illustrated in FIG. 1 in the installed state;
FIG. 3 a sectional view of the rail mounting shown in FIG. 2 ;
FIG. 4 a sectional illustration of a mounting system in the prior art; and
FIG. 5 a sectional view of a further mounting system in the prior art.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
In the following an embodiment of the invention will be described by means of FIGS. 1 to 3 . Here the same components are respectively identified by the same reference numbers.
The exploded view shown in FIG. 1 shows a substructure 20 the construction of which is not essential in order to understand the invention. This can be a sleeper in the turnout area or a fixed track with a first section 20 a lying at the bottom and a bottom casting e.g. made of a quick-casting mortar disposed over the latter, which is suggestively identified by reference number 20 b . In the same way, however, the substructure 20 can be a one-piece concrete sleeper. It is essential that the upper side of the substructure 20 facing towards the rail is not profiled. Bore holes and plugs introduced into the latter in the substructure for receiving the sleeper screws are not shown in the figures.
The assembly unit described below can be pre-assembled on the rail 22 so that after positioning the rail with the pre-assembled rail mounting unit only an electrically insulating intermediate layer can optionally also be disposed between the support unit 26 and the upper side of the substructure 20 .
The pre-assembly unit already attachable to the rail 22 comprises a support unit 26 , support elements 28 , angle guide elements 30 , tensioning clamps 32 , sleeper screws 34 and various elements which can be disposed between the rail foot 22 a and the support unit 26 and will be described later.
The support unit 26 is preferably a steel plate which has bore holes 36 through which the sleeper screws 34 or bolt connections pass and has ribs 38 extending in the longitudinal direction of the rail which in the installed position come into contact with bearing surfaces 40 of the support elements 28 and on the one hand prevent unintentional turning of the support elements 28 , and on the other hand can also at least partially accommodate the transverse forces introduced by the rail 22 via the foot of the latter 22 a into the angle guide element and the support elements. The embodiment shown in FIG. 1 with ribs passing through it is only to be taken as an example here. The ribs can in the same way be made up of a number of individual elevations provided the latter perform the aforementioned functions.
Threaded bolts 42 extend upwards from the support unit 26 perpendicularly to the planar extension of the support unit 26 , i.e. in the direction of the angle guide plates in the installed position. The threaded bolts 42 can be welded here to the support unit 26 or be connected to the latter in some other way, or can be inserted from the lower side, i.e. the side facing towards the substructure, through through bore-holes of the support unit 26 . In the case of separate provision of screws which are inserted from the lower side into the support unit 26 , the use of countersink screws with a conical screw head which offers a high friction surface to the support unit, and moreover does not project over the lower side of the support unit 26 is recommended.
In the exemplary embodiment according to FIG. 1 , within the framework of the pre-assembly an elastic intermediate layer 44 made of plastic is initially attached onto the threaded bolts, followed by a pressure distribution plate 46 made of metal and a second elastic intermediate layer 48 which has dimensions such that it is only located beneath the rail foot 22 a or above the pressure distribution plate 46 . Therefore the threaded bolts 42 extend from the support unit through the elastic intermediate layer 44 and the pressure distribution plate 46 and pass from here through an opening 51 into the respective angle guide elements 30 . This can no longer be seen in the exploded view of FIG. 1 , but is shown for example in FIG. 3 . The threaded bolts 42 then pass through the central loops 32 a of the W-shaped tensioning clamps 32 , the arms of the central loops 32 a respectively enclosing the threaded bolt tightly enough so that the tensioning clamps 32 can be fixed by screwing on the clamping nuts 50 and optionally an intermediate ring shown in the figures
The elastic intermediate layer 44 and the pressure distribution plate 46 have dimensions such that they extend into U-shaped recesses of the angle guide elements 30 facing towards the rail foot 22 a so that even in the case of a loose mounting of the clamping nut 50 onto the threaded bolt 42 the elastic intermediate layer 44 and the pressure distribution plate 46 are connected undetachably to the support unit 26 .
The pressure distribution plate 46 shown in FIG. 1 has different areas, namely two side areas 46 a respectively having the same height and a central area lying between these areas which in the example illustrated has a wedge-shaped cross-sectional form and serves to set a pre-defined rail cant.
There is disposed respectively on the sides of the angle guide elements 30 facing away from the rail foot 22 a a support element 28 that has an angular cross-section which already has the aforementioned bearing surface 40 for resting against one rib 38 respectively of the support unit and a receiving opening 52 for the corresponding sleeper screw 34 .
As can be seen in FIG. 1 , a spacer plate 54 for setting the gauge can be located between the angle guide element 30 and the corresponding support element 28 . These types of spacer plate 54 can be located on one side or on both sides of the rail, but it is also possible to bring about the same effect of graduated gauge setting by means of coordinated sets of angle guide elements.
The angle guide elements 30 are preferably produced from plastic, and the support elements 28 are preferably made of metal or plastic. As known in the prior art, the angle guide elements 30 are provided with bearing shoulders and indentations in order to be able to fix a corresponding tensioning clamp both in a pre-assembly position and an installed position, as can also be seen, for example, by means of the illustrations of the prior art in FIG. 4 and FIG. 5 .
FIG. 2 shows the arrangement according to FIG. 1 in the installed position, it now becoming clear how the tensioning clamp 32 lies with its free spring ends on the rail foot 22 a and on the other hand is supported in the indentation of the angle guide plate.
The illustration according to FIG. 3 makes it clear how on the one hand the elastic intermediate layer 44 extends into cavities of the angle guide elements 30 . On the other hand however the wedge shape of the pressure distribution plate can also be seen in the central area from which the cant of the rail head evident in FIG. 3 results. It is also evident from FIG. 3 that the angle guide plates 30 a and 30 b have different dimensions so as to bring the tensioning clamps 32 respectively to the height suitable for fixing the rail foot when the rail foot 22 a is inclined. Correspondingly, the threaded bolts 42 also have dimensions which are sufficient to be able to accommodate the desired thickness of elastic intermediate layers and the required rail cant. Since the pressure distribution plate made of steel also serves to regulate the height, the normal thickness variation of the latter is also to be taken into consideration when designing the length of the threaded bolts.
The advantage of the solution according to the invention is that the whole assembly illustrated in FIG. 3 starting from the support unit 26 to the rail 22 can be pre-assembled, and only after being placed onto the substructure 20 , optionally providing an intermediate layer 24 , the sleeper screws 34 (not shown in FIG. 3 ) connecting this whole assembly securely to the substructure 20 . In addition the support elements can be connected to the support unit by a clip connection not shown in the figures. In this way the assembly complexity is considerably reduced.
The above description of various embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures disclosed. The applicant seeks, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof. | The invention relates to a device for mounting rail-road tracks ( 22 ) on a substructure ( 20; 20 a, 20 b ), comprising two angle guide elements ( 30; 30 a, 30 b ) disposed on both sides of the rail foot ( 22 a ) for each mounting point, and one support element ( 28 ) on the side facing away from the rail foot ( 22 a ) of each angle guide element ( 30, 30 a, 30 b ), and a support unit ( 26 ) disposed beneath the angle guide element ( 30; 30 a, 30 b ) and support elements ( 28 ) of the mounting point and comprising two threaded bolts ( 42 ) for tightening rail clamps ( 32 ), disposed such that they extend through openings in the angle guide plates ( 30; 30 a, 30 b ) in the installed state. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to barricades for warning approaching vehicles of hazardous conditions, particularly for use to warn vehicular traffic when pedestrians are within a dangerous zone relative to their direction of travel.
2. Description of the Related Art
The use of highway barricades, in particular, those having an A-frame shape, are well known in the art. Variations of this type of barricade have been used for more than forty years. The typical unit has a saw-horse configuration, that is, a pair of spaced apart legs, pivotally joined near the top, with each pair connected by cross-member panels which can also serve to display a warning sign. Various types of incandescent warning lights have frequently been incorporated into the design. When the legs of each pair are spread open, the unit becomes self-standing.
Representative of this genre is U.S. Pat. No. 3,015,804, issued to Nunn on Jan. 2, 1962. Nunn discloses a combined barricade and flashing light signal. In addition to the above general characteristics, Nunn discloses the use of a battery powered incandescent flashing light signal. Nunn discloses that the important consideration is that the battery and the flasher mechanism are housed within a strong metal cabinet. The heavy battery is free to swing so that the light will flash level even if the ground is not level. Due to the weight of this unit, it is not designed to be easily moved from location to location by people such as female crossing guards.
U.S. Pat. No. 3,092,826, issued to Klinger on Apr. 21, 1985, discloses another variation of this type of barricade. This device features the use of two warning lights positioned above each spaced apart pair of legs. As before, a heavy battery is made part of the structure and only incandescent lamps may be used which severely limit the effective range of the light warning.
Still another design is disclosed in U.S. Pat. No. 3,221,300, issued to Elledge on Nov. 30, 1965. This particular variation, recognizing the limitations of prior flashing units, concentrates on improving the flasher. Plastic lenses are used to improve the quality of light transmission. However, as before, the battery is made part of the warning structure and the device is limited to the use of incandescent bulbs.
In U.S. Pat. No. 4,859,983, issued to Kulp et al. on Aug. 22, 1989, still another A-frame type of barricade was disclosed, only this one is made from plastic. A storage compartment is provided to enable the user to increase the weight so that the device is stable in high winds. An incandescent warning light is bolted to the top cross member. As before, the ability of this device to provide a distant warning is limited by the use of an incandescent bulb.
Of general interest to the application are: U.S. Pat. No. 2,648,761, issued to Shamel on Aug. 11, 1953 which discloses a method to secure a light to an A-frame type of barricade; U.S. Pat. No. 3,691,526, issued to Huntington on Sep. 12, 1972, which discloses the use of thin straps to hinge the legs of the A-frame together; and U.S. Pat. No. 2,719,506, issued to Sequira on Oct. 4, 1955, which discloses an A-frame type of design that is to be used with a standard flashlight.
There is not found in the prior art a battery operated safety strobe light utilizing an A-flame type of construction that can easily be transported with the battery section separate from the A-frame and light, that has a rechargeable capability, a low voltage disconnect that prevents the battery from being overly discharged, a circuit breaker to protect the low voltage disconnect board, a voltage meter indicating the charge condition of the battery, and has a telescoping capability that allows the light to be placed higher than the A-frame cross-member.
SUMMARY OF THE INVENTION
It is an aspect of the invention to provide a battery operated safety strobe barricade that utilizes the warning capabilities of a strobe light.
It is an aspect of the invention to provide a battery operated safety strobe barricade that is sufficiently light weight so that it can be carried by an operator from one location to another.
Another aspect of the invention is to provide a battery operated safety strobe barricade that provides at least twenty-four hours of service without recharging the battery.
It is still another aspect of the invention to provide a battery operated safety strobe barricade that has a power pack that is easily disconnected from the strobe light and carried separately.
Another aspect of the invention is to provide a battery operated safety strobe barricade that has a low voltage disconnect feature so that the rechargeable battery will not be completely discharged, thereby prolonging battery life.
It is an aspect of the invention to provide a battery operated safety strobe barricade that can be stored for months, yet the battery will still be available for immediate use.
Another aspect of the invention is to provide a battery operated safety strobe barricade that employs a power pack that utilizes a dual rate charger; that measures battery voltage and adjusts its charge accordingly; and, is safe from being overcharged even when plugged in for months.
Another aspect of the invention is to provide a battery operated safety strobe barricade that has a battery with a pack case that is substantially water resistant and has a handle for comfortable carrying.
It is still another aspect of the invention to provide a battery operated safety strobe barricade that has a strobe light on top of a telescoping pole that will permit the strobe to be positioned higher than the top cross-member of the A-frame, thereby improving visibility.
Finally, it is an aspect of the invention to provide a battery operated strobe barricade that, due to its mobility, low cost, and effectiveness, will be used in situations where strobe warning lights are desirable such as protecting children at school crossings and other school functions, surveyors, emergency situations, road constructions sites, etc. but have not been previously used due to the unsuitability of prior art designs.
The invention is a barricade for providing a warning that a potentially hazardous condition is present. The invention comprises two major components: a stand and a battery pack. The stand comprises a substantially rectangular top shelf having four corners. Four substantially identical legs are provided, wherein each leg is pivotally attached to one of said corners of said shelf. A foldable shelf having an open position and a closed position is provided. Said foldable shelf further has two substantially identical sections connected by a hinge. Said foldable shelf is pivotally connected to said legs. When said shelf is in the open position, said stand is self-supporting in an A-frame type of configuration. When said shelf is in the closed position, said stand may be transported to another location. A strobe light having an electrical connection is provided. Said strobe light is affixed to said top shelf of said stand. A sign is provided. Said sign is rigidly connected to one pair of legs of said stand. A battery pack is provided that is connectable to said stand via an electrical connection. Said battery pack comprises a lead acid battery capable of storing an electrical charge, said battery adapted for providing electrical power to said strobe light. A battery charger is provided that is connected to said battery for recharging said battery once battery has been discharged from supplying electrical power to said strobe light. An outlet for providing electrical power from said battery to said strobe light via the electrical connection of said strobe light is provided. A low voltage disconnect board connected between said outlet and said battery is provided. Said disconnect board disconnects said battery from said outlet if the voltage of said battery drops below a predetermined value. When said stand is in the open position and said battery pack is electrically connected to said strobe light via the electrical connection connected to said outlet, said sign is capable of displaying a warning message and said strobe light is able to provide a flashing warning light at substantial distances, thus enabling said barricade to provide the warning that the potentially hazardous condition is present. When said stand is in the closed position and said battery pack is disconnected from said outlet, said stand and said battery pack can be separately transported to a new location.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the preferred embodiment of the invention with the strobe light in its telescoped position.
FIG. 2 is an isometric view of an alternative embodiment of the invention with the strobe light in its flush mounted position.
FIG. 3 is a detailed view of a support piece used to bolt the legs of the stand into position.
FIG. 4 is a detailed view of the telescopic assembly for the strobe light.
FIGS. 5A-5c are detailed views of the hinged bottom shelf.
FIG. 6 is an isometric view of the battery pack.
FIG. 7 is a block diagram of the battery pack circuitry.
DETAILED DESCRIPTION OF THE INVENTION
The invention 10 is a battery operated safety strobe barricade that is designed to protect anyone who may be in the zone of danger. The powerful strobe light 12 enables approaching vehicles to be forewarned that the vehicle is nearing a dangerous zone, that is, a region where individuals may be in the vehicle's direct path of travel. It is expected that invention 10 will be produced in at least two sizes, a 22 inch wide version and a 13 inch wide version (shown in FIG. 2). Both versions are virtually identical excepting the width. The narrower version is particularly well suited for school crossings and the like. The typical school crossing guard is female or an elderly male where the lighter weight and smaller size will be an advantage.
The invention 10 has two major parts: the stand 11 which includes strobe light 12 and battery pack 50 (shown in FIGS. 6 and 7). Stand 11 is made up of five major parts: top shelf 24, legs 18, legs 28, lower hinge shelf 20 and signs 16.
Top shelf 24 is preferably made from 1/16 inch rectangular aluminum sheet. For the larger version, the size should be approximately 241/4 inches by 87/8 inches and, for the smaller version, the size should be approximately 151/4 inches by 87/8 inches. All four sides of the rectangle are bent approximately 11/8 inches from the end, thus forming a "box" that is open at the bottom. If the unit is to be flush mounted, then a 11/4 inch hole (not shown) is centered in the top with three or more mounting holes surrounding it.
On end sections 31, two 5/16 inch holes are provided through which bolts 30 are attached. Hand grasp 32 is preferably an opening that is provided about 11/2 inches from each end, 1/4 inches from the top, and 3/4 inches from the bottom of end section 31. Hand grasp 32 is used to carry stand 11.
The underside of L-shaped anchoring sections 33 (shown in FIG. 3) are provided. The length matches the width of top shelf 24 after it has been bent to form the "box", that is, approximately 61/2 inches long. Both legs 62 and 65 are preferably about 13/8 inches long. Two holes 64, each being 5/16 inches in diameter are provided to line up with bolts 30. Anchoring sections 33 are preferably welded to the underside of top shelf 24.
In the preferred embodiment, the telescoping variation, the center hole in top shelf 24 is made 7/8 inches in diameter rather than 11/4 inches. Referring now to FIG. 4, telescope assembly 70 will be described. Pipe 14 is preferably a 3/4 inch by 161/2 inch aluminum pipe having a 1/16 inch wall thickness. Pipe 14 is attached to strobe 12 so that strobe 12 can be raised above the surface of top shelf 24 for better visibility.
Since strobe 12 is being used in an outside environment under all kinds of weather conditions, it must be temperature-resistant and sealed against entry of dirt, water or dust. Further, it must be resistant to damage by shock or vibration. Strobe 12 is preferably a PULSATOR Model 551 as manufactured by Target Tech of Kent, Wash. 98032. This particular model can be mounted either flush or as a pipe mount. When mounted in a telescope version, the flange plate provided by the manufacturer is not used. Plate 73 is substituted which is preferably a 31/2 inch square aluminum plate having a thickness of about 0.063 inches. Pipe 14 is preferably welded to plate 73. Plate 73 is then bolted between lower strobe plate 74 and upper strobe plate 75 via four 10/32 bolts. Plug 78 is inserted into a hole provided in the lower end of pipe 14. This part of the assembly is completed by feeding power cable 79 and attached plug 92 through pipe 14.
Telescope assembly 70 is completed using pipe 77 which is welded to the bottom side of top self 24. As noted above, hole 94 is a 3/4 inch opening centered in top shelf 24. Pipe 77 is centered under this 3/4 inch opening. Pipe 77 is preferably a 7/8 inch aluminum pipe about 4 inches long. A milled slot 76 is provided that has a width that corresponds to the diameter of plug 78. Pipe 14, power cable 79 and attached plug 92 are then fed through hole 94, and through pipe 77. To raise pipe 14 to its uppermost position, a user will merely pull up strobe 12 until plug 78 engages slot 76, wherein plug 78 is placed into position 72, and strobe 12 is held in its uppermost position. To lower, a user merely pulls up strobe 12 slightly while turning strobe about a quarter turn so that strobe 12 can be lowered down substantially flush with top shelf 24.
All four legs are constructed from 1 inch square aluminum stock having 1/8 inch walls. Preferably legs 18 and 28 are about 351/2 inches long. Holes are provided near the top so that legs 18 and 28 can be bolted via bolts 30. Hinged bottom shelf (discussed in detail in FIG. 5) is attached via 3/8 inch holes that are provided in legs 18 and 28 about 71/4 inches from the bottom of the legs. Sign 16 which is preferably a rectangular sheet of aluminum on which various warning or caution indicia can be placed, such as the word "SCHOOL", or the word "CAUTION", etc. Sign 16 is bolted to legs 18 via 10/32 bolts.
Now referring to FIGS. 5A-5C, the details of hinged bottom shelf 20 are discussed. Shelf 20 is used to support the 26 pound battery pack 50. By positioning battery pack 50 in this location, the additional weight adds stability to stand 11. Two substantially identical rectangular sections 27 of aluminum plate (10 by 11 inches for the 13 inch stand ) are fastened together with piano hinge 25 which is welded to sections 27. On the opposite side, rods 26 are welded to one section 27 and rods 22 are welded to both ends of the respective section 27 as shown. In this manner, when legs 18 are moved toward legs 28, shelf 20 collapses so that the stand 11 can be folded compactly.
The parts of stand 11 can be finished in a variety of methods well known in the art. The preferred finish is powder coat as it is the most durable, however, painting or dipping could also be utilized.
Referring to FIGS. 6 and 7, the details of battery pack 50 will be discussed. As noted above, battery pack 50 which contains sealed lead acid battery 80 is heavier than the remaining part of the unit. Therefore, by making the battery pack removable, the each part is more easily carried than would be the case if battery pack 50 were integrated into stand 11. Tongue and groove case 62 is preferably manufactured from impact and weather resistant materials such as ABS plastic. Cover 64 is provided with an O-ring seal 65 so that water resistant sealing is assured. Cover 64 is removable if desired. Handle 68 enables battery pack 50 to be easily carried. Mounting plate 63 holds the various components within case 62. While various cases could be used, Model SDB-1-35 as manufactured by MTM Molder Products Company of Dayton, Ohio 45413, is preferable.
Battery 80 is preferably Model No. PS-12260 as manufactured by the Power Sonic Corporation of Redwood City, Calif. 94063. Battery 80 is a sealed construction which allows trouble-free operation in any position.
Battery charger 86 is preferably Model #PSC-122000A also manufactured by Power Sonic Corporation. This unit is an automatic dual rate charger that senses battery requirements and automatically switches from the fast charge condition (2 amperes) to a float charge condition (milliampere), thereby combining the advantages of cycle and float chargers. Battery 80 will be safe from overcharge even when plugged in for months. As an added safety feature, cover 64 is open whenever the battery is being charged.
Under normal expected operating conditions, it is anticipated that four or five years of service can be expected or between 20 and 1,000 charge/discharge cycles depending on the depth of discharge.
To ensure obtaining the maximum number of charge/discharge cycles, the battery 80 is prevented from discharging below 11.1 volts by use of low disconnect board 82, Model No. LVCO2-1 as manufactured by Xenotronix of Longwood, Fla. 32752. The use of board 82 prevents catastrophic discharge. If the load on the battery is cut-off when battery 80 reaches only 20% of its capacity, then battery life can be extended up to fifty times than otherwise would be the situation.
Voltage indicator 54 enables a user to obtain the current status of the battery. Preferably, indicator 54 is Coral #13010 as manufactured by Faria Instruments of Uncasville, Conn. 06382. Indicator 54, once activated by switch 60, read from empty to full, by quarters. To charge, a user merely inserts plug 58 which is attached to cord 56 into a standard 110 outlet and battery pack 50 will be charged. Battery pack 50 may be left plugged into a 110 source when not being used, so that battery 80 will always be ready for use when required.
A 10 amp circuit breaker 84 prevents low voltage disconnect board 82 from being overloaded. Circuit Breaker 84 is preferably model 30055-10 as manufactured by Cole Hersee Company of South Boston, Mass. 02127. Power outlet 52 is a female receptacle to which plug 92 is connected. Plug 92 and retractable cord 79 are preferably Model #SAFCO 50 as made by SAFCO Corporation of Chicago, Ill. 60631. This unit has a protective fuse in plug 92 that prevents overload of strobe 12.
While there have been described what are at present considered to be the preferred embodiments of this invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the invention and it is, therefore, aimed to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A battery operated safety strobe barricade, particularly suited for school crossings. The use of a battery pack that is rechargeable and can be separated from the barricade enables the apparatus to be particularly well suited to safety situations where high visibility and weight are considerations. The A-frame stand section is fabricated from low weight aluminum so that it can be carried by even the smallest crossing guard. The rechargeable battery pack features a dual rate charger so that the unit can be left to charge continuously. The battery pack has a low voltage disconnect feature so that catastrophic battery discharge is avoided thus prolonging the life of the battery. A high visibility strobe light mounted on a telescoping pipe enables the unit, despite its light weight construction, to provide a warning beacon that can be easily seen at great distances, even in the daylight. |
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This is a continuation of application Ser. No. 548,500, filed Feb. 10, 1975, now abandoned.
BACKGROUND OF THE INVENTION
This invention is an improvement of that disclosed in U.S. application Ser. No. 408,778 filed Oct. 23, 1973, now abandoned. The present invention concerns the automatic control of the position of the working tool of an earth working machine and, according to the preferred embodiment, the position of the blade of the motor grader. More specifically, the present invention concerns the control of the transverse slope of the working tool or blade of an earth working machine. The preferred embodiment of the invention relates to the slope control of the blade of a motor grader although it is recognized that other types of machines may be controlled by the present invention.
In view of today's highway requirements, particularly high speed travel over modern highways, the demand for greater accuracy in preparing roadbeds for surfacing is substantial. At the same time, the grading operation must be accomplished quickly and efficiently in order to cope with the long distances over which our today's modern highways are to span. The present invention results in quick and efficient operation of a grading machine as well as a highly accurate grading operation by providing refinements in the automatic slope control system of the machine.
SUMMARY OF THE INVENTION
One such refinement results in a more accurately simulated slope of the motor grader blade. If the blade and blade circle arrangement of a grader are always maintained in a plane which is parallel to the line of flight of the machine, the rotation of the blade about an axis perpendicular to this plane will not affect the slope angle of the blade. But if this plane is not maintained parallel to the line of flight of the machine, the slope angle of the motor grader blade changes upon rotation of the blade support circle as is discussed in U.S. Pat. Nos. 3,229,391 and 2,961,783. It is necessary, therefore, to introduce a correction factor dependent upon the rotation of the blade circle into the control system in order to effectively control the blade at the desired slope angle.
This control is accomplished in the instant invention by providing for the slope sensor, which may take the form of a pendulum, a support platform assembly for correcting the attitude of the slope sensor dependent upon the angle of the blade circle plane with respect to the line of flight of the machine and the rotation of the blade about an axis perpendicular to this plane.
A characteristic of some machines is that the blade of a grader can be swung either to the right or left of the machine so that the blade assumes a vertical position alongside the machine. In the apparatus shown in the above mentioned patent application Ser. No. 408,778, such movement of the blade would result in damage to or destruction of the slope sensing structure. A further refinement of the instant invention is, therefore, an arrangement of the slope control system which will allow such movement of the blade without resulting in damage to or destruction of the slope sensing apparatus.
Other advantages of the present invention will be apparent from a review of the following specification, wherein a preferred form of the invention is described, by reference to the accompanying drawings.
SHORT DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of the motor grader with the control system components mounted thereon.
FIG. 2 is a side view of the slope control apparatus with in the housing 21 shown in FIG. 1.
FIGS. 3-5 show various sub-assemblies of the slope control apparatus 21.
DETAILED DESCRIPTION
In FIG. 1 there is shown a motor grader 10 having rear wheels 11 and front wheels 12. The front wheels 12 rotate about an axle 13 which is transversely pivotable around its connection to the front of the machine. The blade 14 of the machine is supported from a blade circle 15 the elevation of which is controlled by hydraulic rams 16 and 17 which also control the slope of the machine blade. The circle 15 is supported at the front of the machine by a drawbar assembly 18.
The drawbar assembly 18 comprises an A-frame having a cross-bar member 19 attached to the blade circle 15 by gears or other suitable means to allow for the rotation of the blade circle 15 with respect to cross-piece 19 and drawbar assembly 18. The drawbar assembly 18 is pivotally secured at 20 to the front of the machine frame and allows for both slope and grade adjustments of the blade. Hydraulic rams 16 and 17 are connected to respective ends of the cross-member 19. Hydraulic ram 16 has been broken away to show in detail the A-frame and circle assemblies. A control box 21 is securedly affixed, by suitable means not shown, to the drawbar assembly 18.
A side view of the contents of control box 21 is shown in FIG. 2. A slope sensor 22 is supported from a platform 23 the rear of which is suspended from the top of the housing 21 by a ball and socket arrangement 24 which is shown in more detail in FIG. 3. A member 25 supports the platform 23 and is arranged for rotational as well as vertical movement. The support member 25 is in the form of a tapered cylinder as shown in FIGS. 2 and 4.
The support member 25 is biased against the platform 23 by a spring 26 which surrounds a shaft 27 and the shaft 27 is supported for rotation by a bearing 28 and a bearing 29. The shaft 27, which is connected to a gear 30, extends through bearing 29, through appropriate holes in the platform 23 and support member 25 to the bearing 28. The platform 23 is biased against the support member 25 by an additional spring 31.
FIG. 4, which shows an enlarged frontal view of only a portion of the apparatus of FIG. 2 and in particular the manner in which the platform 23 is supported to be maintained parallel to the line of flight of the machine, shows in more detail how the support member 25 is supported on the shaft 27. The member 25 has a cylindrical opening to allow the shaft 27 to pass therethrough resulting in the support member 25 being slidably supported by the shaft 27 in cooperation with the spring 26. The shaft 27 has a slot 32 therein and the support member 25 has a slot 33 therein. A key 34 fits into both of the slots 32 and 33 to prevent any rotational movement of the support member 25 with respect to the shaft 27. The key 34 is help captive, by suitable means not shown, to the shaft 27.
In FIG. 2, radial arm 44 is attached to the front of the platform 23 by a joint 35 and joint 35 is shown in more detail in FIG. 4. A bracket 66, affixed to platform 23, has a pin 36 supporting a ball 37 in socket 38. The socket 38 is connected by an arm 39 to a member 40 which is fixedly secured to a shaft 65. As shown in FIG. 2, radial arm 44 is fixedly connected at its other end to shaft 41. As shown in FIG. 1, shaft 41 has a cam follower 42 thereon which follows a cam surface 43 fixed to the earth working machine. The radial arm 44 is rotatably supported on the shaft 65 and held in place by retaining clips 45 and 46.
In order to provide floating proportional positional control as described in U.S. Pat. No. 3,908,765, an arm 47 is frictionally driven by the shaft 41 and has mounted on the end thereof a magnet 48 with pole pieces 49 and 50. Limits 51 and 52 are provided in accordance with the teachings of the above mentioned application to limit the sweep of the arm 47. The magnet and pole piece assembly 48-50 is designed to cooperate with the Hall effect sensor 53 which provides a proportional electrical output signal dependent upon the position across its surface of the magnetic assembly supported at the end of arm 47.
FIG. 5 shows how the arm 47 is frictionally driven by the rotation of shaft 41. The friction drive arrangement comprises a collar 54 which is fixedly secured to the shaft 41 and a cork disc 55 which is secured by suitable means between the collar 54 and the arm 47. The cork disc 55 and arm 47 fit over a flared sleeve 56 which is secured to the shaft 41. A wave spring 57 fits between the arm 47 and a collar 58 which is held in place by the flared end of sleeve 56. Because the cork disc is flexible, the rotation of shaft 41 will cause the rotation of the arm 47 until the arm 47 butts against a limit 51 or 52. At that time, the cork disc will flex and, although the shaft 41 may continue to rotate, the arm 47 will remain stationary against the limit.
The gear 30 shown in FIG. 1 has a chain 59 wrapped therearound and cooperates with a gear 60 rotatably supported on the cross-piece 19 of the drawbar frame 18. The gear 60 is rotated by a connection therefrom through member 19 to a member 61 fixedly secured upon the blade circle. Thus, as the blade circle is rotated, the gear 60 rotates which, through the chain 59, rotates the gear 30.
IN OPERATION
Assuming that the blade circle 15 and drawbar frame 18 are in a plane parallel to the line of flight of the machine, rotation of the blade circle 15 and blade 14 will not affect the slope angle of the blade 14. Furthermore, as the gear 30, in FIG. 2, rotates, support member 25 will also rotate. However, since the platform 23 is also parallel to the line of flight of the machine, the slope of the platform 23 will not be altered by rotation of the blade circle; and thus, the output signal from the slope sensor 22 will represent the true slope of the machine.
Assuming that the hydraulic rams 16 and 17 move the blade circle 15 and drawbar frame 18 to a position below this plane, the movement is sensed by the cam follower 42 and causes shaft 41 to rotate the radial arm 44 of FIG. 2 in a counterclock wise direction pushing down on the front of platform 23. This movement maintains the platform 23 parallel to the line of flight of the machine. However, the shaft 27 and support member 25 retain the same orientation with respect to the housing 21 that they had when the blade circle was parallel to the line of flight of its machine. Now if the blade circle assembly 15 is rotated, the gear 30 will rotate the support member 25 which will change the slope of the platform 23, and thus the sensor 22, by an amount dependent upon the amount of rotation of the blade circle 15.
If the hydraulic rams 16 and 17 operate the blade circle 15 to a position above this plane, the cam 42 and shaft 41 will sense this movement to rotate the radial arm 44 of FIG. 2 in a clock wise direction which will raise the front of the platform 23. The platform 23 is again maintained parallel to the line of fight of the machine and shaft 27 and member 25 remain in their fixed attitude with respect to housing 21. Therefore, any rotation of the gear 30 and member 25 will result in a change in the slope of the platform 23 and sensor 22 by an amount dependent upon the amount of rotation of the blade circle 15. Thus, the sensor 22 will sense the true slope of the blade.
Since the shaft 41 rotates by an amount dependent upon the movement of the drawbar frame 18 with respect to the machine 10, the movement of the arm 47 is also dependent upon movement of the drawbar frame 18 with respect to the machine 10 which control is disclosed in U.S. Pat. No. 3,908,765 above mentioned. Thus the output from the Hall effect sensor 53 can be used in the feedback circuit of a grade control system. | In a slope control apparatus for the working tool of a motor grader or other earth working machine, the slope sensor used for controlling the slope of the tool is mounted on a revolving platform the attitude of which is corrected by a factor related to the rotational angle of the tool about a vertical axis and also related to the angle of the tool with respect to the line of flight axis of the machine. The apparatus is mounted in a fashion to allow the tool to be swung to a vertical position without damage to said apparatus. |
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RELATED APPLICATIONS
[0001] This non-provisional application claims priority from provisional application No. 60/205,330, filed on May 18, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates generally to apparatuses used on a construction job site and, more specifically, to a multiple function job site work cart.
[0004] 2. Description of the Related Art
[0005] Persons working on a construction site require the use of a number of different apparatuses during the construction process. For example, materials carts and wheelbarrows are needed to transport items on the job site, a storage box is needed to store tools and the like in a secure manner, and ladders and scaffolds are needed to access the structure being built.
[0006] Currently, these apparatuses are discrete; i.e., they tend to perform only one function. Thus, a wheelbarrow would not also be useable as a ladder, scaffold, storage box, etc. As a result, there is generally a need to acquire a separate apparatus to perform each desired function. As a result, these many apparatuses can be relatively costly and can take up a relatively large amount of space, making them relatively unportable as a group.
[0007] A need therefore existed for a job site apparatus capable of performing multiple functions, including preferably that of materials cart, wheelbarrow, storage box, ladder, scaffold, and others. The multiple function apparatus should be portable, both within the job site and so as to be movable from one job site to another. The present invention satisfies these needs and provides other, related, advantages.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a job site apparatus capable of performing multiple functions.
[0009] It is a further object of the present invention to provide a job site apparatus capable of serving as a number of different apparatuses useable on a job site, including that of materials cart, wheelbarrow, storage box, ladder, scaffold, and others.
[0010] It is a still further object of the present invention to provide a portable job site apparatus capable of serving as a number of different apparatuses useable on a job site.
[0011] The foregoing and other objects, features, and advantages of the invention will be apparent from the following, more particular, description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] In accordance with one embodiment of the present invention, a multiple function work cart is disclosed. It comprises, in combination: a cart having a base and two opposing side walls coupled at a right angle to the base so as to form an essentially U-shaped structure when viewed from an end thereof having two open ends; wheels coupled to the cart; and dividers adapted to be removably coupled to at least one of the open ends.
[0013] In accordance with another embodiment of the present invention, a multiple function work cart is disclosed. It comprises, in combination: a cart having a base and two opposing side walls coupled at a right angle to the base so as to form an essentially U-shaped structure when viewed from an end thereof having two open ends; wheels coupled to the cart; wherein the wheels comprise two wheels located proximate a first end of the base, two wheels located proximate a second end of the base, and one wheel located proximate a top portion of each the side wall so that the cart may optionally be rolled in each of a horizontal and vertical configuration; dividers adapted to be removably coupled to at least one of the open ends; means for removably coupling handles to the cart; a door adapted to be hingedly coupled to one of the side walls opposite the base; at least two ladder-shaped frame member comprising two vertical members joined by at least one horizontal member and wherein an end portion of the vertical members is adapted to be removably coupled to the cart proximate corner portions of the side walls; at least one step adapted to be positioned across the horizontal members of the two ladder-shaped frame members when in position on opposing ends of the cart; and a coupling member adapted to permit the coupling of two ladder-shaped frame members in a vertical direction so that one the ladder-shaped frame member is positioned directly on top of another.
[0014] In accordance with yet another embodiment of the present invention, a multiple function work cart is disclosed. It comprises, in combination: a cart having a base and two opposing side walls coupled at a right angle to the base so as to form an essentially U-shaped structure when viewed from an end thereof; two wheels located proximate a first end of the base; two wheels located proximate a second end of the base; and one wheel located proximate a top portion of each the side wall so that the cart may optionally be rolled in each of a horizontal and vertical configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a perspective view of the multiple function job site work cart of the present invention, in a horizontal orientation.
[0016] [0016]FIG. 1A is a side view of the multiple function job site work cart of the present invention, configured as a wheelbarrow.
[0017] [0017]FIG. 2 is a perspective view of the multiple function job site work cart of the present invention, in a vertical orientation.
[0018] [0018]FIG. 2A is a perspective view of the multiple function job site work cart of the present invention in a vertical orientation and in use as a step ladder.
[0019] [0019]FIG. 2B is a perspective view of the multiple function job site work cart of the present invention in a vertical orientation and with a door thereon, in use as a storage box.
[0020] [0020]FIG. 3 is a perspective view of the multiple function job site work cart of the present invention configured for storage and transport.
[0021] [0021]FIG. 4 is a perspective, partially exploded view of the frame storage portion of the multiple function job site work cart of the present invention.
[0022] [0022]FIG. 5 is a perspective view of the multiple function job site work cart of the present invention configured as a scaffold.
[0023] [0023]FIG. 5A is a perspective view of a frame joining member.
[0024] [0024]FIG. 6 is a perspective view of a portion of the multiple function job site work cart of the present invention when configured as a scaffold, illustrating the positioning of a work table thereon.
[0025] [0025]FIG. 6A is a perspective view of a stabilizing bar.
[0026] [0026]FIG. 7 is a perspective view of the multiple function job site work cart of the present invention, when configured to position plastic sheeting or the like proximate a work area.
[0027] [0027]FIG. 8 is a perspective view of a walkway.
[0028] [0028]FIG. 8A is a perspective view of a support member for the walkway of FIG. 8.
[0029] [0029]FIG. 9 is a perspective view of the multiple function job site work cart of the present invention, illustrating the use of the walkway of FIG. 8 in combination with the work cart configured as a scaffold.
[0030] [0030]FIG. 10 is a perspective view of a ladder formed using frame member portions useable with the work cart of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Referring first to FIG. 1, the multiple function job site work cart 10 (hereinafter “cart 10 ”) of the present invention is shown, in its most basic configuration. In the configuration shown in FIG. 1, the cart 10 can be seen to comprise, when in a horizontal orientation, a base 12 and two opposing rectangular side walls 14 perpendicular to the base 12 . Each of the base 12 and side walls 14 are preferably formed by welding sheet metal over a steel frame. Portability is imparted to the cart 10 in its horizontal orientation by large wheels 16 located at a first end of base 12 and small wheels 18 located at a second end of base 12 . Small wheels 18 are preferably pivoting, so as to impart maneuverability to the cart 10 , and locking, so as to permit the cart 10 to be secured in a desired location.
[0032] The cart 10 in the configuration shown in FIG. 1 can serve as a materials cart. Thus, materials can be placed within the space defined by the base 12 and side walls 14 , and moved around the job site with the user grasping one or both side walls 14 and pushing or pulling the cart 10 in the desired direction. (The cart 10 could also be maneuvered by inserting one or more Y-shaped brackets 32 , described below, into corner receiving shafts 25 , also described below.) Because both ends of the cart 10 between the side walls 14 are open, the cart 10 could particularly efficiently be used to transport oversized items such as 2×4's, which can project out one or both sides of the cart 10 .
[0033] Still referring to FIG. 1, it can be seen that dividers 20 can be positioned in one or both open ends of the cart 10 , between side walls 14 . Coupling of the dividers 20 to ends of the cart 10 is accomplished by positioning L-shaped insertion shafts 22 projecting from sides of the dividers 20 into receiving shafts 24 located at end portions of the side walls 14 and at two other points along the length of the side walls 14 . (As shown in FIG. 1, the receiving shafts 24 are preferably adjacent the steel frame members on the side walls 14 that run perpendicular to the base 12 .) When dividers 20 are positioned in the receiving shafts 24 at both ends of the cart 10 , it takes on the orientation of a closed-end materials cart or wheel barrow.
[0034] It can be seen that permanent handles 26 are positioned at an end of the base 12 on the same side of the base 12 as the large wheels 16 , and project outward from the base 12 . When using the cart 10 as a wheel barrow, a user can, optionally, grasp the permanent handles 26 and lift an end of the cart 10 off of the ground, so that only the large wheels 16 are contacting the ground. (It should be noted that when a divider 20 is positioned only in the end of the cart 10 proximate the large wheels 16 , it takes on the orientation of a materials cart or wheel barrow in which oversized materials can be transported at an angle with the user grasping the permanent handles 26 and lifting an end of the cart 10 —so that the materials will contact the divider 20 on one side and may project outward from the cart 10 in the direction of the user on the other.)
[0035] Referring now to FIGS. 1 and 1A, located on the base 12 along both sides thereof, and opening at both ends thereof, are receiving shafts 28 . Among other things, the insertion shafts 28 are dimensioned to receive the insertion shaft portion 30 of Y-shaped brackets 32 . These Y-shaped brackets 32 should be inserted into the insertion shafts 28 to the desired depth, and secured at that position by the insertion of a pin 34 through an opening 36 in the insertion shaft 28 and through an aligned opening 38 in the insertion shaft portion 30 of the Y-shaped bracket 32 . (Although only one is shown, the insertion shaft portion 30 preferably contains a plurality of openings 38 along the length thereof, to facilitate coupling to the insertion shaft 28 at different points so as to enable the adjustment of the position of the Y-shaped bracket 32 .) As shown in FIG. 1A, when in position, the Y-shaped brackets 32 serve as handles for the cart 10 , permitting it to be raised so that it travels only upon the large wheels 16 in wheelbarrow fashion.
[0036] Referring now to FIGS. 2, 2A and 2 B, the cart 10 is shown in a vertical orientation, positioned on the large wheels 16 and on small wheels 40 , which small wheels 40 are preferably pivoting and locking. (The small wheels 40 are located proximate a top corner of side walls 14 when viewed in a horizontal orientation, and on the same end of the cart 10 as the large wheels 16 .) Dividers 20 should in this orientation be positioned at least at the end of the cart 10 most proximate the ground, and dividers 20 may be placed in other receiving shafts 24 so as to form shelves or steps.
[0037] In the vertical orientation, the cart 10 can serve as a dolly (FIG. 2), as an upright storage unit (FIG. 2B), or as a step ladder (FIG. 2A). Where the cart 10 is to serve as a storage unit, it will be desired to position a door 27 to cover the open front of the upright unit, with the door 27 being hingedly coupled to one side wall 14 with hinges 29 . (Preferably, each hinge 29 comprises a two-part assembly, with one part being affixed to a side wall 14 and a mating second part being affixed to the door 27 —so that the door 27 can be hingedly coupled to the side wall 14 by coupling the two mating portions of the hinges 29 .) In this configuration, a locking device can further be used—such as a chain locked in position around the door 27 , side walls 14 and base 12 —so as to provide a secure storage location for tools and the like.
[0038] Referring to FIGS. 2 and 2A, where additional stability is required, an outrigger 42 can be inserted into corner receiving shafts 25 , located at each of the corners of the side walls 14 distal from the base 12 . The outrigger 42 includes adjustable length legs 44 . Such additional stability may especially be desired where, as shown in FIG. 2A, the cart 10 is to be used as a step ladder.
[0039] Referring now to FIGS. 4 - 5 , several of the other basic components which may be used together with the cart 10 are illustrated. Preferably four frames 46 are provided, each having an essentially ladder configuration and consisting of two vertical members 46 a connected by two horizontal members 46 b therebetween (see also FIG. 5). The frames 46 are dimensioned so that end portions of the vertical members 46 a may be inserted within the corner receiving shafts 25 , so that the frames 46 will be perpendicular to the ground and will project upward. Referring briefly to FIG. 5A, where it is desired to couple two frames 46 vertically, a coupling device 48 is used, comprising an insertion shaft 50 adapted to be inserted into the ends of the vertical members 46 a of the frame 46 , which insertion shaft 50 has a stop region 52 thereon. The stop region 52 is dimensioned to be too large to be inserted into the vertical members 46 a of the frame 46 , and will be exposed between two frames 46 when the coupling device 48 is positioned therebetween.
[0040] Referring now to FIG. 5, the configuration of the cart 10 as a scaffold is illustrated. In this configuration, frames 46 are inserted into receiving shafts 25 on both short sides of the cart 10 . Preferably, two frames 46 are positioned on either side of the cart 10 , which frames 46 are joined by the coupling devices 48 . Across horizontal member portions of the frames 46 are positioned steps 54 , which steps 54 are preferably rectangular-shaped and comprise a steel framed over which is positioned a mesh screen or the like. The steps 54 further comprise at least one tab 56 extending from each short side thereof, which is dimensioned to secure the step 54 relative to the horizontal member 46 b of the frame 46 . To provide further stability, a stabilizing bar 58 (see FIG. 6A) may be coupled across the vertical member 46 a portions of two opposing frames 46 . The stabilizing bar 58 comprises a horizontal bar 58 a and a bracket 58 b at each end of the horizontal bar 58 a , which brackets 58 b are dimensioned to be fitted snugly over vertical members 46 a.
[0041] At a top portion, the Y-shaped brackets 32 may be inserted into the exposed ends of the vertical member 46 a of the frames 46 . In this position, the Y-shaped brackets 32 comprise handles useable by a person on the scaffold. Moreover, a reduced-width step 60 (with tabs 61 projecting downward from end portions thereof) may be positioned across at least one of the Y-shaped brackets 32 , so as to constitute a work table for the user. A reduced-width step 60 may also be positioned, as shown in FIG. 5, at a ninety degree angle to a step 54 , so as to constitute a toe board for the user. As also shown in FIG. 5, additional stability can be provided by positioning outriggers 42 at both ends of the cart 10 .
[0042] Referring now to FIG. 7, the cart 10 when configured as a scaffold can also be used to support a plastic sheet (or similar type of material) 62 , which can be used to protect a work area. The sheet 62 is suspended from a bar 64 , which bar 64 is preferably supported by the Y-shaped brackets 32 . Additional stability can be provided by one or more outriggers 42 .
[0043] Referring now to FIGS. 8 - 9 , the use of a walkway 66 in combination with the cart 10 is shown. Referring first to FIG. 8, the basic components of the walkway 66 are a plank 68 and two support members 70 . The support members 70 are of adjustable length. As shown in FIG. 9, a single support member 70 can be positioned alongside the cart 10 , and the plank 68 extended from the cart 10 to the support member 70 so as to provide an extended walkway/scaffold combination.
[0044] Referring now to FIG. 10, it can be seen that the frames 46 can be used to form a ladder. In the embodiment shown in FIG. 10, the frames 46 are joined at top portions thereof with a joining member 71 , so as to form a substantially A-shaped ladder. While the ladder in FIG. 10 is formed from two frames 46 , it would be possible to form a ladder from, for example, four frames 46 , with each side of the ladder comprising two frames 46 joined by coupling devices 48 . It would also be possible to form a standard ladder from one or more frames 46 , of the type that can be simply leaned against a structure—such as a wall or tree—that is to be climbed. As shown in FIG. 10, length adjusting members 73 may be coupled to bottom portions of the frames 46 , so as to make the ladder formed herein adjustable in height.
[0045] Referring now to FIGS. 3 and 4, the storage of the cart 10 and the components disclosed herein is shown. Referring first to FIG. 4, the frames 46 may be positioned on a frame storage cart 72 . The frame storage cart 72 has insertion shafts 74 at an end thereof, over which are inserted ends of the vertical member portions of the frame 46 . At one end of the frame storage cart 72 are wheels 76 . At the opposing end of the frame storage cart 72 may be inserted Y-shaped brackets 32 . The Y-shaped brackets 32 may be grasped by a user and used to raise that end of the frame storage cart 72 , so that it may be wheeled upon wheels 76 . The steps 54 may be positioned over the frames 46 when the frames 46 are in position on the frame storage cart 72 , so as to create a series of covered compartments which may be used for storage.
[0046] The frame storage cart 72 may be coupled to the cart 10 , as shown in FIG. 3, by inserting insertion shafts 78 located at the four corners of the base of the frame storage cart 72 into the receiving shafts 25 on the cart 10 . The frame storage cart 72 may be secured to the cart 10 with BUNGEE® cords (not shown), chains (not shown), or the like. The entire apparatus may then be placed in the bed of a pickup-type truck. Alternatively, a trailer assembly may be affixed to the cart 10 , permitting it to be towed by a vehicle having a receiver hitch.
[0047] Before the cart 10 is configured for transport, the individual components discussed herein and not illustrated as being coupled to the exterior of the cart 10 —with the sole exception of the plank 68 —may be stowed within the cart 10 or the frame storage cart 72 . Additionally, the outriggers 42 may be coupled along the sides of the cart 10 as shown in FIG. 3, by coupling the outriggers 42 to insertion shafts (not shown) located below the base 12 of the cart 10 .
[0048] While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention. While the cart 10 has been discussed with respect to its possible construction applications, it should be understood that the cart 10 could be useable for a large variety of uses. This would include, for example, the installation of Christmas lights, painting, trimming of trees, swap meet displays, etc. | A multiple function job site work cart in which the basic component is a wheel-based cart having a base, two opposing sides perpendicular to the base, and capable of being rolled in a horizontal or vertical orientation. With the incorporation of additional components including dividers, steps, a door, frames, outriggers, stabilizing bars, brackets, and others, the cart can be configured as a materials cart, wheelbarrow, storage cart, scaffold, ladder, dolly, sheet support, and other structures useful in a work setting. When not in use, the components can be packed into or coupled to the car for storage and/or transport. |
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FIELD OF THE INVENTION
[0001] This invention relates to the equipment and system used to perform drill-hole survey and geological surveys of the sub-surface of earth, either onshore or offshore, wherein the equipment is given access to the subterranean strata by way of pre-prepared exploratory drill-holes.
BACKGROUND OF THE INVENTION
[0002] Geological surveys are critical activities used by mining and resource companies to determine the viability and operation of mines and wells. The accuracy and timeliness of the acquired data is an important factor in finding the next big ore deposit, or oil or gas well. When it comes to geological surveying, time and precision are critical factors. Cost is an important factor as well. Lower cost surveys allow an operator to conduct more surveys within a set survey budget for a particular site.
[0003] It is common practice that a series of drill-holes are created so that professional geoscientists, such as geologists can use a variety of equipment and survey technology and techniques to get as much data as physically possible that relates to the subterranean strata deep within the Earth's crust at that location.
[0004] One of the problems associated with the practice is that these geological surveys are typically slow and costly to perform. The common practice is to have an on-site a drilling team that performs the drilling operation and creates the drill-hole, and then there is a survey team that subsequently works on the drill-hole with their equipment and performs the necessary geological survey. The survey team then returns to their office with their collected data and start processing it to generate a survey report that mining or resource companies use to guide the planning and decision making relating to the operation of an existing asset, or the creation of a whole new operation.
[0005] Another problem associated with the common practice is that the tools and equipment used by the survey team are often highly specialised and complex, often requiring significant training and years of experience to operate correctly and effectively. In addition, the equipment is often expensive to maintain. Also there is currently only limited access to real-time data produced by the survey. Often this data is not analysed for days, weeks or months after the survey has been performed.
[0006] Ideally it would be best if the professional survey personnel were able to remain at the place where they are able to analyse and collate the survey data acquired as soon as possible after the survey operation has been completed and the data has been obtained.
[0007] Another problem is that drillers usually maintain a paper log of drill site activity, and this adds delays to the processing times of the geological survey data, and also adds delays to the processing of payments to the drillers for their work, and has the potential of introducing human error into the log.
[0008] Also geological survey personnel such as geologists often take an ad-hoc approach to the storage of the acquired geological survey data.
[0009] Due to the complexity and specialization of skills needed to effectively use the tools and equipment to conduct the survey, it is often not possible to have the drill operators perform the geological survey of a high and known quality, in addition to creating the drill-hole.
[0010] It is an object of the present invention to at least ameliorate some or all of the aforementioned problems.
DISCLOSURE OF THE INVENTION
[0011] The present invention is a drill-hole survey and geoscientific data acquisition system that includes a down-hole tool including:
a sensor control module, at least one sensor module, and data, control and electrical power connection means,
[0015] wherein the sensor control module, the at least one sensor module, and the connection means are each sized and shaped so that they can be placed within a drill-hole and can travel along the length of the drill-hole, and can travel along the drill-hole. the sensor control module is a discreet control module, and each of said at least one sensor modules are also each a discreet sensor module, and each of the discreet control and sensor modules are inter-connectable via said data, control and electrical power connection means so that the series of modules are connected end to end to make one continuous elongate tool that contains a series of interconnected modules. The sensor control module controls the tool and provides electrical power to, and sends control signals to, and receives data from, each of the at least one sensor module. The tool collects data along the drill-hole.
[0016] Preferably the tool collects geoscience data at discreet places along the drill-hole when the tool is stopped.
[0017] Alternatively the tool continuously collects geoscience data as the tool travels along the drill-hole.
[0018] Preferably the tool includes data transmission means that sends data up to the operator at the ground surface, and said transmission means is either wired or wireless.
[0019] Preferably the tool includes two wireless communication modes, one that is high powered, and the other that is low powered, and only one or the other is typically in operation at any one time.
[0020] Preferably the high powered mode is used to transfer a large amount of data as quickly as possible, such as firmware upgrades to the modules, and/or large amounts of sensor data, and is subsequently switched off when no longer required to preserve the tool's battery power reserves.
[0021] Preferably the low powered wireless communications mode is used to send short quick commands back and forth from the tool, and when only small amounts of data need to be transferred.
[0022] Preferably the tool is capable of self-determining which wireless communication mode to use for any particular data transfer task, or the operator can manually select the wireless communication mode using remote commands.
[0023] Preferably the tool is capable of continuously transmitting said geoscience data back to the operator while the tool is down the drill-hole.
[0024] Alternatively the geoscience data can be collected and stored within the tool, and this collected data can then be uploaded into a handset by an operator after the tool has been retrieved from the drill-hole.
[0025] Preferably at least one gyroscope is included inside a discrete gyroscope module that is connected to, and forms a part of the elongate tool.
[0026] Alternatively at least one gyroscope is incorporated into the sensor control module.
[0027] Preferably the gyroscope is a microelectromechanical type gyroscope, also known as a MEMs gyroscope.
[0028] Preferably the gyroscope module includes four gyroscopes, and these are installed “nose to tail” so that the length of the gyroscope module is minimised.
[0029] Preferably each sensor module includes one or more types of sensor technology.
[0030] Typical sensor types used within a discrete sensor module include, but are not limited to:
a. magnetic induction sensing, or b. gamma ray sensing, or c. electrical resistance sensing, or d. acoustics sensing, or e. video surveillance, or f. temperature sensing, or g. gravity gradiometer, or h. pressure sensing.
[0039] The down-hole tool is capable of being transported to the drill-hole site by the drilling operators in a disassembled condition, and the tool is capable of being assembled on-site and accurately calibrated so that the tool includes all the appropriate modules required for any particular geoscientific survey to be performed on a particular drill-hole.
[0040] Preferably the tool can be disassembled and safely stored after the survey operation has been completed by the drilling operators, ready to be transported to the next survey site.
[0041] Preferably the discrete modules are screwed together to form the elongate tool.
[0042] Preferably the sensor control module has the data transmission means at its end nearest to the opening of the drill-hole, and has data, control and electrical power connection means at the other.
[0043] Preferably each of the sensor modules and the gyroscope module has data, control and electrical power connection means at each end, and when each discrete module is screwed together with a neighbouring module, the data, control and electrical power connection is made between each module that makes up the tool.
[0044] Preferably the connection means includes an array of spring loaded electrical connector pins at one end, and a plurality of discrete electrical contacts at the other, so that when two modules are screwed together, the spring loaded pins of one module are forced into electrical contact with a desired electrical contact on its neighbouring module.
[0045] Preferably each module includes a data logger that is relevant to that particular module.
[0046] Preferably each module includes the capability of shutting down power to its neighbouring module to preserve its own operational integrity.
[0047] Preferably the sensor control module includes a temperature sensor for the tool.
[0048] Preferably the sensor control module includes a tamper sensor that indicates if any of the modules have been tampered with.
[0049] Alternatively each of the modules that makes up the tool includes a tamper sensor that indicates if the particular module has been tampered with.
[0050] Preferably the tool is capable of processing the data acquired by the sensors within the tool, so that the amount of data that is stored within the tool and transferred or transmitted from the tool is minimised.
[0051] Optionally at least one of the modules is filled with a suitable material such as oil to dampen the rate of variations in temperature which may adversely affect the efficacy or accuracy of the particular sensor.
[0052] Optionally the tool, including each module, and/or ancillary equipment, such as the handset, and/or associated software, includes digital rights management technology that can be remotely enabled or disabled by an authorised third party, such as a distributor and/or owner of the tool, and wherein the tool, including each module, and/or ancillary equipment such as the handset, and/or associated software, can only be operated when the digital rights management technology is enabled.
[0053] In another form, the present invention is a down-hole survey system that uses the down-hole tool that has been previously described, and includes:
a tool controller, an access point, at least one server, and a plurality of computers,
[0058] wherein the tool controller and the access point are located in the vicinity of the drill-hole. The tool controller is used to operate the tool, and collect the geophysical data acquired by the tool. This data is sent to the access point, and the access point is capable of wirelessly transmitting the acquired data over a wide area network, such as the internet, to the at least one server and plurality of computers.
[0059] Preferably the tool controller is a ruggedised handset.
[0060] Preferably the access point is capable of creating a gateway between the local area network at the survey site, and a wide area network, such as the internet, so that data to/from the down-hole tool, and/or to/from the handset, and/or to/from the at least one server, and/or to/from any one of the plurality of computers, passes via the gateway.
[0061] Optionally the access point is integrated into the ruggedized handset so that the handset is capable of functioning as both the tool controller and the access point.
[0062] The present invention includes the arrangement where both the at least one server and at least one computer are geographically remote from the survey site.
[0063] Preferably the at least one server and the at least one computer in the plurality of computers are located within a master control facility, and at least one of the plurality of computers is located in a separate office remote from the master control facility.
[0064] Preferably the master control facility, both in conjunction with, or independently of, the separate office, prepares and dispatches a drilling program to a driller onsite, who will compare instrument data with a planned drill-hole plan so that the driller can make any last minute adjustments to the drilling program.
[0065] Preferably the master control facility, either in conjunction with, or independently of, the separate office, is capable of using the survey data it receives from the survey site so that the drilling program and drill-holes can be analyzed.
[0066] Preferably the handset is capable of acquiring and transmitting data relating to the operational status and condition of the tool so that either or both the operator at the drill-hole site or the professional personnel at the master control facility are alerted if/when critical aspects of the tool has fallen out of proper calibration, or has in some other way moved outside of acceptable operational parameters for the particular survey operation being undertaken.
[0067] Preferably personnel at the master control facility can react to alerts relating to critical aspects of the tool falling out of proper calibration, or in some other way has moved outside of acceptable operational parameters for a particular survey operation, by sending corrective and/or instructional data back to the drill site, including firmware for the hardware, and/or updated associated software, in order to attempt to get the tool, or an included module within the tool, back into proper calibration, and/or back to within acceptable operational parameters for that particular survey operation being undertaken, or to upgrade the equipment so that it operates at peak efficiency.
[0068] Preferably an authorised third party, such as a distributor and/or owner of the tool, including each module, and/or ancillary equipment such as the handset, and/or associated software, can enable or disable the digital rights management technology associated with that equipment and associated software, depending on the licence status of the operator at the time that the operator is preparing to use the equipment and/or associated software to perform a survey on a drill-hole.
[0069] Preferably the handset has a simplified user interface that enables and empowers a driller at the survey site to perform highly specialised and complex survey activities under the supervision and instruction of professional geological survey experts, such as geologists, located at the master control facility, or at a remote office, thereby giving the professional survey experts virtual access to the drill site and remote oversight of the survey operation for any particular drill-hole survey operation being undertaken.
BRIEF DESCRIPTION OF THE DRAWINGS
[0070] FIG. 1 is an exploded isometric view of a tool having a control module, a gyroscope module and a sensor module.
[0071] FIG. 2 is an isometric view of the electrical power, control and data connection means.
[0072] FIG. 3 is a side cut away view of the gyroscope module showing four gyroscopes installed.
[0073] FIG. 4 is a schematic of the complete survey system including the tool.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] Turning firstly to FIG. 1 we see an exploded view of the down-hole survey tool 1 . The survey tool 1 can be assembled from a sensor control module 3 and a gyroscope module 13 , and a plurality of sensor modules, selected from a kit containing a wide variety of sensor module types. Starting with the sensor control module 3 , typically the gyroscope module 13 is connected to the sensor control module 3 via the external and internal screw thread pair 5 and 7 respectively. Each module has matching internal and external screw threads, thereby enabling the tool to be assembled in a wide variety of configurations. A different selection of sensor modules are assembled together for each specific survey task.
[0075] The sensor control module 3 is the master controller for the device. It includes the power supply for the tool, as well as the controller and monitoring means for each other module in the tool assembly. In addition, the sensor control module 3 includes data receiving and transmitting means. An example of suitable means is the wireless data receiving/transition means 11 . As an alternative to wireless means, the sensor control module could also communicate with the ground surface via a wire.
[0076] In another preferred embodiment, the tool may incorporate two wireless communication modes. The first is a high power mode that is capable of sending and receiving comparatively large amounts of data more quickly and effectively. The other mode is a low power mode, and this mode is suitable for small amounts of data transfer. Typically only one mode is in operation at any one time. Because the high power mode consumes more power from the battery power reserves for the tool, it is only switched on when needed, and at other times it is turned off The tool is capable of self-determining which mode it needs to use based on a variety of factors, such as the amount of data to be transferred, and/or whether there is enough power in the battery to be able to be used. In addition to this, either the driller, or a remote operator can remotely command the tool to use one mode or the other.
[0077] The end of the sensor control module 3 furthest from the opening of the drill-hole includes a set of electrical contact rails. When a module is screwed onto the sensor control module, and electrical connection is made between them. This electrical connection permits the flow of data, electrical power and control signals throughout the tool.
[0078] Within the scope of the present invention, the sensor control module may also include one or more gyroscopes. In this embodiment, there is no need to have a separate gyroscope module 13 . In another embodiment, the sensor control module 3 may also include a sensor, such as a temperature sensor, thereby removing the need for including a temperature sensing module in the tool. In yet another embodiment, the sensor control module 3 may include a tamper alert sensor that is capable of alerting the operator or owner of the tool to an unauthorised tamper event on any of the modules of the tool.
[0079] In another embodiment, some or all the modules include a respective tamper alert sensor that alerts the operator or owner of the tool of an unauthorized tamper event on any of the respective modules of the tool.
[0080] Each sensor module 15 is capable of doing at least one specific sensor or survey task, including, but not limited to:
magnetic induction sensing gamma ray sensing electrical resistance sensing acoustics sensing video surveillance temperature sensing gravity gradiometer pressure sensing
[0089] Each sensor module may operate either autonomously, or may be controlled by the control module. Sensor data collected by a particular sensor module may either be stored locally in that particular sensor module, or the data may be stored in the control module, or a combination of both for the sake of redundancy.
[0090] Each module within the tool 1 includes a data logger.
[0091] Turning to FIG. 2 , we are shown opposite ends of a sensor module. We can see that there is an array of multiple spring loaded connector pins 17 at one end, and a plurality of concentric electrical contact rails 19 at the other. When two modules are screwed together, the spring loaded connector pins are forced into electrical contact with the electrical contact rails 19 . Depending on the requirements for that particular module, the pins 17 are arrayed so that only the appropriate contact rails 19 are connected to.
[0092] When the tool is assembled, it becomes a rigid elongate tool that is dimensioned to be lowered down the drill-hole. In another form of the invention, small bendable connectors are located between each module, thereby allowing individual modules to bend with respect to its neighbor. This assists in special circumstances where the tool needs to pass around a bend in the drill-hole that is would otherwise not be capable of passing in its rigid form.
[0093] Turning to FIG. 3 we can see a cut away side view of the gyroscope module 13 . In this embodiment we can see that is includes four MEMs type gyroscopes. The internals for the entire gyroscope module are capable of turning under the influence of a motor. The internals of the module are connected at each end to the bearings 23 . The more gyroscopes that are installed in the tool thereby gives the tool a capability to reach an acceptable level of directional orientation precision in a shorter period of time, compared to a tool with fewer gyroscopes installed.
[0094] In a preferred embodiment, up to four MEMs gyroscopes are used inside the gyroscope module, and these are installed in a “nose to tail” configuration so that the length of the gyroscope module is considerably reduced.
[0095] In an alternative embodiment, it is possible that some, or all of the individual modules used in the tool are filled with a suitable substance, such as an oil, so as to dampen the rate at which temperature varies within the tool. Some efficacy and/or accuracy of some types of tools is degraded if it is subjected to temperature variations.
[0096] Turning to FIG. 4 we are shown a schematic of the down-hole survey system 25 that uses the down-hole tool 1 as previously described. The system includes the down-hole survey tool 1 , a handset 27 , an access point 29 , at least one server 31 . The access point 29 acts as a gateway between the local area network 35 , and the wide area network, such as the internet, that connects to the remote server 31 and the computer 33 . In a preferred embodiment, the server 31 is remotely located from both the survey site and the computer 33 . Preferably the server is located inside a Master Control Facility 37 that can be physically located anywhere in the world. The computer 33 is located at a client survey office 39 , also located anywhere in the world. Geophysical scientists, such as geologists can be located at either facility and can oversee and run survey remotely from the survey site. There is a high degree to communications flexibility designed within the system. The down-hole tool 1 is can be configured to communicate directly with the access point 29 , or via the handset 27 to the access point, and also it can be configured to communicate directly with the computer 33 or the server 31 .
[0097] Additionally the master control facility 37 can monitor and maintain the equipment at the survey site in real time. If the module issues an alert that one or more of the modules have gone out of acceptable operational limits, the master control facility 37 can send back corrective instructions to the tool, and/or send instructions to the drilling operator about how to correct the problem.
[0098] The master control facility 37 enables the geophysical professionals to remotely plan and control the drilling program for the client at a particular survey site. At the commencement of a survey, the survey plan would be sent via the wide area network link to the handset and down-hole tools onsite. The handset, or in some cases a laptop computer or tablet that is being used by the driller will compare the instrument data with the planned survey data and provide guidance to the driller on parameters such as actual drill-hole deviation from planned direction to suit the specific geology of the survey location. A client company, such as a geoscience laboratory, at their office 39 , can also enter in assay or other relevant information into the server records relating to the particular survey.
[0099] Furthermore, the master control facility can perform analytics based on the geo-location of the survey and the theoretical accuracy of the down-hole tool based on its location on the earth can be accounted for. This is required because Gyroscopic based sensors change accuracy depending on the latitude at which they are used, while Magnetics tools require declination corrections to calculate true north depending on the latitude and longitude.
[0100] The other main aspect of the invention is that a user, such as a drilling contractor, or a mine site, can create a local area geophysical data network in a region by installing an access point 29 and that allows the down-hole tool and/or handset to directly and wirelessly communicate with both the master control facility's server, and/or client survey office 39 .
[0101] In another form of the present invention, the access point 29 is incorporated into the handset, so that the handset also performs the function of the access point.
[0102] Another important aspect of the invention is that down-hole tool 1 undertakes the majority of the sensor data processing and thereby reduces the amount of data that needs to be transferred to the handset. This reduces the processing required on the handset, and reduces the amount of data to be transmitted to the handset from the instrument, and to the master control facility server 31 . For the user at the survey site, it offers them a simple handset which is very easy to use, and requires minimal training, thereby allowing a drilling contractor to also perform the physical operations required to perform the survey.
[0103] Another important aspect of the invention is that the owner and/or distributor of the tool, ancillary equipment, and associated software, can remotely upgrade or service it as required so that the tool and its ancillary equipment and associated software can function at peak efficiency. Upgrades include updated software, or firmware for relevant hardware used either in or associated with the tool.
[0104] In another aspect of the invention, at least some of the modules, and/or the ancillary equipment such as the handset, and any associated software, has digital rights management technology incorporated with it. When the digital rights management technology is activated, the tool, and ancillary equipment, is in a usable condition. When the digital rights management technology is disabled, the tool and/or ancillary equipment is in a non-usable condition. Furthermore the distributor and/or owner of the tool is able to remotely enable or disable the digital rights management technology. This arrangement thereby enables the distributor and/or the owner of the tool and ancillary equipment to lease/rent out the equipment to an operator and ensure that it can only be used when the operator is in compliance with their relevant lease/rental agreement.
[0105] There are also other significant advantages to the system of the present invention. Under current practice, drillers maintain a paper log of drill site activity. This manual process introduces delay into the processing and payment times for the field services they have provided. Under this system, payments to the drillers for their field services can be processed much quicker.
[0106] Finally, by having the data collected by the tool sent directly from the drill-site to the remote office, the integrity and security of the data kept more secure.
[0107] Whilst the above description includes the preferred embodiments of the invention, it is to be understood that many variations, alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the essential features or the spirit or ambit of the invention.
[0108] It will be also understood that where the word “comprise”, and variations such as “comprises” and “comprising”, are used in this specification, unless the context requires otherwise such use is intended to imply the inclusion of a stated feature or features but is not to be taken as excluding the presence of other feature or features.
[0109] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that such prior art forms part of the common general knowledge in Australia. | The present invention is a drill-hole survey and geoscientific data acquisition system that includes a down-hole tool including:
a sensor control module, at least one sensor module, and data, control and electrical power connection means,
wherein the sensor control module, the at least one sensor module, and the connection means are each sized and shaped so that they can be placed within a drill-hole and can travel along the length of the drill-hole, and can travel along the drill-hole. the sensor control module is a discreet control module, and each of said at least one sensor modules are also each a discreet sensor module, and each of the discreet control and sensor modules are inter-connectable via said data, control and electrical power connection means so that the series of modules are connected end to end to make one continuous elongate tool that contains a series of interconnected modules. The sensor control module controls the tool and provides electrical power to, and sends control signals to, and receives data from, each of the at least one sensor module. The tool collects data along the drill-hole. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of U.S. application Ser. No. 08/576,998 filed Dec. 26, 1995, now U.S. Pat. No. 5,575,117 which is a continuation in part of U.S. application Ser. No. 08/204,114, filed Mar. 1, 1994, now U.S. Pat. No. 5,501,054.
BACKGROUND OF THE INVENTION
The invention relates generally to wooden structural members used in construction and more specifically to a reinforcement method for notched wooden beams.
Wooden beams may be used in construction to provide a horizontal span between walls or between walls and a central girder, for example as floor or ceiling joists. In such applications, the grain of the wood is aligned with the horizontal span.
Wood has relatively little strength perpendicular to the grain in comparison to its strength along the axis of its grain. For example, a sample of Douglas-fir might have parallel-to-grain tensile and compressive strengths of 15,600 and 3,470 PSI, respectively, but perpendicular-to-grain tensile and compressive strengths of only 360 and 340 PSI, respectively.
The strength of a wooden beam in a spanning application derives from the fact that the forces experienced by the beam when loaded are primarily oriented along the grain (tension, compression and shear) with essentially no cross-grain tension. This assumes, however, that the beam is supported underneath its ends and that the beam is of essentially uniform cross section without cuts or notches. This latter assumption may not always be true in practice. Beams may be cut or notched in various places to run utilities or to fit against other structural members. Notches that extend a significant distance into the beam may be an unavoidable part of the building's design or may occur from poor construction techniques.
Generally, a notch in a beam causes some of the loading of the beam to be manifest as cross grain tension, a mode in which wood is relatively weak. Additionally, the stress concentration at the notch re-entrant corner produces stresses to initiate and propagate a crack. As a result, if a spanning beam is to be notched, it is necessary to use reduced loading figures for that beam resulting in the need for larger or more beams than would otherwise be necessary. In renovation projects, where beam number and size is fixed, notching of the beams may not be allowable.
BRIEF SUMMARY OF THE INVENTION
The present inventors have recognized that the loss of strength caused by the notching of spanning beams and the like results not only by the lower strength of wood across its grain, but also because of the dynamics of crack propagation where cross grain tensile stresses are concentrated at the apex of an advancing crack. This concentration of tensile stress significantly decreases the effective strength of the beam in what is already its weakest mode.
Accordingly, the present invention provides localized high tensile reinforcement across the grain of the beam and spanning a line of anticipated crack propagation. By blocking crack propagation, the strength of a notched beam is significantly increased. Further, the need for extensive reinforcement of the entire beam is avoided.
Specifically, the present invention provides a structural member formed of a wooden beam having a grain directed along the length of the beam between ends and across a width of the beam between edges, the length and width defining an area of opposing beam faces. The beam is notched and the notch has a first cut starting at an edge and crossing the grain and extending less than the width of the beam and second cut abutting the first cut at a corner. A tensile reinforcing material is bonded to at least one opposing face across a hypothetical split line starting at the corner and extending parallel to the grain where an axis of tensile strength of the reinforcing material is directed across the grain.
Thus, it is one object of the invention to provide a reinforcement technique that addresses the mechanism of crack propagation through lumber at notches in the lumber. A limited amount of reinforcement near the notch can increase the strength of notched lumber for cross grain loads over its entire length by stopping crack propagation.
It is another object of the invention to provide a substantial increase in the effective load carrying capacity of beams without the need for extensive reinforcement of the entire beam.
A second beam, substantially equal in length and width to the first beam, may be bonded to the first beam to sandwich the tensile reinforcing material between the beam and the one face.
Thus, it is another object of the invention to provide a reinforcement for a notch centered within the likely path of crack propagation.
In one embodiment, the flexible fiber reinforcing material is a patch having fibers running along an axis. An adhesive is applied to one side of the patch and indicia is attached to the patch indicating a desired alignment of the patch with wood grain. The flexible fiber patch may be applied to a wooden beam with the axis perpendicular to the grain of a wooden beam.
Thus it is another object of the invention to provide a reinforcement method which may be used on site when notching of beams is necessary. The indicia is used to properly align the patch and the adhesive to attach the patch to the beam after the notch has been cut.
The foregoing and other objects and advantages of the invention will appear from the following description. In this description, reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration, a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference must be made therefore to the claims for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a fragmentary, perspective view of a notched wooden beam showing a projected split line extending from a corner of the notch and showing placement of localized reinforcement per the present invention to span this split line;
FIG. 2 is a simplified elevational view of the beam of FIG. 1 without localized reinforcement showing propagation of a crack along the split line with beam loading;
FIG. 3 is an exploded perspective view of a reinforcement according to the present invention and suitable for application in the field;
FIG. 4 is a fragmentary perspective view of a beam similar to that of FIG. 1 having pre-positioned internal reinforcement along an anticipated spit line; and
FIG. 5 is a perspective view of second beam, similar to that of FIGS. 1, 2 and 4 but having an internal notch.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a wooden beam 10, terminating at a first end 14, has grain 12 running along its length. The wooden beam 10 has generally rectangular cross section taken perpendicular to the grain 12 and presents generally parallel first and second opposed faces 16 and 18, respectively. Faces 16 and 18 have lengths commensurate with the length of the beam 10 and heights commensurate with the width of the beam 10. In use, the wooden beam 10 may be positioned with faces 16 and 18 oriented in vertical planes and with the length of the wooden beam 10 extending horizontally.
A notch 20 is cut in the first end 14 starting at a lower edge and is characterized by having a first cut 22 cutting across the grain 12 to a corner 24 within the wooden beam 10. At the corner 24, the first cut 22 meets with a second cut 26, the latter which extends along the grain 12 from the corner 24 toward the first end 14. The first cut 22 extends less than the width of the beam 10 so that the notch 20 provides an overhang portion 28 at near end 14 of the beam 10 such as may rest against a sill plate or the like.
Referring now to FIG. 2, when beam 10 is positioned with the overhang portion 28 resting on top of a support surface 30 (shown schematically as an upward arrow), downward loading on the beam 10 (shown by arrow 32) creates a tensile force (shown by arrow 33) on the material of the beam at the corner 24. The notch 20 causes this tensile force 33 to concentrate at the corner 24 promoting a split 34. The split 34 travels along a split line 36 extending parallel to the grain 12 of the beam 10 and thus along the length of the beam 10.
As the split 34 progresses, its apex 38 continues to define a point of concentrated tensile stress permitting the split 34 to expand further even though the total tensile forces 33, if distributed evenly over the length of the beam would be insufficient to separate the grain 12 of the beam 10.
Referring again to FIG. 1, present invention recognizes that localized reinforcement of the beam 10 crossing the split line 36 can substantially increase the working load of a notched beam 10 in spanning applications. In particular, an inverted L-shaped reinforcement patch 40 having a plurality of fiberglass fibers 42 extending along a fiber axis 44, is attached to one face 16 of the beam 10 by means of an epoxy adhesive 46 applied to the face 16. The L-shape of the patch 40 allows it follow the first and second cuts 22 and 26 of the notch 20.
In particular, a vertical, generally rectangular portion 48 of the patch 40 extends somewhat less than the height of the beam 10 to have a lower extent adjacent to the first cut 22 on the face 16 and an upper extent spanning the split line 36. The fibers 42 and fiber axis 44 are arranged vertically in this portion 48 to cross the grain 12 and the split line 36.
A second portion 50 of patch 40 extends from the upper extent of the first portion 48 along the direction of the grain 12 onto the overhang portion 28. The fibers 42 and fiber axis 44 in this portion 50 are also are arranged vertically to cross the grain 12.
The first portion 48 of the patch 40 serves to check any progress of a crack along the split line 36. The second portion 50 serves primarily as an alignment guide for the patch 40, but also increases the strength of the overhang portion 28 against cross grain and shear forces.
A similar patch 40 may be applied to the opposite face 18 of the wooden beam 10 to oppose the first patch 40 and to provide yet further reinforcement. For pre-manufactured beams 10, these patches 40 may be applied at a factory site.
In an alternative embodiment, the patch 40 shown in FIG. 3 may be adapted to field installation. In this case, the fibers 42 may be attached to a carrier 52 such as a polyester film or the like. An adhesive 46 may then be applied on the opposite side of the carrier 52 and may include a removable backing 54 to expose the adhesive 46 prior to placement of the patch 40 on the beam 10. The adhesive may be an epoxy such as those advertised under the tradename WEST SYSTEM such as is commercially available from Gougeon Brothers, Inc. of Bay City, Mich. A cover sheet 56 may then be placed over the fibers 42 on the side opposite the adhesive 46 to provide indicia 58 indicating proper alignment of patch 40 with the grain of beam 10. In a preferred embodiment, the indicia provides a printed arrow indicating the grain direction in the beam 10 when the patch 40 is properly affixed to the beam 10.
Such a patch 40 may be used on the work site when it is necessary to notch a beam 10 for utilities and the like. When the notch 20 is positioned in the middle of the beam multiple patches 40 may be used on each face 16 and 18 to flank the notch 20 and thus, it may be desirable to produce a right and left handed version of the patch 40 with the placement of the cover sheet 56 and the adhesive 46 reversed in the two versions.
Referring now to FIG. 4, a prefabricated notchable beam 10' may be constructed by ripping a normal beam 10 along its length midway between faces 16 and 18 to separate the beam 10' into two parts. Fibers 42 may be glued with an adhesive 60 to the cut face of one half of the beam 10' across an anticipated split line 36' near the ends 14 of the beam 10'. The fibers may be laid solely cross grain. The same adhesive 58 is then used to join the halves of the beam 10' together again about the fibers 42 to hold and stabilize the fibers 42.
Because the exact location of the notch may not be known in advance, the fibers 42 may be placed to extend along the middle one-third of the width of the beam for the last several feet of the beam 10+ at each end or other locations to accommodate reasonably expected notching operations as the beam ends. The fiberglass fibers 42 as embedded in the beam 10' may be readily cut with ordinary wood saws.
Referring now to FIG. 5, the present invention is also applicable in a beam 10" where the notch 20" is placed between ends 14" where the cuts of the notch start and end at an edge of the beam 10". Here the left and right hand versions of the patch 40 (indicated as 40a and 40b) may be used to reinforce the split lines 36" extending in two directions from the notch 20" along the line of the grain 12.
The above description has been that of a preferred embodiment of the present invention. It will occur to those that practice the art that many modifications may be made without departing from the spirit and scope of the invention. In order to apprise the public of the various embodiments that may fall within the scope of the invention, the following claims are made: | A localized fiber reinforcement places strong tensile strength fibers across a hypothetical split line near notches in beams to curtail split propagation caused by cross-grain tension that may otherwise significantly reduce the strength of a beam used as a spanning member. An adhesive coated patch may be applied after a notch is cut in the beam or fibers may be attached to a beam at a factory near the location of an anticipated notching. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 11/385,359 filed Mar. 21, 2006 now U.S. Pat. No. 7,152,626.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None.
BACKGROUND OF THE INVENTION
This invention relates generally to a device for connecting a dispenser to a water outlet. More particularly, it relates to a combined faucet spout and diverter valve for diverting water from a water outlet to the dispenser.
Diverter valves for connecting spray devices to a shower head are shown in U.S. Pat. No. 5,560,548 and U.S. Pat. No. 5,624,073. A diverter valve for connecting a spray device to a toilet is disclosed in U.S. Pat. No. 6,704,946. These devices are specifically designed for use with a shower head or a toilet. They do not lend themselves for use in conjunction with a faucet.
There is a need for a combined faucet and diverter valve which can be attached to a water outlet in a manner to provide a normal water flow from the faucet and alternatively afford a diversion of water from the faucet to a dispenser. There is also a need for a diverter valve for use with a faucet which affords a stable connection to a water outlet.
Accordingly, there is a need for an improved diverter valve for use with a water outlet.
The objects of the invention therefore are:
a. Providing an improved diverter valve.
b. Providing a combined faucet and diverter valve.
c. Providing a combined faucet and diverter valve of the foregoing type which is easily connected to a water outlet.
d. Providing a combined faucet and diverter valve of the foregoing type which includes a by-pass function.
e. Providing a combined faucet and diverter valve of the foregoing type which can be manufactured without special tooling and thus be cost effective.
SUMMARY OF THE INVENTION
The foregoing objects are accomplished and the shortcomings of the prior art are overcome by the combined faucet spout and diverter valve of this invention which include a valve housing having an annular cavity defined within said valve housing, a fluid inlet, a first fluid outlet, and a second fluid outlet. The annular cavity allows fluid communication between the fluid inlet, the first fluid outlet and the second fluid outlet. A shuttle valve is slidingly mounted in the annular cavity of the valve housing. There are means for constraining the shuttle valve within the cavity. The shuttle valve is constructed and arranged to be slideable within the annular cavity by water pressure to a first position in which said shuttle valve is seated adjacent said means for constraining said valve such that fluid flows between the fluid inlet and the first fluid outlet. The shuttle valve is slideable within the annular cavity to a second position in which said shuttle valve is positioned in the annular cavity of said valve housing such that fluid flows between the fluid inlet and the second fluid outlet. A faucet spout is connected to the first fluid outlet.
In a preferred embodiment, a valve member is positioned in the shuttle valve.
In another preferred embodiment, there is a biasing member positioned to close the shuttle valve and a valve opening member to open the shuttle valve.
In one aspect there is a third fluid outlet or bypass wherein the annular cavity allows fluid communication with the third outlet when the shuttle valve is in the second position.
In another aspect, a flow passage is constructed and arranged to permit the passage of water to the first fluid outlet at a slower rate than that when the shuttle valve is moved to the second position to permit the passage of water to the second fluid outlet.
In still another aspect, a flexible conduit is fastened to a connecting member opposite the connection to the valve housing and a chemical spray device is connected to the fluid conduit at an end opposite the connection to the connecting member.
In yet another aspect, the connecting member is a quick connect-disconnect member.
In another preferred embodiment, the first fluid outlet is in the form of a faucet outlet.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing the combined faucet spout and diverter valve in conjunction with a multifunction dispenser of FIG. 1 ;
FIG. 2 is a side view showing the combined faucet spout and diverter valve of FIG. 1 ;
FIG. 3 is a view similar to FIG. 2 of the combined faucet and diverter valve rotated ninety degrees;
FIG. 4 is a cross section view of the diverter valve of the combined faucet and diverter valve in a non-diverting position;
FIG. 5 is a view similar to FIG. 4 showing the diverter valve in a diverting position with a connecting member attached thereto; and
FIG. 6 is a cross-sectional view of the diverter valve showing a by-pass feature.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , the combined faucet and diverter valve generally 10 is shown connected to a Multiple Function Dispenser generally 11 by the hose 13 . This preferred dispenser is described in U.S. Pat. No. 6,708,901.
As shown in FIGS. 2-3 , combined faucet and diverter valve 10 includes a valve housing 12 connected to a faucet 20 by means of threaded connectors 15 and 17 . At the opposite end is another thread connector 45 for connecting the valve housing 12 to the usual valved plumbing fixture (not shown).
Referring to FIGS. 4 and 5 valve housing 12 includes a first annular cavity 14 with a second annular cavity 17 connected thereto. A fluid inlet passage 16 is provided by the threaded opening 63 in fluid communication with annular cavity 14 . There is a cavity 18 in fluid communication with annular cavity 14 which conveys fluid to faucet 20 . A one-way valve 19 is located in cavity 18 .
A pipe interrupter/backflow device 47 is positioned in cavity 14 . There are the usual openings 49 in the valve housing 12 for this purpose. Slideably positioned in annular cavities 14 and 17 is a shuttle valve 22 . A ball valve 23 is positioned in cavity portion 31 of shuttle valve 22 . It is biased against valve seat 26 by spring 39 acting against retainer 25 and valve actuating member 28 . Shuttle valve 22 is in contact with valve actuating member 28 having a seal 32 for contact with shoulder 30 in housing member 21 . Additional seals 40 and 43 are also provided on actuating member 28 .
A Gardena connecting device in the form of a quick connect-disconnect coupling part is shown in FIG. 5 at 41 . It is readily available from Gardena Manufacturing GmbH. It comprises an outer sleeve 42 and an inner retaining collar 44 with an annulus portion 48 for retentive contact with tabs 46 extending from outer sleeve 42 . There are locking elements 50 pivotally attached to retaining collar 44 and extending through apertures 51 . A spring 52 biases the tabs 46 of outer sleeve 42 against the annulus portion 48 . A one-way valve 54 is disposed in the central passageway 38 of the coupling part 41 . A seal is provided at 56 as seen in FIG. 5 .
As described in FIG. 6 , water bypass 64 with housing 65 is connected to valve housing 12 . Housing 65 has a passageway 68 in fluid communication with cavity 14 . A metering device 66 is positioned in passageway 68 . This provides a flow rate of 0.1 gpm. It is available from Neoperl Inc. in Waterbury, Conn. A push in, pull to lock tube fitting 67 is also located in passageway 68 . It seals swivel elbow 71 , as seen in FIG. 3 , to seal 69 . Tube fitting is available from John Guest International Ltd. Located in Middlesex, England. There are seals shown at 69 . The swivel elbow 71 is attached to housing 65 with a discharge tube 73 connected to elbow 71 .
OPERATION
A better understanding of combined faucet and diverter valve 10 will be had by a description of its operation. Referring to FIGS. 1-4 , combined faucet and diverter valve 10 is connected to a valved plumbing fixture (not shown) by means of threaded connector 45 . Water flows into inlet 16 , into cavity 14 , into passage 18 , through one-way valve 19 and out through faucet 20 . This is shown by the directional arrows. Water pressure in cavity 14 acts against shuttle valve 22 to move it and activating member 28 to the position shown in FIG. 4 .*** In this position, shuttle valve 22 is restrained from further movement by seal 32 engaging shoulder 30 .
When it is desired to dispense product from dispenser 11 as seen in FIG. 1 , the Gardena coupling part 41 is moved over actuating member 28 and a portion of housing member 21 until the Gardena coupling part 41 engages connecting member 24 of housing member 21 . This is illustrated in FIG. 5 . At the same time, flexible locking elements 50 engage the reduced diameter section 55 of housing member 21 . The movement of locking elements 50 onto the reduced diameter section 55 is effected by the flange 57 moving against them. In this position, actuating member 28 contacts valve 54 to open it and moves shuttle valve 22 and moves shuttle valve to the position shown in FIG. 5 . In this position, it is seen that shuttle valve 22 covers a portion of cavity 14 and blocks flow therethrough. At the same time projecting member 58 engages ball valve 23 to open it. This causes pressurized water to flow through into cavity portion 31 . From there, water passes through orifice 34 , into passage 33 between valve 22 and valve housing member 12 , and into passage 37 . From there it passes into orifices 36 , into passage 38 , through valve 54 and into hose 13 through coupling 62 which connects to threaded portion 59 of retaining collar 44 . This is shown by the directional arrows.
When it is no longer desired to dispense product from dispenser 11 , the Gardena coupling part 41 is grasped on opposing sides through slots such as 60 on slotted shield 27 and pulled in a direction away from valve housing 12 . This is best seen in FIG. 1 . This pulling action releases the contact of flange 57 with locking elements 50 and allows movement of the locking elements 50 out of the reduced diameter section 55 as well as the movement of shuttle valve away from cavity 14 and projecting member 58 . This causes ball valve 23 to close and assume the position shown in FIG. 4 . Water then flows through cavity 18 and aerator 35 as in its normal position. Aerator 35 causes a slower flow rate to faucet 20 when the combined faucet and diverter valve 10 is in a non-diverting position shown in FIG. 4 , than when in the diverting position shown in FIG. 5 . This small amount of back pressure caused by the aerator acts on valve 22 and assists in moving it to the non-diverting position.
Referring to FIG. 6 , when the combined faucet and diverter valve 10 is in the diverting position, water will flow at a rate of 0.1 gpm through bypass 64 . Flow is metered by valve 66 . This feature is required by some plumbing codes to indicate that water is being diverted.
An important aspect of diverter valve 10 is the use of spring biased ball valve 23 and the projecting member 58 to open it. This affords closing the water flow out of passage 38 and not onto the user.
It will thus be seen there is now provided a combined faucet and diverter valve 10 which offers a quick-connect and disconnect with a water source. The combined faucet and diverter valve 10 is activated by coupling part which is readily available in the market place, thus reducing design and components costs. The combined faucet and dispenser valve 10 also provides a water bypass 64 which gives a visual and auditory indication that water is being diverted. In addition, this diverter valve 10 will allow users to attach many water powered devices without having a dedicated water source having a garden house thread. A diverter valve is placed between a faucet base and faucet arm thus providing backflow prevention, a connection point for a Gardena fitting, cross connection flow through and the ability to adapt to the three most popular North American faucets such as T&S, Fisher, and Chicago. When the water is turned on the combined faucet and diverter valve 10 , it comes by default out of the normal faucet arm outlet. When a dispensing device is connected by means of the Gardena fitting, the water is then diverted to only the dispenser and the cross connection flow through. Once the dispenser 11 is disconnected, the water defaults back to the faucet arm 20 . If one were to push in the valve actuating member 28 and turn on the water, the shuttle valve 22 automatically closes such that a leak is prevented. The back pressure of the aerator pushes shuttle valve 22 back to default position. This is assisted by the ball valve that wants to close outlet passage 38 .
Another important aspect is in providing a combined faucet and diverter valve which obviates the need for a spring. This reduces maintenance costs due to faulty springs.
The preferred material for composing valve housing 12 and shuttle valve 22 is glass filled polypropylene. However, other plastic materials and metals can be employed. For example, acetyls and polycarbonates, as well as brass and aluminum.
The combined faucet and diverter valve 10 has been described for use with a particular Gardena connect-disconnect coupling part 41 . It will be appreciated any such coupling part could be employed which provides movement of the actuating member 28 of the shuttle valve 22 . Neither is it essential that the combined faucet and diverter valve 10 be employed with a particular dispenser 11 . It can be utilized in conjunction with any liquid dispensing device or apparatus. Slotted shield 27 could be eliminated. However, it does reduce accidental contact with actuating member 28 when extended from housing member 21 . A bypass 64 has been described to show water diversion. This is not an essential component and could be eliminated. All such and other modifications within the spirit of the invention are meant to be within its scope as defined by the appended claims. | A combined faucet spout and diverter valve for attaching a dispensing system to a water source. In a first mode, water flows through the diverter valve to a first outlet which can be a faucet outlet. In a second mode, water is diverted to a fluid conduit which is fastened to a connecting member and a chemical dispenser. The connecting member provides movement of a shuttle valve which directs water in the second mode to the fluid conduit. |
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BACKGROUND OF INVENTION
The present invention relates generally to water run-off collected in sheet flow into a special drain. The invention has particular utility in any construction which requires surface water from roadways, parking lots, swimming pool decks, etc. essentially be completed drained away. The open portion of the drain is placed level with, or slightly below, the ground or paved surface, so that water will flow through the opening and into the attached drainpipe, which is installed below the ground.
A variety of drains to carry away water are known. U.S. Pat. No. 3,815,213 to Evans, et al, disclosed, generally, drains which include a lower pipe section which has a longitudinal opening along on the upper side to form a slot in which a slotted grate is attached. The grate is formed by placing a pair of spaced plates, firmly attached, to either side of the longitudinal slot. Spacers, of multiple arrangements, are secured to the inside of each plate. These spacers comprise either solid cross-bars, which extend perpendicularly to the axis of the pipe, or a sinusoidal plate, which goes between the two (2) side plates. The plates and spacers were attached by traditional metallic welding processes. The grate is hot-dipped galvanized after fabrication. The grate is attached to galvanized pipe by metallic welding. The weld scar is repaired by applying a zinc-rich paint.
Since the '213 patent to Evans, there has been variations of slotted drains. In U.S. Pat. No. 5,380,121 to Schluter, it was disclosed a grate assembly that could be collapsible or expandable, in which to adjust for specific height requirements. The grate portion is welded, by traditional metallic processes, to a longitudinal slot in the lower pipe assembly. The grate portion comprises an upper grate portion and a lower grate portion, which are moveably fixed to one another. The grate portion is then metallic welded to the lower pipe assembly. The weld scar is covered with zinc-rich paint.
In U.S. Pat. No. 4,490,067 to Dahowski, the invention discloses a modular draining system which comprises a single piece of plastic extruded in the shape of a pipe during assembly. This assembly is pre-fabricated with little or no modification at the construction site.
Although there have been a number of drain structures disclosed, they suffer from a number of disadvantages. A number of prior drain structures involved welding metal grate portions to metal drain portions. Weather, chemicals and non-galvanizing after fabrication has a corrosive effect on metal, and, in time, may destroy the welded bond between the grate portion and the pipe portion, thus causing the drain system to be unstable. In an attempt to overcome this disadvantage, the '067 patent to Dahowski discloses a single piece drain assembly made of extruded plastic. The disadvantage with this invention is that it does not allow for any modification to the drain assembly for height adjustment. Also, size limitations of extruded full scale finished product would be impractical beyond small diameters.
The prior drainage systems either do not adequately address the concerns surrounding the corrosiveness of the welded bond by water and chemicals or, when attempting to address this problem, go to the other extreme, and do not allow flexibility in the assembly and construction of such a drain assembly. It is thus apparent that a need exists for an improved, drain assembly which permits flexibility in the assembly thereof, yet addressing the concerns dealing with the corrosive nature of water, chemicals and the welding bond as well as the durability of the entire system. Additionally, a system adaptable over a wide range of diameters is needed in the market place. This invention will span 4" through 18" and easily modified to go larger.
SUMMARY OF INVENTION
The present invention provides an improved drain assembly system, whose components is provided totally of chemical and weather resistant plastic. The assembly comprises two (2) extruded plastic sections that are joined together to form one unit by introducing spacers on designated distances. This unit assembly is attached to a plastic carrier pipe which has been prepared with a designated longitudinal section removed to form a longitudinal slot. The extruded assemblies include a vertical portion and a curved portion, referred to as a skirt portion. The assembly is attached to the prepared carrier pipe.
A lower part of the vertical portion projects into the plastic carrier pipe to a depth of at least to pipe wall thickness. This insures a transfer of ring compression for the plastic carrier pipe. The skirt width is wide enough to reinforce the carrier pipe, and extends a distance to provide bonding and reinforcement of the plastic carrier pipe. Further, since the assembly is in the form of a single piece of extruded plastic, there is no weld seams or other metal on metal to contend with. Thus, the invention eliminates the concerns surrounding corrosion and long term durability.
The unit is attached to the plastic carrier pipe by a chemical welding process. Self-tapping stainless steel screws may be used to draw the skirt into contact with the plastic carrier pipe and to hold the unit in place during the curing time of the weld.
The extruded assemblies can be of various lengths but a standard length would be used in standard production. The joining of sections would be done by using standard sleeve couplings that are cut in half, and are chemically welded to permit the drain assembly to be butted together for a tight and continuous grate assembly. The leg heights of the assemblies can be made in a variety of heights. Conversely, the assembly can be made taller, using sheared strips separated by small diameter or heavy wall pipe cut to specific lengths and held in place with stainless steel bolts. The assembly can be either increased in height or the slope of the drain can be adjusted by solvent welding strips of plastic to the inside of the assembly. Where surface traffic would dictate, spacers can be installed in the stacking portion as well.
In the event that a guard is needed to be placed over the opening, the drain assembly is capable of different methods of supporting such a guard. The assembly would allow for manipulation of the spacer height coupled with the use of stainless steel bolts in which to support a guard being placed on the top portion of the assembly. The spacers would also be able to support the weight of the guard which could be placed inside the assembly. Further, internal supports can be chemically welded or hot welded to the inside of the vertical portion of the assembly. The guard would then be able to rest upon those supports. A method for inserting spacer units into a prepared groove is available and preferred. This groove allows spacers to be inserted in a uniform manner and can be secured by chemical welding or hot welding.
The plastic used as the extrudant is prepared to withstand the exposure to the elements, thus preventing UV degradation. Colorant is possible if desired in certain architectural settings.
The advantages of the invention will be more fully appreciated by reference to the figures and drawings, a brief description of which follows, in conjunction with the following detailed description of the preferred embodiments of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1: A perspective view of the present invention.
FIG. 2: A side view of the present invention.
FIG. 3: A cross sectional view of FIG. 2 taken along Line AA
FIG. 4: An expanded view of the extruded plastic sections of the present invention.
FIG. 5A: A side view of the second embodiment of the present invention.
FIG. 5B: A cross section of FIG. 5A.
FIG. 6A: A side view of the third embodiment of the present invention.
FIG. 6B: A cross section of FIG. 6A.
FIG. 7: A fourth embodiment of the extruded plastic section.
FIG. 8: A fifth embodiment of the extruded upper plastic section.
DETAILED DESCRIPTION OF THE INVENTION
The invention has been illustrated and described in considerable detail, so that the configuration and advantages of the improved slotted drain may be readily appreciated by those skilled in the art. It will be understood, however, that various changes may be made in such details without departing from the spirit or scope of the invention.
As shown in FIG. 1, a drainage system (10) of the present invention include a carrier pipe (18) and an upper assembly (11). Plastic carrier pipe (18) has a longitudinal axis (19) and an elongated slot (21) extending lengthwise along the top of its surface. Upper assembly (11) includes two extruded plastic sections (12) connected by multiple spacers (24). Each extruded plastic section (12) consists of a vertical portion (14) and a curved portion (16). Curved portion (16) is positioned in such a manner as to create lower lip (17). Vertical portion (14) also includes multiple spacer grooves (22) as shown in FIG. 2. The vertical portion (14) has a bottom portion.
Upper assembly (11) is created by joining two extruded plastic sections (12) by placing multiple spacers (24) within the respective spacer grooves (22) of each extruded plastic section (12). Spacers (24) are secured to the extruded plastic sections (12) by either a chemical or hot welding process. An opening is created between the extruded plastic sections (12) so that water run-off can be collected in sheet flow within plastic carrier pipe (18).
Upper assembly (11) is secured to plastic carrier pipe (18) by placing lower lip (17) within the longitudinal slot (21) to the extent that curved portion (16) is in contact with the exterior upper surface of plastic carrier pipe (18). Upper assembly (11) is secured to plastic carrier pipe (18) by a chemical welding process. Self-tapping stainless steel screws may be used to hold upper assembly (11) in place during the curing time of the weld.
Drain assembly (10) can be made of various lengths depending upon the needs of the individual project. These individual sections are joined together by using a sleeve coupling (20) wherein two drain assembly (10) with a single sleeve coupling (20) secured to the exterior lower surfaces of both drain assemblies (10).
In some instances a guard is needed to be placed over the opening created by the spacers (24) positioned between the extruded plastic sections (12). FIGS. 5A and 5B show an embodiment of this aspect of the present invention wherein the height of spacers (24) are less than the heights of vertical portion (14) of the extended extruded plastic sections (12). Further, a cylindrical spacer (30) is positioned near the top of horizontal portion (15) and secured to the vertical portion (14) by means of bolt (34) and securing nut (32). A guard is then able to rest upon cylindrical spacers (30).
Referring now to FIGS. 6A and 6B, shows another embodiment of this portion of the invention wherein spacers (24) are just less than flush with the top of vertical portion (14). A guard is able to be placed on top of spacers (24).
Referring now to FIG. 7 which shows an additional embodiment of the present invention which includes internal supports (36) which are connected to the internal walls of vertical portion (14) by means of self-tapping stainless steel screws (38). The internal supports (36) are located near the top of vertical portion (14) that allows for a guard to rest within the opening created by spacers (24).
While preferred embodiments of the present invention have been described above, various other modifications will become readily apparent to those of ordinary skill without departing from the scope of the invention. An applicant intends to be bound only by the claims appended hereto. | Below ground drain and conduit member to receive surface water. The member comprises two (2) extruded plastic assemblies that are joined together to form one (1) unit. This unit assembly is attached to a plastic carrier pipe, in a longitudinal fashion. The unit assembly is attached to the carrier pipe by a chemical welding process or other means. |
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0001] N/A
RELATED APPLICATIONS
[0002] N/A
BACKGROUND OF THE DISCLOSURE
[0003] 1. Field of the Disclosure
[0004] The present disclosure relates generally to a new sliding hand tool for the formation of cornices along upper edges between the wall and the ceiling without the need to use of complex machinery.
[0005] 2. Discussion of the Background
[0006] The finishing of cornices or crown moldings during construction is a difficult, expensive and time-consuming process. In most cases, pre-constructed moldings are used to complete the cornices. Most moldings are made by machinery which limits the design, a design which in most cases is discontinued. Also it needs to be ordered, which affects construction time and therefore delays in the construction. Furthermore, some cornices are made of wood which requires more time to be prepared. Others are made of cement over a light weight structure, such as foam or plastic structure.
[0007] The use of current machinery for the preparation of cornices cannot be afforded by most construction workers or home owners. Most of the time companies are the only ones that can afford the machinery. Further and due to profit inquiries the companies limit cornice patterns or the possibilities of a customized design for a cornice.
[0008] Therefore, there is a need to provide a tool and method for molding cornices which overcomes the disadvantages and shortcomings of the prior art.
SUMMARY OF THE DISCLOSURE
[0009] The present disclosure overcomes the limitations of the previous tool and methods for molding a cornice. Accordingly, it is an object of the present disclosure to provide a light weight tool that is easy to use and capable of providing a smooth look for the cornice.
[0010] The first exemplary embodiment in accordance with the principles of the present disclosure comprises a hand tool comprising a main body and a contact body, wherein the main body is attached to the contact body and wherein the main body is made of a light weigh material and the contact body is made of a metal, such as stainless steel, for providing a smooth surface for the cornice.
[0011] It is another object of the present disclosure to provide a method for molding cornices without the use of expensive machinery. In accordance with the principles of the present disclosure the method for the construction of a cornice comprises placing a mesh on a foam molding and placing a substance that sets and hardens independently, such as cement, on the foam mold using the cornice hand float tool.
[0012] The disclosure itself, both as to its configuration and its mode of operation will be best understood, and additional objects and advantages thereof will become apparent, by the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings.
[0013] The Applicant hereby asserts, that the disclosure of the present application may include more than one disclosure, and, in the event that there is more than one disclosure, that these disclosures may be patentable and non-obvious one with respect to the other.
[0014] Further, the purpose of the accompanying abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the disclosure of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the disclosure in any way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated herein, constitute part of the specifications and illustrate the preferred embodiment of the disclosure.
[0016] FIG. 1 shows a first general structure in accordance with the principles of the present disclosure.
[0017] FIG. 2 shows a second general structure in accordance with the principles of the present disclosure.
[0018] FIG. 3A-3D show the general structure of the first exemplary embodiment of the hand tool in accordance with the principles of the present disclosure.
[0019] FIG. 4A-4D . show the general structure of the second exemplary embodiment of the hand tool in accordance with the principles of the present disclosure.
[0020] FIG. 5A-5B show an exemplary embodiment of the base plate of the first exemplary embodiment of the hand tool disclosure.
[0021] FIG. 6A-6B show an exemplary embodiment of the base plate of the first exemplary embodiment of the hand tool disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring to FIG. 1 , it shows a first exemplary general structure embodiment in accordance with the principles of the present disclosure. A first sliding hand tool 1 is located on top of a cornice light weight mold 2 . The sliding tool is slid on top of the cornice light weight mold 2 for the formation of cornices along upper edges between the wall and the ceiling without the need of the use of complex machinery.
[0023] FIG. 2 is directed to a second exemplary general structure embodiment in accordance with the principles of the present disclosure. A second sliding hand tool 10 is located on top of a second cornice light weight mold 20 . In the same manner, as explained above, the second sliding tool 10 is slid on top of the second cornice light weight mold 20 for the formation of cornices along upper edges between the wall and the ceiling without need of the use of complex machinery.
[0024] FIG. 1 and FIG. 2 disclose, as mentioned, at least two parts. Therefore the process to complete a cornice comprises two main parts, the cornice hand tool 1 , 10 and the light weight cornice mold 2 , 20 . The material of the mold is a light weight material, such as foam which is easy to carry. The selection of the material depends on several factors such as the environmental exposure of the cornice and/or the person which is going to be carrying the mold to place it along upper edges between the wall and the ceiling.
[0025] The light weight mold, if desired, can be configured to have a particular pattern or shape. The shape is selected by the user in most cases. In the instant case both light weight molds 2 , 20 are curved. One advantage of selecting the proper material for the light weight mold 2 , is that the selected material can be a material easy to be configured or shaped, such as foam.
[0026] FIG. 3A through 3D are directed to the first exemplary hand tool 1 . The first exemplary hand tool 1 comprises a main body 12 and a contact body 11 . The main body 12 and contact body 11 are mechanically attached to each other by attaching means such as glue, screws, magnets or any other mean that holds or avoids any displacement between these two parts. FIG. 3A presents a front view of the first exemplary hand tool 1 wherein said contact body 11 is at least attached to a lower part of the main body 12 . In the instant case the contact body 11 extends around the main body 12 , as shown in FIG. 3B , however the main purpose of the contact body 11 is to be placed at the part of the main body that is closer to the light weight mold 2 during the molding process which is explained below. The contact body 11 , as shown in FIG. 3C , comprises a lower part 11 a which is configured to have a desired curved body. The desired curved body of the lower part resembles the cornice shape desired by the user. The contact body 11 further includes an extended body 11 b which serves as a cover for the main body 12 .
[0027] Further, the main body, as shown in FIG. 3D , may comprise a shape that fits inside the contact body 11 . However, it has to be understood that the purpose of the main body 12 is to assist the user to handle the first hand tool 1 . Therefore, the shape may vary, however both pieces need to be fixed to each other, as mentioned before, in such way that prevents any displacement between these two parts.
[0028] FIG. 4A through 4D are directed to the second exemplary hand tool 2 . The second exemplary hand tool 2 comprises a second main body 102 and a second contact body 101 . Similarly to the first exemplary hand tool 1 , the second main body 102 and second contact body 101 are mechanically attached to each other by attaching means such as glue, screws, magnets or any other mean that holds or avoids any displacement between these two parts. FIG. 4A presents a front view of the second exemplary hand tool 10 wherein said second contact body 101 is at least attached to a lower part of the main body 102 . In the instant case the second contact body 101 extends around the main body 102 , as shown in FIG. 4B , however, as explained above, the main purpose of the contact body 101 is to be placed at the part of the second main body 102 part that is closer to the light weight mold 2 during the molding process which is explained below. The contact body 11 , as shown in FIG. 4C , comprises a second lower part 101 a which is configured to have a desired curved body. The desired curved body of the lower part resembles the cornice shape desired by the user. The second contact body 101 further includes a second extended body 101 b which serves as a cover for the main body 102 .
[0029] Further, the second main body 102 , as shown in FIG. 4D , may comprise a shape that fits inside the second contact body 101 . However, it has to be understood that the purpose of the main body 102 is to assist the user to handle the second hand tool 10 . Therefore, the shape may vary, however both pieces need to be fixed to each other, as mentioned above, in such way that prevent any displacement between these two parts.
[0030] The main body 12 , 102 for the first exemplary hand tool 1 and second exemplary tool 2 are made of a light weight material such as wood, plastic or any light weight resistant material. It is preferred to be a solid structure to avoid deformation of the main body, more particularly during the sliding procedure of the hand tool 1 , 10 over the light weigh mold 2 , 20 .
[0031] The contact body 11 , 101 for the first exemplary hand tool 1 and second exemplary tool 2 are made of a resistant material such stainless steel or any resistant material capable of providing a smooth surface over the light weight mold 2 . The material should provide properties to avoid the cement to be attached to the lower part 11 a , 101 a surface.
[0032] FIG. 5A through FIG. 5B clearly disclose the lower part 11 a of the first hand tool 1 . FIG. 6A through FIG. 6B clearly disclose the lower part 11 a of the first hand tool 1 . As mentioned above, the lower part is configured to resemble the cornice shape desired by the user. During the molding procedure, as described below, the lower part assists to shape the light weight molding.
Method for Molding a Cornice
[0033] After selecting a light weight mold 2 , 20 , as explained above, and selecting the preferred design for the lower part of the hand tool 1 , 10 the user lays the mold on a surface, preferably a flat surface, to complete the molding procedure. The molding procedure comprises:
Step 1: Putting the Mesh on the Molding
[0000]
1. Start adding adhesive, for example by spraying an adhesive, such as glue, on a mesh and the light weight mold 2 , and carefully adhering the mesh to the top of the light weight mold 2 , utilizing a flexible blade, such as a spatula, to make sure no gaps are formed.
2. Repeat same process until entire molding is covered with the mesh.
Step 2: Putting the Cement on the Molding
[0000]
1. Place the top light weight mold 2 cover with the mesh on the table, which uses a tube as a guide for the stainless steel piece used to sheath the cement to the molding.
2. Pour cement on the light weight mold 2 .
3. Slide the stainless steel hand tool 1 , 10 (which has the form of the desired cornice), using the tube as a guide, on top of the light weight mold 2 , so the cement covers the entire light weight mold 2 .
4. Repeat process until entire molding has a generous and even coat of cement.
5. Wait three to four hours until cement is dried.
6. Repeat the coating process according to user's desired thickness for the light weight mold 2 .
[0042] The disclosure is not limited to the precise configuration described above. While the disclosure has been described as having a preferred design, it is understood that many changes, modifications, variations and other uses and applications will, however, become apparent to those skilled in the art without materially departing from the novel teachings and advantages of this disclosure after considering this specification together with the accompanying drawings. Accordingly, all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the disclosure are deemed to be covered by this disclosure as defined in the following claims and their legal equivalents. In the claims, means-plus-function clauses, if any, are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures.
[0043] All of the patents, patent applications, and publications recited herein, and in the Declaration attached hereto, if any, are hereby incorporated by reference as if set forth in their entirety herein. All, or substantially all, the components disclosed in such patents may be used in the embodiments of the present disclosure, as well as equivalents thereof. The details in the patents, patent applications, and publications incorporated by reference herein may be considered to be incorporable at applicant's option, into the claims during prosecution as further limitations in the claims to patently distinguish any amended claims from any applied prior art. | A tool and method for molding cornices comprising a sliding hand tool for the formation of cornices comprising a main body and a contact body, wherein the main body is attached to the contact body and wherein the main body is made of a light weight material and the contact body is made of a metal, such as stainless steel, for providing a smooth surface for the cornice. The method comprises the steps of placing a mesh on a foam molding and placing and shaping cement on the foam mold using a cornice hand float tool. |
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RELATED APPLICATIONS
This application is based on a prior provisional application Ser. No. 61/426,357, filed on Dec. 22, 2010, the benefit of the filing date of which is hereby claimed under 35 U.S.C. §119(e).
BACKGROUND
Oil and gas wells commonly bypass significant productive formations that may be uneconomic to complete at the time the well was drilled. These formations may be relatively thin and low pressure so simply perforating the zone does not provide significant new production. However, lateral drilling into such thin, horizontal oil bearing formations can result in substantial new oil production. The lateral well should be drilled at an angle as close as possible to 90 degrees relative to the vertical well to ensure that the lateral drilling tools stay within the productive zone. This objective can be accomplished by feeding a flexible lance equipped with a compact rotary jet drill though a shoe incorporating a curved passage that deflects the drill at a high angle into the formation. This approach is referred to as zero-radius lateral drilling, since the angle is defined entirely within the wellbore, as opposed to drilling a curved hole in the formation.
Conventional mechanical drilling requires high thrust and torque to penetrate rock. Applying high torque and thrust though a tight radius curve is extremely difficult. A rotary jet drill of the type described in U.S. Pat. No. 7,198,456 provides the ability to penetrate a range of underground formations with very low thrust load and no torque. The rotary jet drill includes a reaction-turbine jet rotor that spins a pair of forward facing jets that erode the formation. The jet drill face has a gage ring which, provided that the drill is kept pressed against the rock face, ensures drilling of a close tolerance circular section borehole.
It would be desirable to provide improved method and apparatus for zero-radius lateral drilling, for example, by using the rotary jet drill in a system that can apply the required torque and thrust through the tight curve defined within a borehole.
SUMMARY
This application specifically incorporates by reference the disclosures and drawings of each patent application and issued patent identified above.
This disclosure describes a jet drilling lance assembly that is capable of providing high-pressure fluid to power a rotary jet drill while providing sufficient thrust to maintain face contact while drilling and sufficient lateral stiffness to prevent the lance from buckling and diverting from a straight lateral trajectory. The invention further discloses a method for deploying the lance and drilling the lateral.
This Summary has been provided to introduce a few concepts in a simplified form that are further described in detail below in the Description. However, this Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
DRAWINGS
Various aspects and attendant advantages of one or more exemplary embodiments and modifications thereto will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1A shows an overview of the lateral drilling system at the start of drilling;
FIG. 1B shows the system after a portion of the lateral has been drilled;
FIG. 2 shows a rotary jet drill;
FIG. 3 shows a jet lance and cable tensioner;
FIG. 4 shows the internal features of the jet lance and cable tensioner;
FIG. 5 shows a detailed section of the jet lance;
FIG. 6 shows an axial section of the jet lance;
FIG. 7 shows an axial section of the jet lance in the curved configuration; and
FIGS. 8A-8C show details of how the lance is deployed though the deflection shoe.
DESCRIPTION
Figures and Disclosed Embodiments Are Not Limiting
Exemplary embodiments are illustrated in referenced Figures of the drawings. It is intended that the embodiments and Figures disclosed herein are to be considered illustrative rather than restrictive. No limitation on the scope of the technology and of the claims that follow is to be imputed to the examples shown in the drawings and discussed herein. Further, it should be understood that any feature of one embodiment disclosed herein can be combined with one or more features of any other embodiment that is disclosed, unless otherwise indicated.
Referring to FIG. 1A , a jet drilling assembly is shown in a casing 112 of a wellbore, in the earth 100 . The jet drilling assembly is run into a guide tube 106 , which is supported by slips 108 and casing 112 . At the lower end of the guide tube, a packer 124 is removably set in the casing. In one exemplary embodiment, the packer is set in a desired position mechanically by rotation of the guide tube and is thereby locked in place within the casing by tension. The packer further supports a deflection shoe 120 that is distally disposed below the packer. The same guide tube, packer, and deflection shoe may be used to deploy a milling assembly to mill a window or orifice in the casing at the elevation where the lateral well is to be drilled, so that the lateral can be drilled by advancing the jet drill through the window so that it can drill into the surrounding formation. When the mechanical milling assembly used to mill the window is removed, the jet drilling assembly is run into the well through the guide tube without changing the position of the guide tube, or packer, so that the shoe maintains its alignment with the window. The jet drilling assembly comprises a high-pressure fluid swivel 102 on the surface, high-pressure tubing 104 , a cable tensioner assembly 114 , a flexible jet lance 116 , and a jet drill 122 .
The jet drilling assembly may be lowered into and raised out of the well with a winch 126 , a cable 130 , and a block assembly 134 that is supported on a frame 132 . Pressurized fluid is supplied to the swivel from a pump 128 . The use of swivel 102 enables rotation of the jet drilling assembly, which is suspended below in the bore, to orient the drilling assembly as desired. For example, the tubing string may be rotated with a pipe wrench that is applied to the string on the surface.
FIG. 1B shows the lateral well drilled after the jet drilling assembly is lowered into the well. In an exemplary embodiment, the flexible jet lance is capable of passing though a 6-inch radius curve. For example, if the well casing diameter is 4.5-inches, the lateral well inclination is about 70 degrees from the casing axis. In wells having a larger casing, the same lance can drill a well at about 90 degrees inclination relative to the well axis.
Those skilled in the art will understand that various types of weight indicators are available and well known to observe the weight of the jet drilling assembly and high-pressure tubing. The weight is commonly calculated with an accuracy of about ±100 lbf. After the jet drill passes though the shoe and window in the well casing, it will tag the rock face, and the indicated weight of the jet drilling assembly and high-pressure tubing will drop. In one exemplary embodiment, the face of the jet drill is covered with a plastic cap that mechanically protects the jet drill during deployment and prevents wellbore fluid from flowing up into the assembly. Once the face of the jet drill with the cap in place tags the formation, fluid is pumped to the tool at high pressure. The jet of high pressure fluid at the drill will remove the cap and initiate drilling into the formation. The assembly is then fed into the formation, while maintaining nominal weight to ensure that the jet drill stays in contact with the formation.
In one embodiment, jet drill 122 is a rotary type, such as disclosed in U.S. Pat. No. 7,198,456, and shown in FIGS. 2A , 2 B, and 2 C. This jet drill is capable of drilling a circular hole with a uniform diameter. The jet drill operates on high-pressure fluid, typically water, which can be supplied though a flexible, high-pressure hose. Shown in FIGS. 2A , 2 B, and 2 C are a housing 200 , a gage ring 202 , a rotor 204 , and outer nozzle port 206 a and inner nozzle port 206 b . A hose barb 208 enables the nozzle to be attached to the end of a high-pressure hose using a crimp fitting. Nozzle port 206 a directs a jet of fluid at an outer edge of the gage ring. The rotor rotates so that the outer jet erodes the rock at the outer circumference of the gage ring Inner nozzle port 206 b directs a jet of fluid across the centerline of the rotor to erode the rock in the center of the hole. As disclosed in U.S. Pat. No. 7,198,456, this configuration enables drilling of a uniform diameter hole, provided that the distal edge of the gage ring is kept in contact with the rock face. Ports 210 are provided to enable rock cuttings and fluid to escape the face where the pressurized jets are drilling into the formation, for transport up the annulus between the hose lance and the borehole. The jet drill requires that a nominal thrust be applied toward the formation to overcome the thrust generated by the jets and to ensure that the face of the jet drill is kept pressed against the rock being cut. In one exemplary embodiment, the jet drill produces a 1.125-inch diameter hole using a hose lance outer diameter of about 1 inch.
The jet drill is coupled to a distal end of flexible jet lance 116 , which is coupled to a distal end of tensioner assembly 114 , as shown in FIG. 3 . Referring to FIG. 5 , the flexible jet lance includes an inner high-pressure hose 500 through which pressurized fluid is supplied to the jet drill, spacers 502 , tension cables 400 , and a thrust liner 300 .
High-pressure hose 500 can be of a multilayer wire-wrap or wire mesh reinforcement wrapped around an impermeable inner liner. Those skilled in the art will recognize that these types of hoses are capable of withstanding high pressure, while maintaining flexibility, without significant changes in diameter or length due to the applied fluid pressure. In one exemplary embodiment, a 6-layer hose capable of withstanding continuous operation at 20,000 psi is used.
Spacers 502 are arc shaped and are disposed between the high-pressure hose and the outer thrust liner 300 to form a slip fit. In one exemplary embodiment, four spacers are provided and disposed so that they are equally spaced apart around the hose. Alternate arrangements with more or fewer spacer segments can instead be used. The spacer can be constructed of a high-shear-strength polymer, such as nylon or acrylonitrile-butadiene-styrene (ABS), which is capable of withstanding immersion in water and oil and heating to temperatures of 100° C. or more. Longitudinally reinforced polymer with transverse flexibility, but high transverse shear strength, may also be used for the spacers.
Thrust liner 300 can be fabricated from heavy gage steel wire with a quadrilateral cross section, i.e., wire having a roughly square or rectangular cross section, which is wound as a helical spring having coils in solid contact. The winding pitch can be small, and adjacent surfaces of the wire coils should be in solid and continuous contact along the longitudinal axis of the thrust liner when the hose is straight. The square wire section can thus support a high compression load. As long as the helical spring of thrust liner 300 is straight and in compression as shown in FIG. 6 , it will have an elastic modulus and buckling resistance comparable to a steel tube. This relatively high stiffness enables the assembly to be delivered into a long horizontal hole without buckling.
As shown in FIG. 7 , when the flexible jet lance assembly is forced to bend in a curve when passing though the curved deflection shoe, the adjacent surfaces of the wire segments comprising the helical coil of thrust liner 300 separate slightly along the outer radius of the curve, but maintain contact along the inner radius. Any tendency of the hose to shear due to transverse sliding of the wire segments comprising the helical coil is resisted by spacer segments 502 and pressurized hose 500 , which is flexible, but very stiff in the radial direction.
In an exemplary embodiment, the thrust liner has an outer diameter of 1-inch and is capable of withstanding 2000 lbf of thrust, without buckling or shearing. In this example, the jet drill has a gage diameter of about 1.125 inches and can drill a hole that is about 1.13-inches in diameter. The flexible jet lance in this example is 50-feet long. Those skilled in the art will recognize that maintaining a relatively low ratio between the hole diameter and the thrust enables the application of high thrust before the column becomes elastically unstable.
Tension cables 400 are disposed in gaps between the spacers, within the annulus between thrust liner 300 and pressurized hose 500 . The spacers prevent the cables from all slipping to one side of the annulus and causing the lance to become asymmetric and unstable with respect to compressive or tensile loading. These tension cables are constructed of multi-wire steel, providing high flexibility and tensile strength. Further, the cables have sufficient tensile elasticity to accommodate relative changes in length as the lance assembly is bent though a radius, as shown in FIG. 4 and as is required, to pass though deflection shoe 120 .
As shown in FIG. 4 , tension cables 400 are attached to a hose fitting 302 , which is disposed at the end of the flexible jet lance and to a retainer 402 a inside cable tensioner assembly 114 (see FIG. 1A ). Retainer 402 a is free to move axially inside housing 304 . A retainer support 402 b is threadably engaged by a tensioner 404 . Unthreading tensioner 404 applies tension to cables 400 and thrust to thrust liner 300 . An end cap 406 is affixed to a distal end of housing 304 . Pulling on tension assembly 114 stretches cables 400 so that tensioner 404 comes into contact with end cap 406 , and the pulling force is transferred to the cables though tensioner 404 , retainer support 402 b , and retainer 402 a . The cable pull force is applied through hose fitting 302 so that pulling on the tensioner assembly pushes thrust liner 300 upwards. This configuration makes it possible to pull flexible jet lance 116 and the attached jet drill out of the lateral borehole and out through the deflection shoe. In one exemplary embodiment, there are eight cables 400 for providing a tensile pull capacity of 4000 lbf. This load capacity enables the operator to observe variations in pull load, which can be an indication of hole instability.
A hose spacer 414 is threadably engaged with liner 408 to accommodate variability in the length of hose protruding from thrust liner 300 . A crimped hose fitting 410 connects the hose to an inlet adaptor 306 of the tensioner assembly with a nut 412 .
To summarize, flexible jet lance assembly 116 and tensioner assembly 114 provide a number of functions required for drilling a zero radius lateral bore, including: (1) transmitting high pressure fluid to the jet drill; (2) transmitting thrust to push the flexible jet lance assembly though the deflection shoe and to react the thrust of jet drilling and contact forces without shearing or buckling; (3) transmitting tension to pull the flexible jet lance out from the borehole; and, (4) providing sufficient transverse flexibility to pass though the deflection shoe passage as shown, with minimal thrust.
Referring to FIGS. 8A , 8 B, and 8 C, deflection shoe 120 is held fixed in the borehole by a packer 124 , which is shown schematically. The packer may be mechanically set in the wellbore using a guide string 802 . The packer and deflection shoe have previously been used to guide a flexible milling assembly, which is described in a commonly assigned provisional patent application Ser. No. 61/426,345 “Method and Apparatus for Milling a Zero Radius Window In Casing” and a corresponding utility patent application Ser. No. 13/328,111, which claims priority in that provisional application. The milling assembly disclosed in these two applications can be employed to mill a window or orifice through the well casing that is aligned with the deflection shoe exit.
Jet drill 122 is shown approaching the deflection shoe in FIG. 8A . At this point in the procedure, the jet drill is capped with a plastic cap 800 , which is designed to ease the entry of the tool into the lateral direction through a curved passage 804 of the deflection shoe. A centralizer 118 is configured to slide on jet lance 116 and includes friction grips (not separately identified) on its outer surface that ensure the centralizer stays fixed in place, centrally disposed within casing 112 , while the jet lance and jet drill are tripping into and out of the well.
A curved passage through deflection shoe 120 is smaller in diameter than the centralizer, so that the centralizer stops at a point immediately proximal to deflection shoe, as shown in FIGS. 1A and 8B . The jet lance advances through the shoe and the casing window until it tags the surrounding formation. When the flexible jet lance reaches this point, the weight indicator on the surface shows that the jet drill is in contact with the formation. Fluid is then pumped to the jet drill, which actuates the drill. The rotating high pressure jets on the jet drill erode through cap 800 , enabling the drill to start drilling the lateral through the formation around the well casing. Thrust is continually applied to the jet drill so that it drills a gage hole into the formation as shown in FIG. 8C .
Those skilled in the art will recognize that the weight (or applied thrust) on the jet drill may be monitored by a sensor (not shown) on the surface and maintained as the assembly is fed into the well. In one exemplary method, lengths of high-pressure tubing 104 are added so that a block assembly 134 is at the top of its travel when initiating jet drilling as shown in FIG. 1A . The weight is maintained at a relatively constant level throughout the drilling process until the block assembly has moved to the bottom of its travel and the lateral is complete as shown in FIG. 1B . The lateral is thus completed in a single pass so that the gage diameter of the borehole is maintained at the minimum diameter required to accommodate the gage ring of the jet drill. A typical workover rig capable of providing this service can accommodate 60-feet of high pressure tubing and this length of tubing is the upper limit on the length of a lateral bore that may be drilled in a single pass. This procedure provides a uniform, minimum diameter hole. The buckling stability of the lance is inversely related to the clearance between the lance and the hole. Small increases in gage diameter will significantly reduce the resistance of the lance to buckling. Stopping to pull the jet drill out of the well can enlarge the lateral bore and reduce buckling stability. Accordingly, it may be preferable in this procedure to reduce the flow rate of fluid to the jet drill to the point where jet drilling stops before the jet drill and flexible jet lance are withdrawn from the lateral bore hole.
Although the concepts disclosed herein have been described in connection with the preferred form of practicing them and modifications thereto, those of ordinary skill in the art will understand that many other modifications can be made thereto within the scope of the claims that follow. Accordingly, it is not intended that the scope of these concepts in any way be limited by the above description, but instead be determined entirely by reference to the claims that follow. | A jet drill coupled to a distal end of a flexible jet lance is lowered into a well casing and advanced through a curved passage formed in a deflection shoe oriented to direct the jet drill through an orifice milled in the well casing. The jet drill is actuated with a pressurized fluid produced by a pump on the surface that is conveyed through a high pressure hose that runs through the flexible jet lance. Force transmitted through a thrust liner of the jet lance advances the jet drill while the lateral bore is being drilled. The thrust liner comprises helical coils of steel wire providing a high elastic modulus and buckling resistance, even while passing through the curved passage. Tension cables in the jet lance maintain tension on the thrust liner and enable the assembly to be pulled from the lateral bore and well. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation application of parent U.S. application Ser. No. 12/283,929, filed Sep. 17, 2008 now abandoned and entitled “PROTECTIVE SHIELD ASSEMBLY”, which parent application is incorporated by reference herein in its entirety.
FIELD
The present disclosure relates to protective shields for the exteriors of buildings. More particularly, the present disclosure relates to a protective shield assembly which can be assembled on a soffit or fascia of a building to protect the exterior of the building from storm damage or the like.
BACKGROUND
Many buildings have a soffit or protective cladding at the underside of a flight of stairs, a projecting cornice or the underside of a ceiling at the corner of the ceiling and wall. In houses, the soffit (or eave) forms a ceiling from the top of an exterior wall to the outer edge of the overhanging roof and bridges the gap between the exterior wall and the roofline. A soffit that extends from the horizontal to the vertical is known as a fascia or façade.
Placement of exterior protective material on soffits, fascias and facades of buildings and houses may be necessary in geographical areas which are vulnerable to storm conditions to prevent the damaging effects of winds which could otherwise penetrate or damage the soffit, fascia or façade. For example, buildings and houses in coastal and other geographical areas which receive high-velocity winds, as well as the exteriors of high-rise buildings, may require the use of exterior protective cladding. Therefore, a protective shield assembly which can be assembled on a soffit or fascia of a building or house to effectively protect the exterior of the building or house from storm damage or the like is needed.
SUMMARY
The present disclosure is generally directed to a method of protecting an existing surface. An illustrative embodiment of the method includes providing a surface to be protected; providing at least one shield section including a plurality of protective shield assemblies, each of the protective shield assemblies including a corrugated panel and a protective shield base carried by the corrugated panel; and attaching the corrugated panel to the surface with the protective shield assembly facing away from the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will now be made, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a rear perspective view of an illustrative embodiment of the protective shield assembly;
FIG. 2 is an enlarged sectional view, taken along section line 2 in FIG. 1 , of an illustrative embodiment of the protective shield assembly;
FIG. 3 is a side view, taken along viewing lines 3 - 3 in FIG. 1 , of an illustrative embodiment of the protective shield assembly'
FIG. 4 is an enlarged sectional view, taken along section line 4 in FIG. 3 , of a corner portion on an illustrative embodiment of the protective shield assembly;
FIG. 5 is an enlarged sectional view, taken along section line 5 in FIG. 3 , of an opposite corner portion on an illustrative embodiment of the protective shield assembly;
FIG. 5A is a transverse sectional view of a portion of an illustrative embodiment of the protective shield assembly, more particularly illustrating attachment of the corrugated panel to the protective shield base using an insulating adhesive;
FIG. 5B is a cross-sectional view of a panel ridge of the corrugated panel, more particularly illustrating a galvanized coating on the corrugated panel;
FIG. 6 is a perspective view of an illustrative embodiment of a half protective shield assembly;
FIG. 7 is a side view, taken along viewing lines 7 - 7 in FIG. 6 , of an illustrative embodiment of the half protective shield assembly;
FIG. 8 is a bottom view of a ceiling section having multiple protective shield assemblies and a pair of half protective shield assemblies;
FIG. 9 is a sectional view, taken along section lines 9 - 9 in FIG. 8 , more particularly illustrating adjacent alternating tab attachment of a pair of protective shield assemblies to each other in the ceiling section;
FIG. 10 is a sectional view, taken along section lines 10 - 10 in FIG. 8 , more particularly illustrating end-to-end overlapping attachment of a pair of protective shield assemblies to each other in the ceiling section;
FIG. 11 is a bottom view of the ceiling section, with a ceiling section frame (illustrated in phantom) supporting the protective shield assemblies in the ceiling section.
FIG. 12 is an end view of a stud element of the ceiling section frame;
FIG. 12A is a perspective view, partially in section, of a stud element of the ceiling section frame, with a channel beam attached to the stud for attachment of the stud to a ceiling;
FIG. 13 is a side view of a stud, with multiple protective shield assemblies attached to the stud;
FIG. 14 is a side view (partially in section) of a stud, more particularly attachment of a pair of adjacently alternating tab protective shield assemblies to the stud via a hat channel beam;
FIG. 15 is an enlarged sectional view, taken along section line 15 in FIG. 13 , more particularly illustrating an exemplary manner of attaching the stud of the ceiling section frame to a framing track;
FIG. 16 is a perspective view of a ceiling section and an adjacent fascia section each having multiple protective shield assemblies;
FIG. 17 is a side view of the ceiling section and the fascia section illustrated in FIG. 16 , with the ceiling section attached to a ceiling (in section) and the fascia section attached to a fascia (in section) of a building;
FIG. 18 is a bottom view of a ceiling (partially in section), with multiple ceiling sections each having multiple protective shield assemblies attached to the ceiling;
FIG. 19 is a top view, partially in section, of adjacent protective shield assemblies, more particularly illustrating side-to-side engagement of the protective shield assemblies with each other;
FIG. 20 is a side view, partially in section, of adjacent protective shield assemblies, more particularly illustrating side-to-side engagement of the protective shield assemblies with each other;
FIG. 21 is a top view, partially in section, of adjacent protective shield assemblies, more particularly illustrating end-to-end engagement of the protective shield assemblies with each other; and
FIG. 22 is a side view, partially in section, of adjacent protective shield assemblies, more particularly illustrating end-to-end engagement of the protective shield assemblies with each other.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the invention and are not intended to limit the scope of the invention which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
Referring initially to FIGS. 1-7 of the drawings, an illustrative embodiment of the protective shield assembly, hereinafter assembly, is generally indicated by reference numeral 1 in FIGS. 1-5A . Some applications of the protective shield assembly 1 , which will be hereinafter described, may additionally utilize one or more half protective shield assemblies 1 a , an illustrative embodiment of which is illustrated in FIGS. 6 and 7 . The assembly 1 includes a protective shield base 2 which may be aluminum, for example and without limitation. The protective shield base 2 has a base panel 3 which may be generally planar, elongated and rectangular. First and second base panel end walls 4 and 4 a , respectively, extend from the base panel 3 along respective ends thereof. First and second base panel side walls 5 and 5 a , respectively, extend from the base panel 3 along respective edges thereof. As illustrated in FIGS. 4 and 5 , each base panel end wall 4 , 4 a (and each base panel side wall 5 , 5 a ) may be disposed in generally perpendicular relationship with respect to the plane of the base panel 3 . As illustrated in FIG. 2 in some embodiments a filler material 6 , which may be as caulk, for example and without limitation, may be provided between the edges of each base panel end wall 4 , 4 a and adjacent base panel side wall 5 , 5 a.
As illustrated in FIGS. 4 and 5 , a first base panel end flange 8 extends outwardly from the first base panel end wall 4 ( FIG. 4 ) and a second base panel end flange 8 a extends outwardly from the second base panel end wall 4 a ( FIG. 5 ). Each base panel end flange 8 , 8 a may be disposed in generally perpendicular relationship with respect to the plane of the corresponding base panel end wall 4 , 4 a from which it extends. As illustrated in FIG. 1 , a first set of multiple side shield attachment flanges 9 extends outwardly from the first base panel side wall 5 in spaced-apart relationship with respect to each other. A first set of flange gaps 12 separates the adjacent side shield attachment flanges 9 from each other. A second set of multiple side shield attachment flanges 9 a extends outwardly from the second base panel side wall 5 a in spaced-apart relationship with respect to each other. A second set of flange gaps 12 a separates the adjacent side shield attachment flanges 9 a from each other. As illustrated in FIG. 1 , the side shield attachment flanges 9 of the first flange set may be offset or staggered with respect to the respective side shield attachment flanges 9 a of the second flange set. Likewise, the flange gaps 12 of the first gap set may be offset or staggered with respect to the respective flange gaps 12 a of the second gap set. A shield fastener opening 10 may extend through each side shield attachment flange 9 of the first flange set and each side shield attachment flange 9 a of the second flange set for purposes which will be hereinafter described.
A corrugated panel 16 is provided on the base panel 3 of the protective shield base 2 between the first and second base panel end walls 4 and 4 a , respectively, and between the first and second base panel side walls 5 and 5 a , respectively. The corrugated panel 16 may be steel, for example and without limitation, and has multiple panel ridges 17 and intervening panel troughs 18 . As illustrated in FIG. 1 , the panel ridges 17 and panel troughs 18 of the corrugated panel 16 may extend transversely across the longitudinal axis of the base panel 3 , in generally perpendicular relationship with respect to the first base panel side wall 5 and the second base panel side wall 5 a and in generally parallel relationship with respect to the first base panel end wall 4 and the second base panel end wall 4 a of the protective shield base 2 .
As illustrated in FIG. 5A , in some embodiments an electrically-insulating adhesive 7 attached the corrugated panel 16 to the base panel 3 . However, it is to be understood that the corrugated panel 16 may be attached to the base panel 3 using welding, fasteners (not illustrated) and/or other suitable attachment technique which is known by those skilled in the art. As further illustrated in FIG. 5B , in some embodiments a galvanized coating 3 a may be provided on the respective surfaces of the corrugated panel 16 . The galvanized coating 3 a may be a zinc coating which may be applied to the surfaces of the corrugated panel 16 using a hot dip coating process or any other suitable coating process or technique which is known by those skilled in the art. The half protective shield assembly 1 a which is illustrated in FIGS. 6 and 7 may be similar in design to that of the protective shield assembly 1 which was heretofore described with respect to FIGS. 1-6 , except the length of the half protective shield assembly 1 a may be approximately half or slightly less than half the length of the protective shield assembly 1 .
Referring next to FIGS. 8-15 and 18 - 22 of the drawings, an exemplary shield section 20 which utilizes multiple meshing protective shield assemblies 1 and a pair of half protective shield assemblies 1 a is illustrated in FIG. 8 . As illustrated in FIG. 18 and will be hereinafter described, multiple shield sections 20 can be attached to a surface 48 such as an exterior soffit, ceiling or fascia, for example and without limitation, of a building or structure (not illustrated) in adjacent meshing relationship with respect to each other to shield and protect the surface 48 from high winds and flying debris during storm conditions. The exemplary shield section 20 which is illustrated in FIG. 8 has five meshing protective shield assemblies 1 and two meshing half protective shield assemblies 1 a ; however, it is to be understood that each shield section 20 may have a greater or lesser number of meshing protective shield assemblies 1 and half protective shield assemblies 1 a . A half shield access gap 34 may be defined between the adjacent half protective shield assemblies 1 a to facilitate access to ceiling fixtures (not illustrated) and the like through the shield section 20 when the shield section 20 is attached to a ceiling or other surface (not illustrated), as will be hereinafter described.
As illustrated in FIGS. 19 and 20 , adjacent protective shield assemblies 1 which are disposed alongside each other in the shield section 20 may engage each other in a meshing manner by insertion of the side shield attachment flanges 9 of one protective shield assembly 1 into the respective registering flange gaps 12 a which extend between the side shield attachment flanges 9 a of the adjacent protective shield assembly 1 . In like manner, the side shield attachment flanges 9 a of one protective shield assembly 1 are inserted in the respective registering flange gaps 12 of the other protective shield assembly 1 . As illustrated in FIG. 20 , the side shield attachment flanges 9 , 9 a may alternate with each other to define a seam between the adjacent protective shield assemblies 1 .
As illustrated in FIGS. 21 and 22 , adjacent protective shield assemblies 1 which are disposed in end-to-end relationship with respect to each other in the shield section 20 may engage each other by insertion of the base panel end flange 8 a of one protective shield assembly 1 over the non-registering base panel end flange 8 of the adjacent protective shield assembly 1 . Along one longitudinal edge of each shield section 20 , the side shield attachment flanges 9 and the flange gaps 12 of a pair of end-to-end protective shield assemblies 1 remain exposed, whereas along the opposite longitudinal edge of each shield section 20 , the side shield attachment flanges 9 a and flange gaps 12 a of another pair of end-to-end protective shield assemblies 1 remain exposed to facilitate side-to-side meshing engagement of adjacent shield sections 20 in the same manner as the individual protective shield assemblies 1 are meshed with each other as was heretofore described. Likewise, along one transverse edge of each shield section 20 , the base panel end flanges 8 of three side-to-side protective shield assemblies 1 remain exposed whereas along the opposite transverse edge of the shield section 20 the base panel end flanges 8 a of three other side-to-side protective shield assemblies 1 remain exposed to facilitate end-to-end engagement of the adjacent shield sections 20 .
As illustrated in FIG. 11 , an exemplary shield section frame 21 which is suitable for supporting the meshing protective shield assemblies 1 in the shield section 20 is illustrated in phantom. The shield section frame 21 may include multiple frame studs 22 which extend along the transverse axis of the shield section 20 in generally parallel, spaced-apart relationship with respect to each other. As illustrated in FIG. 12 , in some embodiments each frame stud 22 may include a stud core 23 having a generally square or rectangular cross-sectional shape. A pair of C-channel beams 24 may be attached to opposite sides of the stud core 23 using stud fasteners 25 and/or any other suitable attachment technique. Each frame stud 22 may have any alternative construction which is consistent with the use requirements of the frame studs 22 in the shield section frame 21 .
Multiple generally elongated, parallel, spaced-apart hat channel beams 26 may extend along the longitudinal axis of the shield section 20 in intersecting relationship with respect to each frame stud 22 . Each hat channel beam 26 may be attached to each frame stud 22 according to any suitable technique which is known by those skilled in the art. As illustrated in the sectional view of FIG. 10 (which is taken along section lines 10 - 10 in FIG. 8 ) and the sectional view of FIG. 14 (which is taken along section lines 14 - 14 in FIG. 11 ), in some embodiments this may be accomplished by extending the stud fasteners 25 through fastener openings (not illustrated) provided in the hat channel beam 26 and threading the channel beam fasteners 25 into respective fastener openings (not illustrated) provided in the frame stud 22 .
As further illustrated in FIG. 14 , the hat channel beams 26 attach the meshing protective shield assemblies 1 to the frame studs 22 . The protective shield assemblies 1 may be attached to each hat channel beam 26 according to any suitable technique which is known by those skilled in the art. In some embodiments, a shield fastener 27 may be extended through each shield fastener opening 10 ( FIG. 1 ) which extends through each side shield attachment flange 9 , 9 a of each protective shield assembly 1 . The shield fastener 27 is threaded through a registering shield fastener opening (not illustrated) provided in the hat channel beam 26 . As illustrated in FIGS. 9 and 14 , in some applications, a seal or insert 30 and a filler 31 , such as caulk, for example and without limitation, may be inserted in the gap between the base panel side wall 5 of one protective shield assembly 1 and the base panel side wall 5 a of the adjacent protective shield assembly 1 for sealing purposes. As illustrated in FIG. 10 , a seal or insert 30 and a filler 31 may also be inserted in the gap between the base panel end walls 4 , 4 a of adjacent end-to-end protective shield assemblies 1 . As illustrated in FIG. 15 , a backing 42 and a sealant (not illustrated) such as caulk may be provided between the outer edge of each protective shield assembly 1 which extends along at a longitudinal edge of the shield section 20 and the outermost hat channel beam 26 .
In typical application of the protective shield assembly 1 , multiple shield sections 20 are pre-assembled and then attached in meshing relationship with respect to each other to a surface 48 ( FIG. 18 ) such as an exterior soffit, ceiling or fascia of a building or house, for example and without limitation, to protect the surface 48 from damage due to storm conditions such as high winds and flying debris. Accordingly, each frame stud 22 in the shield section frame 21 of each shield section 20 may be attached to the surface 48 using any suitable technique which is known by those skilled in the art. As illustrated in FIG. 12A , in some applications, multiple channel beams 28 (one of which is illustrated) may be attached to each frame stud 22 using channel beam fasteners 29 and/or other suitable technique known by those skilled in the art. Each channel beam 28 may be attached to the surface 48 or to a structural element (not illustrated) of the surface 48 typically using suitable fasteners (not illustrated). Accordingly, the corrugated panel 16 of each protective shield assembly 1 in each shield section 20 typically faces the surface 48 , whereas the base panel 3 on the protective shield base 2 of each protective shield assembly 1 typically faces away from the surface 48 , as illustrated in FIG. 18 . Adjacent shield sections 20 are engaged with each other in side-by-side and meshing relationship with respect to each other by inserting the side shield attachment flanges 9 on the protective shield assemblies 1 along one longitudinal edge of each shield section 20 in the flange gaps 12 a between the side shield attachment flanges 9 a on the protective shield assemblies 1 along the opposite longitudinal edge of the adjacent shield section 20 . Adjacent shield sections 20 are engaged with each other in end-to-end relationship with respect to each other by inserting the base panel end flanges 8 a on the protective shield assemblies 1 along one transverse edge of each shield section 20 over the base panel end flanges 8 on the protective shield assemblies 1 along the opposite transverse edge of the adjacent shield section 20 . At least one of the shield sections 20 may include a pair of adjacent half protective shield assemblies 1 a having a half shield access gap 34 through which fixtures (not illustrated) and the like on the surface 48 can be accessed. It will be appreciated by those skilled in the art that the panel ridges 17 and the panel troughs 18 of the corrugated panel 16 of each protective shield assembly 1 and half protective shield assembly 1 a impart torsional resistance to each protective shield assembly 1 and resists wind loads which would otherwise be applied against the surface 48 as well as debris which may otherwise strike and damage the surface 48 . The shield sections 20 may be disassembled and removed from the surface 48 by reversing the steps which were outlined above.
Referring next to FIGS. 16 and 17 of the drawings, in some applications one or multiple ceiling sections 46 , each having multiple meshing protective shield assemblies 1 , can be used to cover and shield a first surface 48 ( FIG. 17 ) such as a soffit or ceiling, for example and without limitation. One or multiple fascia sections 54 , each also having multiple meshing protective shield assemblies 1 , can be used to cover and shield a second surface 55 ( FIG. 17 ) such as an exterior fascia on a building, for example and without limitation, which may be disposed generally adjacent to and at an angle with respect to the first surface 48 . In each of the ceiling section 46 and the fascia section 54 , the side shield attachment flanges 9 , 9 a of each protective shield assembly 1 may be attached to a pair of C-channel beams 47 such as by assembly fasteners 58 , as illustrated in FIG. 17 . As further illustrated in FIG. 17 , each C-channel beam 47 on the ceiling section 46 may be attached to the first surface 48 using multiple channel beam fasteners 59 or other suitable technique known by those skilled in the art. Each C-channel beam 47 on the fascia section 54 may be attached to the second surface 55 also using multiple channel beam fasteners 59 or any other suitable technique which is known by those skilled in the art. As illustrated in FIG. 16 , a filler 50 such as caulk, for example and without limitation, may be applied to the gaps between adjacent protective shield assemblies 1 in the ceiling section 46 and the fascia section 54 . Accordingly, the ceiling section or sections 46 and the fascia section or sections 54 cover and protect the first surface 48 and the second surface 55 , respectively, from wind loads and flying debris during storm conditions, for example.
While the illustrative embodiments of the disclosure have been described above, it will be recognized and understood that various modifications can be made to the embodiments and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the disclosure. | A method of protecting an existing surface includes providing a surface to be protected; providing at least one shield section including a plurality of protective shield assemblies, each of the protective shield assemblies including a corrugated panel and a protective shield base carried by the corrugated panel; and attaching the corrugated panel to the surface with the protective shield assembly facing away from the surface. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to and benefit from U.S. Provisional Patent Application No. 61/873,812 titled “Apparatus And Method For Rapidly Immobilizing A Land Vehicle” filed on Sep. 4, 2013, the entire content of which is herein expressly incorporated by reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to an apparatus and a method for affecting movement of a land vehicle. More particularly, the present disclosure relates to apparatuses, systems and methods for deterring, slowing, disabling, restraining and/or immobilizing a motor vehicle by entangling one or more tires of the vehicle.
BACKGROUND
[0003] Conventional devices for restricting the movement of land vehicles include barriers, tire spike strips, caltrops, snares and electrical system disabling devices. For example, conventional spike strips include spikes projecting upwardly from an elongated base structure that is stored as either a rolled up device or an accordion type device. These conventional spike strips are tossed or thrown on a road in anticipation that an approaching target vehicle will drive over the spike strip. Successfully placing a conventional spike strip in the path of a target vehicle results in one or more tires of the target vehicle being impaled by the spike(s), thereby deflating the tire(s) and making the vehicle difficult to control such that the driver is compelled to slow or halt the vehicle.
[0004] Conventional spike strips may be used by first response personnel, law enforcement personnel, armed forces personnel or other security personnel. It is frequently the case that these personnel must remain in close proximity when deploying spike strips. For example, a conventional method of deploying a spike strip is to have the personnel toss the spike strip in the path of an approaching target vehicle. This conventional method places the security personnel at risk insofar as the driver of the target vehicle may try to run down the security personnel or the driver may lose control of the target vehicle while attempting to maneuver around the spike strip and hit the security personnel. Further, rapidly deflating only one of the steering tires may cause a target vehicle to careen wildly and possibly strike nearby security personnel, bystanders, or structures.
[0005] There are a number of disadvantages of conventional spike strips including difficulty deploying the strip in the path of a target vehicle and the risk that one of the spikes could injure security personnel while deploying or retracting the strip. The proximity of the security personnel to the target vehicle when it runs over strip places the security personnel at risk of being struck by the target vehicle. Further, allowing the strip to remain deployed after the target vehicle passes the strip places other vehicles at risk of running over the strip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic perspective view of a land vehicle approaching a device according to an embodiment of the present disclosure.
[0007] FIGS. 2A-2D are schematic perspective views showing an exemplary device that may be utilized with an embodiment of the present disclosure in an unarmed arrangement, an armed arrangement, and a deployed arrangement, respectively.
[0008] FIG. 3A is a perspective view of a netting package and an exemplary inflator device and an optional retractor device that may be utilized with an embodiment of the present disclosure before the device is deployed.
[0009] FIG. 3B is a schematic view of an exemplary inflator device that may be utilized with an embodiment of the present disclosure.
[0010] FIG. 3C is a detailed view showing an exemplary, optional retractor device that may be utilized with an embodiment of the present disclosure.
[0011] FIG. 3D is a schematic diagram showing an exemplary control system that may be utilized with an embodiment of the present disclosure.
[0012] FIG. 3E is a partial plan view showing an exemplary control panel that may be utilized with an embodiment of the present disclosure.
[0013] FIGS. 4A and 4B are side views of an arrangement of segments in a stacked configuration according to an embodiment of the present disclosure.
[0014] FIG. 4C is a side view of an arrangement of segments in a stacked configuration without netting according to an embodiment of the present disclosure.
[0015] FIG. 4D is a side view of an arrangement of segments in a partially stacked configuration according to embodiments of the present disclosure.
[0016] FIG. 4E is a side view of a plurality of segments in an unstacked configuration according to an embodiment of the present disclosure.
[0017] FIG. 5 is a view of a segment according to an embodiment of the present disclosure.
[0018] FIG. 6 is a partial view of an embodiment of exemplary netting that may be utilized in an embodiment of the present disclosure.
[0019] FIG. 7 is a perspective view of an embodiment of a tether and a spike for a snaring netting package that may be utilized in an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0020] Specific details of embodiments according to the present disclosure are described below with reference to devices for deflating tires of an oncoming land vehicle. Other embodiments of the disclosure can have configurations, components, features or procedures different than those described in this section. A person of ordinary skill in the art, therefore, will accordingly understand that the disclosure may have other embodiments with additional elements, or the disclosure may have other embodiments without several of the elements shown and described below with reference to the figures.
[0021] FIG. 1 is a schematic perspective view of a land vehicle approaching a device 10 according to an embodiment of the present disclosure. First response personnel, law enforcement personnel, armed forces personnel or other security personnel may use the device 10 to slow, disable, immobilize and/or restrict the movement of the land vehicle. Examples of land vehicles may include cars, trucks or any other vehicles that use tires to transport the land vehicle. The term “ground” may refer to natural or manmade terrain including improved roadways, gravel, sand, dirt, etc. FIG. 1 shows a car C supported, steered, and/or accelerated by pneumatic tires T relative to a roadway R.
[0022] Certain embodiments according to the present disclosure deploy the device 10 in the expected pathway of a target vehicle, e.g., the car C. The undeployed device 10 may be placed on the ground, e.g., on or at the side of the road R, and then armed. For example, the device 10 can be armed by making a power source available in anticipation of deploying the device 10 . The device 10 is deployed, e.g., extended across the expected pathway of the target vehicle, as the vehicle approaches the device 10 . The device 10 may be deployed when the target vehicle is a short distance away, e.g., less than 100 feet. This may avoid alerting the driver to the presence of the device 10 and thus make it more likely that the target vehicle will successfully run over the device 10 . Similarly, remotely or automatically deploying the device 10 may reduce the likelihood that the driver will notice the device 10 or take evasive action to avoid running over the device 10 . Remotely deploying the device 10 also allows the device operator (not shown) to move away from the target vehicle and thereby reduce or eliminate the likelihood of the vehicle striking the operator.
[0023] FIGS. 2A-2D illustrates a layout of the apparatus 10 in undeployed and partially deployed states according to embodiments of the disclosure. The apparatus 10 includes a housing 20 for transporting and/or handling the overall device 10 and for storing the segments. In some embodiments, the housing 40 may be a box-type configuration. As can be seen in FIG. 2B , the housing 20 includes a base or bottom portion 20 a and a closable lid 20 b that is opened during the process of deployment. In some embodiments, the closable lid can be divided into two parts, a top portion 20 b and a front portion 20 c. The lid can be manually opened to arm or activate the device, or in other embodiments, a switch can be tripped or otherwise a remote controlled signal can be used to arm the device and cause the lid to become opened. In some embodiments, the housing 40 can be made so as to be watertight when the apparatus is in the un-deployed state. The housing 40 also may include carrying handles or otherwise may be configured for easy carrying and transportation when the apparatus is in an undeployed state.
[0024] As shown in FIG. 2B , in an undeployed state, the housing 20 contains a series of segments in a netting package 30 . FIG. 2C provides a transparent view of the housing 20 with the netting package 30 removed, but with other components remaining within the housing, including an inflation device 40 , a retractor device 60 and a power source 70 (such as a battery pack). When the apparatus 10 is deployed these components operate to unfurl the segments out of the housing 20 and onto the roadway in the expected path of an oncoming vehicle, and then to retract the segments out of the roadway after the vehicle has made contact with the segments.
[0025] FIG. 2D illustrates the apparatus 10 in a partially deployed state. As can be seen, the plurality of segments in the netting package are arranged linearly when the apparatus is deployed. The segments are coupled together by coupling links, such as link 35 . The segments are configured to be lodged across a roadway (or other ground surface) as the apparatus is being deployed.
[0026] FIG. 3A is a perspective view of the netting package 30 including the inflator device 40 and the retractor device 60 according to an embodiment of the present disclosure before the device 10 is deployed. The netting package 30 includes a plurality of segments 32 (ten plates 32 a - 32 j are shown in FIG. 3A ) that are pivotally coupled by alternating first and second hinges. Individual first hinges 34 (four first hinges 34 a - 34 d are shown in FIG. 3A ) include a single pivot axis between adjacent segments 32 , and individual second hinges 36 (five second hinges 36 a - 36 e are shown in FIG. 3A ) include two separate pivot axes spaced by a link between adjacent segments 32 . According to the embodiment shown in FIG. 3A , second hinge 36 a pivotally couples segments 32 a and 32 b, first hinge 34 a pivotally couples segments 32 b and 32 c, second hinge 36 b pivotally couples segments 32 c and 32 d, first hinge 34 b pivotally couples segments 32 d and 32 e, second hinge 36 c pivotally couples segments 32 e and 32 f, first hinge 34 c pivotally couples segments 32 f and 32 g, second hinge 36 d pivotally couples segments 32 g and 32 h, first hinge 34 d pivotally couples segments 32 h and 32 i, and second hinge 36 e pivotally couples segments 32 i and 32 j. Accordingly, the netting package 30 includes an articulated series of segments 32 and hinges 34 and 36 .
[0027] The undeployed or stacked arrangement of the netting package 30 shown in FIG. 3A includes the segments 32 a through 32 j overlying one another. In particular, segment 32 j overlies segment 32 i (they are separated by second hinge 36 e ), segment 32 i directly overlies segment 32 h (they are coupled by first hinge 34 d ), segment 32 h overlies segment 32 g (they are separated by second hinge 36 d ), segment 32 g directly overlies segment 32 f (they are coupled by first hinge 34 c ), segment 32 f overlies segment 32 e (they are separated by second hinge 36 c ), segment 32 e directly overlies segment 32 d (they are coupled by first hinge 34 b ), segment 32 d overlies segment 32 c (they are separated by second hinge 36 b ), segment 32 c directly overlies segment 32 b (they are coupled by first hinge 34 a ), and segment 32 b overlies segment 32 a (they are separated by second hinge 36 a ). The spaces between the segments 32 due to the separation provided by the second hinges 36 accommodate penetrators and netting that are part of the segments 32 as will be discussed in greater detail below.
[0028] The segments 32 and/or the second hinges 36 can include a base section comprised of fiberglass, corrugated plastic or cardboard, wood, or another material that is suitably strong and lightweight. For example, G10 is an extremely durable makeup of layers of fiberglass soaked in resin that is highly compressed and baked. Moreover, G10 is impervious to moisture or liquid and physically stable under climate change. The base section of the segment 32 should provide a platform suitable for supporting an assembly that includes inflatable hoses, netting, and spikes, as will be described below. The size of the segments 32 may affect how far the netting package 30 extends in the deployed arrangement, e.g., shorter segments 32 may result in a shorter netting package 30 being deployed for a narrow roadway.
[0029] The inflator device 40 includes inflatable bladders 42 (two inflatable bladders 42 a and 42 b are shown in FIG. 4 ) that are also accommodated in the spaces between the segments 32 due to the separation provided by the second hinges 36 . The inflator device 40 additionally includes a pressure source 44 , e.g., a pressurized gas cylinder, gas generator, an accumulator, etc., and a manifold 46 coupling the pressure source 44 to the bladders 42 . The bladders 42 are mounted to the segments 32 and, in response to being inflated by the pressure source 44 , expand to deploy the netting package 30 . Certain embodiments according to the present disclosure include tubular bladders 42 mounted lengthwise along the segments 32 such that, in the stacked arrangement of the netting package 30 , the bladders 42 are temporarily creased at the first and second hinges 34 and 36 . Accordingly, each bladder 42 defines a series of chambers that may be sequentially inflated starting at the end of the bladder 42 coupled to the manifold 46 . As each chamber is inflated, the expanding bladder unstacks, e.g., unfolds, unfurls, or otherwise begins to deploy, adjacent overlying segments 32 until the bladders 42 are approximately fully expanded and the netting package is deployed, e.g., as shown in FIG. 2C . The pivot axes of the first and second hinges 34 and 36 may assist in constraining the netting package 30 to deploying in a plane, e.g., minimizing or eliminating twisting by the netting package 30 about its longitudinal axis when it is being deployed.
[0030] The inflator device 40 may also include a sensor (not shown) for sensing an approaching vehicle and automatically deploying the netting package 30 . Examples of suitable sensors may include magnetic sensors, range sensors, or any other device that can sense an approaching vehicle and deploy the netting package 30 before of the vehicle arrives at the device 10 . The inflator device 40 may alternatively or additionally include a remote actuation device (not shown) for manually deploying the netting package 30 . The sensor and/or the remote actuation device may be coupled to the device 10 by wires, wirelessly, or another communication system for conveying a “deploy signal” to the device 10 . Examples of wireless communication technology include electromagnetic transmission (e.g., radio frequency) and optical transmission (e.g., laser or infrared).
[0031] FIG. 3B is a schematic view of a multiple discharge, cold gas inflator device 400 according to an embodiment of the present disclosure. The inflator device 400 shown in FIG. 3B includes a high pressure reservoir 410 for supplying a compressed gas, e.g., nitrogen, to an accumulator tank 420 . The supply of compressed gas can be controlled by a supply valve 412 and/or a pressure regulator 414 along a supply line 416 coupling the high pressure reservoir 410 and the accumulator tank 420 . The supply valve 412 can supply or shutoff a flow of the compressed gas from the high pressure reservoir 410 through the supply line 416 . According to certain embodiments of the present disclosure, the high pressure reservoir 410 can have a volume of approximately 50 cubic inches (in.sup.3) and can be initially pressurized to approximately 3,000 pounds per square inch (psi). The accumulator tank 420 can have a volume less than, similar to, or greater than that of the high pressure reservoir 410 . For example, certain embodiments of the present disclosure can include an accumulator tank 420 having a slightly larger volume, e.g., approximately 62 in.sup.3, and the pressure regulator 414 can be adjusted to pressurize the accumulator tank 420 to a relatively lower pressure, e.g., to approximately 600 psi. In general, the volume and pressure of the accumulator tank 420 may be related to the volume of the bladders 42 and the desired time for deploying the netting package 30 with the bladders 42 . For example, greater deployment pressure and/or volume may reduce the time it takes to deploy the netting package 30 whereas lower deployment pressure and/or volume may provide a more controlled deployment of the netting package 30 . A gauge 418 can be coupled to the supply line 416 between the high pressure reservoir 410 and the supply valve 412 to indicate the pressure in the high pressure reservoir 410 . Certain other embodiments may use a different gas or mixture of gases, may include reservoirs or tanks with different volume(s), may include fixed or adjustable pressure regulators, and/or may use different pressure(s).
[0032] A drain valve 422 coupled to the supply line 416 downstream of the accumulator tank 420 can drain residual pressure in the accumulator tank 420 by opening the supply line 416 to the atmosphere. A gauge 424 can be coupled to the supply line 416 between the supply valve 412 and the drain valve 422 to indicate the pressure in the accumulator tank 420 .
[0033] Compressed gas for deploying the netting package 30 can flow along a deployment line 430 that couples the supply accumulator tank 420 and the manifold 46 . A deployment valve 432 is positioned along the deployment line 430 between the supply accumulator tank 420 and the manifold 46 to control flow of the compressed gas to the netting package 30 . According to certain embodiments of the present disclosure, the deployment valve 432 can include a 0.5 inch NPT normally closed solenoid valve with an approximately 15 millimeter orifice, a 1500 psi pressure capability, and can be actuated by a direct current signal, e.g., 24 volts. A signal to deploy the netting package 30 energizes the solenoid of the deployment valve 432 to allow compressed gas in the accumulator tank 420 to flow through the deployment line 430 and the manifold 46 to the bladders 42 , thereby deploying the netting package 30 . A vent valve 440 coupled to the deployment line 430 downstream of the deployment valve 432 and/or coupled to the manifold 46 can vent compressed gas in the bladders 42 to the atmosphere. According to certain embodiments of the present disclosure, the vent valve 440 can include a 0.125 inch NPT normally closed solenoid valve with an approximately 1.2 millimeter orifice and can also be actuated by a 24 volt direct current signal. A signal to vent the bladders 42 energizes the solenoid of the vent valve 440 to release to atmosphere the gas in the bladders 42 , for example, before and/or during operation of the retractor device 60 .
[0034] FIG. 3C is a perspective view of a retractor device 600 according to an embodiment of the present disclosure. The retractor device 600 may be electrically, pneumatically, mechanically (e.g., with a resilient element such as a torsion spring), or otherwise powered. The retractor device 600 shown in FIG. 3C includes a torque source 610 , e.g., an electric motor, a torque multiplier 620 , e.g., reduction gearing, a torque limiter 630 , e.g., a friction plate slip-clutch, a coupling 640 , and a one-way clutch 650 , e.g., a drawn cup needle clutch bearing. One or more brackets 660 (two brackets 660 a and 660 b are shown in FIG. 3C ) may support the retractor device 600 with respect to the housing 20 . Certain embodiments of the retractor device 600 can include a 60-80 Watt direct current electric motor 610 rated at 3000 revolutions per minute and a 6:1 ratio planetary gear reducer 620 . The coupling 640 can be a steel mandrel for transferring driving torque to a drive pulley 62 for winding a cable 64 on the drive pulley 62 . An example of a drawn cup needle clutch bearing is part number RC-081208 manufactured by The Timken Company of Camden, Ohio. The one-way clutch 650 may be interposed between the coupling 640 and the drive pulley 62 . Accordingly, operating the torque source 610 engages the one-way clutch 650 thereby driving the drive pulley 62 and winding the cable 64 onto the drive pulley 62 to retract the netting package 30 . Moreover, the one-way clutch 650 allows the drive pulley 62 to turn generally freely to allow the cable 46 to pay-out when, for example, the netting package 30 is being deployed.
[0035] The electronics for the control of the device 10 can include at least two options for triggering deployment: (1) a wireless frequency operated button (“FOB”) and/or (2) a wired control box. Embodiments of option 1 according to the present disclosure can include a three-channel, 303 MHz wireless radio frequency board (e.g., Model Number RCR303A manufactured by Applied Wireless, Inc. of Camarillo, Calif.) in the housing 20 and a three-button FOB (e.g., Key Chain Transmitter KTX303Ax also manufactured by Applied Wireless, Inc.) that can be separated and remotely located from the housing 20 . Some other embodiments use radio frequency transmission equipment having a LINX RXM-418-LR 418 MHz receiver, CMD-KEY#-418-S5 transmitter, and LINX LICAL-DEC-MS001 decoder (which decodes the encrypted digital string sent by the transmitter). The wireless transmissions can be encoded at 24 bits (allowing for 16.7 million unique addresses) to negate the possibility of cross-talk between another nearby unit. Embodiments of option 2 according to the present disclosure can include a control box that can be separated and remotely located from the housing 20 but remains electrically coupled via a cable. Both options may be incorporated into the device 10 to provide a backup for controlling deployment of the netting package 30 .
[0036] FIG. 3D is a schematic diagram of an electronic circuit 500 for controlling the inflator device 400 and the retractor device 600 according to an embodiment of the present disclosure. The electronic circuit 500 shown in FIG. 3D includes the power supply 70 , e.g., a 24 volt direct current battery, and a system switch 510 for turning ON/OFF the device 10 . The electronic circuit 500 may also include a first indicator 512 for showing the status of the device 10 based on the setting of the system switch 510 and a second indicator 514 for showing the voltage of the power supply 70 . A microprocessor 520 receives input signals, e.g., “FIRE” and “RETRACT,” from a wireless radio frequency board 530 (i.e., option 1) and/or an auxiliary handheld control box 540 (i.e., option 2) and sends output signals to (a) a solenoid coil 550 for the deployment valve 432 , (b) a solenoid coil 560 for the vent valve 440 , and/or (c) a motor winding 570 for the torque source 610 .
[0037] The electronic circuit 500 can also include circuitry to handle the timing and control of operational events. Such a circuit may be useful if, for example, there is a difference in voltage provided by the wired control box 540 (e.g., approximately 14-17 volts direct current) versus the voltage required to operate the deployment valve 432 and/or vent valve 440 (e.g., approximately 24 volts direct current). This other circuit operates based on operator input for each event from either the wireless radio frequency board 530 (i.e., option 1) and/or the wired control box 540 (i.e., option 2).
[0038] FIG. 3E is a partial plan view showing a control panel 700 according to an embodiment of the present disclosure. The control 700 can be coupled to the housing 20 and include the gauge 418 to indicate the pressure in the high pressure reservoir 410 , the gauge 424 to indicate the pressure in the accumulator tank 420 , the second indicator 514 for showing the voltage of the power supply 70 , the system switch 510 , the first indicator 512 for showing the ON/OFF status of the device 10 based on the setting of the system switch 510 , a knob 412 a operating the supply valve 412 to supply or shutoff the flow of the compressed gas from the high pressure reservoir 410 , and a knob 422 a operating the drain valve 422 to drain residual pressure in the accumulator tank 420 and purge the inflator device 400 , for example, when storing the device 10 .
[0039] FIGS. 4A and 4B illustrate in further detail an exemplary subset of stacked (folded) segments that may be incorporated into a netting package 30 of device 10 in an undeployed state, As delineated in FIG. 4B , FIGS. 4A and 4B illustrate four stacked segments, 801 , 802 , 803 , 804 , arranged such that they are inverted lengthwise. Although four stacked segments are illustrated in FIGS. 4A and 4B , it will be appreciated that device 10 may incorporate more segments when the netting package is incorporated into device 10 . The number of total segments to be included, and the length of each segment, will be determined such that the netting package, when unfurled for deployment, traverses the roadway, or at least a substantial width of the roadway, so that an oncoming vehicle will make contact with at least one of the segments. The length of each segment may be determined based in part upon weight and the ease and speed with which the segments will unfurl from the stacked position when the deployment hoses are inflated, and the ease of retracting the segments after the targeted vehicle has made contact with the device.
[0040] As can be seen in FIG. 4A , each segment may include a plate or backing 805 . The plate incorporates hinge tabs or is otherwise affixed to tabs or some other mechanism to connect the segments together via hinges. In the embodiment depicted in FIGS. 4A and 4B , the plate is a rigid surface as described above with reference to FIG. 3A . In alternative embodiments, however, the backing may be made of a flexible material, or may be made of a strong cloth. A small hinge 820 a can be used to connect the backing 805 at one end of a first segment to a second segment, and a large hinge 820 b can be used to connect the other end of the backing 805 of the first segment to a third segment. As can be seen, the small hinge 820 a connects the backings 805 of two segments arranged “back-to-back,” whereas the large hinge 820 b connects the backings 805 of two segments stacked “front-to-front.”
[0041] Atop the backing 805 , each segment will include netting 810 , a portion of which will be exposed at the side where the small hinge 820 a is located when the segments are in the stacked configuration. Additionally, the segments each contain a plurality of spikes, quills or other penetrators 840 capable of penetrating into the tires of the targeted oncoming vehicle. As can be seen, when the segments are in the stacked configuration, the spikes point toward the opposing segment. Sufficient spacing must be provided such that, when the segments are in the stacked configuration, they are not penetrating into the opposing segment in a manner that would prevent the segments from unfurling when the deployment hoses are being inflated.
[0042] As shown, the segments also include a spike ramp 850 at a leading edge of the backing 805 . The spike ramp may be incorporated within the backing or may be made of a different material. The spike ramp holds a plurality of spikes in place, at an angle that facilitates having the spikes penetrate into the tires of an oncoming vehicle when the segments are unfurled for deployment.
[0043] As shown in FIG. 4B , each spike includes a spike tether 860 , which connects the base of the spike to the netting 810 . When the device 10 is deployed, at least one tire of an oncoming vehicle travels up the spike ramp 850 and is punctured by a spike 840 . The spike is then lodged in the tire, and via the tether, the netting is pulled from the segment, as will be described in further detail below.
[0044] Lastly, FIGS. 4A and 4B show portions of the deployment hoses 830 a and 830 b , which run the length of the segments. At one end of the segments, the uninflated deployment hose will fold tightly near the small hinge 820 a, from backing-to-backing of two segments. At the other end, the uninflated deployment hoses extend from the backing of one segment to the other, flanking the large hinge 820 b.
[0045] FIGS. 4C and 4D illustrate the segments, with the netting removed. FIG. 4C illustrates three segments 802 , 803 , 804 in a stacked configuration, with the netting removed. A single deployment hose 830 a and a single spike 840 is depicted. FIG. 4D illustrates the three segments, also with the netting removed, in a partially unstacked configuration. This provides a clear view of the rear side of the backing 805 of one segment as well as the front side of the backing for another segment. The front side of the backing 805 includes the spike ramp 850 and supports both deployment hoses 830 a and 830 b.
[0046] FIG. 4E illustrates four segments 801 , 802 , 803 , 804 in an unstacked arranged, such as when in state that is ready for deployment. In this configuration, it can be seen that each deployment hose (such as 830 a ) is continuous from segment to segment. When unstacked, the spikes 840 are aligned facing the same direction, along with the spike ramp 850 . The netting 810 is also continuous from segment to segment. FIG. 4E also shows an optional segment cover 860 , which covers the segment itself but not the portion in which two segments are connected via a large hinge 820 b. In some embodiments, the segment cover 870 may be part of the netting packaging. Or in other embodiments, no segment cover is required.
[0047] FIG. 5 provides a close-up view of a single segment that may be incorporated into device 10 in accordance with an embodiment of the disclosure. A portion of the net package 810 is housed by the segment (but the netting continues from segment to segment) and is folded so that it sits flush between the two deployment hoses (hose 830 a is shown). Above the front deployment hose 830 a, a plurality of spike tethers 860 connect the spikes (not shown) to the netting 810 . The spikes sit in the spike ramp 850 and are retained via a series of spike clip/retainers 855 in the spike ramp so as to stay in place until one or more spikes is dislodged by penetrating the tire of an oncoming target vehicle.
[0048] FIG. 6 is a partial plan view showing portions of opposite corners of an embodiment of the netting 810 in an extended, unfolded configuration. The netting 810 can be comprised of, for example, a polyethylene mesh net, having a width W preferably suitable for encompassing the track of the wheels of a target vehicle and a length L preferably suitable for extending at least approximately 1.25 times around the circumference of the wheels of the target vehicle. For example, if the target vehicle has a track of approximately 65 inches and rides on wheels having an outer diameter of approximately 28 inches, the net 700 may have a width W of approximately 190 inches and a length L of at least approximately 110 inches. The dimensions the net 810 may be selected in part based upon the width of the roadway and also the circumference of the wheel of the type of vehicle that is desired to be restrained by the device. A preferable minimum length of the net 700 in the example may be selected by computing 1.25 times the circumference of the wheel.
[0049] The net 810 can have meshes that, in the contracted, folded arrangement of the net, have an approximately diamond shape with a major axis M1 between distal opposite points approximately three to four times greater than a minor axis M2 between proximal opposite points. For example, the size of individual meshes in the widthwise direction may be approximately one inch in the contracted arrangement, e.g., stowed configuration, of the net 700 , and the size of individual meshes in the lengthwise direction may be approximately 3.5 inches in the contracted arrangement of the net. Certain other embodiments according to the present invention may have approximately square shaped meshes.
[0050] The net 810 may be assembled according to known techniques such as using “Weavers Knots” and/or a “Fisherman's Knot” to join lengths of cord and form the mesh. Certain embodiments according to the present disclosure may include coating the net material with an acrylic dilution, e.g., one part acrylic to 20 parts water, to aid in setting the knots and prevent them from slipping or coming undone.
[0051] It may be desirable to provide a widthwise stretch ratio of approximately 3:1. Accordingly, each mesh is reshaped or stretches in the widthwise direction, e.g., parallel to the wheel track of the target vehicle, to a dimension approximately three times greater than its initial dimension. For example, a net having a 1.75 inch by 1.75 inch mesh size (unstretched) may be approximately 3.75 inches measured on the bias (stretched) when the net is entangled around the wheels of a target vehicle in the fully deployed configuration of the device 10 . According to this example, approximately 65 inches of the contracted net that is captured by the wheel track of the target vehicle is expanded to approximately 245 inches that may become entangled on features of the undercarriage of the target vehicle approximately within its wheel track.
[0052] The netting may also include a first strip 910 along a leading edge 904 a of the net 810 , a second strip 920 along a trailing edge 904 b of the net 810 , and/or lengthwise strips 930 (individual lengthwise strips 930 a and 930 b are shown in FIG. 6 ). The first strip 910 may include, for example, approximately one inch wide nylon webbing that is sewn to the net 810 with rip-stitching. Accordingly, the style and/or material of the stitching securing the first strip 910 to the net 900 allows the first strip 910 to at least partially detach from the net 810 in response to the wheels of the target vehicle extracting the net 810 from the device. The second strip 920 includes a single strip extending approximately the entire width of the net 810 . The second strip 920 may include, for example, approximately two inch wide nylon webbing that is securely sewn to the net 810 such that the second strip 920 remains at least approximately secured to the net 810 in response to the wheels of the target vehicle extracting the net 810 from the device. Individual lengthwise strips 930 may include single strips intertwined with the meshes of the net 810 between the first and second strips 910 and 920 . The lengthwise strips 930 may be securely coupled to the first and second strips 910 and 920 such that the lengthwise strips 930 remain at least approximately secured to the first and second strips 910 and 920 in response to the wheels of the target vehicle extracting the net 810 from the device.
[0053] The first, second and/or lengthwise strips 910 , 920 and 930 may maintain the approximate size and approximate shape of the net 810 in its contracted configuration, e.g., in a stowed configuration of the device. The second strip 920 that is secured to the trailing edge 904 b of the net 810 may aid in cinching the net onto the wheels of the target vehicle so as to seize rotation of the entangled wheel(s) and thereby immobilize the target vehicle. The lengthwise strips 930 also may aid in cinching the netting onto the wheels of the target vehicle and/or minimize net flaring as the net 810 wraps around the wheels of the target vehicle.
[0054] FIG. 7 is a detailed view of one embodiment of a tether 902 coupled to an individual spike 840 . The tethers 860 may couple individual meshes at the leading edge 904 a of the net to corresponding spikes 840 . Individual tethers 860 may be made of the same material as the net or any other material that is suitable for coupling the spikes 840 and the net. Loops may be formed at either end of the tether 860 by known weaving or braiding techniques.
[0055] A method according to embodiments of the present disclosure for implementing a vehicle immobilizing device will now be described. A vehicle immobilizing device 10 is to be positioned in along the side of a roadway. In some embodiments, the device can be permanently left in position at the roadside, and may be disguised. In other instances, the device can be transported in the trunk of an automobile, such as a police car or military vehicle. When the police or military are engaged in a chase and need to restrain a vehicle, the device 10 can then be quickly positioned along the roadway in the expected path of the vehicle. When the device is in an undeployed state, it may be a completely enclosed box, resembling, for example, a suitcase. In this undeployed state, the segments contained therein, which include the netting 810 , are in a stacked position inside the housing, as depicted in FIG. 3A .
[0056] Once the target vehicle is in close proximity to the device 10 , the device can be deployed, either by a sensor, manually, or via remote control. Upon deployment, the inflator is powered and begins to quickly pump air into the deployment hoses 830 . Because the hoses are folded multiple times, the hoses are inflated in sections. As each section is inflated, segments begin to rotate about the hinges 820 a and 820 b so as to unfold and lie end to end. Because the device is positioned along the roadway, the segments then lay in a linear fashion across the roadway, just at, or near the time that the target vehicle is approaching.
[0057] As the vehicle's tires make contact with segments of the device, the tires are lifted slightly by the spike ramp 850 and then make contact with at least one spike 840 . In a preferred embodiment, the spikes 840 are placed sufficiently close together such that the vehicle's tires contact multiple spikes. The spikes penetrate into the front tires of the vehicle and become lodged in those tires. This cause the spikes to become dislodged from the spike clip/retainer 855 in the spike ramp 850 .
[0058] As the spikes are drawn around the circumference of the tire, the base of the spikes pulls the spike tethers 860 , which in turn is connected to the netting 810 . The netting is then pulled from the segments. The netting has been folded in a manner that it will be drawn out from the net packaging in a continuous motion. As the netting is drawn from the device 10 , it proceeds to wrap around the tire as it continues to rotate. The netting then proceeds to twist and becomes entangled around the rotating tires. The entangled snaring members then will continue to twist until leverage against the under carriage of the vehicle brings the tires to a stop. Accordingly, the vehicle can be slowed and stopped in a controlled and non-lethal manner.
[0059] The above detailed description of embodiments is not intended to be exhaustive or to limit the invention to the precise form disclosed above. Also, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the present disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. As an example, certain embodiments of devices according to the present disclosure may include a pressure generator disposed in a device control housing with other operating elements, such as, but not limited to, a pressure delivery manifold, control circuitry to arm and deploy, a proximity detector, a signal receiving and sending circuit and any other hardware, software or firmware necessary or helpful in the operation of the device. As another example, the device may be housed in a clamshell-type briefcase or ammunition box type housing and include a pressure manifold and a pressure-generating device, such as compressed gas or a gas generator connected to the manifold. In other embodiments more than one manifold and more than one pressure generating device, or any combination thereof, may be included in the device.
[0060] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of including, but not limited to. Additionally, the words “herein”, “above”, “below”, and words of similar connotation, when used in the present disclosure, shall refer to the present disclosure as a whole and not to any particular portions of the present disclosure. Where the context permits, words in the above Detailed Description using the singular or plural number may also include the plural or singular number respectively. The word “or”, in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.
[0061] While certain aspects of the invention are presented below in certain claim forms, the inventors contemplate the various aspects of the invention in any number of claim forms. Accordingly, the inventors reserve the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention. | An apparatus to be positioned at the side of a roadway for ensnaring tires of an oncoming land vehicle is described. The apparatus comprises a plurality of segments flexibly attached end-to-end. At least a subset of the segments further comprise a spike ramp. The segments are connected at the ends via hinges. The segments are adapted to house a net package in a stowed-away configuration. The net package includes a set of spikes tethered to netting. A deployment hose is connected to a subset of the segments to cause the segments to become unstacked for deployment when the deployment hose is inflated. |
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CROSS-REFERENCE TO RELATED APPLICATION
This invention is not disclosed in any co-pending application for patent or any issued patent.
SUMMARY OF THE INVENTION
This invention is an improvement in hydraulic dredges used to clear channels in rivers and shorelines and in underwater mining. This invention may be used with the standard cutter dredge and any of the well-known variety of cutters or cutter heads.
A hydraulic or cutter dredge is normally employed to cut a channel of a certain width and depth. With the current price of fuel, the hourly operating cost is substantial and therefore the operating efficiency of these dredges is very important.
This invention is particularly useful for dredges operating in soft bottom material such as mud or silt which is easily displaced. The conventional cutter may have to make several passes to remove all of the material since it will slide around and behind the cutter during the first pass of the cutter head.
While the cutter is being returned for a second pass, or while the dredge is being backed up, the dredge is pumping mostly water, which pumping costs nearly as much as the mud or silt but accomplishes very little. This invention substantially reduces this expensive dead time.
It is an object of this invention to modify the standard cutter to permit increased productivity, particularly in soft material dredging.
It is a further object to permit more accurate cutting of a channel in producing a smoother cut at the prescribed dredging depth and within the required dredging tolerance.
It is a further object to provide for sweeping material behind the suction orifice back to the orifice while cutting material in front of the orifice and forcing it backwards into the suction orifice.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the annexed drawings in which;
FIG. 1 is a diagrammatic perspective view of a hydraulic dredger employing the cutter extension cone;
FIG. 2 is an enlarged view of the end of the beam or ladder including the cutter and cutter extension cone;
FIG. 3 is a side view of the cutter extension cone;
FIG. 4 is a partial side view showing the ladder, in raised and lowered positions, with the cutter and cutter extension cone;
FIG. 5 is a detailed side view of the end of the ladder showing the cutter and cutter extension cone and the spiral helical blades of both, one wound clockwise and the other wound counterclockwise; and
FIG. 6 is a front section taken on lines 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
As is shown in FIG. 1, a conventional hydraulic dredge 11 is shown cutting a channel 12 in an underwater bank 13.
The dredge pivots on submerged spud 14A and is pulled from side to side by anchor lines 15. The barge is walked forward by sinking the second spud 14B. The ladder or beam 16 carries the drive shaft 17, suction line 18 and cutter 20. The ladder is pivoted on the hull allowing the depth of the cutter to be controlled by a conventional block and tackle 21 which is attached to bow gantry 19.
The end of the ladder may optionally have a known second pivot 22, controlled by hydraulic or other means 23 to provide more rapid and precise adjustment to the cutter position. A second advantage of this auxiliary pivot is that it allows the lower surface of the cutter extension cone to be horizontal, whatever the depth of the cutter.
The drive shaft is axial and passes through a fixed circular ring 24 to connect to the cutter. There are a number of conventional cutter designs, some with spiral helical blades 25 and serrations or teeth 26. As shown, the blades spiral forward clockwise when viewed from the front. The cutter turns clockwise, thus cutting into the material of the bank and forcing it toward the rear.
The ring 24 contains a generally elliptical aperture 27 which forms the open end of the suction pipe 18.
The cutter extension cone 30 of this invention is not a mere extension of the cutter 10 as the name might imply. Rather it is in some ways just the opposite. The cone attaches at its front 31 to the back of the cutter 20. The cone surface 32 extends outwardly and backwardly. The particular dimensions form no part of the invention and those illustrated in FIG. 3 are exemplary only.
Generally the angle between the cone surface 32 and the axis will approximate the angle between the drive shaft itself and the bottom when the cone is in its operating position. This allows the bottom portion of the cone to be approximately horizontally on the surface of the channel being cut. Actually the surface does not lie horizontally as the cone rotates with the cutter head.
On the surface of cone 30 are a series of generally spiral helical blades 33. The number and dimensions are not critical to the invention although they will normally approximately equal, in number and depth, the spiral helical blades of the cutter head. Likewise the spiral helix need not be precisely geometrical. What is critical to the invention is the direction of the cone helix. The cone helix direction is opposite to the cutter helix direction.
As shown in FIGS. 2, 4, 5 and 6, the direction of rotation of the drive shaft, the cutter and the cutter extension cone, is clockwise, viewed from the front. The spiral helical blades 25 of the cutter have a forward spiral in the clockwise direction. The spiral helical blades 33 of the cutter extension cone have a forward spiral in the counterclockwise direction . While the helixes can go in either direction, they must be opposite on the particular cutter and the matching cutter extension cone.
By way of illustration only, a cutter extension cone for a cutter with an eight (8) foot diameter could have the following dimensions. Front diameter eight (8) feet, cone length along axis five (5) feet, diameter at rear of cone fifteen (15) feet.
In operation the cutter cuts the material and sweeps it back to the suction orifice. At high levels of lateral movement in soft material, not all of the material makes it through the orifice in the first pass. Substantial amounts flow back on either side of the cutter. This is particularly true when a cave-in or collapse of the wall has occurred. If the material slides back further than the length of the cutter, the blades cannot pick the material up without stepping the entire dredge to the rear. This is time consuming and expensive.
The cutter extension cone rests on the bottom and its spiral helical blades force material forward as the cutter and cone rotate. Due to its greater diameter at the rear it will catch material thrown back by the cutter and will return it to the suction orifice.
The cutter extension cone provides a greater surface resting on the bottom and can also therefore eliminate the ridges formed by incremental sweeps of the cutter head as is shown in FIG. 4. This means that the average depth of the cut may be the target depth, rather than forcing the operator to ensure that the minimum depth, the peaks between the troughs, is the target depth. Thus less material need be dredged to ensure a channel of a given depth.
Although the present invention has been described with reference to a particular embodiment thereof, it should be understood that those skilled in the art may make many other modifications and embodiments thereof which will fall within the spirit and scope of the principles of this invention. | An extension cone for a cutter for a hydraulic dredge. The cone has spiral helical blades with an opposing helix to the cutter head to force the material forward as the cutter rotates, thus smoothing the bottom and returning any material which was cut and has passed the cutter head back to the suction orifice. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to a safety system for garage door openers and particularly to a light beam obstruction detection system for garage door openers.
2. Description of the Prior Art
Safety systems for a garage door openers which detect the presence of an obstruction to door movement are known in the art. Typically the garage door moves on curved tracks. An electric motor opens and closes the door by means of a driving mechanism. Safety systems are intended to control door movement in response to certain sensed conditions. One such system, disclosed in U.S. Pat. No. 4,922,168, uses a light transmitter and a light receiver which are laterally opposed near the edges of the door opening. The light transmitted is generally infrared. The transmitter and receiver cooperate to detect an obstruction in the path of the transmitted signal. When the obstruction interrupts the signal from the transmitter to the receiver, the controller prevents the door from closing.
There are several problems with the prior art obstruction detectors. The transmitter and receiver are located near the ground at the door opening which exposes them to rain, snow and physical contact from people and objects passing through the door. Such physical abuse can cause the components to malfunction or degrade; thus, more frequent repair and replacement are required. The transmitter and receiver must be in electrical communication with the door operator which is generally located near the ceiling of the garage some distance from the transmitter and receiver. Multiple enclosures must be used which are costly and more difficult to install than a single enclosure. Often, the space for installing the transmitter and receiver near the door is limited making installation difficult if not impossible. Proper alignment of the relatively large enclosures can also be difficult. Costly power and signal conductors must run from the door operator to the transmitter and receiver. Worn insulation on the conductors is a potential safety hazard which can cause system failure resulting from a short circuit.
It would be preferable to have an obstruction detection device which provides simple installation, improved durability and a minimum number of pieces without compromising the reliability or effectiveness of the system.
SUMMARY OF THE INVENTION
This invention overcomes the problems of the prior art by locating the transmitter and receiver for the obstruction detector in the enclosure with the garage door controller. One end of a fiber optic cable is coupled with the transmitter and the other end has a lens arrangement which is installed near the bottom of one side of the garage door opening where the transmitter of the prior art system would have been located. The transmitter transmits a light beam through the cable and across the garage door opening to the end of a second fiber optic cable. The second cable is installed similarly to the first cable on the opposite side of the door opening and is coupled to the receiver so that the receiver receives the signal transmitted by the transmitter through the first cable, across the garage door opening and through the second cable. An object in the doorway will obstruct the beam. When the beam is interrupted the controller prevents closing of the garage door as in the prior art system.
Accordingly, an object of the present invention is to protect the transmitter and receiver from physical abuse without compromising the performance of the prior art obstruction detection system. This is accomplished by locating the transmitter and receiver in or near the door operator enclosure and providing fiber optic means for communication between the transmitter/receiver and the door opening. All garage door control components can be contained within a single enclosure to reduce the volume of space required by the garage door control system components and, in particular, to reduce the space occupied adjacent the doorway.
This invention provides simpler installation of the system components and eliminates the need for running power lines near the doorway to increase safety and reduce cost.
A fuller understanding of the invention may be had by referring to the following description and appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially schematic, partially perspective view of the prior art light beam detection system;
FIG. 2A is a partially schematic, partially perspective view of the invention installed on a typical garage door with the transmitter and receiver in the control circuit enclosure;
FIG. 2B is a schematic view showing the transmitter and receiver mounted separately from the control circuit enclosure;
FIG. 3 is a perspective view detail showing one installation of the optic cable end;
FIG. 4 is a perspective view detail showing another installation of the optic cable end;
FIG. 5 is a perspective view showing several light beams and an automobile which could obstruct the door path without obstructing a light beam near ground level;
FIG. 6 is a partially schematic, partially perspective view showing optic cables installed at several levels; and
FIG. 7 is a partially schematic, partially perspective view showing a single optic cable installed on one side of the door and a reflector on the opposite side.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a typical sectional garage door 11 and electro-mechanical opener 12. Generally, the door travels on a curved track 15. This invention can also be applied to door openers for other types of doors such as one piece garage doors. The opener has an enclosure 13, a main control circuit 14, a motor 16 and a reversible drive train 17. A driven member 18 is connectable to and releasable from the drive train by a handle 19. The control circuit 14 operates the motor 16 in response to commands from an operator. The motor moves the driven member 18 via the drive train 17. When the driven member 18 moves toward the motor 16, it pulls the door 11 up and back along the track 15 until the door is completely open; then the control circuit 14 stops the motor 16 and the door 11. When the driven member 18 moves away from the motor 16, it pushes the door forward and down along the track 15 until the door is closed; then the control circuit 14 stops the motor 16 and the door 11.
FIG. 1 shows a prior art safety control system 21 which has monitor means responsive to an obstruction 24 to door closing movement. The monitor means has a light transmitter 25 which directs a beam of light across the door opening and a light receiver 26 which detects the beam. The light beam is preferably infrared, but can be visible light or other frequencies. The control circuit 14 supplies power to the receiver and transmitter through conductors 30 and 32. The receiver 26 sends a signal to the control circuit 14 through a conductor 31 to indicate whether it is receiving the light beam from the transmitter 25. If an object 24 obstructs the beam, the receiver 26 will not receive the beam and will signal the control circuit 14 to take appropriate action.
The action taken by the control circuit 14 in response to detection of an obstruction depends on the mode of operation of the garage door at the time the obstruction is detected. If the door 11 is open, the door is prevented from closing. If the door 11 is closing, the door is stopped and reversed so that it will open. If the door 11 is opening, the door will continue to open. The control circuit 14 performs these functions by controlling the operation of the motor 16.
The operation of the garage door, opener and safety system including all components referenced above comprise the prior art an example of which is described in more detail in U.S. Pat. No. 4,922,168 which is incorporated by reference into this specification in its entirety.
FIG. 2A shows the components of the present invention which replace the prior art safety system. A light transmitter 45 and light receiver 46 which are substantially similar to the transmitter 25 and receiver 26 of the prior art are located in the opener enclosure 13 with the control circuit 16 which enclosure is typically mounted on the ceiling of the garage.
The transmitter 45 is connected to an optical cable 47. The distal end of the cable has a lens arrangement 49 of a type known in the art. The lens arrangement 49 is mounted near the bottom of one side of the door opening 51 so that a light beam generated by the transmitter 45 is sent through the cable 47 and the lens arrangement 49 across the door opening.
The receiver 46 is connected to an optical cable 48. The distal end of the cable has a lens arrangement 50 similar to the transmitter lens arrangement 49. The receiver lens arrangement 50 is mounted near the bottom of the garage door opening 52 on the side opposite the transmitter lens arrangement 49 so that the light beam is transmitted across the door opening through the lens arrangement 50 and optical cable 48 to the receiver 46.
Plastic optical cables 47 and 48 are preferred as they are relatively inexpensive and durable, but glass or other types are suitable.
The transmitter 45 sends a signal through the optical cable 47, through the lens arrangement 49, across the door opening, through the lens arrangement 50, through the optical cable 48, to the receiver 46. The preferred signal is infrared, but other frequencies are contemplated. Further, the signals can be pulsed or coded to prevent stray signals such as sunlight or reflections from giving erroneous indications. The receiver 46 is in communication with the control circuit 14 so that when the receiver 46 is receiving the signal, it provides an indication to the control circuit that there is no obstruction to closing of the garage door 11. This is the normal operating condition. When an obstruction 24 interrupts the signal, the signal does not reach the receiver 46. The receiver then indicates to the control circuit 14 that an obstruction is present. The control circuit 14 can prevent closing of the door 11 by preventing or stopping operation of the motor 16. If the door 11 is closing when an obstruction is detected, the motor 16 can be reversed to open the door.
As shown in FIG. 2B, the transmitter 45 and receiver 46 can be located separately from the enclosure 13, but it is preferred that they remain in close proximity to the control circuit 14.
A typical lens and cable mounting configuration employing a bracket 53 mounted on the track 15 is shown in FIG. 3, but other configurations are contemplated. The lens could be mounted on or near the door frame or, as another example, FIG. 4 shows the lens 49 mounted on a retractable spring device 55 attached to the bottom of the door 11 so that when the door is closed the lens 49 and mount 55 are forced into the retracted position by the ground or garage floor. The configuration of FIG. 4 has the advantage that the light beam is always adjacent the leading edge of the door which is where obstacles will obstruct the door. However, the FIG. 4 configuration has the disadvantage that wear on the cable will increase and an unsecured loop can be created if the cable is not retracted when the door is open. Also, the mount may be knocked out of alignment or become stuck.
FIG. 5 shows one case where the door mounting of FIG. 4 is superior to the frame mounting of FIG. 3. The trunk 60 of a car extends into the path of the garage door 11, but because it is elevated, it does not obstruct the beam 61a near the ground. A door mounted lens, FIG. 4, would detect the trunk 60 immediately before the door 11 reached the trunk 60.
Alternatively, FIG. 6 shows how several beams 61a, 61b, and 61c can be directed across the door opening at different levels by installing several transmitter lenses 49a, 49b, and 49c and cables 47a, 47b, and 47c and several receiver lenses 50a, 50b, and 50c and cables 48a, 48b, and 48c. With multiple beams, obstacles which are not near the bottom of the door opening can be detected.
FIG. 7 shows another alternative detection system in which the system uses only a single cable 70 which is connected to a combined transmitter/receiver 44. The cable has, at its end, a lens arrangement 71 of the type known in the art which is mounted as described above. Opposite the lens arrangement a reflecting device 72 is mounted so that the transmitter part of the transmitter/receiver 44 sends a signal through the cable 70 and lens arrangement 71 across the door opening to the reflector 72 which reflects the signal back across the door opening through the lens arrangement 71 and cable 70 to the receiver part transmitter/receiver 44. The cable 70 can have multiple fiber optic elements or the signal can be multiplexed and transmitted and received through a single element. Similar configurations could include separate lenses, cables, reflectors and/or transmitter/receivers. Such a system is simpler and less costly because it has fewer components. Potential drawbacks include the need to clean the reflector periodically and possible inadvertent reflections, for example, from a reflective obstruction.
The present disclosure describes several embodiments of the invention, however, the invention is not limited to these embodiments. Other variations are contemplated to be within the spirit and scope of the invention and appended claims. | A light beam transmitter and receiver are located in or near a door opener enclosure, and fiber optics connect the transmitter and receiver to the sides of the door opening. Lens arrangements are attached to the ends of the optic cables and are mounted near the bottom of the door frame. Thus, the transmitter and receiver do not need to be located near the door which eliminates the need for wiring from the enclosure to the door area and protects the transmitter and detector from physical abuse at the doorway. |
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This is a division of application Ser. No. 550,944, filed Jul. 11, 1990, now abandoned.
This invention relates to a precast concrete panel, a support pedestal constructed therefrom and methods of construction suitable for constructing such a support pedestal, the pedestal being suitable for supporting an elevated liquid storage tank consisting of a welded steel liquid-containing tank portion supported atop the support pedestal.
BACKGROUND OF THE INVENTION
Historically, most elevated liquid storage tanks in the USA have been constructed entirely of mild carbon steel. During the past ten years, the concept of "composite" elevated tanks has been introduced within the USA. A composite elevated tank utilizes both steel and reinforced concrete. The storage tank (the liquid containing boundaries) are generally constructed of steel and the supporting structure is constructed of reinforced concrete. This method generally utilizes each construction material to its principal advantage; steel as a liquid-tight membrane in tension and reinforced concrete as a supporting structure in compression. This method has been limited to sitecast concrete construction using formwork assembled onsite. Slipformed and jumpformed techniques have been developed for sitecast construction. Details and methods of construction are disclosed in U.S. Pat. Nos. 4,403,460, 4,578,921, 4,312,167, 4,327,531, 4,486,989 and 4,660,336.
Sitecast concrete construction requires a continuous, uninterrupted supply of concrete once a pour has been committed and started. Any delays in delivery of concrete to the jobsite or placement into the forms may lead to coldjoints and/or voids or other defects within the pour. Severe weather (such as heavy rain and/or high winds) which render continued onsite activities impractical or unsafe can result in problems. Temperature extremes, either hot or cold, can have a deleterious effect on the structural and aesthetic qualities of the concrete. Mechanical breakdowns of pumping or placing equipment can cause delays in pouring the concrete into the formwork at higher elevations. Sitecast concrete construction also generally requires a site location that is accessible by concrete trucks from a local ready mix concrete plant.
Examples of precast concrete panels use in the construction of structures such as silos are found in U.S. Pat. Nos. 4,324,081 and 4,555,883. The precast concrete panels of these patents are designed to withstand hoop stresses resulting from containment of solids, semiliquids or liquids within the structures built from the panels. They are not designed to withstand substantial vertical loading as is required of a pedestal used to support a large containment structurs such as a large water tank. Consequently, the panels of these patents emphasize reinforcement in the hoop direction and interconnections at the vertical joints of the structure constructed from the panel designed for strength in the hoop direction without significant attention being paid to design features to withstand large continuous vertical loads coupled with side loads resulting from wind forces and other transverse loads which may be created by the forces of nature.
Reference is also here made to U.S. Pat. No. 3,483,704 which is concerned with a precast concrete panel designed for use as a tunnel liner. Here the design effort is directed at producing a panel which may be used to construct tunnelling capable of withstanding significant pressures, from the outside, which produce compressive hoop stresses. As with the panels designed for silo construction there is little need for significant strength parallel to the axis of structures built from the panels and no design emphasis is placed on strength in that direction.
PURPOSE OF THE INVENTION
It is an object of the present invention to provide a precast concrete panel suitable for use in the onsite construction of pedestals or towers for the support of structures such as large water tanks.
It is also an object of the present invention to provide such panels which are economical to produce and which facilitate rapid economic construction of the pedestals or towers concerned.
It is a further object of the present invention to provide a method of constructing pedestals or towers for the support of heavy structures, such as large water tanks, utilizing precast concrete panels of the present invention.
This invention eliminates many of the difficulties associated with sitecast concrete construction. The reinforced concrete panels can be precast prior to the start of onsite construction of the support pedestal. The casting can take place in a controlled environment less sensitive to weather and temperature extremes. The consequences associated with problems encountered during onsite casting into forms are likely to be more severe than precast panels. Larger quantities of concrete are usually involved and requires placement at elevations exceeding 100'. Defects within a pour may cause onsite activities to cease until the extent of the defect is determined and remedial procedures developed. The costs associated with remediation of defects in sitecast concrete can be significant, whereas the worst scenario for precast panels is the rejection of the individual panels.
This invention reduces the length of time required to construct a composite elevated tank. The panels can be cast during the period of time that other preparatory site work, such as grading, excavation and foundation forming and pouring is taking place. The assembling of the precast panels will take less time than onsite jumpformed construction where the forms must be detached and repositioned between each pour and each pour must be given adequate time for curing.
This invention reduces the cost required to construct composite elevated tanks. Because better control can be exercised during precasting than onsite casting, higher strength concrete may be used, thereby reducing the wall thickness and concrete quantities. The shortened construction schedule also reduces construction costs.
SUMMARY OF THE INVENTION
This invention utilizes individual concrete elements or panels which have been precast under controlled conditions in specially manufactured forms to construct, onsite, a pedestal to support, for example, a welded steel tank for the storage of liquids. The method and details of attaching the individual panels to one another so that the completed structure behaves as a shell structure to sustain all anticipated loads is of particular importance. The liquid containing tank, is, for example, a steel shell that is supported atop the concrete pedestal.
According to the invention there is provided a precast concrete panel for use in the onsite construction of pedestals to support structures atop thereof comprising a concrete panel of generally rectangular shape with a substantially constant thickness incorporating steel reinforcement and defining opposed horizontal edges and opposed vertical edges, each said vertical edge incorporating connection means adapted to facilitate connection of that vertical edge to the vertical edge of another similar panel, said connection means being cast into the panel in an overlapping relationship with the reinforcement means to provide structural integrity in the panel between the vertical edges and including metal means projecting from the associated vertical edge for cooperation with a similar means of said other similar panel for secure attachment thereto to provide structural integrity of the connection between panels along adjacent vertical edges thereof, and a bore extending normal to the horizontal edges, from one said horizontal edge to the other, substantially centrally disposed within the thickness of the panel to accommodate means for connecting panels together with their horizontal edges adjoining one another, means being provided for aligning adjacent horizontal edges of similar panels relative to one another with the bores therethrough in alignment.
According to the invention there is also provided a pedestal for the support of structures such as water storage tanks atop thereof a pedestal constructed of panels according to claim 1, said panels being disposed to define a hollow vertical shell defining a vertical axis about which the shell is symmetrically disposed, said pedestal being constructed from said panels connected together along their vertical edges to form horizontal rows of panels stacked one above the other with the horizontal edges of the panels located relative to one another by said alignment means with the bores in alignment throughout the vertical extent of the pedestal, vertical reinforcing means extending throughout the vertical extent of the bores to provide vertical integrity of the structure.
According to the invention there is also provided a method of constructing pedestals for the support of structures such as water storage tanks atop thereof a process of constructing a pedestal for the support of a structure atop thereof comprising providing a foundation with vertical panel alignment rods projecting therefrom, constructing a lowermost horizontal row of panels in the form of a closed geometric figure with vertical bores in engagement with the reinforcement rods projecting from the foundation, passing vertical reinforcement rod segments through said bores of said lowermost horizontal row of panels and connecting these to the rods projecting from the foundation, placing a second row of panels immediately above said lowermost row, said second row of panels being staggered relative to said lowermost row with the bores extending therethrough in alignment with the bores of lowermost row, passing reinforcement rod segments through the bores of said second row and interconnecting these with the rods of the lowermost row, continuing to add horizontal rows of panels to form a vertical pedestal with each row being staggered relative to adjacent rows until the complete pedestal is formed with the reinforcement rod segments forming a continuous reinforcement extending throughout the vertical height of the pedestal.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a partly sectioned elevation of a pedestal, according to the present invention, with a water tank supported atop thereof, the pedestal being constructed from precast concrete panels, also according to the present invention;
FIG. 2 is an elevation of a reinforced concrete panel, according to the present invention, suitable for use in the construction of the pedestal illustrated in FIG. 1, the exterior pedestal surface of the panel being shown;
FIG. 3 is a plan view of the panel illustrated in FIG. 2;
FIG. 4 is a fragmentary sectional plane on section line IV--IV of FIG. 2;
FIG. 5 is a fragmentary vertical section of portions of two panels according to FIG. 2 illustrating means for locating the panels relative to one another when a horizontal joint is formed therebetween;
FIG. 6 is a fragmentary horizontal section through a vertical joint between two panels according to FIG. 2, showing the interconnection of those panels;
FIG. 7 is a fragmentary elevation in the direction of arrow VII of FIG. 6;
FIG. 8 is a fragmentary view of a horizontal joint between two panels, according to claim 2, at the location of a threaded tension rod installation joining the panels together;
FIG. 9 is a fragmentary vertical section illustrating the joint between the lowermost panel in a pedestal according to the present invention and the pedestal's foundation taken at the location of a threaded tension rod joining that panel and the foundation together; and
FIG. 10 is a fragmentary vertical section of the joint between the uppermost panel in a pedestal according to the present invention and a water tank support ring taken at the location of a threaded tension rod joining that panel and the ring together.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts the general arrangement of a composite elevated tank. Details of the individual precast reinforced concrete panels and joints therebetween are depicted in FIGS. 2 through 10. Continuity through the joints between adjacent panels is provided in the circumferential direction by fabricated steel plates that are embedded in the vertical edges of the panels and are then welded together onsite after the adjacent panels have been erected in their final position. After erection and welding, the spaces in the vertical joints between the panels are filled with a grout in order to provide a weather tight structure. Continuity in the vertical direction as well as attachment of the concrete pedestal to the foundation and steel tank is provided by aligned threaded steel bars that run the full length of the concrete pedestal. The horizontal joint between panels is coated with a bonding adhesive immediately prior to joining adjacent panels together.
With reference first to FIG. 1, the major components for utilizing the inventive concept include a steel storage tank T supported by a reinforced concrete pedestal 1 constructed of numerous individual precast concrete panels 2. The tank and concrete pedestal are supported by a reinforced concrete foundation F. Typically, the concrete pedestal will include an opening TD for a truck access door and a smaller opening PD for a personnel access door. For clarity, details such as reinforcing steel and aesthetic treatments have been omitted in FIG. 1.
As can be seen in FIG. 1, successive rows of panels 2 are staggered relative to one another with each row of panels comprising eight panels disposed to form a horizontal circle, the pedestal 1 being cylindrical and defining a vertical axis symmetrically disposed under the tank T.
FIGS. 2 through 10 illustrate details of the individual precast concrete panels 2 and joints therebetween. As shown by FIG. 2, each panel is rectangular in elevation and is curved to the radius of the concrete pedestal. As required by the design parameters for each specific location, each panel includes reinforcing steel bars in the horizontal (circumferential) direction 3 and the vertical directions 4. As illustrated, reinforcing steel bars 3 and 4 are spaced 18 inches apart to form two rectilinear parallel grids of reinforcement spaced apart over the elevation of the panel. Additional reinforcement bars may be used adjacent the edges of the panel. Two vertically extending conduits 5 are embedded to allow placement of threaded bars 15 in the vertical direction. To facilitate the staggered arrangement of the panels and the alignment of the conduits 5 from row to row of panels, the conduits are spaced apart by one half of the panels width and are located at one quarter of the panels width from each vertical edge. Threaded lifting inserts 6 are provided to facilitate lifting and handling of the panels. Projecting keys 8 and recessed keyways 7 help align and secure the panels, in the desired staggered arrangement, during erection. The vertical edges of each panel include a fabricated connection system consisting of projecting plates 9 aligned one with each bar 3, vertical plates 10 and anchorage bars 11.
The projecting plates 9 are welded to the vertically extending plate 10 at each edge of the panel while this plate 10 is supported in place by a plurality of anchorage bars 11 of weldable rebar, to which plate 10 is welded, extending into the panel and overlapping adjacent horizontal bars 3, thereby to retain the circumferential integrity of the reinforcing structure. The exterior finish of the pedestal is fragmentarily illustrated in the center of the elevation of FIG. 2. This exterior finish plays no part in the constructional integrity of the panels. Each panel's curvature subtends an angle of 45° degrees so that eight of the panels will complete one complete circumferential row of the pedestal.
An important feature is continuity in the circumferential direction. Each precast panel must be attached to adjacent panels of the adjacent row such that the completed structure behaves as a shell and is capable of sustaining all anticipated loads. Continuity in the circumferential direction is provided by the embedded connection system 9, 10 and 11. These are fabricated together as assemblies and placed in the forms, together with bars 3 and 4, conduits 5 and threaded inserts 6, prior to pouring concrete. As each precast panel is placed in its final position in the pedestal, the embedded connectors 9, 10 and 11 assist in properly locating the panel. Once properly aligned, the projecting plates 9 between adjacent panels overlap and are welded together, thereby providing continuity with the circumferential reinforcement through the vertical joints between panels. FIGS. 6 and 7 illustrate this joint in detail. After completion of the welding and subsequent inspection, a temporary form 12 is placed over the vertical joint on the inside of the pedestal. Grout 13 is then placed in the void between the panels. A foam backer rod 14 prevents the grout from escaping to the outside of the pedestal.
Continuity in the vertical direction is provided by aligned vertical threaded bars 15. FIG. 8 shows typical details at a horizontal joint between panels. A threaded coupler 16 is provided along with a washer plate/centering device 17 at each splice location. The threaded bars are installed in the conduit tubes 5 onsite as the panels are erected. After erection, the tubes are filled with grout 18. The bars 15 act together to provide continuous vertical reinforcement extending from the foundation F to the water tank base plate BP, see FIG. 10.
The bottom row of precast panels is anchored to the foundation by means of the vertical threaded bars 15. As shown by FIG. 9, the bars are attached to threaded bars 19 embedded in the foundation by the use of a threaded coupler 16. The bottom row of panels is levelled with shims which are later removed and the space filled with non-shrink grout 20.
FIG. 10 illustrates the attachment of the steel tank T to the top of the concrete pedestal. The vertical threaded bars 15 project beyond the top of the uppermost panels and through an opening in the base plate BP of the tank skirt plate TS. A reinforced opening RO provides access through the skirt. Nuts 21 secure the base plate BP to the panels. After levelling the base plate, the void is filled with non-shrink grout 22.
It will be appreciated that there are many variations that may be made to this designer panel without departing from the inventive advance provided by the present invention. However, it is important to retain the continuity of the vertical threaded bar reinforcement in order that the bars, in effect, extend throughout the entire height of the pedestal in one continuous interconnected line. Of course, the segmented bars could be replaced by a single threaded bar (although this may not prove very practical) and the threaded bars themselves could be bars threaded only at their ends as appropriate to provide the necessary interconnection with adjoining bars. Also the threaded bars could, without departing in the inventive advance, be replaced by bars that are welded together during assembly to produce the longitudinally extending reinforcement of a substantially continuous nature (any desired prestress being applied by well known means). Such arrangements will be apparent to those skilled in the art and are not discussed in detail here. Similarly, the vertical joint construction might be varied providing that the circumferential integrity of the pedestal is assured by the manner of interconnecting the panels. However, the construction defined with respect to the vertical joints is economical, reliable and effective thereby providing the best mode of operation of the invention currently known. Similarly the segmented rod vertical reinforcement is the best mode of operation presently known with respect to vertical integrity of the structure provided by this invention.
The associated inventive process for constructing a pedestal in accordance with the present invention involves manufacture of a plurality of the panels described above and their erection to form the desired plurality of staggered circumferential rows of panels (FIG. 1). Initially the base row of panels is supported on the foundation F which carries vertically extending cast in reinforcement threaded rods 19. The base row of panels is shimmed to align them horizontally and threaded rods 15 are inserted through conduits 5 of these base panels and connected to the reinforcement threaded rods 19 by means of threaded couplers 16. At an appropriate point during construction, the shims are removed and a non-shrinkable grout 20 is placed under the lower panels to support them in their horizontally aligned positions. Similarly at an appropriate point in construction the conduits 5 are filled with grout 18 to lock the threaded bars 15 into position. This grout also serves to close the opening which provides access to the threaded couplings 16 during construction.
Subsequent circumferential rows of panels are assembled on top of the base row with their keys and keyways 7 and 8 interacting to align these panels and their conduits 5. Further threaded bars 15 are inserted through the conduits 5 for connection to the threaded bars below by means of couplings 16. In each case, at an appropriate time, the conduits and openings providing access to the couplings 16 are filled with grout.
The top row of panels has the base plate BP of the skirt plate TS placed thereon over extending portions of the upper threaded rods 15. Nuts 21 are used on these threaded rods to anchor the base plate to the pedestal. At appropriate times during construction, any required preload of the threaded reinforcement rods may be provided. Also at an appropriate time, non-shrinkable grout 22 is applied under the base plate to level that plate with respect to the pedestal.
During construction the vertical joints are formed by welding the overlapping plates 9 together and subsequently filling the gaps between the panels with grout as facilitated by the use of the temporary forms 12. Escape of the grout of the outside of the pedestal is prevented by the foam backer rod caulking 14. Horizontal joints are bonded together by an adhesive during construction.
It will be appreciated that while the present invention has been described with respect to the construction of a vertical cylindrical pedestal for support of a water tank, the panel construction is equally applicable to pedestals of other cross-sections, for example, hexagons, octagons, etc. In these alternative designs, the panels would be flat. Additionally, it will be appreciated that although the basic design premise of the present application is directed to the support of vertical loads stemming from water tanks or other structures placed atop the pedestal, the structure is capable of withstanding hoop loads which with appropriate design parameters render the pedestal suitable for the storage of the materials for example, solid materials, semi-liquid materials or liquid materials. This latter use of the construction is, however, secondary to its main purpose to provide a pedestal to withstand substantial continuous vertical loads applied from above. | A composite elevated storage tank is constructed utilizing precast concrete panels for a pedestal which supports a steel storage tank. The precast concrete panels are poured in a controlled environment not subject to the difficulties inherent with sitecast concrete construction. A simple and practical method of attaching the panels to each other as well as to the foundation and steel tank ensures the concrete pedestal behaves as a shell to sustain all loads. This method, which uses cast in plates welded together at vertical joints and vertical aligned threaded rods for horizontal joints, serves to reduce the length of time required to construct a composite elevated tank and also reduces the construction costs. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to systems designed to use treated timber for landscape purposes, and more specifically to systems utilizing modular timber units with interconnecting end portions secured with braces and angled spikes and periodic deadman joints to provide overall support.
2. Description of the Prior Art
While the use of treated timber for landscape purposes such as retaining walls or boxed gardens has been known for a considerable period of time, the most common and popular method for installing such timber has remained relatively unchanged and unimproved. Generally, this method requires the timber to be cut at a specific length and many times at angles of less than 90 degrees. Because these cuts are made at the landscape site, they are usually made with a chain saw, a tool which is both dangerous and difficult to operate for the novice. Next, the timber is drilled so that large spikes, lag bolts or other type fasteners can be driven through one piece and into the next piece immediately below for stability. The ultimate problem with this cumbersome process is that it provides for relatively weak and unstable joints, and over a period of time, pressure exerted on these joints will simply cause them to pull apart.
Retaining wall and planter construction systems using modular components are disclosed in U.S. Pat. Nos. 3,343,301 and 4,869,018. While the devices disclosed in these patents utilize a shoulder and socket system to connect the modular units, both rely upon the earth to rigidly secure such joints along with the relative positioning of each unit. Vertically aligned pins used to connect these joints do not, in and of themselves, prevent rotational movement by the units.
A landscaping system utilizing modular timber units is manufactured by Thompson Industries, Inc. Essentially, these units or timbers interconnect with each other through the use of rabbet-type joints with each unit having a male and female end. Once the units are an interlocking position, a wooden dowel may be passed through holes contained in the ends of the adjoining timbers and thus provide some stability to the interlocking joint. However, as with the systems disclosed in the '301 and '018 patents, this dowel does not prevent rotational movement between the interconnected members. Thus, some other stabilizing element is required, such as the earth that is being retained.
SUMMARY OF THE INVENTION
The present invention is a modular unit landscaping system with each unit having a ball joint and socket joint to provide a method to connect adjacent units. The system also utilizes angled spikes and braces to rigidly secure the positioning of such units, and deadman joints to stabilize the generally vertical orientation of a number of units contained in a plurality of vertically aligned layers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective side view of a modular first member that forms a part of the present invention and has a ball joint and a socket joint.
FIG. 2 is a perspective view of the ends of two linearly connected adjacent first members and their adjoining ball and socket joints.
FIG. 3 is a perspective view of two non-linearly connected adjacent first members.
FIG. 4a is a top view of a brace that forms a part of the present invention and has a pair of recessed holes.
FIG. 4b is a cross-sectional view taken along the line 4b--4b of FIG. 4a.
FIG. 5 is a cross-sectional side view of two pairs of vertically aligned adjoining members with braces and spikes positioned therein.
FIG. 6 is a perspective view of a sample retaining wall utilizing the modular landscape timber system of the present invention having a plurality of vertically aligned layers.
FIG. 7 is a top view of one vertically aligned layer of a number of first members retaining a portion of earth including a deadman joint having a deadman member and a modular second member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, the modular unit landscaping system of the present invention is comprised generally of a plurality of a number of individual components. Such components are an elongated interconnectable modular member 10, a securing brace 11 and a spike 12.
Referring to FIG. 1, the modular member 10 is shown having a ball joint 13 at one end 14, a socket joint 15 at an opposite end 16 and a body portion 17 therebetween. Said modular member 10 is preferably formed from dimensional pretreated lumber; however, other materials such as plastic or rubber may also be used. The cross-sectional dimension of the modular member 10 can be varied as desired to meet the needs of a specific project constructed using the system.
The overall length of the modular member 10 may also be varied and members 10 of differing lengths may be utilized in a single project. Such variance provides a user of the system a significant amount of flexibility. In the preferred embodiment, said members 10 are manufactured to serve as two, four and eight foot modular lengths and to do so each such length has to be one-half inch longer than its desired dimension for the purpose described below.
The ball joint 13 is generally formed by a circular cut at the end 14 which creates notches 20. The socket joint 15 is formed by a concave circular cut at the opposite end 16. End stops 21 are formed at the outer corners of the opposite end 16. The radial arc of the socket joint 15 is generally equal to that of the ball joint 13 so that, as shown in FIGS. 2 and 3, the ball joint 13 of one member 10 precisely fits within the socket joint 15 of an adjacent member 10 to form a joint 23 and as a result of such fit between the ball and socket joints 13 and 15 the extra one-half inch of length of each members 10 is used up in the joint 15 to provide an overall length of two joined members 10 together as being four, eight or sixteen feet. With the ball joint 13 properly placed within the socket joint 15, the joint 23 may be of any desired angle up to 185° in either direction with the end stops 21 designed to prevent further rotational movement by blocking the notches 20.
In order to rigidly secure the joint 23, a first through bore 30 is pre-drilled proximately in the middle of the one end 14 and a second through bore 31 is pre-drilled proximately in the middle of the opposite end 16, as shown in FIG. 5. The first and second through bores 30 and 31 extend from top to bottom of said member 10 on an incline 32 directed away from their respective ends 14 and 16.
The securing brace 11, shown in FIGS. 4a and 4b, is utilized along with two of the spikes 12 and the through bores 30 and 31 to secure the joint 23. The brace 11 has a pair of oppositely situated holes 33, each set in preferably a concentric recessed dimple 34. The holes 33 are spaced apart in direct relation to the distance between the first and second bores 30 and 31 of the two adjacent ends 14 and 16 forming the joint 23. It should be noted that the distance between said first and second bores 30 and 31 will remain the same regardless of the positioning of the adjacent members 10 that form the joint 23. Thus, when said brace 11 is properly placed the joint 23, the first and second bores 30 and 31 are exposed through said holes 33.
The first and second bores 30 and 31 have a recessed upper opening portion 35. The diameter of each of said recessed portions 35 is slightly larger than the diameter of each of said bores 30 and 31. The recessed portions 35 are also sized to receive the recessed dimples 34 of the brace 11 when the brace 11 is placed on said joint 23, as best depicted in FIG. 5.
With two adjacent members 10 positioned as desired, the brace 11 is then placed on the joint 23. Next, two spikes 12 are driven through the holes 33 and each of said bores 30 and 31 into a solid portion 40 of the members 10 located in a layer 41 of members 10 lying directly beneath said joint 23. With the recessed dimples 34 positioned in the recessed portions 35, as shown in FIG. 5, seats are formed to spike heads 43 when the spikes 12 are completely driven into their associated members 10.
The incline 32 of each bore 30 and 31 allows their associated spikes 12 to provide both horizontal and vertical stability to each joint 23. In contrast, a vertically aligned spike 12 would essentially act as an axis and, allow some rotational movement between adjoining members 10, thereby leading to weak joints 23. The inclined arrangement of the spikes 12 eliminates this problem by avoiding an axial arrangement of such spikes so that rotational movement between adjoining members 10 can only occur upon bending of the spikes 12. It should be noted that the angle of the incline 32 must be sufficient enough to allow the spike 12 to avoid the brace 11 located in the layer 41 directly beneath the joint 23 as shown in FIG. 5.
In the preferred embodiment, the braces 11 are manufactured from either 12-14 gauge or 14-16 gauge cold roll galvanized steel and the spikes utilized are either one-quarter inch or three-eighths inch shank galvanized steel, depending upon the size of the modular members 10 used. However, it is stressed that different materials with differing dimensions may be used.
In many instances, large retaining walls such as that shown in FIG. 6 are constructed using the present invention. When such walls are constructed, it is necessary to provide support to such walls so that they can retain the earth located directly behind. Furthermore, such support is required so that such walls can maintain a generally vertical orientation.
A deadman joint 50 is depicted in FIG. 7 and is comprised of a deadman member 51, a second elongated modular member 52, a deadman brace 53, and spikes 12. The deadman joint 50 is generally used to provide support when constructing a multi-layer retaining wall. The deadman joint 50 provides such support by tying the wall to the earth being retained.
The deadman member 51 has a deadman ball joint 54 at an outer end 55 and a body 56 that is buried in the earth being retained. The deadman ball joint 54 is constructed similarly to and will generally have the same dimensions as those ball joints 13 of members 10 utilized in a particular project. Furthermore, similar to the ball joints 13, said deadman ball joint 54 has a deadman through bore 57 that is preferably inclined.
The second member 52 has generally concave socket joints 60 at its ends 61. The second member 52 also has through bores 62 in the middle of each of its ends 61 situated similarly to said through bores 31 of the members 10.
The deadman joint 50 is generally tied to a layer 66 of members 10 in which it is contained by positioning such joint 50 between two of the modular members 10 contained in the layer 66, which members will be hereafter referred to as 10' and 10" for purposes of clarity. The second member 52 is part of the layer 66 and has one of its socket joints 60 receiving the ball joint 13 of the modular member 10'. The deadman ball joint 54 is then positioned between the other socket joint 60 of the second member 52 and the socket joint 15 of the modular member 10" so that said deadman member 51 is generally situated perpendicular to said layer 66 and extends into the earth being retained. The longitudinal dimension of the second member 52 together with the ball joint 54 preferably form a two-part member having an overall longitudinal dimension generally similar to the longitudinal dimension of one of the first members 10.
One of the socket joints 60 of the second member 52 is adjoined to the ball joint 13 of the member 10' and is secured to said ball joint 13 in the manner previously described above. The deadman ball joint 54 may be secured to the other of the socket joints 60 of the second member 52 and the socket joint 15 of the member 10" in a number of different manners. In the preferred embodiment, the deadman brace 53 is formed from two braces 11 utilized in a manner so that one of the holes 33 from each brace 11 overlap to form a middle recessed hole 63. The other holes 33 of each brace are outer recessed holes 64 of the deadman brace 53.
Once the deadman joint 50 is in a desired position, the deadman brace 53 is placed thereon so that the middle hole 63 is positioned to expose the deadman through bore 57, one of the outer holes 64 is positioned to expose the second through bore 31 of the member 10", and the other outer hole 64 is positioned to expose adjacent the bores 62 of the second member 52. With the deadman brace 53 in such position, three spikes 12 can then be driven through the respective holes 63 and 64 and the respective bores 31, 57 and 62 and into portions of members 10 located in the modular layer directly beneath said deadman joint 50
Another method to secure the deadman joint 50 would not require the use of the brace 53 or spikes 12. Essentially, the static relationship between the deadman ball joint 54 and the adjacent socket joint 15 and 60 would provide a sufficient amount of force to maintain the positioning of the deadman joint 50. It should be obvious to one skilled in the art, however, that there are other methods to secure the deadman joint 50 than those disclosed.
Thus, the present invention provides an efficient and effective modular unit landscaping system for constructing such items as retaining walls and box gardens. Although a specific embodiment has been disclosed herein, it should be well understood by those skilled in the art that numerous modifications can be made to the numerous components of the system without departing from the true spirit and scope of the present invention. | A modular landscape timber system used generally to construct retaining walls and boxed gardens having a plurality of vertically aligned layers of modular first members having ends with ball and socket joint portions that interfit with one another, a plurality of braces, and a plurality of spikes that are driven through the braces on an incline to fasten the ends of the timber members together with a resulting joint that resists rotational movement. The system further includes a deadman joint that serves to maintain the vertical alignment of the layers of first members. |
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PRIORITY
This application claims priority of U.S. provisional applications 61/710,234 filed on Oct. 5, 2012 and 61/788,847 filed Mar. 15, 2013, both of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The invention relates to building materials, in particular to attachment of insulating board and trims on building surfaces.
BACKGROUND OF THE INVENTION
The present invention relates to building materials in particular to attachment of insulating board and trims on building surfaces.
The selection of building siding materials today is vast. The siding may be wood, vinyl, fiber cement, fiber glass or other materials. Essential today is to have insulation underneath the siding to save in energy costs and to protect the building structures from weather elements. Customarily the insulation layer is attached to the building first and the siding is attached on top of the insulation layer.
Once the siding elements are attached on top of the insulation boards, the siding still needs to be trimmed. The trims are usually narrower boards and they are used to finalize the look. It is important that the insulation extends under the trim boards also. Lack of insulation, especially around windows allows hot and cold air to leak and may cause high energy costs.
The usual practice today is that after the insulation boards have been attached to the building sides, the siding boards are attached to the insulation boards and after this smaller board of insulation are attached around the windows, close to the roof, or at the house corners and the look is finalized by attaching trim boards. This is usually done by nailing the trim boards on their place. The trim boards are needed even if no insulation boards are used.
There is a need for an easy and economic way to attach the trim boards, and this application provides such easy and economic way. Furthermore, there is a need for attaching trim boards without leaving the nail heads visible on the board. Thus there is a need for an easy, fast, cost effective, and esthetic way to attach the trim boards.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an easy, economic and an esthetic way to attach trim boards on the building.
It is another object of this invention to provide means to attach trim boards on the building without making through holes on the trim boards.
It is another object of this invention to provide a ready to use combination of trim board and insulation layer to be attached on the building side.
A further object of this invention is to provide clips for attaching trims on buildings without making through holes on the trims.
Another object is to provide an adjustable clip for attaching trim boards on building.
It is an object of this invention to provide an adjustable trim clip for attaching a siding trim on a wall structure, said clip comprising; a first part having a vertical side with a first end and a second end, said first end being attached to a flat bottom and said second end being attached to a horizontal prong extending to same direction as the flat bottom; a second part having a vertical side with a first end and a second end, said first end being attached to a flat bottom and said second end being attached to a horizontal prong extending to same or different direction as the flat bottom; and wherein the flat bottom of the second part slides on top or under the flat bottom of the first part, thereby forming a clip that has an adjustable width.
It is another object of this invention to provide a method to attach a siding trim on a wall, said method comprising the steps of: a) providing at least one trim clip having two vertical sides connected together with a substantially flat bottom having a width substantially similar to the width of the siding trim, b) attaching the trim clip on the wall structure; c) inserting the siding trim into the clip between the vertical sides; and d) providing a pressure by the vertical sides to the trim such that the trim stays securely between the sides.
It is yet another embodiment of this invention to provide a trim clip for attaching a siding trim on a wall structure, said clip comprising; two vertical sides connected together with a substantially flat bottom having a width substantially similar to the width of the siding trim, wherein the bottom has attachment holes or a female/male attachment assembly, and wherein the trim clip is attached to the wall structure with fasteners through the attachment holes or with female/male attachment means, and wherein the siding trim is inserted into the clip between the side walls and hold in place by a pressure provided by the side walls.
A further object of this invention is to provide a method to attach a siding trim on a wall, said method comprising the steps of providing a set of mounting clips having a wall mounting clip and a trim mounting clip, said clips forming a male/female attachment device; attaching said wall mounting clip on the wall and said trim mounting clip on the trim; and attaching the siding trim to the wall by allowing the wall mounting clip and the trim mounting clip form a male/female attachment.
It another object of this invention to provide building trim kit, comprising a siding trim having a front side and a back side, said back side having one or more trim mounting clips attached; one or more wall mounting clips to be attached to a wall, and said trim mounting clips and wall mounting clips forming a male/female attachment device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a horizontal cross section showing a wall and a trim and the mounting clips.
FIG. 1B is a horizontal cross section showing the trim attached to the wall with the mounting clips.
FIG. 2 is a horizontal cross section showing a wall, a trim that is attached to an insulation board and the mounting clips.
FIG. 3 is a horizontal cross section of a house corner, showing the walls, the trims and the mounting clips.
FIG. 4 is a horizontal cross section showing a trim attached to the wall with the mounting clips. The mounting clips form a male/female attachment device.
FIG. 5 is a horizontal cross section showing a wall, a trim attached to an insulation board attached to the wall with the male/female mounting clips.
FIG. 6 is a front view of a trim board and markings on the trim board to show where the mounting clips locate.
FIG. 7A shows an end view of a trim attached on a wall or insulation with a trim clip having rubber lining.
FIG. 7B shows a top view of a trim clip with attachment holes.
FIG. 7C shows a side view of a trim clip with a squeezing lever.
FIG. 8A shows a trim clip for attachment of a trim-insulation combination, where the trim is attached on the insulation with male-female attachments.
FIG. 8B shows a trim clip attached to insulation with male female attachment and a trim attached to the trim clip.
FIG. 9A shows an end view of an embodiment where the trim has attachment grooves and the trim clip have protrusions fitting into the grooves.
FIG. 9B shows the trim attached to the clip and the clip attached to insulation.
FIG. 9C shows the trim attached to insulation and the trim-insulation combination attached to the clip with the clip protrusions fitting into the trim grooves.
FIG. 10A and B show an embodiment where the clip of FIGS. 9A-C is formed of two parts.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiments of the present invention will now be described with reference to FIGS. 1-10 of the drawings. Identical elements in the various figures are identified with the same reference numerals.
FIG. 1A is a horizontal cross section showing a wall and a trim and the mounting clips. The figure shows a wall 10 , a trim board 20 , wall mount clips 30 and trim mount clips 31 .
FIG. 1B is a horizontal cross section showing the trim attached to the wall with the mounting clips. The figure shows a wall 10 , a trim board 20 , wall mount clips 30 and trim mount clips 31 .
FIG. 2 is a horizontal cross section showing a wall, a trim that is attached to an insulation board and the mounting clips. The figure shows a wall 10 , a trim 20 , an insulation board 40 , wall mount clips 30 and trim mount clips 31 . The insulation board 40 may be glued on the trim 20 .
FIG. 3 is a horizontal cross section of a house corner, showing the walls, the trims and the mounting clips. The figure shows the walls 10 , the trims 20 , the wall mount clips 30 and the trim mount clips 31 .
FIG. 4 is a horizontal cross section showing a trim attached to the wall with the male/female mounting clips. The figure shows the wall 10 , the trim 20 , the wall mount clip 30 and the trim mount clip 31 .
FIG. 5 is a horizontal cross section showing a wall, a trim attached to an insulation board attached to the wall with the mounting clips. The figure shows a wall 10 , a trim 20 , an insulation board 40 , a wall mount clip 30 and a trim mount clip 31 .
FIG. 6 is a front view of a trim board 20 showing markings 22 indicating where the mounting clips locate.
FIG. 7A is an end view of another trim clip embodiment. The figure shows a substantially U-formed clip 50 , having two vertical sides 52 and a horizontal bottom 54 . The vertical sides have an inner rubber lining 60 . The figure shows the trim 20 inserted into the clip. The clip 50 is attached to the wall 10 from its bottom 54 .
FIG. 7B shows a top view of the clip 50 of FIG. 7A . The figure shows the vertical sides 52 , the rubber lining 60 , the bottom part 54 and attachment holes 56 in the bottom 54 .
FIG. 7C shows another embodiment of the clip 50 . The figure shows the vertical sides 52 , the horizontal bottom 54 and a squeezing lever 58 . The clip is attached to a wall 10 .
FIG. 8A shows another embodiment of the clip 50 . The figure shows the vertical sides 52 , the bottom 54 , a trim 20 , an insulation board 40 and mounting clips 30 and 31 . The trim 20 is attached to the insulation board with the mounting clips and the trim/insulation combination is inserted into the clip which is attached to the wall 10 .
FIG. 8B shows another embodiment of the clip 50 . The figure shows a trim 20 inserted into the clip. The clip has vertical sides 52 and a bottom 54 . The figure shows an insulation board 40 attached to a wall 10 and the clip attached to the insulation board with wall mounting clip 30 and trim mounting clip 31 .
FIG. 9 shows yet another embodiment of the clip 50 . FIG. 9A-C show the trim 20 with grooves 22 on both of its vertical sides 24 . The figures show the clip 50 with vertical sides 52 , bottom 54 and horizontal prong 59 . Attachments 70 are also shown
FIG. 9B shows the trim 20 inserted into the clip 50 , the prongs 59 snugly fitting in the grooves 22 . The figures shows the clip attached to insulation board 40 with attachments 70 .
FIG. 9C shows the trim 20 attached to the insulation board 40 and the trim/insulation board combination inserted into the clip 50 . The clip is attached to the wall 10 with the attachments 70 .
FIG. 10A and B show another embodiment of the trim clip. The clip now consists of two parts. The first part has a bottom 54 , a vertical side 52 and a horizontal prong 59 . The second part has a bottom 84 , a vertical side 82 and a horizontal prong 89 . The bottom portion 84 of the second part slides on top of the bottom portion of the first part 54 whereby the width of the clip is adjustable.
In FIG. 10A the horizontal prong 89 of the second part extends to opposite direction than the bottom part 84 . In FIG. 10B the prong 89 and the bottom part 84 extend to same direction.
In FIG. 10A the trim 20 is inserted into the clip and the clip is attached to an insulation foam 40 . In FIG. 10B the trim 20 is attached to foam 40 and the trim/foam combination is attached to a wall 10 .
Referring now to FIGS. 1A and B, one preferred embodiment of this invention provides a pair of mounting clips to attach a trim board to a building wall. The pair of clips consists of a wall mounting clip 30 and a trim mounting clip 31 . The wall mounting clip 30 is attached to the wall 10 and the trim mounting clip 31 is attached to the trim 20 . As is shown in FIG. 1B the wall mounting clip 30 forms a female partner and the trim mounting clip 31 forms a male partner. However, one skilled in the art would understand that the invention embraces also an embodiment where the wall mounting clip 30 is a male partner and the trim mounting clip 31 is a female partner. According to this embodiment, by pressing the trim mounting clip 31 toward the wall mounting clip 30 , the male/female design locks the clips together and holds the trim on the wall 10 . It is understood by one skilled in the art, that the way how the female and male partners attach to each other is not a limiting element of this invention, but that any method resulting locking of the female and male partners together is within the scope of this invention. Accordingly, the clips may for example be hooks or hooks and loops that lock together.
Referring now to FIG. 2 , another embodiment of the invention is shown. According to this invention, an insulation board 40 is glued on back of the trim 20 . The trim mounting clips 31 are attached to the insulation board, and the wall mounting clips 30 are attached to the wall 10 . Again by pressing the trim mounting clip 31 toward the wall mounting clip 30 , the male/female design of the clips locks them together and holds the foam and the trim on the wall.
Referring now to FIG. 3 it is shown how the trim is easily attached to a corner of the house. In the shown embodiment the trim 20 on the corner is formed by two separate trims, but it is also possible to provide one trim that has a right angle, so that it fits to the corner. The mounting clips are attached close to the corner and further away from the corner.
FIG. 4 shows one embodiment of the male/female attachment device of the trim mounting clip/wall mounting clip pair. As is shown in the figure the trim mounting clip 31 snugly fits in the wall mounting clip 30 . One skilled in the art would understand, that such male/female pairing can be achieved by various designs. Only illustrative design is shown here. According to a preferred embodiment the dimensions of the mounting clips is such that when the wall clip 30 is attached to the wall 10 and the trim clip 31 to the trim 20 or insulation foam 40 , and the trim wall clip 30 is attached to the wall trim clip 31 , the distance between the wall and the inner side of the trim or the insulation board is less than ¾″, more preferably less than ½″ and most preferably not more than ¼″.
According to one preferred embodiment, the female and male partners are attached to the trim board, insulation board, or the siding board by screwing mechanism. According to another preferred embodiment the female and male partners are attached by pushing. According to yet another embodiment the attachment system may include tubular elements that are attached to the trim board, insulation board, or the siding board and the female and male partners are attached to these tubular elements.
Referring now to FIG. 5 , an embodiment is shown where an insulation board 40 is glued on the inner side of the trim 20 and the trim/insulation combination is attached on wall 10 with male/female mounting clips 30 , 31 .
Referring now to FIGS. 6 , according to one preferred embodiment the location of the mounting clips may be indicated on the top surface of the trim 20 . This would help attaching the trim to the wall with the clips that remain invisible on the back side of the trim. According to a preferred embodiment the attachment with the male/female attachment device is meant to be a permanent attachment. However additional nails or other means for attachment may also be applied.
FIG. 7A shows an end view of a trim or a trim with insulation attached with the trim clip. The figure shows the trim clip 50 having a bottom 54 and two vertical sides 52 . In other words, the clip is substantially U-formed. The inner surfaces of the clip sides are covered with rubber pads 60 or similar material. The trim 20 or the trim with insulation foam is inserted in between the two vertical clip sides. The width of the trim clip (i.e. distance between the rubber pads) is such that the trim snugly fits there and the rubber pads keep the trim secured in place. When insulation is attached to the trim (shown in FIG. 8A ) the clip is attached directly to the wall 10 . When the trim does not include insulation, then the clip is installed on the insulation of the wall structure. In this case the clip may have female/male attachment assembly to attach it to the insulation board ( FIG. 8B ).
FIG. 7B shows a top view of a trim clip of this invention. The clip 50 has two vertical sides 52 and a bottom side 54 . The inner surfaces of the clip sides are covered with rubber pads 60 and the trim bottom has one or more attachment holes 56 for penetrating a nail or screw to attach the clip on the wall. The trim or the trim with insulation is then inserted in the clip between the rubber pads which securely hold the trim in its place.
FIG. 7C shows another embodiment of the invention. Here the trim clip 50 has two vertical sides 52 an a bottom 54 . A squeezing lever 58 is attached to one or both of the vertical sides 52 of the clip. The trim 20 or the trim with insulation foam is inserted in the clip between the two vertical clip sides. When the lever is pushed down the trim side will bend inward and squeezes the trim inside the clip. The lever 58 may then be attached to the wall by nailing or gluing whereby the squeezing pressure of the clip is maintained and the trim or trim with insulation remains securely in place.
According to one embodiment of this invention the clip is substantially of the same length as the trim to be attached. According to another embodiment the length of the clip may vary between about an inch to the full length of the trim. When the trim is substantially shorter than the length to the trim multiple clips may be used to attach the trim.
FIG. 8A shows a trim clip with a trim 20 that is attached to insulation foam 40 . The attachment may be done by wall clip/trim clip assembly 30 / 31 , but other methods may also be used, such as gluing. The insulation foam has either a male attachment or a female attachment and the trim has the counterpart. Pushing the counterpart attachment together will lock them together and the trim 20 will hold on the insulation foam 40 . The clip is attached directly to the wall and the rim with insulation attached to it is inserted into the trim clip.
FIG. 8B shows a trim clip without insulation. In this case the insulation board 40 is attached to the wall 10 and the insulation board has wall clip/trim clip assembly 30 / 31 . The trim clip bottom 54 has the counterpart. Now pushing the counterpart attachment together will lock the parts and the clip will hold on the insulation board. The trim is then inserted into the trim clip.
FIG. 9A shows another embodiment of this invention. The vertical sides 52 of the clip 50 have short horizontal prong 59 at their upper end. The trim 20 in this case has been modified so that it has horizontal grooves 22 in its vertical sides 24 . The prongs 59 snugly fit into the grooves 22 , thereby locking the trim into its place. The clip is attached to the wall or to an insulation board with attachments 70 . The attachments may be screws or nails but they may as well be the male/female mounting clips described above.
FIG. 9B shows the clip attached to an insulation board 40 . The trim is in its place secured by the prongs 59 which are fitted into the grooves 22 .
FIG. 9C shows an embodiment where the trim is attached to an insulation 40 and the insulation/trim combination is inserted into the trim clip. The clip is attached to a wall 10 with attachments 70 . The attachment may be screws or nails but they may also be male/female mounting clips as described above. The trim may be glued onto the foam, but it may also be attached to the foam with male/female mounting clips as described above.
FIG. 10 shows still another embodiment. In this case the clip 50 is made of two parts. The first part has a long bottom part 54 , a vertical side 52 and a short horizontal prong 59 . The second part has a short bottom part 89 , a vertical side 82 and a horizontal prong 89 . The second part slides on top or under the first part so that the width of the clip is adjustable to trims with different widths. In one embodiment shown in FIG. 10A the prong 89 of the second part points to opposite direction than the bottom part 84 and in another embodiment shown in FIG. 10B the bottom part 84 and the prong 89 point to same direction.
In the embodiment shown in FIG. 10 the clip is attached to a insulation board or directly to a wall with attachments that may be nails, screws or male/female assembly shown above in this application. The clip may have several holes in the bottom parts 84 and 54 through which the attachments are attached, or the bottom parts may have elongated slots that coincide for attachments.
According to one preferred embodiment the vertical side 52 / 82 may be 1/16″ to 1″, more preferably the prong is 2/16″ to ½″ and most preferably the prong is about 5/16″. One skilled in the art would understand that the vertical side can be of any length provided that it equals to the thickness of the trim (or trim plus insulation) or is shorter than the thickness. If the length is same as the thickness then the trim does not have the grooves but the horizontal prongs would in that case be on the trim surface.
According to one preferred embodiment the short bottom part 84 is between 1″ and 3″and most preferably about 1.5″. The long bottom part 54 is preferably 5-10″ and most preferably about 7″. However, one skilled in the art would understand that the length of the bottom parts can be adjusted to be anything and the most preferable measures are such that combination of the short and long bottom part would allow attachment of trims of any available widths.
According to one preferred embodiment the length of the horizontal prong 59 / 89 of the clip and the depth of the groove 22 in the trim is between ⅛″ and 1″, more preferably between ¼″ and ½″ and most preferably about ⅜″. Again the skilled artisan would understand that the length of the prong and the depth of the groove can be any reasonable measure as long as the prong fits into the groove and holds the trim in its position.
One skilled in the art would understand that the slidable two part clip shown in FIGS. 10A and B may also be used in connection with other embodiments of this invention, such as the clip having rubber liners as shown in FIG. 7 . Also it is possible to use the male/female attachments in connection with the slidable two part embodiment.
It is understood by one skilled in the art that the method and devices described in this disclosure would be applicable to trim boards of any material, with or without the insulation layer and to trim boards of any size.
The trim clips 50 of this invention may be made of any feasible material, including but not limited to aluminum, plastic, fiber glass,
Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. | This disclosure relates to building materials, in particular to attachment of insulating board and trims on building surfaces. Various embodiments of attachment clips to attach the trims on their place without nails or screws through the trim are provided. This disclosure provides an economical, fast, easy, and esthetic method to attach building trims. |
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This is a continuation-in-part of application Ser. No. 07/927,018 filed Aug. 10 1992, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to survey monuments and more specifically relates to an improved extraction restricting device for utilization therewith.
2. Description of the Prior Art
The prior art is exemplified by post like structures such as fence posts, fence anchors, trap anchoring stakes, ground anchors and picket pins. In most of such devices, flukes are provided to close upon the posts as it is being driven into the ground. However, if an effort is made to raise the post, a spreading out of the flukes will occur and will restrict extraction. For example, see Eddy U.S. Pat. No. 219,703, Runyon U.S. Pat. No. 362,183, Bearse U.S. Pat. No. 742,279, Rivinoja U.S. Pat. No. 1,249,200 and Lee U.S. Pat. No. 4,308,683.
In each of such prior art patents, a relatively complex construction is employed and a special construction of either the post, the devices or both is necessary.
Rousseau et al. U.S. Pat. No. 824,158 and McGreevey U.S. Pat. No. 991,525 show land anchoring means which are of general interest to illustrate the state of the art.
SUMMARY OF THE INVENTION
The present invention is a device to resist the extraction of anchoring systems. In one exemplary embodiment described herein to illustrate the principles, survey stakes are prevented from being displaced by vandalism or by earth movement such as may occur under the influence of frost heave.
A stainless steel wire is configured in a special shape and may be effectively utilized with various types of survey stakes or monuments, whether made of fiberglass, aluminum, stainless steel or any other suitable form of material.
One end of the wire is formed into a curved slip clip adapted to have a simple fit for engaging the peripheral surface of the rod-like body with a snap-on action. One relatively straight leg of the clip may be inserted in a diametral opening formed in the body. In addition to the slip fit snap-on feature, the extraction inhibiting device has an axially extending leg generally parallel to the axis of the rod and which is offset radially outwardly and upwardly in a gentle curved configuration.
The unattached curved end imparts a clockwise rotation around the rod or stake axis as the stake is driven into the ground. This is especially effective when a longer stake is required and threaded extension rods are used since the rotation tends to keep the lengths of rod tightly connected as they are driven into the ground.
However, any extraction forces applied thereto will be inhibited as the spring form member tends to open somewhat similar to an umbrella opening in the wind and resumes its extended offset positioning. In accordance with the present invention, a plurality of such wire form inhibiting devices can be employed and are fastened to the rod-like body in axially and circumferentially spaced relation with respect to one another, thereby providing an array of upwardly extending prongs to restrict extraction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view showing a fiberglass survey monument equipped with a restriction device in accordance with the principles of the present invention inserted into the ground;
FIG. 2 is a perspective view showing the survey monument of FIG. 1;
FIG. 3 is a fragmentary cross-sectional view showing additional details of the survey monument of FIGS. 1 and 2;
FIG. 4 is a cross-sectional view taken on line IV--IV of FIG. 1;
FIG. 5 is a side elevational view of one of the extraction restrictors of the present invention; and
FIG. 6 is an end view of the restrictor of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The improvements of the present invention are of general applicability to any anchoring system utilizing a rod or post-like element driven into the ground and which must be restricted against extraction. For purposes of illustrating the principles of the present invention, a survey monument or stake is shown generally at 10. The survey monument may comprise a rod of cylindrical configuration as shown as 11. It will be understood that the rod can be made of fiberglass as suggested by the cross-sectioning in the drawing or may be made of aluminum or stainless steel or any other suitable material.
A variety of metal caps are available to be used on the stakes or monuments and, if desired, such caps may be equipped with sensors.
Thus, the upper end of a rod or stake element is shown at 12 and may receive a cap 13 having a barrel 14 which is flanged at its upper extremity as at 16 and is closed by a radial end wall 17. The inner diameter of the barrel 14 is made to receive the body 11 in pressed and bonded relationship so that the cap 13 may be assembled in firm assembly with the rod-like body 11.
In order to provide close proximity detection, a magnet or sensing means 18 may be assembled in the top recess of the cap inwardly adjacent the flange 16.
At the opposite lower end of the rod-like body 11, the monument is sharpened to a point 20 which is at the apex of a cone-shaped configuration 21, thereby facilitating a piercing entry of the ground and facilitating the driving of the monument 10 into the ground.
It is contemplated by the present invention that an improved extraction restricting device be provided. Referring to FIGS. 5 and 6 in connection with the other figures of the drawings, it will be noted that a wire form spring member is utilized and is shown generally at 30. A first straight leg 31 is incorporated in the wire form spring member and terminates in a curved co-planar leg 32 which extends through a sufficient arcuate dimension relative to the outer diameter of the rod-like member 11 that it will effect a snap-on assembly with the rod-like member 11 when the straight leg 31 is inserted into a diametral opening 33 formed in the body 11.
To insure that snap-on relationship, it will be noted that the radius of curvature of the curved leg 32 is substantially the same as the curvature of the rod-like body 11. Accordingly, it is contemplated by the present invention that such curved leg 32 will extend through at least 120 to 130 degrees of arc thereby turning the wire form member 30 back upon itself to an arcuate dimension indicated in FIG. 4 as being in the range of 50 to 60 degrees. The curved leg 32 terminates in a sharply turned radius 33 thereby offsetting the wire form member out of the plane of the co-planar legs 31 and 32 and extending in an axial direction generally parallel to the longitudinal axis of the rod 10 in a straight leg portion 34 having an axially extent indicated by the dimension 36 (FIG. 5). At that point, the leg 34 enters into a curved leg portion 37 which is offset both axially and radially in a degree of curvature indicated by the radius 38 (FIG. 5) and which leg portion terminates in an end 39.
Since the extraction inhibiting device 30 is made of spring metal, for example, stainless steel, it will yield to the force of the ground engaging against it and will tend to move towards the axis of the rod 10 and also tends to straighten out the curvature of the leg 37, thereby storing up spring energy.
While the grippers of the device 30 are configured to enter the ground easily, the curved shape of the unattached end imparts a clockwise rotation as the stake is driven into the ground.
It will be understood that the grippers or retraction restricting devices 30 can be utilized with different types of rod-like elements used in anchoring systems. For example, the grippers 30 can be attached to metal extension rods when inserting them into depths up to sixty feet or more. In such mode of use, the grippers 30 apply torque to the assembly or rod-like elements and tend to keep the lengths of rod tightly connected as they are driven into the ground.
With the leg 31 firmly inserted into the diametral opening 33, the axial leg 34 will closely adjoin the rod-like body 11 and the curved leg 32 will effect a snap-on assembly with the rod-like body 11 thereby permitting the end of the wire form member 39 to be spaced outwardly adjacent the peripheral surface of the body 11.
Normally two grippers 30 are sufficient to develop the extraction resistance desired. However, more can be added selectively, for example, to adapt to softer soil conditions.
It is contemplated by the present invention that there be a selected plurality of extraction resistors 30. Thus, the body 11 is provided with a corresponding plurality of diametral openings 33 and such openings 33 are spaced axially from one another as is clearly discernible from FIG. 3 and are also spaced circumferentially from one another as is readily discernible from FIG. 2.
In operation, a typical installation is depicted in FIG. 1 wherein the survey monument 10 is driven into the ground.
In a typical installation, the spring clip 30 is utilized with a 3/4 inch diameter rod that has one or more diamtral openings of approximately 1/8 inch (0.125). Stainless steel spring wire can be advantageously employed and the spring clip 30 snaps over rod thereby facilitating firm assembly so that the spring clip 30 will yield as the stake or monument is driven into the ground but will then be forced outwardly as any force tending to dislodge the monument or to extract the monument from the ground is applied to the rod 10.
Although minor modifications might be suggested by those versed in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art. | A survey monument has a simple spring clip extraction restricting means formed as a wire form spring member to provide a straight leg inserted in a diametral opening in the rod and a curved co-planar leg which effects a snap fit with the outer periphery of the rod. An axially extending leg is offset radially outwardly and yields to displacement while imparting rotational torque to the rod when the rod is driven into the ground, but opens and restricts extraction when the rod is moved in an opposite direction. |
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RELATED U.S. APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO MICROFICHE APPENDIX
Not applicable.
FIELD OF THE INVENTION
The present invention relates to a duct coupler, and more particularly to a coupler for providing a water-tight joint between adjacent sections of duct used to provide a channel for multi-strand post-tensioning of concrete structures.
BACKGROUND OF THE INVENTION
For many years, the design of concrete structures imitated the typical steel design of column, girder and beam. With technological advances in structural concrete, however, its own form began to evolve. Concrete has the advantages of lower cost than steel, of not requiring fireproofing, and of its plasticity, a quality that lends itself to free flowing or boldly massive architectural concepts. On the other hand, structural concrete, though quite capable of carrying almost any compressive load, is weak in carrying significant tensile loads. It becomes necessary, therefore, to add steel bars, called reinforcements, to concrete, thus allowing the concrete to carry the compressive forces and the steel to carry the tensile forces.
Structures of reinforced concrete may be constructed with load-bearing walls, but this method does not use the full potentialities of the concrete. The skeleton frame, in which the floors and roofs rest directly on exterior and interior reinforced-concrete columns, has proven to be most economic and popular. Reinforced-concrete framing is seemingly a quite simple form of construction. First, wood or steel forms are constructed in the sizes, positions, and shapes called for by engineering and design requirements. The steel reinforcing is then placed and held in position by wires at its intersections. Devices known as chairs and spacers are used to keep the reinforcing bars apart and raised off the formwork. The size and number of the steel bars depends completely upon the imposed loads and the need to transfer these loads evenly throughout the building and down to the foundation. After the reinforcing is set in place, the concrete, a mixture of water, cement, sand, and stone or aggregate, of proportions calculated to produce the required strength, is placed, care being taken to prevent voids or honeycombs.
One of the simplest designs in concrete frames is the beam-and-slab. This system follows ordinary steel design that uses concrete beams that are cast integrally with the floor slabs. The beam-and-slab system is often used in apartment buildings and other structures where the beams are not visually objectionable and can be hidden. The reinforcement is simple and the forms for casting can be utilized over and over for the same shape. The system, therefore, produces an economically viable structure. With the development of flat-slab construction, exposed beams can be eliminated. In this system, reinforcing bars are projected at right angles and in two directions from every column supporting flat slabs spanning twelve or fifteen feet in both directions.
Reinforced concrete reaches its highest potentialities when it is used in pre-stressed or post-tensioned members. Spans as great as one hundred feet can be attained in members as deep as three feet for roof loads. The basic principle is simple. In pre-stressing, reinforcing rods of high tensile strength wires are stretched to a certain determined limit and then high-strength concrete is placed around them. When the concrete has set, it holds the steel in a tight grip, preventing slippage or sagging. Post-tensioning follows the same principle, but the reinforcing tendon, usually a steel cable, is held loosely in place while the concrete is placed around it. The reinforcing tendon is then stretched by hydraulic jacks and securely anchored into place. Pre-stressing is done with individual members in the shop and post-tensioning as part of the structure on the site.
In a typical tendon tensioning anchor assembly used in such post-tensioning operations, there are provided anchors for anchoring the ends of the cables suspended therebetween. In the course of tensioning the cable in a concrete structure, a hydraulic jack or the like is releasably attached to one of the exposed ends of each cable for applying a predetermined amount of tension to the tendon, which extends through the anchor. When the desired amount of tension is applied to the cable, wedges, threaded nuts, or the like, are used to capture the cable at the anchor plate and, as the jack is removed from the tendon, to prevent its relaxation and hold it in its stressed condition.
Multi-strand tensioning is used when forming especially long post-tensioned concrete structures, or those which must carry especially heavy loads, such as elongated concrete beams for buildings, bridges, highway overpasses, etc. Multiple axially aligned strands of cable are used in order to achieve the required compressive forces for offsetting the anticipated loads. Special multi-strand anchors are utilized, with ports for the desired number of tensioning cables. Individual cables are then strung between the anchors, tensioned and locked as described above for the conventional monofilament post-tensioning system.
As with monofilament installations, it is highly desirable to protect the tensioned steel cables from corrosive elements, such as de-icing chemicals, sea water, brackish water, and even rain water which could enter through cracks or pores in the concrete and eventually cause corrosion and loss of tension of the cables. In multi-strand applications, the cables typically are protected against exposure to corrosive elements by surrounding them with a metal duct or, more recently, with a flexible duct made of an impermeable material, such as plastic. The protective duct extends between the anchors and in surrounding relationship to the bundle of tensioning cables. Flexible duct, which typically is provided in 20 to 40 foot sections, is sealed at each end to an anchor and between adjacent sections of duct to provide a water-tight channel. Grout then may be pumped into the interior of the duct in surrounding relationship to the cables to provide further protection.
Several approaches have been tried to solve the problem of quickly, inexpensively and securely sealing the joints between adjacent sections of duct used in multi-strand post-tensioned applications. However, all prior art devices have utilized a plurality of arcuate sections which must be assembled at a joint around the ends of adjacent duct sections. Wedges, compression bolts or the like then are used to compress the joined sections into sealing engagement with the duct and with each other. Such prior art devices have been cumbersome to use and have proved somewhat unreliable in their ability to exclude moisture or other corrosive elements from the interior of the ducts.
Several patents have issued relating to duct couplers. For example, U.S. Pat. No. 5,320,319, issued on Jun. 14, 1994 to K. Luthi, describes a coupling element which is fitted with chamfered flanges. The sheaths of the coupler have protrusions which are inserted into the coupling element with a tubular element which forms the end of the sheaths. A sealing ring is inserted between each of the flanges and protrusions of the sheaths. The flanges and the protrusions are held together by sloping surfaces and by a groove worked within each socket. Also, U.S. Pat. No. 5,474,335, issued on Dec. 12, 1995 to the present inventor, describes a duct coupler for joining and sealing between adjacent sections of the duct. The coupler includes a body, flexible cantilevered sections on the end of the body adapted to pass over annular protrusions on the duct and locking rings for locking the cantilevered flexible sections into position, so as to lock the coupler onto the duct.
U.S. Pat. No. 5,775,849, issued on Jul. 7, 1998 to the present inventor, describes a coupler as used for ducts in post-tension anchorage systems. This duct system includes a first duct having a plurality of corrugations extending radially outwardly therefrom, a second duct having a plurality of corrugations extending radially outwardly therefrom, and a tubular body threadedly receiving the first duct at one end and threadedly receiving the second duct at the opposite end. The tubular body has a first threaded section formed on an inner wall of the tubular body adjacent one end of the tubular body and a second threaded section formed on the inner wall of the tubular body adjacent an opposite end of the tubular body. The threaded sections are formed of a harder polymeric material than the polymeric material of the first and second ducts. The tubular body has an outer diameter which is less than the diameter of the ducts at the corrugations. The first and second threaded sections have a maximum inner diameter which is less than the outer diameter of the ducts at the end of the ducts. First and second elastomeric seals are affixed to opposite end of the tubular body and juxtaposed against a surface of a corrugation of the first and second ducts.
U.S. Pat. No. 5,954,373, issued on Sep. 21, 1999 to the present inventor, describes a different type of duct coupler apparatus. The duct coupler apparatus of this patent includes a tubular body with an interior passageway between a first open end and a second open end. A shoulder is formed within the tubular body between the open ends. A seal is connected to the shoulder so as to form a liquid-tight seal with a duct received within one of the open ends. A compression device is hingedly connected to the tubular body for urging the duct into compressive contact with the seal. The compression device has a portion extending exterior of the tubular body. The compression device includes an arm with an end hingedly connected to the tubular body and having an abutment surface adjacent the end. The arm is movable between a first position extending outwardly of an exterior of the tubular body and a second position aligned with an exterior surface of the tubular body. A latching member is connected to an opposite end of the arm and serves to affix the arm in the second position. The abutment surface of the arm serves to push a corrugation of the duct against the seal and against the shoulder so as to form a liquid-tight seal between the duct and the interior of the coupler.
U.S. Pat. No. 6,764,105, issued on Jul. 20, 2004 to the present inventor, describes a duct coupler apparatus for use with precast concrete segmental construction. This coupler has a first duct, a first coupler member extending over and around an exterior surface of the first duct and having a seat opening adjacent an end of the first duct, a second duct, a second coupler member extending over and around an exterior surface of the second duct and a seat opening adjacent to an end of the second duct, and gasket received in the seats of the first and second coupler members. An external seal is affixed to an opposite end of the first coupler member and affixed to an exterior surface of the first duct. The seats of the first and second coupler members have slots facing one another. The gasket is received within these slots.
U.S. Pat. No. 6,752,435, issued on Jun. 22, 2004 to the present inventor, describes a symmetrical coupler apparatus for use with precast concrete segmental construction. This coupler member has a first duct, a first coupler member extending over and around an exterior surface of the first duct and an end opening adjacent an end of the first duct, a second duct, a second coupler member extending over and around an exterior surface of the second duct and an end opening adjacent to an end of the second duct, and a gasket received in the ends of the first and second coupler members. The gasket serves to prevent liquid from passing between the ends of the coupler members into an interior of either of the first and second ducts. An external seal is affixed to an opposite end of the first coupler member and affixed to an exterior surface of the first duct. An internal seal is interposed in generally liquid-tight relationship between an interior surface of the second coupler member and an exterior surface of the second duct.
U.S. Pat. No. 6,834,890, issued on Dec. 28, 2004 to the present inventor, teaches a coupler apparatus for use with a tendon-receiving duct in a segmental precast concrete structure. This coupler apparatus includes a coupler body having an interior passageway for receiving the duct therein. The coupler body has a generally U-shaped channel formed at one end thereof. The coupler element has a connector element formed on interior thereof adjacent one end of the coupler body so as to allow the coupler element to receive a variety of implements for the formation of the precast concrete segment.
U.S. Pat. No. 6,874,821, issued on Apr. 5, 2005 to the present inventor, describes a coupler apparatus for use with angled post-tension cables in precast concrete segmental construction. This coupler apparatus has a first duct, a first coupler member extending over and around the first duct, a second duct, a second coupler member extending over and around the second duct and a gasket received at the ends of the first and second coupler members so as to prevent liquid from passing between the coupler members into an interior of either of the ducts. The ducts extend at a non-transverse acute angle with respect to the ends of the coupler members. Heat shrink seals are affixed to the opposite ends of the coupler member so as to secure the coupler members to the ducts in liquid-tight relationship. The ends of the coupler member have generally V-shaped grooves facing each other. The gasket is received in compressive relationship within the V-shaped grooves.
U.S. Pat. No. 7,273,238, issued on Sep. 25, 2007 to the present inventor, teaches a duct coupler apparatus with compressible seals. This apparatus is used for joining the ends of a pair of ribbed ducts together. The apparatus has a collar with an interior suitable for receiving the ends of the pair of ducts therein. A first coupler element is translatably secured adjacent a first end of the collar. A compressible seal is disposed between a surface of the first coupler element and the first end of the collar. A second coupler element is secured adjacent a second end of the collar. A second seal is disposed between a surface of the second coupler element and the second end of the collar. The coupler elements are translatable so as to compress the seal such that a surface of the seal will bear against a respective rib of the pair of ducts.
U.S. Pat. No. 7,267,375, issued on Sep. 11, 2007 to the present inventor, describes a duct coupler apparatus. This apparatus is for joining ends of a pair of ducts together in end-to-end relationship. The apparatus has a collar with a first end portion and a second end portion. A first coupler element is translatably secured to an exterior of the collar for moving the first end portion between first and second positions. A second coupler element is translatably secured to the exterior of the collar so as to move the second end portion between first and second positions. The end portions have a plurality of fingers that are movable so as to be free of the surfaces of the duct when in the first position and which contact a rib of the duct when in the second position. The collar and the coupler elements form a liquid-tight seal over the respective ends of the pair of ducts.
FIGS. 1-3 herein describe the prior art coupler apparatus similar to that disclosed in U.S. Pat. No. 7,267,375. Referring to FIG. 1 , there is shown the coupler apparatus 10 in of the prior art. The coupler apparatus 10 includes a collar 12 , a first coupler element 14 and a second coupler element 16 . A first duct 18 is received within the interior of the collar 12 and within the interior of the first coupler element 14 . A second duct 20 is received within the collar 12 and within the interior of the second coupler element 16 . The collar 12 has an interior suitable for receiving the ducts 18 and 20 in end-to-end relationship and in generally longitudinal alignment. The collar 12 has first end portion 22 at one end thereof and a second end portion 24 at an opposite end thereof. Each of the end portions 22 and 24 are movable between a first position (illustrated by end portion 24 ) spaced away from the interior of the collar 12 and a second position (illustrated by end portion 22 ) which extends toward the interior of the collar 12 . The first coupler element 14 is translatably secured to the exterior of the collar 12 . The first coupler element 14 is translatable so as to move the first end portion 22 between the first and second positions. The second coupler element 16 is also translatably secured to the exterior of the collar 12 . The second coupler element 16 is translatable so as to move the second end portion 24 between the first and second positions.
As can be seen in FIG. 1 , the first duct 18 has a plurality of ribs 26 formed thereon. Longitudinal channels 28 extend between the ribs 26 and allow liquid and grout therein to communicate between the ribs 26 . Longitudinal channels 28 have an outer edge which is flush with the outer diameter of the respective ribs 26 . The first duct 18 has an outer wall which extends between the ribs 26 and defines the interior of the duct 18 . The second duct 20 similarly has a plurality of ribs 32 , longitudinal channels 34 and wall 36 . The first duct 18 is identical to the second duct 20 . In normal use, the ducts 18 and 20 will receive tendons therein and allow a grout material to fill the interior thereof. The respective channels 28 and 34 allow grout to fill the interior of the respective ducts 18 and 20 and to flow into the ribs 26 and 32 , respectively.
As can be seen, the first end portion 22 has a plurality of finger elements 38 , 40 , 42 , 44 and 46 extending outwardly therefrom. In FIG. 1 , for the purposes of illustration, the finger element 38 is illustrated in its second position which serves to lock the first duct 18 in its proper position. The finger element 22 has a lower surface 48 which will reside in surface-to-surface relationship with the wall 30 of duct 18 . An extension element 50 extends outwardly as a tip from the finger element 38 so as to reside over the outer surface of the rib 26 . An inclined surface extends between the tip 50 and the surface 48 so as to reside against the slanted surface of the rib 26 . The remaining finger elements 40 , 42 , 44 and 46 are illustrated in the first position extending away from the surface of the duct. In normal use, the finger elements 38 , 40 , 42 , 44 and 46 will move cooperatively relative to the translation of the first coupler element 14 on the collar 12 .
The collar 12 has a plurality of finger elements 52 , 54 , 58 , and 60 extending outwardly from an opposite end thereof of finger elements 22 . Each of the finger elements 52 , 54 , 58 , and 60 is illustrated in the first position spaced away from the exterior surface of the duct 20 . The coupler element 16 is translatable relative to the collar 12 so as to move the finger elements 52 , 54 , 58 , and 60 to the second position.
In FIG. 1 , it can be seen that there is an indented portion 62 formed in the collar 12 generally between the ends of the ducts 18 and 20 . The indented surface 62 will have an interior surface aligned with interior surface of the respective ducts 18 and 20 .
The collar 14 is translatable about one end of the collar 12 . The translating motion in the preferred embodiment of the present invention is established by a threaded relationship between the exterior surface of the collar 12 and the interior surface of the coupler 14 . In other embodiments of the present invention, the coupler element 14 is translatable by slidable or ratcheting motion. Suitable hinging mechanisms or other cantilever or lever actions can be incorporated within the apparatus 10 so as to facilitate proper translatable motion of the coupler elements 14 and 16 on the collar 12 . Coupler element 16 will have a configuration similar to that of coupler element 14 and will translate in the same manner as coupler element 14 . Each of the coupler elements 14 and 16 has a plurality of ribs 64 formed on an exterior surface thereof. Each of the plurality of ribs 64 extends longitudinally for at least a portion of the length of the respective coupler elements 14 and 16 . The plurality of ribs are radially spaced from each other around the diameter of the respective coupler elements 14 and 16 . Ribs 64 facilitate the ability of a worker to grasp the exterior surface of the coupler elements 14 and 16 and to provide the necessary translatable motion with respect to the movement of the coupler elements 14 and 16 onto the respective end portions 22 and 24 .
FIG. 2 illustrates the collar 12 as having the end portions 22 and 24 in the first position away from the respective ducts 18 and 20 . In FIG. 2 , the collar 12 is illustrated as having the indented portion 62 formed between the respective ends 66 and 68 of ducts 18 and 20 . The inward surface of the indented portion 62 is in coplanar alignment with the inner surface 70 of duct 18 and inner surface 72 of duct 20 . The collar 62 has an annular seal 74 extending around the interior of the collar 12 . A second annular seal 76 is also affixed to the collar 12 and extends around the interior of the collar 12 . The annular seals 74 and 76 can be formed of a suitable elastomeric material such that the seal 74 establishes a liquid-tight relationship with the rib 26 of duct 18 . The annular seal 76 will establish a liquid-tight seal with the rib 32 of duct 20 . It can be seen that the collar 12 has an inner surface which will generally abut the tops of the respective shoulders 26 and 32 of the ducts 18 and 20 . As such, the ducts 18 and 20 can be easily installed within the interior of the collar 12 by slidably inserting the ends 66 and 68 of ducts 18 and 20 into opposite ends of the collar 62 .
In FIG. 2 , it can be seen that the collar 12 has a threaded exterior surface 78 . The collar 12 also has another threaded exterior surface 80 formed thereon. The end portion 22 is integrally formed with the collar 12 at one end of the collar 12 . The second end position 24 is also integrally formed with the collar 12 at the opposite end of the collar 12 . The threaded portions 78 and 80 are respectively interposed between the indented portion 62 and the end portions 22 and 24 . The end portion 22 has a shoulder 82 formed thereon. The end portion 24 also has a shoulder 84 formed thereon. Underlying surface 48 extends from shoulder 82 outwardly therefrom. Another underlying surface 86 is formed on the end portion 24 and extends outwardly from the shoulder 84 . End surfaces 48 and 86 will extend generally upwardly at an acute angle with respect to a longitudinal axis of the collar 12 . In FIG. 2 , the first position of the end portions 22 and 24 is particularly illustrated. As such, the shoulders 82 and 84 , along with the surfaces 48 and 86 , will be generally spaced away from the respective ducts 18 and 20 so as to allow for the free insertion of the ends 66 and 68 of ducts 18 and 20 into the collar 12 .
The first coupler element 14 is illustrated as having interior threads 88 engaged with the exterior threads 78 of the collar 12 . The first coupler element 14 has an abutment end 90 extending into contact with a surface of the end portion. Similarly, the second coupler element 16 has an interior threaded section 92 threadedly engaged with the exterior threads 80 of the collar 12 . An abutment end 94 is formed on the coupler element 16 so as to reside against the surface of the end portion 24 .
FIG. 3 illustrates how the coupler elements 14 and 16 translate so as to move the end portions 22 and 24 into their second or locking positions. In normal use, the coupler elements 14 and 16 will be rotated so that the interior threads 88 will translate along the exterior threads 78 at one end of the collar 12 . The second coupler element 16 will similarly have its interior threads 92 rotate with respect to the exterior threads 80 . This causes the abutment end 90 of coupler element 14 to urge against the surface of the end portion 22 and to move the end portion 22 downwardly. As a result, the shoulder 82 will reside in contact (illustrated in broken line fashion) against a surface of rib 26 . The second coupler element 16 will work in a similar manner so that the shoulder 84 will reside in contact against a surface of the rib 32 . In this locked position, it will be impossible to pull the first duct 18 away from the second duct 20 . A secure seal is formed between the interior surfaces of the collar 12 and the exterior surfaces of the ducts 18 and 20 . The annular seal 74 and 76 will further provide a strong liquid-tight seal against the outer surfaces of the respective ducts 18 and 20 .
It has been found with the prior art coupler apparatus illustrated in FIGS. 1-3 that it is often somewhat complicated to properly install the apparatus. In certain circumstances, the installation can be somewhat time consuming. As such, it has been found that there is a need to provide a coupler apparatus for ducts which allows workman at the construction site to easily connect the ends of the ducts through a use of a coupler. The coupler should be of a type that is suitable for effectively engaging the ends of the ducts in a liquid-tight manner. The coupler apparatus should have a minimum number of moving parts so as to effectively create the necessary seal while, at the same time, avoids complexities in the actual manufacturing injection molding of such a coupler apparatus.
It is an object of the present invention to provide a duct coupling system that allows the ends of tendon-receiving ducts to be joined in a proper end-to-end relationship.
It is another object the present invention to provide a duct coupling system that effectively establishes a liquid-tight seal between the respective coupled ducts.
It is another object of the present invention to provide a duct coupling system which allows the coupler to be formed through an injection molding process.
It is still another object of the present invention to provide a duct coupling system which allows the ducts to be effectively coupled in a minimal amount of time with a minimum complexity.
These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims.
BRIEF SUMMARY OF THE INVENTION
The present invention is a duct coupling system that comprises a first duct, a second duct, and a coupler that joins the first duct to the second duct. The first duct has an interior passageway at a first end. The first end has threads thereon. The interior passageway opens at the first end of the first duct. The second duct also has an interior passageway at a first end. The interior passageway of the second duct opens at the first end of the second duct. The first end of the second duct has threads thereon. The coupler is a generally tubular body with a first end and a second end and an interior passageway extending therebetween. The first end of the tubular body is threadedly engaged with the threads of the first end of the first duct. The second end of the coupler is threadedly engaged with the threads at the first end of the second duct.
The interior passageway of the first duct and the interior passageway of the second duct and the interior passageway of the coupler are axially aligned.
The thread of the duct has a unique configuration. The thread of the first end of the first duct has a narrow width portion and a wide width portion. This thread extends radially outwardly of the first duct for a lesser distance at the narrow width portion than a distance at the wide width portion. The narrow width portion of this thread is spaced from the narrow width portion of an adjacent thread. The wide width portion is offset by approximately 90° from the narrow width portion.
Each of the first and second ducts has a ridge extending circumferentially therearound adjacent the first end thereof. The coupler has a first lip extending longitudinally outwardly therefrom so as to overlie the ridge of the first duct. The coupler having a second lip extending longitudinally outwardly therefrom so as to overlie the ridge of the second duct. The body of the coupler has a first ring seal juxtaposed between an inner surface of the body and a surface of the ridge of the first duct. The body of the coupler also has a second ring seal juxtaposed between another inner surface of the body and surface of the ridge of the second duct. The body of the coupler has a radially indented area extending circumferentially therearound between the first and second ends of the coupler. This radially indented area is positioned between the first end of the first duct and the first end of the second duct. The first end of the body of the coupler has a square threads extending inwardly therefrom and engaged with the threads at the first end of the first duct. The second end of the body of the coupler has square threads extending inwardly therefrom and engaged with the threads at the first end of the second duct. The thread at the first end of the first duct has an end and a portion circumferentially spaced from this end of the thread. The end of the thread extends radially outwardly of the first duct for a lesser distance than a distance that the portion extends outwardly of the first duct. The first end of the body of the coupler is slidable over the ends of the thread. The coupler is rotatable relative to the first duct so that the threads at the first end of the body of the coupler engaged with the portion of the threads at the first end of the first duct.
In the present invention, each of the first duct and the second duct and the coupler are integrally formed of a polymeric material. A plurality of tendons extend through the interior passageways of the first duct, the second duct, and the coupler.
The present invention is also a duct coupler that includes a generally tubular body having a first end and a second end with interior passageway extending therebetween. The first end and the second end are interiorly threaded. The body is formed of a polymeric material. The threads at the first end and the threads at the second end of the body are square threads. The body has an outer surface with a first lip extending longitudinally outwardly at the first end and a second lip extending outwardly at the second end. A first ring seal is affixed against an inner surface of the body adjacent the first lip. A second ring seal affixed against an inner surface of the body adjacent the second lip. The body has a radially indented area around a circumference thereof in an area between said first and second ends.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a side elevational view of a prior art duct coupler.
FIG. 2 is a cross-sectional view showing the end portions of the collar of the coupler apparatus of the prior art in a first position.
FIG. 3 is a cross-sectional view showing the end portions of the collar of the coupler of the prior art in the second locked position.
FIG. 4 is a cross-sectional view showing the duct coupling system in accordance with the preferred embodiment of the present invention.
FIG. 5 is a cross-sectional view showing the duct coupling system of the present invention with the coupler rotated 90° with respect to the duct.
FIG. 6 is a upper perspective view of an end of either the first duct and a second duct as used with the coupler apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 4 , there is a shown the duct coupling system 100 in accordance the preferred embodiment of the present invention. The duct coupling system 100 includes a first duct 102 , a second duct 104 and a coupler 106 . Coupler 106 joins the ducts 102 and 104 in a liquid-tight relationship.
The first duct has an interior passageway 108 and a first end 110 . The interior passageway 108 opens at the first end 110 . The first end 110 has threads 112 formed thereon. The second duct 104 has an interior passageway 114 and a first end 116 . The interior passageway 114 of the second duct 104 opens at the first end 116 . The first end 116 of the second duct 104 has threads 118 formed thereon.
The coupler 106 has a generally tubular body 120 . The tubular body 120 has a first end 122 and a second end 124 . The coupler 106 also has an interior passageway 125 extending between the first end 122 an the second end 124 . It can be seen that the first end 122 of the body 120 is threadedly engaged with the threads 112 at the first end 110 of the first duct 102 . The second end 124 of the coupler 106 is threadedly engaged with the threads 118 at the first end 116 of the second duct 104 .
The interior passageway 108 of the first duct 102 and the interior passageway 114 of the second duct 104 and the interior passageway 125 of the coupler 106 are longitudinally axially aligned.
In FIG. 4 , it can be seen that the first duct 102 has a ridge 130 extending circumferentially therearound adjacent to the first end 110 thereof. The coupler 106 has a first lip 132 extending longitudinally outwardly therefrom so as to overlie the ridge 130 of the first duct 102 . The coupler 106 also has a second lip 134 extending longitudinally outwardly therefrom so as to overlie the ridge 136 of the second duct 104 . It can be seen that there is a first elastomeric ring seal 138 juxtaposed between an inner surface of the body 120 of the coupler 106 and a surface of the ridge 130 of the first duct 102 . A second elastomeric ring seal 140 is juxtaposed between another inner surface of the body 120 of the coupler 106 and a surface of the ridge 136 of the second duct 104 .
The coupler 106 has a radially indented area 142 extending circumferentially therearound between the first end 122 and the second end 124 of the coupler 106 . This radially indented area 142 is positioned between the first end 110 of the first duct 102 and the first end 116 of the second duct 104 .
In FIG. 4 , it can be seen that the first end 122 of the body 120 has square threads 150 extending inwardly therefrom and engaged with the threads 112 at the first end 110 of the first duct 102 . The second end 124 of the body 120 of coupler 106 also has square threads 152 that are engaged with the threads 118 at the first end 116 of the second duct 104 .
FIG. 5 shows another form of the present invention in which the coupler 106 is illustrated as being located in another position with respect to the threads of the respective ducts 200 and 202 . It can be seen in FIG. 5 that the first elastomeric ring seal 204 that juxtaposed against an inner surface of the lip 206 at the end of coupler 106 and an outer surface of the first duct 200 . There is also another elastomeric ring seal 208 that is juxtaposed in liquid-tight relationship between the end 210 of the coupler 106 and an outer surface of the duct 202 . In this embodiment, the lips at the end of the coupler 106 do not overlie the ridge 220 of the first duct 200 and the ridge 222 of the second duct 202 .
FIG. 6 shows the ends of the respective ducts. In particular, duct 104 is particularly illustrated in FIG. 6 . The unique configuration of the threads 118 adjacent to the end 116 of the duct 104 are particularly illustrated. The duct 104 is illustrated as having interior passageway 114 opening at the end 116 and extending therethrough. The duct 104 is also illustrated as having the ridge 136 extending circumferentially therearound and forming a raised surface with respect the to threads 118 .
In particular, in FIG. 6 , it can be seen that there is illustrated a single thread 300 . The threads 300 includes a narrow width portion 302 and a wide width portion 304 . The narrow width portion 302 is of set by approximately 90° from the wide width portion 304 . In the preferred embodiment of the present invention, the narrow width portion 302 extends outwardly of the surface 306 of the duct 104 for a distance less than the distance that the wide width portion 304 extends outwardly from surface 306 . The narrow width portion 302 is in spaced relationship to another narrow width portion 310 of an adjacent thread. The narrow width portion 310 of the adjacent thread 312 extends pass the end of the thread 300 . The alignment of the various narrow width portions of the various thread 300 will serve to allow the teeth of the duct coupler to be slidably positioned thereover. To install the duct, it is only necessary to push the threaded portion of the coupler over the narrow width portion so that the end of the coupler abuts the ridge 136 . The coupler can then be rotated upwardly or downwardly such that the threads become wedged between the wide width portion 304 of the various threads 300 . As such, a 90° rotation of the coupler in one direction or another will cause the coupler to be installed effectively in a liquid-tight sealing manner. As such, installation in the coupler can be accomplished in a very efficient and effective manner. If it is desired to remove the coupler for any reason, it is only necessary to rotate the coupler backward by 90° so that the threads can slide over the narrow width portions of the duct 104 . A similar operation can be used so as to install the coupler over the respective threads of the first duct 102 .
In the present invention, the coupler is able to establish a liquid-tight seal in a fast and efficient manner. Additionally, the coupler can be formed through an injection molding process. It is only necessary to form the threads on the inner surface of the coupler. The lips of the coupler will extend outwardly so as to effectively center the coupler with respect to ridges formed on the ducts. As such, a proper alignment of the couplers with the duct is effectively achieved. The liquid-tight sealing relationship is established by virtue of the rotation of the coupler with respect to the ducts.
The foregoing description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated construction may be made within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents. | A duct coupling system has a first duct with and end having a threads thereon, a second duct having an end with threads thereon, and a coupler having a first end threadedly engaged with the threads of the first duct and a second end threadedly engaged with the threads of the second duct. The ducts and the coupler are each integrally formed of a polymeric material. A plurality of tendons extend through the interior passageways of the ducts of the coupler. |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/961,561, filed Oct. 8, 2004. Such application is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a structural framing system and components thereof, preferably for use in buildings and other such structures. Buildings have long been constructed of structural framing systems. For example, most homes are constructed of an all wood frame consisting of 2×4s, 2×6s, etc. and plywood to create the overall frame of the outside of the house and the interior walls. Obviously, other materials and equipment are also used, but the essential framing of the structure is of wood. In recent times, and usually, but not always, for use in commercial real estate structures, steel and/or other metal alloy structural components have been created to replace the wood framing components.
[0004] An improved steel or other metal alloy structural framing component and component system is the subject hereof.
SUMMARY OF THE INVENTION
[0005] A structural framing system is provided. The system comprises at least one first framing component having upper and lower flange elements separated by a web element, the web having a depth as measured between the upper and lower flange elements, the upper and lower flange elements having corresponding upper and lower positioning dimples spaced therealong, the dimples protruding from the upper flange element toward the lower flange element and the lower dimples protruding from the lower flange element toward the upper flange element in such manner that a distance between a lower most surface of the upper dimples and an upper most surface of the lower dimples is less than the depth of the web, at least one second framing component having a depth adapted to fit between the upper and lower flange elements of the first framing component, the second framing component further adapted to extend from positions along the first framing component substantially corresponding to a pair of the corresponding upper and lower positioning dimples, and at least one third framing component for securing together the first and second framing components, the third framing component comprising a first plate member adapted to be secured to the web of the first framing component and having a height substantially equal to the depth of the web of the first framing component, a second plate member adapted to be secured to a surface of the second framing component, a portion of the second plate member having a height less than the distance between the surfaces of the dimples so as to avoid interference with the dimples during attachment of the third framing component to the first and second framing components.
[0006] Other objects of the invention will impart the obvious and will impart the apparent from the following description.
[0007] The invention accordingly comprises assemblies and components possessing the features, properties and the relation of components which will be exemplified in the products hereinafter described, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a fuller understanding of the invention, reference is made to the following description, taken in connection with the accompanying drawings, in which:
[0009] FIG. 1 is an exploded perspective view of a structural framing system encompassed by the scope of the invention;
[0010] FIG. 2 is a perspective view of a joist track component;
[0011] FIG. 3 is a cross sectional view taken along line 3 - 3 of FIG. 2 ;
[0012] FIG. 4 is a perspective view of web stiffener structural framing components;
[0013] FIG. 5 is a perspective view of a blocking structural framing component; and
[0014] FIG. 6 is a perspective view showing connection of the blocking structural framing component of FIG. 5 to adjacent joists of a structural framing system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] A structural framing system is shown in FIG. 1 . This system includes at least framing components 20 , 30 and 40 . As shown in FIG. 6 , the system may also include framing component 60 , used between two of components 30 to help stabilize the system. Usually the system will include a plurality of components 20 , 30 , 40 and 60 .
[0016] Directing attention to FIGS. 2 and 3 , track component 20 is seen to have a web 22 and first and second flange members 21 and 23 separated from each other by a depth “D” of web 22 . Spaced along flanges 21 and 23 are dimples 24 a , 24 b , 25 a , 25 b , 26 a , 26 b , etc. In a preferred, but not mandatory, embodiment the dimples are pared together along first and second flanges 21 and 23 in such a way that dimples 24 a and b on first flange 21 are essentially vertically in line with dimples 24 a and b of flange 23 , and the space between dimples 24 a and 24 b along both flanges 21 and 23 are designed to snugly hold the thickness of flange elements 31 and 33 of frame components 30 (as best seen in FIG. 1 ). However, use of a single dimple on the first flange and a corresponding single dimple on the lower, second flange for easy alignment purposes of components 30 , is also anticipated.
[0017] As seen in FIG. 2 , dimples 24 , 25 , 26 , etc. of first flange 21 extend in a direction toward second flange 23 , while dimples 24 , 25 , 26 , etc. of lower flange 23 extend in an upward direction toward flange 21 . Track components 20 are designed to correspond to and fit with components 30 , so that the depth of components 30 (as measured between flanges 31 and 33 ), fit between flanges 21 and 23 of components 20 . The height “H” of dimples 24 , 25 and 26 , etc. must at least be such that when second flange 33 of component 30 is resting on flange 23 of component 20 the dimples extending downward from flange 21 far enough so as to retain component 30 in an upright position prior to securing the components together.
[0018] Turning now to a discussion of FIG. 4 , in a preferred embodiment component 40 is seen to have a first plate member 42 and a second plate member 44 . First plate member 42 , as seen in FIG. 1 , abuts against web 22 of component 20 , while second plate member 44 , as also seen in FIG. 1 , abuts against web 32 of component 30 . There are predrilled holes 45 in second plate member 44 for aiding securement to web 32 . It is shown in FIG. 4 that the preferred angle between plates 42 and 44 of component 40 is ninety degrees, as the usual case will be for component 30 to be extending perpendicularly from component 20 of system 10 . However, it is anticipated herein that angles ranging between 0 and 180 degrees are possible for the angle of connection between components 30 and 20 , and therefore between first and second plates 42 and 44 of components 40 . Such construction angles are typically determined with regard to aesthetics and strength considerations.
[0019] In order for component 40 to be easily and quickly secured onto webs 22 and 32 of components 20 and 30 , respectively, with minimization of interference with the placement thereof by the dimples extending downward and upward from flanges 21 and 23 of component 20 , FIG. 4 shows a non-continuous notch 48 in the top and bottom edges of plate 44 ; i.e., after notch 48 the length of plate 44 increases back to its original length.
[0020] Finally, turning to FIGS. 5 and 6 , blocking component 60 is seen to have web 62 , upper flange 61 , lower flange 63 and securing tabs 65 a, b, c and d . Appearing in cross section, component 60 may either be a “C″” shaped channel or an “I” shaped channel. In addition, securing tabs 65 a - d can either be separate structures attached to flanges 61 and 63 , or may be formed integrally therewith, so long as tabs 65 a - d extend past the ends of web 62 so that they can be attached between adjacent components 30 , as seen in FIG. 6 through predrilled holes 67 .
[0021] Unless otherwise expressly indicated, when used throughout this document the term “substantially” shall have the meaning of “approximation”, not “magnitude”; i.e., it shall have the meaning, “being largely but not wholly that which is specified.” See, Webster's Ninth New Collegiate Dictionary , Merriam-Webster Inc., 1989. Hence, applicant is not using the term “substantially” to denote “considerable quantity” or “significantly large,” but is instead using the term as a qualifier/minimizer of a term. For example, in the fictitious phrase “the head portion is substantially above the body portion,” using the above intended definition, the phrase “substantially above” is meant to indicate that while most of the head portion can be located above the body portion, there is certainly at least some of the head portion located in planes with the body portion, or even below parts of the body portion. As a further example, as used in the fictitious phrase “substantially hollow,” using the above intended definition, the phrase “substantially” is meant to indicate that there are areas where the item is not hollow, without regard to a quantity of hollow verses non-hollow areas. These examples are meant to be illustrative of the meaning to be attributed to the term “substantially” as used throughout this document, even if these particular phrases are not found herein.
[0022] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0023] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the inventions herein described and all statements of the scope of the inventions, which, as a matter of language, might be said to fall therebetween. | A structural framing system is provided that includes at least one first framing component having upper and lower flange elements separated by a web element having a depth measured between the upper and lower flange elements, the upper and lower flange elements having upper and lower positioning dimples spaced therealong. The dimples protrude in such manner that a distance between the upper and lower dimples is less than the depth of the web. |
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BACKGROUND OF THE INVENTION
The present invention relates to anchor point devices, systems and methods for use in fall protection, and, especially, to mobile, overhead anchoring devices, systems and methods for use by personnel working at an edge, for example, the leading edge of a construction project or other structure.
Fall protection systems including safety harnesses and lanyards are commonly used to protect persons subjected to the potential of a fall from a height. Typically, a lifeline or lanyard is connected to an overhead anchorage point on a structure. However, in many cases (for example, leading edge work and work on the highest completed deck of a construction project), suitable overhead fall protection anchorage may not exist.
For example, FIG. 1 illustrates a worker 10 positioned at the leading edge of a portion of a deck of a construction project. In general, in extending the deck in a horizontal direction, lateral I-beams 20 (for example, aluminum I-beams) or other lateral support structures are placed at a predetermined spacing (for example, 16 inches) on beams 30 extending from a more formed or completed section or portion 40 of the decking, and supported by some structure extending to the floor below.
Under current practice, workers such as worker 10 are not anchored via a lifeline when working at a leading edge of a construction project as illustrated in FIG. 1 because there is no suitable anchorage point available. In that regard, as the deck under construction is typically the highest deck of the construction project, there is no suitable overhead anchorage point.
It is possible to “horizontally” anchor worker 10 to an anchorage point A positioned generally horizontally or laterally from worker 10 on a completed portion of the decking via a generally horizontally extending lifeline or lanyard 50 which can be part of a retractable lanyard system 60 (see, for example, U.S. Pat. No. 5,771,993, the disclosure of which is incorporated herein by reference). An example of a commercially available, retractable lanyard is the MILLER MIGHTYLITE self-retracting lifeline, available from Dalloz Fall Protection of Franklin, Pa. Retractable lanyard systems such as retractable lanyard system 60 typically include a breaking mechanism (not shown in FIG. 1 ) to arrest the fall of a mass or person attached thereto once an internal, tensioned drum (not shown in FIG. 1 ) reaches a predetermine angular velocity (corresponding to a certain rate of fall). The drum of self-retractable lanyard system 60 is preferably is under adequate rotational tension (provided, for example, by a spring) to reel up excess extended lifeline 50 without hindering the mobility of the user 10 . Lanyard 50 can, for example, be connected to a D-ring 70 of a safety harness 80 worn by worker 10 .
Although a lifeline anchorage as illustrated in FIG. 1 may provide some level of protection for construction workers working on the leading edge of deck placement or working on the highest completed deck of a construction project, workers falling from the edge of a deck who are tied off to such a lifeline anchorage can suffer injuries if, for example, they swing during or after the fall or if they strike a lower deck or structure extending to the floor below. For example, the worker can be in free fall until at least that time when lanyard 50 falls a distance X to contact the edge of forward beam 20 . In general, only after lanyard 50 contacts beam 20 will the drum of retractable lanyard system experience an angular velocity corresponding to the rate of fall. The fall of worker 10 may not, therefore, be arrested before worker 10 strikes something below. In that regard, lower decks are often only approximately eight to twelve feet below an upper deck under construction. Moreover, with or without use of retractable lanyard system 60 , worker 10 can swing into an obstruction during the fall or after the fall has been arrested. The worker could also strike the support structure for beams 30 . Non-retracting lanyards can be substituted for retractable lanyards, but non-retracting lanyards tend to either limit the mobility of the worker, or allow excessive free fall that is more likely to cause a strike on structure below the work surface.
It is desirable, therefore, to develop devices, systems and methods that reduce or eliminate the above problems.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides an anchoring system including an anchor member to anchor a lifeline and at least one extending unit to extend the anchor member out to a working position beyond (horizontally) and above (vertically) an edge to provide for an overhead anchoring point. The anchoring system preferably further includes a support to which the extending unit is attached. The support immobilizes the overhead anchoring system so that the anchor member remains at the working position (even in the case of a fall by the worker).
The extending unit can, for example, include at least two extending members and the anchor member can extend between the two extending members. The anchor member can be of sufficient length to accommodate the lifelines of a plurality of workers. The support can, for example, include an attachment member (for example, a clamp) to fix the anchoring system in a desired position. At least one counterweight can be in operative connection with the support to, for example, prevent tipping of the anchoring system.
The support can, for example, include wheels for transport of the anchoring system. Preferably, such a mobile systems includes an immobilizer to fix the anchoring system in a desired position. The immobilizer can, for example, includes at least one jack in operative connection with the support to remove at least part of the weight of the support from at least one of the wheels of the support. In one embodiment, the support rests on a pallet jack to move the anchoring system and to fix the position of the anchoring system. The immobilizer can also include at least one abutment member that abuts a surface of the structure. Alternatively, the immobilizer can include at least one braking unit on at least one of the wheels.
In one embodiment, the extending unit includes at least one horizontally extending member to extend the anchor member out to the working position and at least one generally vertically extending member to which the horizontally extending member is attached to elevate the anchor member to the working position.
At least one handle can be attached to a mobile support to accommodate manual movement of the anchoring system. The anchoring system can also include lifting attachments to lift the system to a location. The anchoring system can be made to be disassembled for storage or transport. In case of disassembly, each component of the anchoring system can include lifting attachments to facilitate lifting of the system to a location.
The system can further include a lifeline and a harness to be worn by the worker. The harness is connectible to the lifeline (via, for example, a D-ring as known in the art). The system can further include a self-retractable lanyard system in which the lifeline is in operative connection.
In another aspect, the present invention provides an anchoring system for use in fall protection including an anchor member to anchor a lifeline and at least one extending unit to extend the anchor member to a working position vertically above an edge of a work area to provide for an anchoring point vertically higher than a worker's head. The anchoring system also includes a support to which the extending unit is attached. The support immobilizes the overhead anchoring system so that the anchor member remains at the working position.
In still a further aspect, the present invention provides a method of anchoring a fall protection lifeline for use by a worker working at or beyond an edge. The method includes the steps of elevating an anchor member to position the lifeline above the head of a worker and supporting the anchor member at the working position. The method can also include the step of extending the anchor member to a working position horizontally beyond and above the edge.
The present invention thus provides devices, systems and methods for anchoring a lifeline for use in fall protection to an overhead anchor member in situations in which an overhead anchorage is not otherwise available. The anchoring devices and systems of the present invention can, for example, be positioned at the leading edge of a roof or a deck construction, or any unguarded edge, to provide overhead support.
The systems and methods of the present invention greatly increase the fall protection for a worker at the leading edge or the top deck of a structure by providing an overhead anchorage for the worker's lifeline. In general, the present invention is preferably mobile so that it can be positioned in the most favorable location on, for example, a roof or a deck to give a worker an optimal overhead anchorage point.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of worker on the leading edge of a portion of a deck under construction in which the worker is connected to a generally horizontal lifeline anchorage.
FIG. 2 illustrates a perspective view of one embodiment of an overhead anchoring system of the present invention.
FIG. 3 illustrates a side view of the anchoring system of FIG. 2 .
FIG. 4 illustrates a top view of the anchoring system of FIG. 2 showing one configuration of an anchor member that can accommodate two lifelines.
FIG. 5A illustrates a side view of the support of the anchoring system of FIG. 2 disconnected from the other components thereof.
FIG. 5B illustrates a top view of the support of FIG. 5A .
FIG. 5C illustrates a side view the generally horizontal extending member of the anchoring system of FIG. 2 disconnected from the other components thereof.
FIG. 5D illustrates a top view of the generally horizontal extending member of FIG. 5C .
FIG. 5E illustrates a side view of the generally vertical extending member of the anchoring system of FIG. 2 disconnected from the other components thereof.
FIG. 5F illustrates a top view of the generally vertical extending member of the anchoring system of FIG. 5E .
FIG. 6 illustrates a side view of another embodiment of an anchoring system of the present invention including a support having a pallet jack to mobilize the anchoring system and to immobilize or fix the anchoring system in place.
FIG. 7 illustrates a perspective view of another embodiment of an anchoring system of the present invention.
FIG. 8 illustrates a side view of the anchoring system of FIG. 7 in which a breaking system is engaged to fix the anchoring system in place.
FIG. 9 illustrates a side view of the anchoring system of FIG. 7 in which the breading system is disengaged to mobilize the anchoring system.
FIG. 10 illustrates a perspective view of another embodiment of an anchoring system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the embodiment illustrated in FIGS. 2 through 5F , the present invention provides an overhead anchoring device or system 100 that includes an anchor member 105 attached to one end of a generally horizontally extending member 110 . In the embodiment of FIGS. 2–5F , horizontal extending member 110 includes a first generally horizontal member 112 to which two extending member 114 a and 114 b are attached at generally opposing angles in the form of a “Y”. Anchor member 105 , in this embodiment, is a transverse bar extending between the forward end of extending members 114 a and 114 b . Anchor member 105 can, alternatively, be attached directly to a horizontal extending member such as generally horizontal member 112 in the general form of a “T”.
As used herein, the term “forward” refers to a direction toward the anchor member of the anchoring devices or systems of the present invention. The term “rearward”: refers to an opposite direction, away from the anchor member.
Generally horizontal extending member 110 is attached at its rearward end to the elevated end of generally vertically extending member 120 . The opposite and lower end of vertically extending member 120 is attached to the front end of a support 130 . Weighted members 140 are preferably positioned at the rear end of support 130 to provide a counterweight to prevent overhead anchoring system 100 from tipping forward when a load (for example a person suspended by a lifeline) is applied to anchor member 105 through, for example, a lifeline 50 attached to D-ring 70 of safety harness 80 as worn by a worker 10 (see FIG. 3 ). An example of a safety harness suitable for use in connection with the anchoring systems of the present invention is described in U.S. Pat. No. 6,006,700, the disclosure of which is incorporated herein by reference.
As further illustrated, for example, in FIGS. 2 and 3 , a plurality of wheels 150 a–f (six in this embodiment), can be mounted to the bottom of support 130 to make overhead anchoring system 100 mobile. In that regard, support 130 includes a generally longitudinal base 132 (for example, a steel beam) to which front wheel support members 134 a and 134 b are attached. Wheel brackets 136 extend downward from support members 134 a and 134 b to attach wheels 150 a and 150 b.
Support 130 also includes a rear platform 138 . Wheel brackets 136 extend downward from platform 138 to attach wheels 150 c–f . A swivel caster 154 (see FIG. 2 ) can be provided at approximately the center of base 132 so that, for example, if wheels 150 a and 150 b move over a hole or edge in a surface over which anchoring system 100 is being transported, wheels 150 a and 150 b will not fall into that hole.
Platform 138 can, for example, support one or more containers 160 in which counter weights 140 (for example, steel plates or concrete) are positioned.
Containers 160 can, for example, be fabricated from plastic and can be removable from platform 138 . In FIGS. 3 , 4 , 5 A and 5 B, containers 160 have been removed. Containers 160 , can, for example, be replaced with steel plates or other counterweights 140 placed on, bolted on or welded to platform 138 . Containers 160 can be open on the top thereof to provide for removal of or addition of weighted members 140 .
Attached to and extending up from support 130 of the embodiment illustrated in FIGS. 2 through 5F is a rearward handle 170 to facilitate manual movement of overhead anchoring system 100 . A second, forward handle 174 can, for example, be provided on vertical extending member 120 to facilitate maneuvering of the front of anchoring system 100 .
As illustrated in FIG. 2 , overhead anchoring system 100 preferably can also be moved or lifted by, for example, a crane by rigging overhead anchoring system 100 through one or more lifting attachments 180 mounted on overhead anchoring system 100 . A plurality of lifting attachments 180 (for example, I-bolts) can be provided for a balanced lift of entire system 100 or of individual components thereof. If, for example, positioned at the center of gravity, a single lifting attachment can be used.
As illustrated, for example, in FIGS. 5A through 5F , each of horizontal extending member 110 , vertical extending member 120 and support 130 preferably can be disassembled to facilitate lifting or other transporting thereof into position on, for example, an upper deck of a construction project. Each disassembled component (for example, horizontal extending member 110 , vertical extending member 120 and support 130 ) of an anchoring system of the present invention can include one or more lifting attachments 180 (see FIG. 2 ). Although multiple lifting attachments 180 are illustrated on each of horizontal extending member 110 , vertical extending member 120 and support 130 , a single lifting attachment 180 can provide a balanced lift for each such disassembled component if positioned at or near the center of gravity thereof.
Once positioned on a desired deck, horizontal extending member 110 , vertical extending member 120 and support 130 can be assembled using, for example, connectors such a bolts as known in the art. Wheels 150 a through 150 f then facilitate movement of assembled anchor system 100 to the leading edge of, for example, deck 40 so that horizontal member 110 extends over the leading edge of the construction (see, for example, FIG. 3 ).
Preferably, anchoring system 100 is immobilized or fixed in position once placed at the leading edge of the construction as illustrated, for example, in FIG. 3 . Anchoring system 100 , for example, includes one or more jacks 190 a and 190 b . The base of each of jacks 190 a and 190 b can be lowered to remove at least part of the weight of anchoring system 100 from one or more of wheels 150 a–f . In FIG. 3 , the base of forward jack 190 a has been lowered to contact formed decking 40 , while the base of rearward jack 190 b remains elevated above deck 40 . The weight of anchoring system 100 and friction between the bases of jacks 190 a and 190 b and deck 40 prevent movement of anchoring system 100 when one or more workers 10 is anchored to anchor member 105 , or experience a fall.
FIG. 6 illustrates another embodiment of overhead anchoring system 100 ′ similar in operation to anchoring system 100 . In the case of anchoring system 100 ′, however, 130 ′ is designed and sized to rest upon the forks of a fork lift or upon a pallet jack 200 as known in the art to mobilize anchoring system 100 and to immobilize or fix anchoring system 100 ′ at a desired position. Like components of anchoring system 100 ′ are numbered similarly to corresponding components of anchoring system 100 with the addition of a “′” designation. However, rear transverse member or platform 138 can include, for example, weighted members such a steel beams that act as counterweight(s), thereby removing the need for a container 160 ′ (illustrated in dashed lines in FIG. 6 ) for holding such counterweights. One or more such containers can be included, however, to facilitate increasing the amount of counterweight. The mobility of overhead anchoring system 100 or anchoring system 200 can be automated or facilitated by adding a powered device or drive to one or more of the wheels thereof.
To facilitate the assembly and disassembly of overhead anchoring system 100 for storage and transport, the attachment of horizontally extending member 110 to the elevated end of vertically extending member 120 and the attachment of the opposite and lower end of vertically extending member 120 to support 130 can be made with bolts or other attachment devices as described above that can be taken apart by workers using traditional and readily available construction tools such as wrenches. Alternatively, attachment points can be loosened so that, for example, horizontally extended member 110 can fold back on vertically extended member 120 , which in turn can fold back on support 130 .
A pivoting joint can be incorporated between horizontally extending member 110 and vertically extending member 120 and/or between vertically extending member 120 and support 130 to allow a worker to turn anchor member 105 up to, for example, 360 degrees. Horizontally extending member 110 can also be made extendible (for example, by allowing member 112 and/or members 114 a and 114 b to telescope) to increase or decrease the reach of overhead anchoring system 100 . Base 132 of support 130 can also be extendible, for example, by telescoping steel member. In cases that horizontal extending member 110 is extended forward, it may be desirable to extend base 132 in a rearward direction to increase the lever arm associated with counterweight(s) 140 . Vertically extending member 120 can also be made extendible to adjust the height of anchor member 105 , for example, via telescoping as known in the art.
Another embodiment of an anchoring system 300 is illustrated in FIGS. 7 through 9 . In anchoring system 300 , an anchor member 305 is supported beyond the leading edge of, for example, formed decking 40 and above a worker by a plurality of angled extending members 310 a , 320 a , 310 b and 320 b . Extending members 310 a and 320 a from a first angled A-frame, while extending members 310 b and 320 b form a second angled A-frame.
Each of angled extending members 310 a , 320 a , 310 b and 320 b is attached to a support 330 , which rests upon a surface such as deck 40 . In the embodiment of FIGS. 7 through 9 , support 330 of anchoring system 300 includes a first longitudinal member 332 a and a second longitudinal member 332 b in spaced connection via a forward transverse member 334 and a rear transverse member 336 . Two counterweight systems or units 340 a and 340 b are provided upon a rearward end of support 330 . In the embodiment of FIGS. 7 through 9 , counterweight units 340 a and 340 b include a plurality of steel plates. Support 330 also includes wheels 350 a–d as described above in connection with anchoring system 300 . In this embodiment, wheels 350 c and 350 d are double-wheel sets. Support 330 further includes handles 370 a and 370 b to facilitate maneuvering of anchoring system 300 during transport thereof.
Like anchoring systems 100 and 100 ′, anchoring system 300 includes an immobilizer to fix anchoring system 300 in a desired position and to prevent movement thereof. In that regard, anchoring system 300 includes braking arms 380 a and 380 b on each of the assemblies of wheel sets 350 c and 350 d . In FIGS. 8 and 9 , the outside wheel of back wheel set or pair 350 c has been removed to show braking arms 380 a , and 380 b . As clear to one skilled in the art, positioning the breaking mechanism so that it rotates with the wheels as illustrated in FIGS. 8 and 9 , facilitates braking operation by ensuring that the maximum braking force is generally aligned with the wheels.
Breaking arms 380 a and 380 b move in the manner of scissor arms to be brought into fixed abutment with a surface such a deck 40 (see FIG. 8 ) to immobilize anchoring system 300 and to be removed from contact with a surface such as deck 40 (see FIG. 9 ) to allow movement of anchoring system 300 thereover via wheels 350 a–d . As illustrated in FIG. 9 , each of breaking arms 380 a and 380 b can include a serrated section 382 a and 382 b , respectively, to improve the braking aspect thereof. Such serrated sections can, for example, dig into a wooden or other deformable or roughened surface.
The open nature of support 330 allows a worker to walk therethrough (between weighting units 340 a and 340 b and over transverse member 336 and 334 ) to reach the leading edges of deck 40 to, for example, facilitate the transfer of materials to the work area.
FIG. 10 illustrates another embodiment of an anchoring system 400 of the present invention. Unlike anchoring systems 100 , 100 ′ and 300 , anchor member 405 of anchoring system 400 is not extended beyond the edge of the work area. In that regard, anchoring system 400 includes two generally vertically extending supports 410 a and 410 b . Anchor member 405 (for example, a steel bar) extends between vertically extending supports 410 a and 410 b at or near the elevated end thereof. In the embodiment of FIG. 10 , vertically extending supports 410 a and 410 b include extending members 412 a and 420 a and extending members 412 b and 420 b , respectively, connected generally in the form of A-frames. Anchoring system 400 can also include a support or base 430 , which can include generally longitudinal member 432 a and 432 b connected between extending members 412 a and 420 a and extending members 412 b and 420 b , respectively. Base 430 can also include generally latitudinal or transverse members 434 and 436 connected between generally longitudinal member 432 a and 432 b.
Although it is desirable that an anchor point be located above the head of worker 10 as well as generally in line vertically with worker 10 , the present inventors have discovered that it is beneficial to have an effective anchor point positioned in the vicinity of an edge of a work area as high as possible (preferably above the head of worker 10 ) even if that anchor point is not generally vertically aligned with worker 10 . As used herein, the term “effective anchor point” refers generally to the anchor point experienced by worker 10 , which need not be the same point to which a lanyard or lifeline 60 supporting worker 10 is attached. In FIG. 10 , for example, self-retractable lanyard 60 is connected to anchor A, which can be any stable anchor member such as a column or heavy weight. As discussed in connection with FIG. 1 , anchor A is positioned generally laterally or horizontally with respect to D-ring 70 of harness 80 worn by worker 10 . However, in the system of FIG. 10 , lanyard 50 passes over anchor member 405 , creating an effective anchor point or height A′. Self-retractable lanyard 60 or other lifeline system can also be anchored directly to anchor member 405 .
Should worker 10 fall, the drum of self-retractable lanyard 60 will much more quickly experience an angular velocity corresponding to the rate of fall of worker 10 than is the case with the system of FIG. 1 , thereby stopping the fall of worker 10 more quickly. Although, worker 10 can still swing during or after a fall, the rate of descent and the vertical length of the fall will be decreased as compared to the system of FIG. 1 , thereby reducing the risk of injury. Preferably, anchoring system 400 is placed as close to worker 10 (that is, as close to the edge of deck 40 as possible. Moreover, the higher anchor member 10 is above the head of worker 10 , the greater the protection afforded. Preferably, for example, anchor member 405 is 6 to 12 feet above the head of worker 10 .
Anchoring system 400 can be fabricated to be fairly light and readily and manually movable, for example, by two workers. Support 430 can also include wheels and an immobilizing or breaking system as described above for anchoring systems 100 , 100 ′ and 300 . Similar to anchoring system 300 , the open nature of anchoring system 400 allows a worker to walk therethrough (between weighting supports 410 a and 410 b and over transverse member 434 and 436 ) to reach the edge of a work area (for example, the leading edge of deck 40 ) to, for example, facilitate the transfer of materials to the work area.
Although the present invention has been described in detail in connection with the above examples, it is to be understood that such detail is solely for that purpose and that variations can be made by those skilled in the art without departing from the spirit of the invention except as it may be limited by the following claims. | An anchoring system includes an anchor member to anchor the lifeline and at least one extending unit to extend the anchor member out to a working position beyond (horizontally) and above (vertically) an edge to provide for an overhead anchoring point. The anchoring system preferably further includes a support to which the extending unit is attached. The support immobilizes the overhead anchoring system so that the anchor member remains at the working position (even in the case of a fall by the worker). A method of anchoring a fall protection lifeline for use by a worker working at or beyond an edge includes the steps: elevating an anchor member to position the lifeline above the head of a worker and supporting the anchor member at the working position. The method can also include the step of extending the anchor member to a working position horizontally beyond and above the edge. |
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BACKGROUND OF THE INVENTION
The present invention relates to structural panel assemblies, and particularly to an improved insulated structural panel incorporating a pair of oppositely located structurally reinforced load-bearing skins.
The ever-increasing cost of obtaining useful heat energy from sources such as oil, coal, wood, and the sun has caused a great deal of effort to be directed to the design of building enclosures having low thermal conductivity, for the retention or exclusion of heat. Some builders have increased wall thicknesses by using wider stud members, increasing wall thickness to measurements as great as 24 inches, in order to accommodate insulating materials such as fiberglass. Such construction is undesirably expensive, in terms of the cost of insulating materials, the amount of heat conducted through building wall stud members, and the labor used to build an enclosure having sufficient structural strength and insulation. In addition, such large cavities filled with loose insulating material in floors, walls, ceilings, and roof spaces create concern over proper ventilation, control of fires, control of insect and rodent infestation, and control and exclusion of humidity and prevention of thermal cycling within the interior portion of the panels and air infiltration into the building through the effects of vacuum and pressures caused by wind and heated air rising and finding an outlet to the outside. Maintenance costs, particularly in the event any of the enclosed material volume becomes wet or is infested with vermin, could be sizable, and repair could be difficult to accomplish. Fires in such large cavities in floors, walls, or roofs, would be quick to spread and difficult to control, and may result in rapid impairment of the structural system of the building. Recently, building codes have required that panel skins and/or the thermal barriers must remain in place for certain periods of time depending on the particular code classification of the building.
Some builders have recently begun using post-and-beam construction combined with insulated structural panels having a pair of parallel skin members of plywood and the like, interconnected and insulated by expandable plastic foam, using the panels to close the spaces defined by the post-and-beam structures. Such panels, however, have a limited amount of aesthetic appeal in architectural designs and as interior finishing panels, and such panels make only a limited contribution to structural strength.
Other building panels in use in home construction, smaller office buildings, and cold storage structures, have frames of lumber to carry structural loads, to which are attached exterior and interior plywood panel faces, with the spaces between the panel faces being filled with various insulating materials. The opposite panel faces are, thus, interconnected by wooden load-bearing members which span the entire distance between the opposite panel faces. Building panels of such construction are able to support considerable loading and are usable as floor, wall and roof panels. Such construction, however, still permits too great an amount of heat to be conducted between panel faces through the structural strength members in such building panels.
These and other related problems have been dealt with more or less satisfactorily in the past, as is shown, for example, in Jamison U.S. Pat. No. 4,471,591, which discloses a wall assembly having studs located alternately on opposite sides of a wall, with cured foam insulation located along an exterior side skin, and conventional fiberglass batts filling the space between the foam and an interior skin. Peterson U.S. Pat. No. 4,224,774 discloses a structural column member built up of a pair of dimension lumber stud elements joined by a core of mineral fibers bonded together by a resin. This structural member is used to support the inner and outer face coverings of a wall or the like, with apparently fibrous insulating material filling the remainder of the interior of the wall.
Turner, Jr. U.S. Pat. No. 4,285,184 discloses a wall construction including alternately located studs supporting the opposite skins of the wall, with the space between the skins being filled with an unspecified thermal insulating material. Coutu, Sr. U.S. Pat. No. 4,443,988 and Day et al. U.S. Pat. No. 4,147,004 disclose composite wall panels including skins of wood sheet material bonded adhesively to rigid expanded foam core material. LeMaitre U.S. Pat. No. 4,395,853 discloses a roof structure including a pair of opposite metal skins spaced apart from each other by metal spacers, with thermal insulation being located between the skins.
Butcher U.S. Pat. No. 3,258,889 discloses a prefabricated building panel in which closed cell foam is used to fasten a skin to one side of a frame structure for a wall of a mobile home.
None of the above-mentioned structures, however, has fully met the need for a building panel which is acceptably strong, light, and thermally insulative, yet low in cost and able to maintain structural integrity when subjected to the stresses of a harsh climate, high winds, structural loadings and earthquake loading.
SUMMARY OF THE INVENTION
The present invention provides a composite building panel assembly providing the insulating properties of rigid foamed-in-place plastic foam core within a panel having a pair of oppositely located, stressed skin members supported by wooden strength members which span only a part of the distance separating one skin of the panel from the opposite one. The strength members are located between the two opposite skin members of the panel and attached alternately to each of them. The skin members are supported at the desired separation from one another, both during construction of the panels and during use of the panels, by a plurality of relatively small bridge elements whose size, for example, only 71/2 square inches out of 32 square feet (4,608 square inches) in a preferred embodiment of the invention, permits conduction of only a minor fraction of the amount of heat or cold from one side to the other of the panel. This is a much smaller amount than is conducted by wooden or metal strength members which extend from one skin the entire distance to the opposite skin.
In a preferred embodiment of the invention a pair of parallel plywood skin members are separated from one another by a distance greater than the width of a stud, joist, or rafter member of sufficient strength for the intended loading of the panel, with the strength members being located between the skins, spaced apart from one another along the panel and attached alternately to the opposite ones of the skins by both an adhesive and mechanical fasteners. A spacer member of foam plastic material of the appropriate size is fastened by an adhesive to each of the strength members and to the opposite skin member along substantially the entire face of the strength member. Along each of the outer marginal portions of the panel an edge stiffening frame which is a composite structural member, comprising a pair of parallel edge stiffening members made up of dimensional lumber, laminated wood, or metal attached by adhesives and mechanical fasteners (nails, staples, screws) to a dense foam edge gap spacer providing a total thickness to match the planned thickness of the panel and its plastic foamed core, is located between the skins, fastened to the skins by an adhesive and mechanical fasteners. A plurality of wooden bridge members normally of 3/8" plywood 2" to 3" wide and as long as the distance between panel skins, are fastened to the edge stiffening frame members at midlength and in locations near each end of the panel, maintaining the desired separation between the skin members during assembly of the panel and thereafter.
The edge stiffening members may be inset a short distance such as 3/4" along the margins of both skins of a panel along one edge, and located so as to extend a like distance beyond the skin members along an opposite edge of the panel to provide a tongue-and-groove type of interlocking joint between adjacent ones of the panels during erection of a structure. Alternatively, the skin members on opposite sides of a panel according to the invention may be offset laterally with respect to one another to provide a ship lap type of joint between adjacent ones of the panels according to the invention. Placing the frame component flush with edges of the panel faces provides a butt joint between adjacent panels. By insetting the frames (11/2" or more) from the edges of both panel skins and on both sides of the panel a space of 3" or more is created as the panels are joined. This space of 3" or more will accept an insulated spline which joins adjacent panels or the space may be filled with structural lumber to create a concealed post or beam for load support.
It is therefore a principal object of the present invention to provide an improved thermally insulating structural panel capable of providing thermal insulation values far greater than those of building walls and panels of normal 2"×4", 2"×6", 2"×8" or larger dimension lumber stud construction.
It is another important object of the present invention to provide a building panel which includes no substantial paths for conducting thermal energy from one side to the other side of the panel, and yet meets structural strength requirements.
A principal feature of the building panels of the present invention is that they include bridge members extending transversely between the opposite skin members to maintain skin member spacing during both construction and use of the building panels, which have structural strengthening members located between skin members and fixedly attached alternately to both of the skin members, with the opposite skin members also being interconnected by the adhesive strength of a rigid foamed-in-place plastic foam core.
lt is an important feature that electrical conduit, outlet boxes and switch boxes may be installed within the panel during construction of the assembly and before placement of the plastic foam. The conduit and boxes being foamed in prevents the conduit and boxes from collecting condensate and channeling cold air into the building.
It is another important feature of the building panels of the present invention that they include bridge members connecting the marginal portions of the skin members surrounding openings for windows and doors.
It is an important advantage of the building panels of the present invention that they provide better thermal insulation than was previously available in a building panel of high volume and low weight and which has a required amount of structural strength and rigidity.
It is another important advantage of the present invention that it provides a building panel which is high in thermal insulative value, but which contains no open voids which could serve as chimneys in case of fire, harbor vermin within a building constructed of such building panels or promote thermal cycling in cavities.
A further advantage of the present invention is that it provides a building panel which, having no substantial wood or metal members extending through the panel, effectively reduces noise transmission and socalled "telephoning" of sound along nails and wood paths.
The invention also has the advantage of providing a building panel which is of itself an aadequate vapor barrier and does not require a separate interior vapor barrier and an exterior wind or water barrier.
Still another important advantage of the invention is that the incorporation of structural and thermally insulating frame or stud components act to prevent structural "creep" that may occur in foam sandwich panels having only a foam core and no stiffeners or studs as structural components.
The foregoing and other objectives, features, and advantages of the present invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a wall panel constructed in accordance with the present invention.
FIG. 2 is an end view of the wall panel shown in FIG. 1.
FIG. 3 is a sectional view of the panel shown in FIG. 1, taken along line 3--3.
FIG. 4 is a detail view showing the manner in which one of the bridge members is included in the panel shown in FIGS. 1-3.
FIG. 5 a perspective view of another panel similar to that shown in FIGS. 1-4, but including a window opening through the panel.
FlG. 6 is a top view of a shiplap joint between two adjacent panels according to the invention.
FIG. 7 is a top view of a detail of a wall constructed using panels according to the invention in a concealed post-and-beam type of frame construction.
FIG. 8 is a top view of a detail of a wall constructed of panels according to the invention, using a spline joint between adjacent panels.
FIG. 9 is a view similar to that of FIG. 8, showing a tongue-and-groove joint between adjacent panels.
FIG. 10 is a view similar to that of FIG. 8, showing a butt joint between adjacent panels.
FIG. 11 is a view similar to that of FIG. 8, showing a tongue-and-groove joint between adjacent panels in a wall of exposed post construction.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-4 of the drawings, a building panel 10 which is a preferred embodiment of the present invention includes a pair of opposite skin members 12, 14 which are of material such as plywood. Alternatively, one or both of the skin members 12, 14 may be of a board constructed of wood chips adhesively integrated into panel form, or, depending upon the loading and atmospheric conditions to which the panel 10 is to be subjected, a gypsup wallboard.
By way of illustration, the panel 10 shown in FIGS. 1 and 2 has skin members 12, 14 of 3/4 inch thick exterior grade plywood, and has a width 16 of 4 feet and a length 18 of 8 feet. Other dimensions might be used, depending upon the intended use of the panel 10 according to the present invention, which has ample structural strength to be used to construct a self-supporting shell of a building, utilizing the panels 10 including appropriate components, depending upon the strength required, for floor, wall, and roof panels.
Attached fixedly to the skin member 12 are a pair of stiffening strength members 20 separated by a distance of approximately two feet, center-to-center, and extending parallel with one another, lengthwise of the panel 10. Each of the strength members 20 is located approximately one foot from the nearer of the longitudinal edges 22 of the skin member 12. The strength members 20 are attached to the skin member 12 by an adhesive, which may be any appropriately waterproof adhesive having sufficient strength, and by a plurality of mechanical fasteners such as staples 24 extending through the skin member 12 into the respective strength member 20.
A stiffening strength member 26 is attached similarly to the skin member 14 at a location midway between the strength members 20, approximately two feet from each of the longitudinal edges 28 of the skin member 14. Each of the stiffening or strength members 20 and 26 may, in the panel 10, be of nominal 2"×4" dimension lumber, for example, thus having a thickness or smallest dimension 30 of 1 1/2", and a major transverse dimension or depth 32 of 31/2" in the direction toward the opposite one of the skin members 12, 14. Strength members 20, 26 may be of other sizes, depending on the loading to which the panel 10 will be subjected. The interior sides of the skin members 12, 14 are separated from one another by a distance 34 of, for example, 51/2", leaving each of the strength members 20, 24 separated from the opposite one of the skin members 12, 14 by a gap space which is filled by a respective filler block 36, which is preferably of a high density, rigid polyurethane plastic foam material cut to the appropriate size and shape. Each filler block 36 is attached by a suitable adhesive to the respective one of the strength members 20, 26. While one dimension of the filler block 36 will be determined by the distance 34 between the skin members 12, 14, the width 38 of each is preferably equal to the thickness 30 of the respective strength member 20 or 26 to.which the particular filler block is attached.
Extending along each of the longitudinal edges 22, 28 of the panel 10 are a pair of edge stiffener frame members 40. Each edge stiffener frame member 40 is constructed of two nominal 2"×2" (actual dimensions 11/2"×11/2") wooden or lumber stiffeners 42 and one dense foam gap filler block member 44 (21/2"×11/2") and three plywood bridge members 50. A similar edge stiffener frame member 41 extends along each end of the panel 10, as shown in FIG. 2. Depending upon the distance 34 separating the opposite skin members 12, 14 of a particular panel 10, and also depending upon the structural requirements for strength of the panel 10, the dimensions of the edge stiffener members 42 may be equal to those of the stiffening strength members 20, 26 in some cases, although in most cases the depth 46 of each edge stiffener 42 will be less than the depth 32 of the strength members 20 and 26, in order to assure that there is a significant distance separating the opposite edge stiffeners 42 as a barrier to conduction of thermal energy through the panel 10 from one side to the other.
As are the strength members 20, 26, each of the edge stiffeners 42 is attached to the respective skin member 12 or 14 by an appropriate adhesive and fasteners such as staples 24.
Any of the structural strengthening members 20, 26 or the edge stiffeners 42 may be of dimension lumber. Where additional strength requirements are present, these members may instead be of glued parallelgrain, laminated wood construction. In other cases a column member of several 2"×6" members glued and nailed together might be fastened to the interior side of one of the skin members 12, 14 which will be the interior side of a panel 20 included in an exterior wall of a structure.
Extending between the interior surfaces of the skin members 12, 14 are a plurality of wooden bridge members 50, shown in greater detail in FIG. 4. The bridge members 50 each have a length 52 substantially equal to the distance 34 separating the skin members 12, 14. A thickness 54 is preferably 3/8", and, at most, need not be greater than the thickness 30 of the strength members 20, 26. A depth 56 of each bridge member 50 is, for example, about 2", but in no case need the depth 56 be greater than the depth 32 of the strength members 20, 26.
The bridge members 50 are located spaced apart from one another along each of the longitudinal sides of the panel 10, as shown in FIG. 1, with, for example, three of the bridge members being located on each side of a panel 10. Each of the bridge members 50 is located adjacent to and attached to respective coplanar portions of opposite ones of the edge stiffeners 42, by mechanical fasteners such as the staples 58 shown in FIG. 4, which may be inserted using an automatic stapler.
As will be appreciated, the combination of the stiffening strength members 20, 26 and edge stiffeners 42, together with the respective filler blocks 36 and edge gap filler blocks 44, define a plurality of cavities 62, 64, 66, 68 between the opposite skin members 12, 14.
Each of these cavities is filled with a polyurethane or polyisocyanurate foam 70 which is placed in the respective cavities by injecting the necessary mixture of chemical reagents into the cavities 62, 64, 66, and 68, where they react forming a foam core having a density of at least about two pounds per cubic foot, and preferably about 2.5 to 2.75 pounds per cubic foot. A satisfactory material for this application is available from the CPR Division of the Upjohn Company as its CPR® 870 Class I pour or froth polyurethane foam system, which provides a foam having a shear strength of 21 psi perpendicular to the direction of rise of the foam and a compressive strength of as much as 38 psi depending on the direction of stress with respect to the rise of the foam.
Additionally, the foam 70 adheres itself strongly to the surrounding surfaces of the skin members 12 and 14, filler blocks 36, edge gap filler blocks 44, strength members 20, 26, edge stiffeners 40, and bridge members 50. As a result, the panel 10 is a strongly unified and structurally integrated panel in which the skin members 12 and 14, as well as the strength members 20, 26 and edge stiffener frame members 40, 41 all contribute to the overall strength of the panel 10 and its ability to carry the loads imposed by wind pressure, floor and roof loading, and the weight of structure supported above.
Depending upon the intended use of a particular panel in a wall, roof, or floor portion of a building to be constructed of the panels 10 according to the present invention, the actual dimensions of the components of the panel 10 may differ, in order to satisfactorily carry the expected weights and direction of application of loading, and to provide the required amounts of insulation, depending upon the expected exposure of the particular panel in its designed location in a structure. While the panels 10 have been shown having skin members 12 and 14 which are parallel with one another, it may be desirable in some cases for the skin members not to be parallel, depending on the location of a panel within a structure. Nevertheless, the structure of the panels 10 will remain essentially the same, in that the skin members, core, and strength members are unified by adhesive interconnection and the use of bridge members 50.
If desired, an electrical conduit 77 and junction box 79 are provided within the panel, as shown in FIG. 3.
The panel 10 according to the present invention is manufactured by first assembling each of the longitudinal interior strengthening members and assembling edge stiffener frame members 40 and 41. Adhesives are applied on the two opposite 11/2" dimension sides of the foam gap filler block member 44, which is then placed between the two wooden stiffeners 42. The frame member 40 is then placed in a jig set for the depth 46 of the edge stiffener frame member, in this case 51/2".
Three bridge members 50 are fastened as by staples 24 to each (11/2"×11/2") wooden stiffener 42 which is approximately 8 feet long. One bridge member is placed in the middle of the approximately 8-foot dimension and another is placed about 8" in from each end, thus forming one insulating edge stiffener frame structural member 40. A total of two 8-foot edge stiffener frame members 40 and two approximately 4-foot-long members 41 make up the edge frames needed for one 4-foot ×8-foot panel 10. Bridge members 50 are not required for the approximately 4-foot-long end frame members 41.
Intermediate longitudinal members are made up of one nominal 2"×4" (actually 11/2"×31/2") wooden structural strength member 20 or 26 and one (11/2"×11/2") dense foam filler block 36. Adhesives are applied to one 11/2" side of the foam gap filler block 36, and it is placed against the 11/2" edge of the 2"×4" 20 or 26; then the assembly is placed in the jig set for 51/2" width. Staples 24 are driven through the foam edge of the filler block 36 into the 2"×4" 20 or 26 edge to hold the assembly together while the adhesive sets, thus forming one composite insulating interior longitudinal structural member. The edge stiffener frame members 40 and 41 and the composite interior longitudinal members are piled ready to be assembled into the completed panel 10 at the panel assembly tables.
A specially built panel assembly table is designed to assemble panels 10 up to 4 feet wide and 16 feet long. On the assembly table two 8-foot-long and two 4-foot-long frame members 40 and 41 are positioned on edge at the outer portion of the 4-foot width and the ends of the 8-foot length. Three interior longitudinal panel structural members are positioned on 12" centers in a configuration as shown in FIG. 3. Staples 24 are driven through the approximately 4-foot end frame members 41 into the ends of the five approximately 8-foot-long members 41, 20 and 26 at each end of the 8-foot-long members.
While the assembled frame setup is still in place on the assembly table, adhesives are applied to the top edges of the members 20, 26, 40, and 41. The plywood skin member 12 is then positioned on top of the already positioned members 20, 26, 40 and 41 and then staples 24 are set through the plywood skin into the wooden members 20 and 42. The positioning of the skin determines the type of joint the panel 10 being fabricated can form with adjacent panels.
At this phase of the assembly of the panel 10 the electrical wiring conduit 77 or raceways and the outlet boxes 79 may be installed. Also, door and window openings may be framed in (see FIG. 5), using frame members with bridge members 92 equivalent to the edge stiffener frame members 40, 41, included as needed.
The skin member 12 with the frames 16, 18, 20 now attached is taken from the first panel assembly table to a second panel assembly table and positioned with the skin member 12 face down with the attached frames 16, 18, and 20 showing upward. Adhesives are applied to the frame members and skin member 14 is placed in position and stapled 32 through the skin member 14 into the frames 16, 18, and 20, thus framing and skinning a panel 10.
The assembled panels 10 are taken from the table and placed flat on a strongback foaming cart. Separators of 11/8" plywood are placed between adjacent panels 10, and the stack is taken to about a 6-foot height containing several panels 10. A strongback is placed on top of the stack and then fastened very securely to the bottom strongback to prevent bulging of the skins of panels 10 during foam placement.
Foam-forming chemicals are introduced in appropiate quantity into the several cavities 62, 64, 66, and 68 through openings made through the edge gap filler block 44 along an edge of an end edge stiffener frame member 41 of each panel 10. The chemicals then react within the panel cavities to form the insulating foam core 70 of the panels. During the foaming pressures of up to 3 pounds per square inch may occur. This pressure build-up acts to fill all of the cavities 62, 64, 66, and 68 and insures maximum adhesion of the foam to the skins and frame members within the cavities. The secured panel stack is kept restrained for about 30 to 45 minutes depending upon the foam core thickness and the temperatures in the foam room. Thereafter, the panel stack is broken down and the panels 10 are cleaned, checked and stacked for curing from 24 to 48 hours at room temperature before being subjected to outside weather.
It will be appreciated that this construction provides a panel 10 in which there are no members which extend as paths for conduction of heat from one side to the other of the panel, except for the relatively very small bridge members 50. These bridge members 50, however, serve a very important purpose in that they maintain the proper spacing between the skin members 12 and 14 both during and after construction of the panel 10. This helps to preserve the integrity of the panel along the longitudinal edges 22 and 28 and to prevent separation of the adhesive bond between the foam core materials 70 and the interior surfaces of the skin members 12, 14. The bridge members 50 also maintain the integrity of the panel 10 by connecting the edge stiffeners 40, 42, should separation occur between one of the skin members 12 or 14 and the foam materials 70, as, for example, might otherwise occur if the core 70 were ignited. Thus, the bridge members 50 strengthen the structure of a panel 10 whose skin members 12 and 14 are integral load-bearing members, rather than being simply weatherproofing covers, and in which none of the strengthening members 20, 26, or 42 form a path to conduct heat between opposite sides of the panel 10.
Referring now to FIG. 4, a panel 72 which also embodies the invention is essentially similar to the panel 10, except that it includes an opening 74 for a window, or door, which extends through the panel from a skin member 12' to the opposite skin member 14'. Except for the opening 74, the structure of the panel 72 is similar to that of the panel 10, and like parts are indicated in FIG. 4 by the reference numerals used previously in describing the panel shown in the panel 10. The panel 72 is shown without the expanded-in-place foam 70, in the interest of visibility. Surrounding the window opening 74 is a structural frame including edge stiffening members 80, 82, 84, 86 which are fastened to the skin members 12', 14' by adhesives and mechanical fasteners such as staples 88. Edge gap filler blocks 90 similar to the edge gap filler blocks 44 fill the space between the edge stiffeners 80, 82, 84 and 86. Bridge members 92, similar to the bridge members 50, are provided to perform the same functions around the margins of the opening 74 as the bridge members 50 described previously, and the framing around the opening 74 is assembled in the manner described above with respect to the edge stiffener frames 40 and 41.
As shown in FIGS. 1-3, the skin members 12, 14 of a panel 10 intended to be used as part of a wall structure are located, with respect to the edge stiffener frames 40, so that at one side of the panel the skin members extend a slight distance beyond the edge stiffener frame 40, defining a space 94 between the extending portions of the skin members 12, 14, while at the opposite side of the panel, the edge stiffeners 42 extend beyond the respective longitudinal edges 22, 28 by a like distance, so that adjacent panels fit together in a tongue-and-groove manner as shown in FIG. 9, providing an inter-panel joint which is easily weatherproofed.
As shown in FIGS. 6 and 7, the locations of the edge stiffener frames 40, 41 with respect to the skins 12, 14 of a panel 10, may be varied, depending to some extent upon the application in which the particular panel 10 is to be used. Thus, as shown in FIG. 6, a pair of panels 10 are fastened to one another in a shiplap joint configuration in which the skin members 12, 14 are offset with respect to one another. At each side of each panel 10 one of the skin members 12, 14 exposes a portion of the respective edge stiffener 42 and extends beyond the other of the edge stiffeners 40, 42 a similar distance, preferably about one-half the thickness of the particular edge stiffener 42. Fasteners such as nails 98 may be used to join the panels 10 to each other.
In the pair of panels 10 shown in FIG. 7, the edge stiffener frames 40 are set inwardly from the edges 22, 28 a greater distance, corresponding to one-half of the width of a post 96 forming part of a post-and-beam frame of a structure, with the edges 22 and 28 of adjacent panels abutting against one another. Here, too, the bridge members 50 perform their function of maintaining the proper spacing between the opposite skin members 12, 14 of the panels, despite the forces which may be applied to the panels 10 by wind pressure or be transferred into the structural strength members 20, 26, and edge stiffeners 42 of the panels as a result of incorporation of the panels into a structure.
The pair of panels 10 shown in FIG. 8 both have their edge stiffener frame members 40 set inward from the edges 22 and 28 of the skins 12, 14, and a spline member 97, similar to the edge stiffener frames 40 is located between the panels 10. Fasteners such as nails or staples 98 extend through the skin members 12, 14 into the spline member 97 to interconnect the panels 10. As shown in FIG. 10 a pair of panels 10 may have their edge stiffener frame members 40 flush with the edges 22, 28 of the skins 12, 14. The design of the insulated edge stiffener frame member 40 readily permits the use of mechanical locking cams 100, such as the cam manufactured by Kason and described in U.S. Letters Pat. No. 3,784,240, to join panels instead of nails. Such devices are used when buildings must be dismantled and used at other locations, with access to operate each cam 100 provided through a hole 102. FIG. 11 is similar to FIG. 9, and shows the use of fasteners such as nails 98 to fasten panels 10, joined together by a shiplap joint, to an exposed post 104.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown an described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. | A stressed-skin building panel including structural strengthening members located alternately adjacent the two opposite skin members of the building panel, each of the structural strengthening members being spaced apart from the opposite skin member by a block of high-density rigid foam material, and the remainder of the space between the skin members being occupied by a foamed-in-place foam insulating material adhering to the skin members and structural strengthening members and providing a significant amount of strength and resistance to compressive stresses. The opposite skin members are spaced apart from one another and held together at the proper spacing during and after construction by a plurality of bridge members which form the only direct connection between the skin members by other than insulating foam material, so that the insulating quality of the panels is maximized. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 61/122,434, filed Dec. 15, 2008, incorporated herein by reference, is hereby claimed.
U.S. Pat. No. 7,281,589 is incorporated herein by reference.
U.S. patent application Ser. No. 11/778,956, filed Jul. 17, 2007, is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND
In top drive rigs, the use of a top drive unit, or top drive power unit is employed to rotate drill pipe, or well string in a well bore. Top drive rigs can include spaced guide rails and a drive frame movable along the guide rails and guiding the top drive power unit. The traveling block supports the drive frame through a hook and swivel, and the driving block is used to lower or raise the drive frame along the guide rails. For rotating the drill or well string, the top drive power unit includes a motor connected by gear means with a rotatable member both of which are supported by the drive frame.
During drilling operations, when it is desired to “trip” the drill pipe or well string into or out of the well bore, the drive frame can be lowered or raised. Additionally, during servicing operations, the drill string can be moved longitudinally into or out of the well bore.
The stem of the swivel communicates with the upper end of the rotatable member of the power unit in a manner well known to those skilled in the art for supplying fluid, such as a drilling fluid or mud, through the top drive unit and into the drill or work string. The swivel allows drilling fluid to pass through and be supplied to the drill or well string connected to the lower end of the rotatable member of the top drive power unit as the drill string is rotated and/or moved up and down.
Top drive rigs also can include elevators are secured to and suspended from the frame, the elevators being employed when it is desired to lower joints of drill string into the well bore, or remove such joints from the well bore.
At various times top drive operations, beyond drilling fluid, require various substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as the top drive unit is rotating and/or moving the drill or well string up and/or down, but bypassing the top drive's power unit so that the substances do not damage/impair the unit. Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movement by the top drive unit of the drill or well string.
A need exists for a device facilitating insertion of various substances downhole through the drill or well string, bypassing the top drive unit, while at the same time allowing the top drive unit to rotate and/or move the drill or well string.
One example includes cementing a string of well bore casing. In some casing operations it is considered good practice to rotate the string of casing when it is being cemented in the wellbore. Such rotation is believed to facilitate better cement distribution and spread inside the annular space between the casing's exterior and interior of the well bore. In such operations the top drive unit can be used to both support and continuously rotate/intermittently reciprocate the string of casing while cement is pumped down the string's interior. During this time it is desirable to by-pass the top drive unit to avoid possible damage to any of its portions or components.
The following U.S. Patents are incorporated herein by reference: U.S. Pat. Nos. 4,722,389 and 7,007,753.
While certain novel features of this invention shown and described below are pointed out in the annexed claims, the invention is not intended to be limited to the details specified, since a person of ordinary skill in the relevant art will understand that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation may be made without departing in any way from the spirit of the present invention. No feature of the invention is critical or essential unless it is expressly stated as being “critical” or “essential.”
BRIEF SUMMARY
The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner. One embodiment relates to an assembly having a top drive arrangement for rotating and longitudinally moving a drill or well string. In one embodiment is provided a swivel apparatus, the swivel generally comprising a mandrel and a sleeve with a packing configuration, the swivel being especially useful for top drive rigs.
In one embodiment the sleeve can be rotatably and sealably connected to the mandrel. The swivel can be incorporated into a drill or well string, enabling string sections both above and below the sleeve to be rotated in relation to the sleeve. Additionally, the swivel provides a flow path between the exterior of the sleeve and interior of the mandrel while the drill string is being rotated and/or being moved in a longitudinal direction (up or down). The interior of the mandrel can be fluidly connected to the longitudinal bore of the casing or drill string thereby providing a flow path from the exterior of the sleeve to the interior of the casing/drill string.
In one embodiment is provided a method and apparatus for servicing a well wherein a swivel is connected to a top drive unit for conveying pumpable substances from an external supply through the swivel for discharge into the well string and bypassing the top drive unit.
In another embodiment is provided a method of conducting servicing operations in a well bore, such as cementing, comprising the steps of moving a top drive unit rotationally and/or longitudinally to provide longitudinal movement and/or rotation in the well bore of a well string suspended from the top drive unit, rotating the drill or well string and supplying a pumpable substance to the well bore in which the drill or well string is manipulated by introducing the pumpable substance at a point below the top drive power unit and into the well string.
In other embodiments are provided a swivel placed below the top drive unit can be used to perform jobs such as spotting pills, squeeze work, open formation integrity work, kill jobs, fishing tool operations with high pressure pumps, sub-sea stack testing, rotation of casing during side tracking, and gravel pack or frack jobs. In still other embodiments a top drive swivel can be used in a method of pumping loss circulation material (LCM) into a well to plug/seal areas of downhole fluid loss to the formation and in high speed milling jobs using cutting tools to address down hole obstructions. In other embodiments the top drive swivel can be used with free point indicators and shot string or cord to free stuck pipe where pumpable substances are pumped downhole at the same time the downhole string/pipe/free point indicator is being rotated and/or reciprocated. In still other embodiments the top drive swivel can be used for setting hook wall packers and washing sand.
In still other embodiments the top drive swivel can be used for pumping pumpable substances downhole when repairs/servicing is being done to the top drive unit and rotation of the downhole drill string is being accomplished by the rotary table. Such use for rotation and pumping can prevent sticking/seizing of the drill string downhole. In this application safety valves, such as TIW valves, can be placed above and below the top drive swivel to enable routing of fluid flow and to ensure well control.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIGS. 1A and 1B are a schematic views showing a top drive rig with one embodiment of a top drive swivel incorporated in the drill string;
FIG. 2 is a perspective view of one embodiment of a top drive swivel;
FIG. 3 is a sectional view of a mandrel which can be incorporated in the swivel of FIG. 2 ;
FIG. 4 is a perspective view of a sleeve, clamp, and torque arm which can be incorporated into the swivel of FIG. 2 ;
FIG. 5 is an exploded view of the sleeve, clamp, and torque arm of FIG. 4 ;
FIG. 6 is a cutaway perspective view of the swivel of FIG. 2 ;
FIGS. 7A and 7B include a sectional view of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
FIG. 8 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 2 ;
FIG. 9 is a perspective view of a spacer;
FIG. 10 is a top view of the spacer of FIG. 9 ;
FIG. 11A is a sectional side view of the spacer of FIG. 9 ;
FIG. 11B is an enlarged sectional side view of the spacer of FIG. 9 ;
FIG. 12 is a perspective view of a female backup ring;
FIG. 13 is a top view of the female backup ring of FIG. 12 ;
FIG. 14A is a sectional side view of the female backup ring of FIG. 12 ;
FIG. 14B is an enlarged sectional side view of the female backup ring of FIG. 12 ;
FIG. 15 is a perspective view of a seal ring;
FIG. 16 is a top view of the seal ring of FIG. 15 ;
FIG. 17A is a sectional side view of the seal ring of FIG. 15 ;
FIG. 17B is an enlarged sectional side view of the seal ring of FIG. 15 ;
FIG. 18 is a perspective view of a rope seal;
FIG. 19 is a top view of the rope seal of FIG. 18 ;
FIG. 20A is a sectional side view of the rope seal of FIG. 18 ;
FIG. 20B is an enlarged sectional side view of the rope seal of FIG. 18 ;
FIG. 21 is a perspective view of a seal ring;
FIG. 22 is a top view of the seal ring of FIG. 21 ;
FIG. 23A is a sectional side view of the seal ring of FIG. 21 ;
FIG. 23B is an enlarged sectional side view of the seal ring of FIG. 21 ;
FIG. 24 is a perspective view of a seal ring;
FIG. 25 is a top view of the seal ring of FIG. 24 ;
FIG. 26A is a sectional side view of the seal ring of FIG. 24 ;
FIG. 26B is an enlarged sectional side view of the seal ring of FIG. 24 ;
FIG. 27 is a perspective view of a male backup ring;
FIG. 28 is a top view of the male backup ring of FIG. 27 ;
FIG. 29A is a sectional side view of the male backup ring of FIG. 27 ;
FIG. 29B is an enlarged sectional side view of the male backup ring of FIG. 27 ;
FIGS. 30A and 30B include a sectional view of another embodiment of the swivel of FIG. 2 along with an enlarged sectional view of the packing area;
FIG. 31 is an exploded view of a set of packing which can be incorporated into the swivel of FIG. 30A ;
FIG. 32 is a perspective view of a spacer;
FIG. 33 is a top view of the spacer of FIG. 32 ;
FIG. 34A is a sectional side view of the spacer of FIG. 32 ;
FIG. 34B is an enlarged sectional side view of the spacer of FIG. 32 ;
FIG. 35 is a perspective view of a female backup ring;
FIG. 36 is a top view of the female backup ring of FIG. 35 ;
FIG. 37A is a sectional side view of the female backup ring of FIG. 35 ;
FIG. 37B is an enlarged sectional side view of the female backup ring of FIG. 35 ;
FIG. 38 is a perspective view of a seal ring;
FIG. 39 is a top view of the seal ring of FIG. 38 ;
FIG. 40A is a sectional side view of the seal ring of FIG. 38 ;
FIG. 40B is an enlarged sectional side view of the seal ring of FIG. 38 ;
FIG. 41 is a perspective view of a rope seal;
FIG. 42 is a top view of the rope seal of FIG. 41 ;
FIG. 43A is a sectional side view of the rope seal of FIG. 41 ;
FIG. 43B is an enlarged sectional side view of the rope seal of FIG. 41 ;
FIG. 44 is a perspective view of a seal ring;
FIG. 45 is a top view of the seal ring of FIG. 44 ;
FIG. 46A is a sectional side view of the seal ring of FIG. 44 ;
FIG. 46B is an enlarged sectional side view of the seal ring of FIG. 44 ;
FIG. 47 is a perspective view of a seal ring;
FIG. 48 is a top view of the seal ring of FIG. 47 ;
FIG. 49A is a sectional side view of the seal ring of FIG. 47 ;
FIG. 49B is an enlarged sectional side view of the seal ring of FIG. 47 ;
FIG. 50 is a perspective view of a male backup ring;
FIG. 51 is a top view of the male backup ring of FIG. 50 ;
FIG. 52A is a sectional side view of the male backup ring of FIG. 50 ;
FIG. 52B is an enlarged sectional side view of the male backup ring of FIG. 50 ;
FIG. 53 shows an alternative combination swivel and ball dropper;
FIG. 54 shows one embodiment of the ball dropper for the combination swivel and ball dropper of FIG. 53 .
DETAILED DESCRIPTION
Detailed descriptions of one or more preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in any appropriate system, structure or manner.
FIGS. 1A and 1B are schematic views showing a top drive rig 1 with one embodiment of a top drive swivel 30 incorporated into drill string 20 . FIG. 1A shows a rig 1 having a top drive unit 10 . Rig 1 comprises supports 16 , 17 ; crown block 2 ; traveling block 4 ; and hook 5 . Draw works 11 uses cable 12 to move up and down traveling block 4 , top drive unit 10 , and drill string 20 . Traveling block 4 supports top drive unit 10 . Top drive unit 10 supports drill string 20 .
During drilling operations, top drive unit 10 can be used to rotate drill string 20 which enters wellbore 14 . Top drive unit 10 can ride along guide rails 15 as unit 10 is moved up and down. Guide rails 15 prevent top drive unit 10 itself from rotating as top drive unit 10 rotates drill string 20 . During drilling operations drilling fluid can be supplied downhole through drilling fluid line 8 and gooseneck 6 .
As shown in FIG. 1B , during operations swivel 30 can be connected to rig 1 through clamp 600 and torque arm 630 . Torque are 630 can be pivotally connected to swivel 30 and can resist rotational movement of swivel sleeve 150 relative to rig 1 . Torque arm 630 can be slidably connected to rig 1 to allow a certain amount of longitudinal movement of swivel 30 with drill string 20 .
At various times top drive operations, beyond drilling fluid, require substances to be pumped downhole, such as cement, chemicals, epoxy resins, or the like. In many cases it is desirable to supply such substances at the same time as top drive unit 10 is rotating and/or moving drill or well string 20 up and/or down and bypassing top drive unit 10 so that the substances do not damage/impair top drive unit 10 . Additionally, it is desirable to supply such substances without interfering with and/or intermittently stopping longitudinal and/or rotational movements of drill or well string 20 being moved/rotated by top drive unit 10 . This can be accomplished by using top drive swivel 30 .
Top drive swivel 30 can be installed between top drive unit 10 and drill string 20 . One or more joints of drill pipe 18 can be placed between top drive unit 10 and swivel 30 . Additionally, a valve can be placed between top drive swivel 30 and top drive unit 10 . Pumpable substances can be pumped through hose 31 , swivel 30 , and into the interior of drill string 20 thereby bypassing top drive unit 10 . Top drive swivel 30 is preferably sized to be connected to drill string 20 such as 4½ inch (11.43 centimeter) IF API drill pipe or the size of the drill pipe to which swivel 30 is connected to. However, cross-over subs can also be used between top drive swivel 30 and connections to drill string 20 . Two sizes for swivel 30 will be addressed in this application—a 4½ inch (11.43 centimeter) version and a 6⅝ inch (16.83 centimeter) version.
FIG. 2 is a perspective view of one embodiment of a swivel 30 . Swivel 30 can be comprised of mandrel 40 and sleeve 150 . Sleeve 150 can be rotatably and sealably connected to mandrel 40 . Accordingly, when mandrel 40 is rotated, sleeve 150 can remain stationary to an observer insofar as rotation is concerned. As will be discussed later inlet 200 of sleeve 150 is and remains fluidly connected to a the central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 .
FIG. 3 is a sectional view of mandrel 40 which can be incorporated in swivel 30 . Mandrel 40 can be comprised of upper end 50 and lower end 60 . Central longitudinal passage 90 can extend from upper end 50 through lower end 60 . Lower end 60 can include a pin connection 80 or any other conventional connection. Upper end 50 can include box connection 70 or any other conventional connection. Mandrel 40 can in effect become a part of drill string 20 . Sleeve 150 can fit over mandrel 40 and become rotatably and sealably connected to mandrel 40 . Mandrel 40 can include shoulder 100 to support sleeve 150 . Mandrel 40 can include one or more radial inlet ports 140 fluidly connecting central longitudinal passage 90 to recessed area 130 . Recessed area 130 preferably forms a circumferential recess along the perimeter of mandrel 40 and between packing support areas 131 , 132 . In such manner recessed area 130 will remain fluidly connected with radial passage 190 and inlet 200 of sleeve 150 (see FIGS. 6 and 7A ).
Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 52 and 5/16 inches (132.87 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. NC50 is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Such tool joint designation is equivalent to and interchangeable with 4½ inch (11.43 centimeter) IF (Internally Flush), 5 inch (12.7 centimeter) XH (Extra Hole) and 5½ inch (13.97 centimeter) DSL (Double Stream Line) connections. Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7G for new rotary shouldered tool joint connections having 6⅝ inch (16.83 centimeters) outer diameter and a 2¾ inch (6.99 centimeter) inner diameter. The Strength and Design Formulas of API 7G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 1,477,000 pounds (6,570 kilo newtons) tensile load at the minimum yield stress; (b) 62,000 foot-pounds (84 kilo newton meters) torsional load at the minimum torsional yield stress; and (c) 37,200 foot-pounds (50.44 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
In another embodiment, Mandrel 40 takes substantially all of the structural load from drill string 20 . In one embodiment the overall length of mandrel 40 is preferably 67 and 13/16 inches (172.24 centimeters). Mandrel 40 can be machined from a single continuous piece of heat treated steel bar stock. 6⅝ inch (16.83 centimeters) FH is preferably the API Tool Joint Designation for the box connection 70 and pin connection 80 . Additionally, it is preferred that the box connection 70 and pin connection 80 meet the requirements of API specifications 7 and 7G for new rotary shouldered tool joint connections having 8½ inch (21.59 centimeter) outer diameter and a 4¼ inch (10.8 centimeter) inner diameter. The Strength and Design Formulas of API 7G—Appendix A provides the following load carrying specification for mandrel 40 of top drive swivel 30 : (a) 2,094,661 pounds (9,318 kilo newtons) tensile load at the minimum yield stress; (b) 109,255 foot-pounds (148.1 kilo newton meters) torsion load at the minimum torsional yield stress; and (c) 65,012 foot-pounds (88.14 kilo newton meters) recommended minimum make up torque. Mandrel 40 can be machined from 4340 heat treated bar stock.
To reduce friction between mandrel 40 and packing units 305 , 405 and increase the life expectancy of packing units 305 , 405 , packing support areas 131 , 132 can be coated and/or sprayed welded with a materials of various compositions, such as hard chrome, nickel/chrome or nickel/aluminum (95 percent nickel and 5 percent aluminum) A material which can be used for coating by spray welding is the chrome alloy TAFA 95MX Ultrahard Wire (Armacor M) manufactured by TAFA Technologies, Inc., 146 Pembroke Road, Concord N.H. TAFA 95 MX is an alloy of the following composition: Chromium 30 percent; Boron 6 percent; Manganese 3 percent; Silicon 3 percent; and Iron balance. The TAFA 95 MX can be combined with a chrome steel. Another material which can be used for coating by spray welding is TAFA BONDARC WIRE—75B manufactured by TAFA Technologies, Inc. TAFA BONDARC WIRE—75B is an alloy containing the following elements: Nickel 94 percent; Aluminum 4.6 percent; Titanium 0.6 percent; Iron 0.4 percent; Manganese 0.3 percent; Cobalt 0.2 percent; Molybdenum 0.1 percent; Copper 0.1 percent; and Chromium 0.1 percent. Another material which can be used for coating by spray welding is the nickel chrome alloy TAFALOY NICKEL-CHROME-MOLY WIRE-71T manufactured by TAFA Technologies, Inc. TAFALOY NICKEL-CHROME-MOLY WIRE-71T is an alloy containing the following elements: Nickel 61.2 percent; Chromium 22 percent; Iron 3 percent; Molybdenum 9 percent; Tantalum 3 percent; and Cobalt 1 percent. Various combinations of the above alloys can also be used for the coating/spray welding. Packing support areas 131 , 132 can also be coated by a plating method, such as electroplating. The surface of support areas 131 , 132 can be ground/polished/finished to a desired finish to reduce friction and wear between support areas 131 , 132 and packing units 305 , 415 .
FIG. 4 is a perspective view of a sleeve 150 , clamp 600 , and torque arm 630 which can be incorporated into swivel 30 . FIG. 5 is an exploded view of the components shown in FIG. 4 . FIG. 6 is a cutaway perspective view of swivel 30 . FIG. 7A is a sectional view of swivel 30 taken along the line 7 A- 7 A of FIG. 6 .
FIG. 6 is an overall perspective view (and partial sectional view) of top drive swivel 30 . Sleeve 150 is shown rotatably connected to mandrel 40 . Bearings 145 , 146 allow sleeve 150 to rotate in relation to mandrel 40 . Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Retaining nut 800 retains sleeve 150 on mandrel 40 . Inlet 200 of sleeve 150 is fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 ; passing through radial passage 190 ; passing through recessed area 130 ; passing through one of the plurality of radial inlet ports 40 ; passing through central longitudinal passage 90 ; and exiting mandrel 40 through central longitudinal passage 90 at lower end 60 and pin connection 80 .
Sleeve 150 can include central longitudinal passage 180 extending from upper end 160 through lower end 170 . Sleeve 150 can also include radial passage 190 and inlet 200 . Inlet 200 can be attached by welding or any other conventional type method of fastening such as a threaded connection. If welded the connection is preferably heat treated to remove residual stresses created by the welding procedure. Lubrication port 210 (not shown) can be included to provide lubrication for interior bearings. Packing ports 220 , 230 can also be included to provide the option of injecting packing material into the packing units 305 , 405 . A protective cover 240 can be placed around packing port 230 to protect packing injector 235 . Optionally, a second protective cover can be placed around packing port 220 . Sleeve 150 can include a groove 691 for insertion of a key 700 . FIG. 7A illustrates how central longitudinal passage 90 is fluidly connected to inlet 200 through radial passage 190 .
Sleeve 150 slides over mandrel 40 . Bearings 145 , 146 rotatably connect sleeve 150 to mandrel 40 . Bearings 145 , 146 are preferably thrust bearings although many conventionally available bearing will adequately function, including conical and ball bearings. Packing units 305 , 405 sealingly connect sleeve 150 to mandrel 40 . Inlet 200 of sleeve 150 is and remains fluidly connected to central longitudinal passage 90 of mandrel 40 . Accordingly, while mandrel 40 is being rotated and/or moved up and down pumpable substances can enter inlet 200 and exit central longitudinal passage 90 at lower end 60 of mandrel 40 . Recessed area 130 forms a peripheral recess between mandrel 40 and sleeve 150 . The fluid pathway from inlet 200 to outlet at lower end 60 of central longitudinal passage 90 is as follows: entering inlet 200 (arrow 201 ); passing through radial passage 190 (arrow 202 ); passing through recessed area 130 (arrow 202 ); passing through one of the plurality of radial inlet ports 140 (arrow 202 ), passing through central longitudinal passage 90 (arrow 203 ); and exiting mandrel 40 via lower end 60 at pin connection 80 (arrows 204 , 205 ).
Sleeve 150 is preferably fabricated from 4140 heat treated round mechanical tubing having the following properties: (120,000 psi (827,400 kilo pascal) minimum tensile strength, 100,000 psi (689,500 kilo pascal) minimum yield strength, and 285/311 Brinell Hardness Range). In one embodiment the external diameter of sleeve 150 is preferably about 11 inches (27.94 centimeters). Sleeve 150 preferably resists high internal pressures of fluid passing through inlet 200 . Preferably top drive swivel 30 with sleeve 150 will withstand a hydrostatic pressure test of 12,500 psi (86,200 kilo pascal). At this pressure the stress induced in sleeve 150 is preferably only about 24.8 percent of its material's yield strength. At a preferable working pressure of 7,500 psi (51,700 kilo pascal), there is preferably a 6.7:1 structural safety factor for sleeve 150 .
To minimize flow restrictions through top drive swivel 30 , large open areas 140 are preferred. Preferably each area of interest throughout top drive swivel 30 is larger than the inlet service port area 200 . Inlet 200 is preferably 3 inches having a flow area of 4.19 square inches (27.03 square centimeters). In one embodiment the flow area of the annular space between sleeve 150 and mandrel 40 is preferably 20.81 square inches (134.22 square centimeters). The flow area through the plurality of radial inlet ports 140 is preferably 7.36 square inches (47.47 square centimeters). The flow area through central longitudinal bore 90 is preferably 5.94 square inches 38.31 square centimeters).
Retainer nut 800 can be used to maintain sleeve 150 on mandrel 40 . Retainer nut 800 can threadably engage mandrel 40 at threaded area 801 . Set screw 890 can be used to lock in place retainer nut 800 and prevent nut 800 from loosening during operation. A set screw 890 (not shown for clarity) can threadably engages retainer nut 800 through bore 900 (not shown for clarity) and sets in one of a plurality of receiving portions 910 formed in mandrel 40 . Retaining nut 800 can also include grease injection fitting 880 for lubricating bearing 145 . A wiper ring 271 (not shown for clarity) can be set in area 270 protects against dirt and other items from entering between the sleeve 150 and mandrel 40 . A grease ring 291 (not shown for clarity) can be set in area 290 for holding lubricant for bearing 145 .
Bearing 146 can be lubricated through a grease injection fitting 211 and lubrication port 210 (not shown for clarity).
FIGS. 4 and 5 best show clamp 600 which can be incorporated into top drive swivel 30 . FIG. 5 is an exploded view of clamp 600 . Clamp 600 can comprises first portion 610 , second portion 620 , and third portion 625 . First, second, and third portions 610 , 620 , 625 can be removably attached by plurality of fasteners 670 , 680 . Key 700 can be inserted in keyway 690 of clamp 600 . A corresponding keyway 691 is included in sleeve 150 of top drive swivel 30 . Keyways 690 , 691 and key 700 prevent clamp 600 from rotating relative to sleeve 150 . A second key 720 can be installed in keyways 710 , 711 . Third, fourth, and additional keys/keyways can be used as desired.
Shackles can be attached to clamp 600 to facilitate handing top drive swivel 30 when clamp 600 is attached. Torque arm 630 can be pivotally attached to clamp 600 and allow attachment of clamp 600 (and sleeve 150 ) to a stationary part of top drive rig 1 preventing sleeve 150 from rotating while drill string 20 is being rotated by top drive 10 (and top drive swivel 30 is installed in drill string 20 ). Torque arm 630 can be provided with holes for attaching restraining shackles. Restrained torque arm 630 prevents sleeve 150 from rotating while mandrel 40 is being spun. Otherwise, frictional forces between packing units 305 , 405 and packing support areas 131 , 135 of rotating mandrel 40 would tend to also rotate sleeve 150 . Clamp 600 is preferably fabricated from 4140 heat treated steel being machined to fit around sleeve 150 .
FIG. 8 shows a blown up schematic view of packing unit 305 . FIG. 7B shows a sectional view through packing area 305 . Packing unit 305 can comprise female packing end 330 ; packing ring 340 , packing lubrication ring 350 , packing ring 360 , packing ring 370 , and packing end 380 . Packing unit 305 sealing connects mandrel 40 and sleeve 150 . Packing unit 305 can be encased by packing retainer nut 310 , spacer 320 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 305 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . Packing unit 405 (shown in FIG. 7A ) can be constructed substantially similar to packing unit 305 . The materials for packing unit 305 and packing unit 405 can be similar.
Spacer 320 can comprise, first end 322 , second end 324 , internal surface 326 , and external surface 328 . Spacer 320 can be sized based on the amount of squeezed to be applied to packing unit 305 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
Packing end 330 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 330 can comprise tip 332 with concave portion 331 . Concave portion 331 can have an angle of about 130 degrees at its center. Tip 332 can include side 333 , recessed area 334 , peripheral groove 337 and inner diameter 335 . Recessed area 334 and inner diameter 335 can be configured to minimize contact of female packing ring or end 330 with mandrel 40 . Instead, contact will be made between packing ring 340 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 330 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 340 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi (20,700 kilo pascals or 27,600 kilo pascals)). It is also believed that packing rings 370 and/or 360 perform the majority of sealing against lower pressure fluids. Female packing ring 330 can include a plurality of radial ports 336 fluidly connecting peripheral groove 337 with interior groove 338 to allow packing injected to evenly distribute around ring and into the actual sealing rings.
Packing ring 340 can comprise tip 342 , base 344 , internal surface 346 , and external surface 348 . Tip 342 can have an angle of about 120 degrees to have an non-interference fit with tip 332 of female packing end 330 which is at about 130 degrees Base 344 can have an angle of about 120 degrees. Packing ring 340 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 342 of packing ring 340 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 334 of the female packing ring or end 330 which would cause side 333 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing. Base 344 being at about 120 degrees is believed to assist in causing packing ring 340 to bear against mandrel 40 , and not side 333 of female packing ring 330 .
Packing lubrication ring 350 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 350 is shown after be shaped by packing rings 340 and 360 .
Packing ring 360 can comprise tip 362 , base 364 , internal surface 366 , and external surface 368 . Tip 362 can have an angle of about 90 degrees. Base 364 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 360 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
Packing rings 360 , 370 can have substantially the same geometric construction. Packing ring 370 can comprise tip 372 , base 374 , internal surface 376 , and external surface 378 . Tip 372 can have an angle of about 90 degrees. Base 374 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 370 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
In an alternative embodiment both packing rings 360 and 370 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
In another alternative embodiment packing ring 370 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 360 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
Male packing end or ring 380 can comprise tip 382 , base 384 , internal surface 386 , and external surface 388 . Tip 382 can have an angle of about 90 degrees. Packing end 380 is preferably an aluminum bronze male packing ring.
Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
Using the above packing configuration it has been surprisingly found that packing life in a displacement job at high pressure can be extended from about 45 minutes to about 10 hours, at rotation speeds of about 30, about 40, about 50, and about 60 revolutions per minute.
In installing packing units 305 , 405 , it has been found that the packing units should first be compressed in a longitudinal direction between sleeve 150 and a dummy cylinder (the dummy cylinder serving as mandrel 40 ) before sleeve 150 is installed on mandrel 40 . This is because a certain amount of longitudinal compression of packing units 305 , 405 will occur when fluid pressure is first exerted on these packing units. This longitudinal compression will be taken up by the respective packing retainer nuts 310 . However, using a dummy cylinder allows the individual packing retainer nuts 310 to cause pre-fluid pressure longitudinal compression on packing units 305 , 405 , but still allow the seals to maintain an internal diameter consistent with the external diameter of mandrel 40 . Such a procedure can avoid the requirement of resetting the individual packing retainer nuts 310 after fluid pressure is applied to the packing units causing longitudinal compression.
Female packing ring or end 330 can include a packing injection option. Injection fitting 225 can be used to inject additional packing material such as teflon into packing unit 305 . Head 226 for injection fitting 225 can be removed and packing material can then be inserted into fitting 225 . Head 226 can then be screwed back into injection fitting 225 which would push packing material through fitting 225 and into packing port 220 . The material would then be pushed into packing ring or end 330 . Packing ring or end 330 can comprise a plurality of radial ports 336 , outer peripheral groove 337 , and inner peripheral groove 338 . The material would proceed through outer groove 337 , through the plurality of radial ports 336 , and through inner peripheral groove 338 causing a sealing effect. The interaction between injection fitting 235 and packing unit 405 can be substantially similar to the interaction between injection fitting 225 and packing unit 305 . A conventionally available material which can be used for packing injection fittings 225 , 235 is DESCO™ 625 Pak part number 6242-12 in the form of a 1 inch by ⅜ inch (2.54 centimeter by 0.95 centimeter) stick and distributed by Chemola Division of South Coast Products, Inc., Houston, Tex.
Injection fittings 225 , 235 have a dual purpose: (a) provide an operator a visual indication whether there has been any leakage past either packing units 305 , 405 and (b) allow the operator to easily inject additional packing material and stop seal leakage without removing top drive swivel 30 from drill string 20 .
FIGS. 30A through 50 show an alternative packing arrangement for packing units 305 , 405 . In this alternative arrangement spacer 420 can include a plurality of radial ports for injecting packing filler material.
FIG. 31 shows a blown up schematic view of packing unit 405 . FIG. 30B shows a sectional view through packing unit 405 . Packing unit 405 can comprise female packing end 430 ; packing ring 440 , packing lubrication ring 450 , packing ring 460 , packing ring 470 , and packing end 480 . Packing unit 405 sealing connects mandrel 40 and sleeve 150 . Packing unit 405 can be encased by packing retainer nut 310 , spacer 420 , and shoulder 156 of protruding section 155 . Packing retainer nut 310 can be a ring which threadably engages sleeve 150 at threaded area 316 . Packing retainer nut 310 and shoulder 156 squeeze packing unit 405 to obtain a good seal between mandrel 40 and sleeve 150 . Set screw 315 can be used to lock packing retainer nut 310 in place and prevent retainer nut 310 from loosening during operation. Set screw 315 can be threaded into bore 314 and lock into receiving area 317 on sleeve 150 . An upper packing unit can be constructed substantially similar to packing unit 405 . The materials for packing unit 405 and upper packing unit can be similar.
Spacer 420 can comprise, first end 421 , second end 422 , internal surface 423 , and external surface 424 . Spacer 420 can be sized based on the amount of squeezed to be applied to packing unit 405 when packing retainer nut 310 is tightened. It is preferably fabricated or machined from bronze.
Packing end 430 is preferably a female packing end comprised of a bearing grade peak or stiffened bronze material. Female packing ring or end 430 can comprise tip 432 with concave portion 431 . Concave portion 431 can have an angle of about 130 degrees at its center. Tip 442 can include side 433 , recessed area 44 , peripheral groove 47 and inner diameter 445 . Recessed area 434 and inner diameter 435 can be configured to minimize contact of female packing ring or end 430 with mandrel 40 . Instead, contact will be made between packing ring 440 and mandrel 40 . It is believed that minimizing contact between female packing ring or end 430 and mandrel 40 will reduce heat buildup from friction and extend the life of the packing unit. It is also believed that packing ring 440 performs the great majority of sealing against high pressure fluids (such as pressures above about 3,000 or about 4,000 psi) (20,700 kilo pascals or 27,600 kilo pascals). It is also believed that packing rings 470 and/or 460 perform the majority of sealing against lower pressure fluids.
Packing ring 440 can comprise tip 442 , base 444 , internal surface 446 , and external surface 448 . Tip 442 can have an angle of about 120 degrees to have an non-interference fit with tip 432 of female packing end 430 which is at about 130 degrees Base 444 can have an angle of about 120 degrees. Packing ring 440 is preferably a “Vee” packing ring—comprised of bronze filled teflon such as that supplied by CDI material number 714 . Tip 442 of packing ring 440 is made at about 120 degrees (which is blunter than the conventional 90 degree tips) in an attempt to limit the braking effect (e.g., caused by expansion of recessed area 434 of the female packing ring or end 430 which would cause side 433 of female packing ring to contact mandrel 40 ) on mandrel 40 when longitudinal force is applied through the packing. Base 444 being at about 120 degrees is believed to assist in causing packing ring 440 to bear against mandrel 40 , and not side 433 of female packing ring 430 .
Packing lubrication ring 450 , preferably includes at least one rope seal such as a Garlock ½ inch (or 7/16 inch or ⅜ inch) (1.27 centimeters, or 1.11 centimeters, or 0.95 centimeters) section 8913 Rope Seal. Rope seals have surprisingly been found to extend the life of other seals in the packing unit. This is thought to be by secretion of lubricants, such as graphite, during use over time. Although shown in a “Vee” type shape, rope seals typically have a square cross section and form to the shape of the area to which they are confined. Here, lubrication ring 450 is shown after being shaped by packing rings 440 and 460 .
Packing ring 460 can comprise tip 462 , base 464 , internal surface 466 , and external surface 468 . Tip 462 can have an angle of about 90 degrees. Base 464 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 460 is preferably a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 .
Packing rings 460 , 470 can have substantially the same geometric construction. Packing ring 470 can comprise tip 472 , base 474 , internal surface 476 , and external surface 478 . Tip 472 can have an angle of about 90 degrees. Base 474 can have an angle of about 120 degrees. 90 degrees for the tip and 120 degrees for the base are conventional angles. The larger angle for the base allows thermal expansion of the tip in the base. Packing ring 470 is preferably a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
In an alternative embodiment both packing rings 460 and 470 are“Vee” packing rings—comprised of teflon such as that supplied by CDI material number 711 .
In another alternative embodiment packing ring 470 can be a “Vee” packing ring—comprised of hard rubber such as that supplied by CDI material number 850 or viton such as that supplied by CDI material number 951 ; and Packing ring 460 can be a “Vee” packing ring—comprised of teflon such as that supplied by CDI material number 711 .
Male packing end or ring 480 can comprise tip 482 , base 484 , internal surface 486 , and external surface 488 . Tip 482 can have an angle of about 90 degrees. Packing end 480 is preferably an aluminum bronze male packing ring.
Various alternative materials for packing rings can be used such as standard chevron packing rings of standard packing materials.
FIG. 53 shows an alternative combination swivel and ball dropper.
FIG. 54 shows one embodiment of the ball dropper for the combination swivel and ball dropper of FIG. 53 .
The following is a list of reference numerals:
LIST FOR REFERENCE NUMERALS
(Part No.)
(Description)
Reference Numeral
Description
1
rig
2
crown block
3
cable means
4
travelling block
5
hook
6
gooseneck
7
swivel
8
drilling fluid line
10
top drive unit
11
draw works
12
cable
13
rotary table
14
well bore
15
guide rail
16
support
17
support
18
drill pipe
19
drill string
20
drill string or work string
30
swivel
31
hose
40
swivel mandrel
50
upper end
60
lower end
70
box connection
80
pin connection
90
central longitudinal passage
100
shoulder
110
interior surface
120
external surface (mandrel)
130
recessed area
131
packing support area
132
packing support area
140
radial inlet ports (a plurality)
145
bearing
146
bearing
150
swivel sleeve
155
protruding section
156
shoulder
157
shoulder
158
packing support area
159
packing support area
160
upper end
170
lower end
180
central longitudinal passage
190
radial passage
200
inlet
201
arrow
202
arrow
203
arrow
204
arrow
205
arrow
210
lubrication port
211
grease injection fitting
220
packing port
225
injection fitting
226
head
230
packing port
235
injection fitting
240
cover
250
upper shoulder
260
lower shoulder
270
area for wiper ring
271
wiper ring (preferably Parker part number
959-65)
280
area for wiper ring
281
wiper ring (preferably Parker part number
959-65)
290
area for grease ring
291
grease ring (preferably Parker part number
2501000 Standard Polypak)
300
area for grease ring
301
grease ring (preferably Parker part number
2501000 Standard Polypak)
305
packing unit
310
packing retainer nut
314
bore for set screw
315
set screw for packing retainer nut
316
threaded area
317
set screw for receiving area
320
spacer
322
first end
324
second end
326
internal surface
328
external surface
330
female packing end and packing injection
ring
331
concave portion
332
tip
333
side
334
recessed area
335
inner diameter
336
radial port
337
peripheral groove
338
interior groove
340
packing ring
342
tip
344
base
346
internal surface
348
external surface
350
packing ring
360
packing ring
362
tip
364
base
366
internal surface
368
external surface
370
packing ring
372
tip
374
base
376
internal surface
378
external surface
380
packing end
382
tip
384
base
386
internal surface
388
external surface
405
packing unit
410
packing retainer nut
414
bore for set screw
415
set screw for packing retainer nut
416
threaded area
417
set screw for receiving area
420
spacer and packing injection ring
421
first end
422
second end
423
internal surface
424
external surface
437
radial port
438
peripheral groove
439
interior groove
430
female packing end
431
concave portion
432
tip
433
side
434
recessed area
435
inner diameter
436
external diameter
440
packing ring
442
tip
444
base
446
internal surface
448
external surface
450
packing ring
460
packing ring
462
tip
464
base
466
internal surface
468
external surface
470
packing ring
472
tip
474
base
476
internal surface
478
external surface
480
packing end
482
tip
484
base
486
internal surface
488
external surface
600
clamp
605
groove
610
first portion
620
second portion
625
third portion
630
torque arm
650
shackle
660
shackle
670
plurality of fasteners
680
plurality of fasteners
690
keyway
691
keyway
700
key
710
keyway
711
keyway
720
key
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention set forth in the appended claims. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | For use with a top drive power unit supported for connection with a well string in a well bore to selectively impart longitudinal and/or rotational movement to the well string, a feeder for supplying a pumpable substance such as cement and the like from an external supply source to the interior of the well string in the well bore without first discharging it through the top drive power unit including a mandrel extending through a sleeve which is sealably and rotatably supported thereon for relative rotation between the sleeve and mandrel. The mandrel and sleeve have flow passages for communicating the pumpable substance from an external source to discharge through the sleeve and mandrel and into the interior of the well string below the top drive power unit. The unit can include a packing injection system and novel seal configuration. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to extruded moldings and, more particularly, to a set of interlocking extrusions for use in attaching panels of a shower enclosure.
2. Background
Certain shower enclosures, such as are used in recreational vehicles and the like, are constructed of prefabricated glass panels and at least one door panel that includes a door and doorframe. During the installation of such a shower enclosure, it is required to join together multiple panels of glass and their respective frames that protect the edges of the glass. One example of such a shower enclosure is designed for a corner installation with three panels, two adjoining the walls and perpendicular thereto, and a third, often comprising the door and doorframe, diagonally between the other two at a 135° angle with respect to each. This is often referred to as a “Neo-Angle” shower design.
There are numerous connection systems for attaching adjoining panels of framed glass of shower enclosures. Most existing shower enclosures use some form of an interlocking design feature to engage multiple glass panels/doorframes within the installation process, however there remains additional room for improvement.
During the installation process it is required to quickly and safely bring together and stabilize multiple glass panels/doorframes prior to permanent engagement. During this initial assembly and adjustment process, there is usually one installer who must maneuver numerous panels/doorframes at the same time prior to fastening them together in a “permanent” engagement. Existing shower enclosures lack a feature that is effective in securing the panels prior to the permanent fastening stage. Disengagement of adjoining panels during installation is problematic as a result of delays in the installation process as well as the risk for damaged property and personal injury to the installer.
SUMMARY OF THE INVENTION
The present invention provides a set of extruded interlocking moldings that provide a unique and superior method of joining together panels of framed glass and/or framed glass doors. A first molding has a channel along an edge of one face and a groove in the opposite face. A second molding has a tongue extending along an edge of one face and a flange along an edge of the opposite face. The channel of the first molding is configured to receive and hold the tongue of the second molding to secure the moldings together as the panels are aligned. The flange of the first molding snaps into the groove of the second molding when the moldings are rotated to a predetermined angle with respect to each other.
Some of the benefits of the present invention are:
An easier, safer and quicker installation. A “leading-outside-engagement feature” of the extrusions engages in a manner so that when the extrusions are rotated toward the permanent engagement position, the connection does not allow separation in the installation process. A secure connection between the door and fixed panels. Following the leading-outside-engagement feature connection, an “inside-engagement feature” then engages in a “snapping” function that locks and holds the panels permanently in the proper alignment. Upon permanent engagement, the relationship of the leading-outside-engagement feature and the inside-engagement feature reduces lateral or twisting action. The resulting strength of the fully assembled joint (i.e. “permanent” engagement) precludes the need of using fasteners to secure the panels together. Saving in material cost. The strength and stability of the fully assembled joint inherent in the moldings of the present invention reduces the amount of frame material required. Conventional frame moldings are thicker to accommodate fasteners, typically 3-5 screws per post, and access thereto. Since no fasteners are needed to assemble the moldings of the present invention, they can be substantially thinner. As a result, it is feasible to reduce the width of the frame material by up to 50%.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prior art shower enclosure.
FIG. 2 is a detailed cross-sectional view of a pair of prior art moldings for forming a corner of a shower enclosure.
FIG. 3 is a detailed cross-sectional view of the moldings shown in FIG. 2 after being permanently attached.
FIG. 4 is a detailed cross-sectional view of a pair of moldings in accordance with an embodiment of the present invention.
FIG. 5 is a detailed cross-sectional view of the moldings shown in FIG. 4 after being permanently attached.
FIG. 6 is a magnified view of the inside engagement feature of the present invention.
FIG. 7 illustrates the reduction in material made possible with the present invention.
DETAILED DESCRIPTION
In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
FIG. 1 is a perspective view of a typical Neo-Angle shower installation utilizing prior art extruded moldings. Enclosure 10 comprises a door and doorframe 12 and two fixed panels 14 , 16 on either side of the door. The fixed panels are attached to the walls and the doorframe is attached between the fixed panels along each side edge.
FIG. 2 is a cross-sectional view of the prior art extruded moldings 18 and 24 that form the adjoining edges of panel 14 and door/doorframe panel 12 . During installation of a typical Neo-Angle shower joint design, the adjoining panels are initially brought together prior to the permanent fastening stage. To facilitate this initial alignment, panel edge molding 18 has a hook-shaped leading edge 20 that engages a rearward facing protrusion 26 on doorframe molding 24 . These features are referred to collectively as “leading-outside-engagement feature” 32 . This engagement feature, while helpful for initially aligning the panels, fails to positively engage the two moldings and therefore allows the panels to become easily disengaged, particularly when subjected to the tilting and twisting forces that are commonly applied during panel alignment. Notice, in particular, how the shape of the leading-outside-engagement feature 32 of extrusions 18 and 24 allows panel 14 to separate from doorframe 12 in any of the indicated directions during the initial assembly and adjustment process.
Prior art moldings 18 and 24 also incorporate an “inside-engagement feature” 34 comprising flange 22 on panel edge molding 18 and groove 28 in doorframe molding 24 . After the leading-outside-engagement feature 32 has been engaged, panel 12 is rotated counter-clockwise to engage flange 22 in groove 28 as shown in FIG. 3 . Note, however, that engagement of both the leading-outside-engagement feature 32 and the inside-engagement feature 34 is insufficient to lock panel 14 and doorframe 12 together into permanent engagement because they fail to hold the panel and doorframe under lateral or twisting forces. Thus, shower enclosures constructed with prior art moldings 18 and 24 require the use of a plurality of fasteners 30 (only one of which is seen in the figure) to “lock” the adjoining panels together. All of the existing connection systems require multiple fasteners, usually three to five screws per connection, to permanently join the frame edges of the door panel and stationary panel. Since these existing connection systems require the use of screws, larger frame sections, which require more raw material, are necessary to allow space both for the screws and for access to the screws during assembly.
Many prior art shower enclosure joint designs use both outside and inside engagement features similar to those described above; however, such engagement features nevertheless allow separation of the adjoining panels. Even with the use of screws 30 to fasten moldings 18 and 24 together, the assembly is still prone to gaps along the joints 32 and 34 due to the flexibility of the aluminum moldings. Note, in particular, that the leading-outside-engagement feature 32 does not positively lock together and therefore allows the moldings to separate as indicated by the arrows in FIG. 3 . The resulting gap is not only aesthetically displeasing, but the separation of the moldings also reduces the structural integrity of the shower enclosure. Typically, only 3-5 screws are used along the length of the moldings. The use of additional screws would reduce the severity of the gaps, but would increase the material and assembly costs. The present invention also uses outside and inside engagement features; however, the design of the engagement features differs from the prior art in form, fit and function to achieve a variety of benefits.
Referring now to FIG. 4 , a pair of extruded moldings in accordance with an embodiment of the present invention are shown in cross section. Doorframe molding 110 is attached to the edge of door/doorframe panel 101 . Molding 110 includes a channel 116 along the edge of front face 112 and a groove 118 in the rear face 114 . Panel edge molding 120 is attached to the edge of fixed panel 102 . Molding 120 includes tongue 126 extending along the edge of front face 122 and a flange 128 along the edge of rear face 124 . A leading-outside-engagement feature, designated generally as 105 , comprises channel 116 of doorframe molding 110 and tongue 126 of panel edge molding 120 . This is the first feature to be engaged during installation.
The leading-outside-engagement feature 105 becomes engaged as tongue 126 is captured within channel 116 . This first occurs when the door/doorframe panel 101 is at an angle of approximately 165° with respect to the fixed panel 102 . Once feature 105 is initially engaged, the door/doorframe panel's angle of orientation can be rotated slightly counter-clockwise (as viewed in FIG. 4 ) toward a permanent engagement position in which feature 105 is in contact along the entire vertical length. At this point, the two moldings are held securely together by the full-length capture of tongue 126 within channel 116 . Note how the shape of the leading-outside-engagement feature 105 of the extrusions engage in a manner so that once engaged, the connection does not allow separation in any direction. This greatly facilitates the initial assembly and adjustment process, when usually one installer must maneuver numerous panels and a doorframe at the same time prior to their “permanent” attachment. The stability of the multiple glass panels afforded by the present invention results in an easier, safer and quicker installation process.
With reference also to FIG. 5 , an inside-engagement feature, designated generally as 106 , comprises groove 118 of doorframe molding 110 and flange 128 of panel edge molding 120 . From the position shown in FIG. 4 , the door/doorframe panel 101 may be further rotated in a counter-clockwise direction to its permanent engagement position where flange 128 “snaps” into groove 118 to lock and hold the panels permanently in the proper alignment, providing a secure connection between the door/doorframe panel 101 and the fixed panel 102 without the use of fasteners. In the example shown, the flange snaps into the groove when the panels are at an angle of about 135°.
Referring also to FIG. 6 , the moldings 110 and 120 are configured so that molding 120 is “sprung” slightly when fully engaged with molding 110 , thereby urging the rear face 124 against rear face 114 and urging flange 128 into groove 118 . This self-locking feature of the joint obviates the need for additional fasteners to secure the panels together. Upon permanent engagement, the relationship of the leading-outside-engagement feature 105 and the inside-engagement feature 106 locks the panels together under any type of lateral or twisting force and thereby greatly reduces vibration and squeaking. The finished joint also allows for an aesthetically desirable flush mating of both the inside and outside surfaces of the shower enclosure, which is a major advantage of the present invention over the prior art.
As explained above, the strength and stability of the fully assembled joint inherent in the moldings of the present invention obviates the need for mechanical fasteners such as screws. This allows for substantially thinner moldings and reduces the amount of frame material required. FIG. 7 presents a comparison of the moldings of the present invention to those of the prior art to illustrate the reduction in material that can be achieved with the present invention.
The present invention has been described with reference to a particular example of a shower enclosure; however, the invention may be applied in any application requiring the connection of adjoining panels. For example, while the invention has been described in the context of panels joined at an angle of 135°, suitably modified moldings substantially similar to those described above may be provided for joining panels at any desired angle. Furthermore, the invention has been described with reference to a tongue and channel engagement feature on the front faces of the interlocking extrusions and a flange and groove engagement feature on the rear faces. However, these engagement features could be reversed, yet still provide similar functionality and benefits.
It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims. | A set of extruded interlocking moldings joins together panels of framed glass and/or framed glass doors. A first molding has a channel along an edge of one face and a groove in the opposite face. A second molding has a tongue extending along an edge of one face and a flange along an edge of the opposite face. The channel of the first molding is configured to receive and hold the tongue of the second molding to secure the moldings together as the panels are aligned. The flange of the first molding snaps into the groove of the second molding when the moldings are rotated to a predetermined angle with respect to each other. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNOLOGICAL FIELD
The disclosure relates generally to the decks and porches. In particular, it relates to the infill below the guardrails of decks and porches.
BACKGROUND
A deck or porch can extend the livable area of a home considerably. Because decking and porches are oftentimes elevated with respect to the surrounding ground, the risk of falling off the deck or porch must be considered. Commonly, a guard rail is constructed at about waist height to prevent falling. However, a child or a seated adult could still fall from the deck despite the guard rail. To prevent this type of injury, pickets, narrow spaced-apart pieces of lumber, are fastened perpendicularly to the guardrail. Even in porches where typical mesh screening is attached below the guard rail, pickets are nonetheless necessary for safety because mesh screening cannot be counted on to prevent someone from falling off the porch or deck. Mesh screening may tear or come loose when subjected to lateral impact.
The area below the guard rail in a porch is referred to as infill. Two typical building code requirements apply to the infill. First, the infill section must be able to prevent a sphere of 10 cm (4 inches) from passing through any part of the infill. Second, when a 125-pound load is applied to a one-square-foot area, from either direction, the infill must not disengage from its framework. Pickets will meet that requirement when placed not more than 4 inches (10 cm) apart. Unfortunately, pickets partially obstruct the view from the deck and are an inconvenience to maintain. They also foreclose any alternate, aesthetic appearance for a deck or porch.
An infill that is safe but avoids the use of pickets would have several useful advantages.
SUMMARY
The present disclosure describes a safety barrier for the infill area, one that withstands lateral forces and can meet code requirements, but without the use of pickets or other obstructions to the view. In particular, use of a mesh with greater tensile strength and a better securement of the mesh to the framing yields the desired strength to prevent falling. Moreover, use of the present safety barrier does not preclude other, more aesthetic treatment of the infill area.
The safety barrier for a deck or porch, according to the present disclosure, includes framing that defines an opening, which is the infill area. A mesh screen having plural strands of at least one material cover the opening. The material is selected to have a greater tensile strength than conventional screening material, which is fiberglass. A convenient choice for the present material is nylon. Other materials can be used including a mixture of conventional screening material and stronger materials in a suitable pattern that provides sufficient overall tensile strength.
To hold the mesh screen to the framing, a base is attached to the framing. The base provides greater resistance to the pull on the mesh from a lateral impact. The base is configured with at least one spline groove and a central channel parallel to and between plural spline grooves. Each spline groove has a spline. The splines are not round and do not hold the marginal portion of the screen by friction. Rather they are flatter and longer and the spline groove is larger in its interior than at its entrance. There is thus an overhang at the entrance and the entrance is just large enough for the edge of the spline groove to be inserted and then rotate so that it is pressed against the overhang. In this position, the marginal portion of the mesh screen is not likely to be pulled free.
A metal plate may be added to the central groove to act as a washer in holding the base to framing. Fasteners, such as screws hold the base to the framing and the metal plate allows the screws to be turned more tightly without damaging the base.
Another aspect of the disclosure is a cap fastened to the base so it covers the base. The cap locks to the base but can be pried off.
Still another feature of the invention is that if pickets are not needed, so a more decorative treatment of the space between the guard rail and the balance of the framing can be used.
These and other features and their advantages will be apparent to those skilled in the art of porch construction and screening from a careful reading the detailed description accompanied by the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Figures
FIG. 1 is a portion of a porch wall showing upper portions and lower portions with two types of mesh screen, according to an aspect of the disclosure;
FIG. 2 is a detail of the lower portion showing the guard rail mesh screen attached to the framing elements, according to an aspect of the disclosure; and
FIGS. 3A, 3B, and 3C show a sequence of views of the mode of attachment of the guard rail mesh to a framing element, according to an aspect of the disclosure.
DETAILED DESCRIPTION
A deck is a surface adjacent to a home that extends the livable space into the out-of-door. Decks are often elevated above the surrounding ground so that they are at the same level as the interior of the home. Because of that elevation, a deck may include a guard rail, set about waist height. The guard rail is supported by posts set at intervals along the perimeter of the deck.
In a porch that is to be covered in mesh screening, wood or other similar material is used to frame the porch, that is, structural members are installed on the porch to divide the perimeter between the porch floor and the roof over the porch into openings which are individually covered with mesh screens.
In both porches and decking, framing is used, for the guard rail in the instance of decks and for the exterior porch wall in the case of porches. The framing is typically made of wood structural members fastened together, including vertical posts and horizontal rails. The term framing is used herein to indicate structural, load-bearing elements, typically, but not always, made of wood, and fastened in place along the perimeter of a porch or deck and which elements when so fastened, define rectangular openings, which may include both upper openings above a rail and lower openings. Framing may be standard-sized lumber cut to convenient lengths and may be treated, stained, painted, or coated in some way to preserve the appearance and structural integrity of the framing when exposed to weather over an extended period of time.
In the case of both decking and porches, it is the lower openings, from and including the guard rail down, that the present disclosure is concerned. This is the infill area which becomes a safety concern when the deck or porch is elevated by more than a few feet. The particular safety concern is the risk of a fall against the infill area.
In the infill area, the present invention is a safety barrier that provides protection from falls through the infill. Furthermore, the protective barrier avoids the need for prior art pickets and, in addition, eliminates the obstruction of pickets to the view through the infill.
The primary covering is mesh screening. The term mesh screen refers to a woven product made of thin strands made of metal or plastic. The weave of the mesh is an open weave, commonly a basket weave, so that air and light may pass readily through it, but ideally, the weave is a sufficiently close to limit or prevent insects from passing through it.
Rather than conventional mesh screening, however, which can tear, the present barrier uses mesh screening made of a material having greater tensile strength than the conventional material used, which is fiberglass. Many stronger materials exist. For the present mesh screen where greater tensile strength is required, nylon, polyester, bronze, para-aramids, and carbon fiber may be used. Nylon is a stronger material than fiberglass and is not unduly expensive and is readily available. As shown in FIG. 2 , mesh 18 ′ may be made of mixtures of strands with one type of strand having a higher tensile strength or a greater thickness than the other strands of mesh 18 ′. For convenience, strands of higher tensile strength are illustrated in FIG. 2 as thicker than strands of a material with lower tensile strength, but may have higher tensile strength as a result of a different composition regardless of thickness than the composition of the second type of strands. For example, strands of fiberglass and nylon or para-aramids may be used in a mesh-within-a-mesh design.
The term strand refers to a thin, long, flexible, wire-like device, that may be circular in cross section but which has a length very much greater than its diameter and which can be woven with other threads in a basket weave pattern. For example, strands of one stronger material may be used on a 10 cm by 10 cm basis, which means one vertical strand of the stronger material every 10 cm and one horizontal strand of the stronger material every 10 cm and strands of a second material between them.
Alternatively, other arrangements may be made such as using strands of the stronger material only in a vertical orientation and strands of the other material only in a horizontal orientations, or vice versa. Still other possibilities include the use of combinations of strands in one direction but only strands of the stronger material in the orthogonal direction, or the use of different sequences of strands 12 , 14 , horizontally than the sequence of them used vertically. To stop insects, spacing between strands 12 and 14 must remain small enough, for example, at most a few millimeters. A modest amount of experimentation can determine if a particular material or combination of material in a particular pattern is sufficient by testing it against code requirements as first stated above.
It is not enough for the mesh screen to be stronger, although the mesh screen must not tear when subject to lateral impact. The manner of securing the marginal portion of the mesh screening to the framing is also important. The marginal portion of the mesh screening is the portion of the mesh screen beyond that required to fit the opening that is for use in attaching the mesh screen to the framing.
Referring now to the figures, FIG. 1 illustrates a portion of a guard rail 10 and framing 14 with a mesh screen 18 attached using a base 22 with a cap 26 attached to it. FIG. 2 shows a portion of a guard rail 10 and framing 14 with a variation of mesh screen 18 ′ and with a part of cap 26 cut away to show base 22 , mesh screen 18 ′, and splines 30 more clearly. FIGS. 3A-3C illustrate in end views the manner in which base 22 , splines 30 and cap capture and hold mesh screen 18 .
To attach the present mesh screening to guard rail 10 and framing 14 , base 22 is first secured to them. Base 22 may be made of extruded material such as vinyl and formed to have spline grooves 34 for receiving the marginal portion of mesh screening. Splines 30 are used to hold the marginal portion of mesh screen 18 in spline grooves 34 and are made of synthetic or natural rubber.
Spline 30 may be a flat spline and spline groove 34 may be a flat spline groove with a rectangular cross section, but may more generally have a major dimension or length, a much smaller minor dimension or width at the thickest part, and a smallest dimension or height, but may not be a true rectangle in cross section. Splines 30 , as shown in FIGS. 3A-3C , have a slightly rounded upper surface. However, splines 30 may be, for example, oval or trapezoidal, as long as they can fit through an entrance 38 in spline groove 34 and fit in interior 42 .
Spline grooves 34 , however, are not conventional slot-shaped grooves but have a specific shape with a relatively smaller entrance 38 than their interior 42 and a pitch so that, when spline 30 is forced inside, it will press against an overhang 46 at the outward side of entrance 38 . For example, spline groove 34 may be boot-shaped with the “toe” of the boot oriented outwards and downwards, as shown in FIGS. 3A-3C , so that spline 30 may be oriented to have its width against the “sole” of the boot. In this position, spline 30 holds the marginal portion of mesh screen 18 mechanically rather than frictionally. The position of spline 30 , when seated, prevent it from coming out of entrance 38 . Spline 30 will not come out of interior 42 of spline groove 34 by pulling on mesh screening 18 , which, if made of a material such as nylon rather than fiberglass, must be cut to release it from base 22 .
Still, the present safety barrier requires that base 22 itself not break free of framing 14 . Accordingly, a central channel 50 is formed as part of base 22 and formed with plural holes 54 ( FIGS. 3A-3C ) for fasteners 58 such as screws. Moreover, a plate 62 , made of metal and also formed with holes 66 that can be placed in registration with holes 54 in central channel 54 of base 22 , is used as a washer for fasteners 58 . Plate 62 serves as a washer in that it distributes the load placed on base 22 by the tightening of fasteners 58 over a greater area of central channel 50 so that damage to base 22 from tightening is minimized. Just as importantly, because plate 62 extends under other fasteners 58 as a unit rather than under just individual fasteners 58 , it provides a more stable hold, even if some fasteners 58 pull loose, because it remains in place while other fasteners 58 are still tight.
Framing 14 is shown in cross-section in FIGS. 3A-3C , together with two splines 30 and mesh screen 18 over base 22 . Mesh screen 18 is shown in an end view. Base 22 is shown attached to framing 14 with a fastener 58 running through plate 62 in central channel 50 and deep into framing 14 .
Above base 22 is cap 26 . Cap 26 carries on its underside two legs 72 , each with a locking foot 74 . Legs 72 are angled laterally outward. Central channel 50 is defined by two spaced apart walls 78 that are shared with spline grooves 34 and serve as the inner wall of spline grooves 34 . Walls 78 have flanges 80 that extend inwardly from the tops of walls 78 to engage locking feet 74 , as illustrated in FIG. 3C , when cap 26 is pressed onto base 22 to lock cap 70 onto base 22 .
Cap 26 has trim flanges 82 that depend from its lateral ends and provide additional securement against the removal of mesh screen 18 by lateral force.
As tangential force is applied to mesh screen 18 in a direction indicated by the letter A as seen in FIG. 3C , spline 30 is compressed widthwise because it is softer than base 22 and presses against overhang 46 . Further tension on mesh screen 18 pulls overhang 46 laterally but also causes the floor of base 40 to deform and squeeze spline 30 against the inner wall of interior 42 . Also, trim flanges 82 may be lifted by the force on mesh screen 18 thereby forcing legs 72 to push harder against walls 78 of central channel. The combined resistance to lateral force on mesh screen 10 , combined with its enhanced tensile strength, enables mesh screen in the infill to withstand perpendicular forces and not give way.
When introducing elements of the present disclosure or exemplary aspects or embodiment(s) thereof, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Although this disclosure has been described with respect to specific embodiments, the details of these embodiments are not to be construed as limitations. | A safety barrier is formed of framing, including a guard rail that defines the infill below the rail without the use of pickets. The infill is covered with mesh screen, which may be made of nylon which has greater tensile strength than conventional fiberglass. The mesh screen is held to the framing by an extruded base. The base has a central channel between two flat spline grooves. Flat splines hold mesh screen in their respective grooves more securely than conventional friction-based channel splines. A metal plate is positioned in the central channel to enables screws that secure the base to be tightened to hold it to the framing better. The elimination of pickets in the infill leaves the view unobstructed and allows other treatments of that portion of a deck or porch that are more aesthetically pleasing without compromising safety. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to building structures. In particular, this invention relates to modular building structure systems. Still further, this invention pertains to panelized building structure systems where the panel members are load bearing. More in particular, this invention relates to modular building structure systems formed of a plurality of panel modules which are prefabricated. More in particular, this invention pertains to building structure systems substantially devised of columns or frame work to which panels would be secured. Still further, this invention relates to modular building structure systems where the panelized modules are constructed to structurally absorb high impact loads.
2. Prior Art
Modular building structure systems are well-known in the art. However, modular systems particularly adaptable to racquet ball or handball courts has not heretofore been utilized in the building construction art. In general, these types of structures must be adapted to take high impact loading and panelized modules have not been previously designed to accept such stresses.
In the building of prior art handball or racquet ball courts, building contractors would generally form a masonry structure and then apply plaster or some like material in small sections. This had the effect of increasing construction labor costs as well as material costs in the erection of such overall masonry structure walls directed to this type of prior art system structure.
In some prior art systems, a steel frame was erected adjacent and attached to cinder or cement block walls. Plastic panels would then be affixed manually to the steel frame. This had the effect of expending great amounts of labor time, as well as incorporating a number of trade skills which increase the time of construction.
In such prior structure systems, the structure housings could not be demounted from the installation base and reconstructed in a displaced area without the loss of considerable time. Additionally, such demounting in prior art systems caused a complete destruction of the structure systems, thus resulting in increased cost should the system be moved to another remote site for construction.
Additionally, where the prior art building systems were constructed without utilization of panelized modules, such systems had to be constructed as a total system housing. Such prior cement block and plaster systems were not able to be incorporated in existing buildings, thus further increasing the costs of such systems. Such systems increased construction time and were not relocatable. In any event, such prior systems were not adapted to prefabricability.
Prior systems required substantially skilled labor to acquire necessary tolerance restrictions particularly for such handball and racquet ball courts which further increased the overall costs of such systems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a section of the modular building structure system;
FIG. 2 is a perspective partially exploded view of floor panel members, ceiling panel members, and wall panel members of the modular building structure system;
FIG. 3 is a sectional view of a wall panel member taken along the section line 3--3 of FIG. 1;
FIG. 4 is a sectional elevation view partially cut away taken along the section line 4--4 of FIG. 1 showing a corner section of the modular building structure system;
FIG. 5 is a sectional view of a common wall panel member taken along the section line 5--5 of FIG. 1;
FIG. 6 is an elevation view of a slip pin member holding two joining wall panel members; and,
FIG. 7 is a partial perspective view of a floor panel member on a foundation base.
SUMMARY OF THE INVENTION
A modular building structure which includes a foundation member having an upper surface defining a base plane. Channel members are secured to the foundation members and a plurality of wall panel members are slidably insertable within the channel members. The wall panel members extend in a plane substantially orthogonal to the base plane defined by the upper surface of the foundation member. Each of the wall panel members are positionally located in abutting relation to a next successive wall panel member. A plurality of ceiling panel members are secured to the wall panel members on an upper surface thereof and the ceiling panel members extend substantially in a plane parallel to the base plane.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-7, there is shown modular building structure system 10 and associated components for providing a substantially pre-fabricated building adapted for use in various sporting facility applications. In particular, modular building structure system 10 may be used in the building of handball and racquet ball courts, or other like sporting structures. System 10 is particularly adaptable, but not solely utilizable for structure systems which may take high stress loading whether dynamic or static, on the various components making up modular building structure system 10. As will be seen in following paragraphs, system 10 provides a substantially panelized concept which includes a system of freestanding steel frames that provide support for the frames themselves as well as the roof or ceiling members so that the panelized system provides its own structural support. Individual panels are constructed of steel studs which have mounted thereto interior and exterior surfaces which are prefabricated in one completely finished panel ready for insert into its proper place within the overall modular building structure system 10. As will be seen, system 10 allows for the vitiation of the general prior art building sub-system or steel skeleton upon which prior art buildings of this type have been built upon.
Referring now to FIG. 7, modular building structure system 10 is seen to be mounted on foundation member 12 having upper surface 14 defining a base plane. Upper surface 14 is generally formed in the horizontal plane for levelling purposes. For purposes of discussion, foundation member 12 as shown in FIGS. 2, 5 and 7, may be formed of a concrete slab extending throughout the overall horizontal peripheral contour of system 10. Of course, it is to be realized, that the foundation as is herein generally discussed, may be in the form of concrete columns 12', as is shown in FIGS. 1 and 3. Whether the foundation includes a concrete foundation member 12, or wall-like foundation members 12', the basic concepts of construction for system 10 are similar in nature.
Referring to foundation member 12, as shown in FIG. 7, member 12 is generally treated with skim coats of concrete which are well-known in the art, and are generally finished to a high degree of accuracy to provide a smooth surface which is adaptable to be levelled in a particular plane of interest. Foundation member 12 is generally formed into a monolithic slab member possibly having expansion joints set therein, however, such is not important to the inventive concept as is herein described and detailed.
Referring once again to FIGS. 2, 5, and 7, floor system 16 is positionally located on foundation member 12, and extends in the horizontal or base plane defined by the plane of upper surface 14. Floor system 16 includes a plurality of floor panel members 18 and 20 mounted in contiguous relation each to the next. Floor panel interior planar member 18 may be formed of a hardwood such as maple, oak, or some like wood composition. Additionally, member 18 may be formed of other compositions not important to the inventive concept as herein detailed, with the exception that such compositions be capable of taking the stresses applied. Floor panel sub-surface planar member 20 is secured to floor panel interior planar member 18 throughout the interfacing plane of contact. As can be seen in FIG. 7, floor system 16 may be formed of a plurality of panel members 18 and 20 each constructed by itself and laid adjacent to a next set of floor panel members 18 and 20. This is clearly seen by interface boundary line 24 showing the mounting of one set of floor panel members 18 and 20 mounted in side by side relation with a next set of floor panel members 18 and 20. Floor panel sub-surface planar members 20 may be formed of plywood, or some like wood construction.
Additionally, gasket members 22 may be secured to floor panel sub-surface planar members 20 to be sandwiched between members 20 and foundation member 12 as is seen in FIG. 7. Gasket members 22 are generally resilient in nature, and may be formed of neoprene or rubber, or some like composition not important to the inventive concept with the exception that gaskets 22 provide resiliency for floor system 16, and to maintain system 16 in a generally stationary positional location on foundation member 12 to minimize any slipping conditional state.
In the embodiment shown in FIGS. 1 and 3, floor system 16 is mounted on foundation wall-like member 12' through floor steel studs 26. Floor panel sub-surface planar member 20 is secured directly to floor steel studs 26 as is shown in FIG. 3, and floor panel interior members 18 are interfaced with an upper surface of planar members 20 as has hereinbefore been described. Securement of steel studs 26 to foundation member 12' may be through a number of techniques, one of which is clearly seen in FIG. 3, where floor angle iron member 28 interfaces and matingly engages a lower corner of steel stud 26, and floor screw or bolt 30 secures stud 26 to angle iron member 28 for ultimate securement purposes to foundation member 12'.
In both types of floor system construction, floor panel interior planar members 18 are generally mounted by tongue-in-groove methods as represented by numeral 32 to provide a secure fit for the sub-members of interior planar member 18. Although dimensionally not important to the inventive concept as is herein described, plywood sub-surface planar member 20 may be approximately 3/4" thick, and floor panel interior planar members 18 are approximately 25/32" thick to provide the necessary structural load bearing requirements of modular building structure 10. Thus, in overall concept, the floor base system is formed of a tri-layer set of components, including foundation member 12 or 12', a plywood sub-surface planar member 20 sandwiched between floor panel interior hardwood members 18 and resilient gaskets 22, all formed into a substantially unitary structure to provide a stationary base for modular building structure system 10.
Referring now to FIGS. 1-6, there is shown a number of wall panel members 34, which are slidably insertable within channel members 36. Channel members 36 are generally placed or positionally located around the periphery of the internal volume of structure system 10, and provides a guide within which wall panel members 34 may be inserted. Additionally, channel members 36 are secured to foundation members 12 or 12' through levelling bolts 38 or some like securement mechanism to provide wall panel members 34 in a substantially extending plane orthogonal to base plane defined by upper surface 14 of foundation 12 or 12'. Levelling bolts 38 are generally well-known in the art, and allow positional location of wall panel members 34 in abutting relation each with respect to a next successive wall panel member 34 to maintain alignment in a vertical dimension.
The total wall panel members 34 include wall panel frame members 40, which are substantially rectangular in contour, and as is seen in FIG. 2, are adapted for slidable insert into channel members 36 around the periphery of the internal volume of building structure system 10. In overall dimension, wall panel frame members 40 are approximately 4' in width, and 20' 6" in height, measured in the vertical direction as is defined by vertically directed arrow 42. Wall panel frame members 40 are formed in a unitary manner through welding and utilizes steel studs for construction purposes. As will be seen in following paragraphs, wall panel frame members 40 are formed in particular structural contour for withstanding stress loads that are generally unique to the construction of racquet ball and handball or other like court systems. It is to be understood that wall panel members 34 of the present invention concept, must structurally withstand high dynamic force load impacts resulting from users hitting ball-like objects at great speeds, thus, wall panel members 34 must withstand larger impact loadings than prior art wall systems.
Wall panel frame members 40 include a pair of opposing side wall panel frame members 44 and 46 which extend in a substantially orthogonal direction to the horizontal or base plane. Additionally, a pair of opposing base wall panel frame members 48 and 50 are secured to side wall panel frame members 44 and 46. As can be seen, lower base wall panel frame member 48 is slidably insertable within channel members 36 for construction purposes. Side wall panel frame members 44 and 46, and base wall panel frame members 48 and 50, are unitarily welded each to the other to provide the overall contour clearly seen in FIG. 2.
Wall panel frame member 40 further includes vertical support member 52, extending in vertical direction 42 and being secured on opposing ends thereof to opposing base wall panel frame members 50 and 48. Vertical support member 52 is generally positionally located substantially central to the displacement dimension of opposing side wall frame members 44 and 46. Vertical support member 52 may be welded or otherwise constructed in unitary fashion with opposing base wall panel frame members 48 and 50. Also included in wall panel frame member 40, is horizontal support member 54 which is secured to vertical support 52 as well as opposing side wall panel frame members 44 and 46. Horizontal support member 54 extends in a direction substantially normal to vertical direction 42, and is positionally located substantially central to the vertical displacement distance between base wall panel frame members 50 and 52. As was the case with the vertical support member 52, horizontal support member 54 is welded or otherwise unitarily constructed with opposing side wall panel frame members 46 and 48, as well as vertical support member 52.
Both of the vertical support members 52, and the horizontal support members 54 associated with each wall panel frame member 40, is provided to maximize the stress capability of each of wall panel members 34. Horizontal support members 54 are utilized in particular to prevent the overall wall panel members 34 from racking or torsionally twisting out of the predetermined contour during the shipment phase and/or erection of modular building structure system 10. Additionally, supporting members 52 and 54 provide additional surface area in order that the interior laminate, to be further discussed in following paragraphs, with additional surface area for attachment thereof.
Mounting of one wall panel member 34 to a next successive wall panel member 34 is accomplished through a combination of tension rods 56 and slip pins 58. Initially, one panel member 34 is slidably inserted into a corresponding channel 36. Conically shaped slip pin members 58 clearly seen in FIG. 6, extend from one side wall panel frame member 46. Slip pin members 58 are welded as shown at 60, or otherwise constructed to extend laterally from side wall panel frame members 46. Correspondingly, an adjacently placed side wall panel frame member 44 includes a tapered recess opening 62 for insert of slip pin member 58. Tapered opening 62 is dimensioned to provide a friction fit for conical extension section 64 of slip pin member 58. Thus, there is provided a tight friction fit between side wall panel frame member 44 of one panel member 34, and an adjacently positioned and contiguous side wall panel frame member 44 of a next wall panel member 34. This friction fit type of mounting allows for alignment between consecutively placed wall panel members 34 and further provides for some rigid stability of a series of panel members 34. Further, tension rods 56 are inserted through tension rod openings 67, provided on opposing side wall panel frame members 44 and 46 as well as through vertical support members 52 to increase the structural stability of the overall system, once constructed. The use of slip pin members 58 has been found to optimize the time of alignment and positional placement of wall panel members 34 in constructing the interior walls of modular building structure system 10.
Interior wall panel member 66 is secured in rigid manner to wall panel frame members 40 to provide a continuous inner wall of modular building structure system 10. Interior wall panel members 66 include planar wood member 68 which may be formed of particle board or other like material, not important to the inventive concept as is herein described with the exception that it take the high impact loads associated with the use of building structure system 10. Planar wood member 68 has mounted on opposing sides thereof, a plastic laminate material forming plastic planar members 70 clearly seen in FIG. 3. Plastic planar members 70 are secured to planar wood member 68 through adhesive attachment such as glue or some like panel adhesive. Additionally, interior wall panel member 66 is mounted to side wall panel frame members 44 and 46 as well as base wall panel frame members 48 and 50 and support members 52 and 54 through adhesive securement. Plastic laminate sandwich members forming interior wall panel member 66 is glued to wall frame members 40, one type of adhesive utilized is an industrial grade construction glue, commonly referred to as Peel 400.
In general, interior wall panel member 66 may generally be mounted to wall panel frame members 40 by means of a mechanical securement of an anchor and a threaded securement through one of the wall panel frame members 40 into particle board or planar wood member 68. As can be clearly seen in FIG. 5, where wall panel members 34 are utilized for common walls between two rooms or courts, there is no access to interior wall panel member 66 once wall panel members 34 are constructed. In this case, it is obvious that adhesive securement is the main bond of interior wall panel members 66 to wall panel frame members 40.
As is seen in FIGS. 3, 4 and 5, there is included metal spline member 72 which is insertable within groove 74 formed within a peripheral surface of planar wood member 68 for securement of interior wall panel member 66 to wall panel frame member 40. Spline 72 is T-shaped and designed to fit into groove 74 for appropriate spacing of wall panel members 34 in order to minimize the seam resulting between two adjacently spaced wall panel members 34. Spline member 72 may be formed of aluminum, or some like metal not important to the inventive concept as is herein described.
As has hereinbefore been stated and disclosed, tension rods 56 may be used for joining adjacently mounted wall panel members 34 each to the other. However, steel strapping may be substituted for tension rods 56 during the construction mode of operation for modular building structure system 10. Steel strapping, which has a high tensile load capability, is formed in coils and includes an extended steel rod member at an initiation point of the coil. The rod may be placed through appropriate tension rod openings 67 through an appropriate number of wall panel members 34. This has the effect of utilizing coils of tension members instead of transporting and otherwise delivering long steel rods onto the construction site, and then passing them through the appropriate tension rod openings 67.
Modular building structure system 10 further includes ceiling panel members 76 which in general are secured to wall panel members 34 on an upper surface thereof. Ceiling panel members 76 are positionally located and extend substantially in a plane parallel to the base plane defined by upper surface 14 of foundation member 12 or 12'. In general, ceiling panel members 76 are formed in the same manner and mode as wall panel members 34. However, wall panel frame members 40 generally include 6" stud members whereas ceiling panel members are formed in 8" steel joists. Ceiling panel members 76 are formed of opposing ceiling side wall panel frame members 78 and 80, and opposing base ceiling frame members 82 and 84, all welded together or otherwise unitarily formed in the same manner as wall panel frame members 40. As was the case with wall panel members 34 and associated wall panel frame members 40, ceiling panel members 76 include support members 86 and 88 passing in the same direction relative to the base panels 82 and 84 and the side panel frame members 78 and 80, as was provided for support members 52 and 54 for wall panel frame members 40.
As is clearly seen in FIGS. 3 and 5, interior wall panel members 66 formed by planar wood member 68 sandwiched between plastic planar members 70, is secured to frame members 78, 80, 84, 86 and 88. As seen in FIG. 3, ceiling panel members 76 may be joined to structural angle iron 90 through bolts 92 or some like mechanical securement not important to the inventive concept as is herein described. In FIG. 5, ceiling panel members 76 are joined each to the other and to a centrally disposed wall panel frame member 40 through ceiling bolts 94 and 96. In this case, it is seen that wall panel member 34 is a common ball between two separate rooms in a court structure. In the case of ceiling panel members, there is still provided slip pins 58 formed external to ceiling side panel frame member 80 for the same purposes as has been discussed in previous paragraphs for wall panel members 34. Additionally, tension rods may be inserted through tension rod openings 67 for maintaining ceiling panel member 76 in tension aligned displacement each with respect to the other.
Although not important to the inventive concept, modular building structure system 10 may include as is shown in FIG. 3, rigid insulation decking 98 which may be formed of 3" tectum or some like material and dimensional thickness. Insulation decking 98 may be applied to sleepers 100 which are formed on ceiling frame members 80, 82, 84 and 78. Sleepers 100 are tapered in generally continuous manner, in order that the low point would be a water drain for system 10.
It is to be understood that these and other modifications may be resorted to without departing from the spirit or scope of the invention. Equivalent elemental structures may be substituted for those specifically shown and described, certain features may be used independently of other features, and in some cases, portions may be reversed, all without departing from the spirit or scope of the invention. It is to be understood that the invention is therefore only limited by the claims appended hereto. | A modular building structure system for optimally minimizing construction as well as demounting time for the structure system. The structure system is particularly adaptable to structures which endure large dynamic impact loading. The structure system is mainly formed of panelized members which are covered with interior and possibly exterior surfacing formed in a prefabricated manner in order to provide a completely finished panel member acceptable for placement in a predetermined location within the system. Wall panel members of the modular building structure system are load bearing structures and provide a bearing structure for ceiling panel members mounted directly on the wall panels. The wall panel module members are inserted in channels which are mounted to a foundation upon which the structure is built. The wall panel module members are positionally located in abutting relation each with respect to a next successive wall panel module member, and mounted each to the other through tension rods and frictionally interfitting slip pin members. Ceiling or roof panel module members are secured to upper surfaces of the wall panel modules to provide a complete structure system. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims foreign priority from a Taiwan Patent Application, Ser. No. 100118894, filed on Jun. 1, 2011.
BACKGROUND OF INVENTION
1. Field of Invention
This invention relates to a modified reinforced concrete structure, which has less than 4% cross-section area ratio of steel, thus is referred as a modified reinforced concrete structure with respect to conventional SRC structure.
2. Description of the Prior Art
With the development of various construction materials and applications, the modern architecture has various diversities, in which the walls of the building structure, floor structure also have a lot varieties. Such varieties of wall and floor structures facilitate the building designers, and constructors to select the appropriate wall plate with an appropriate unit weight, compressive strength, lateral tensile strength in construction, and then consider the suitability of the construction costs, so that the design of buildings can be more convenient and flexible.
In conventional reinforced concrete structures, only simple overlap is used between steel or wire binding, and there is no ability to transfer stress between the two but alone concrete bonding. Before concrete grouting, safety supports are required to sustain the steel structure, thus leads to a messy construction site and steel construction can not achieve the accuracy and standards. And it is often result in inaccuracy of protective layer thickness, lack of reinforcement spacing, or short of numbers of stirrups in joints, and such defects usually cause failure after the earthquake occurred. The reinforcement without bonding strength often buckles and fails when encountering ultimate strength limitation. The core concrete cannot be confined and extend the cross-sectional strength, thus results in brittle damage.
The current combination of a variety of conventional steel structural wall, floor, or roof does not require setting up mold plates, and does not need to wait for the curing of concrete. It has the advantages such as high construction speed, easy to control the construction progress, thus is widely applied for the architecture engineering, as well as for modern ultra-high-rise buildings. However, it still has following shortcomings.
When constructing steel structure of particular structural steel design, the components of the structure should be “tailor-made,” and a special manufacturing line should be arranged. Unlike general building materials, those particular structural steel design lack practicability and progressiveness.
Particular structural steel or building materials of particular shapes are not for widespread use. The size of a particular design or manufacture of building materials required to open an individual molds, resulting in increase of the overall costs.
The production of structural components should be set up additionally, and there is usually no spare production line. Therefore once the production is delayed, it will affect the construction progress. And once the production is over the requirement, it will cause the waste of discarded building materials.
Because of structural construction is different from the pre-assembled composite wall or floor, the constructor should assemble the composite wall or floor of particular design according to construction drawing. If constructors are not familiar with, or negligence, or misunderstanding the case of construction drawings, the construction efficiency and the quality are of great concerned. It may seriously affect the quality of construction and completion on schedule.
Therefore, the conventional combination of rigid frame structure, the assembly structure of floor and construction method still need for improvement.
SUMMARY OF INVENTION
In view of above, the present invention provides an architectured reinforcement structure, which is composed of a plurality of interconnected steel box units. Through various design of the side plates and end plates of the steel box unit, the steel box unit can be configured as a beam steel box unit, a column steel box unit, and a beam/column joint steel box unit. And with the interconnection in the X direction, the Y direction, and the Z direction, the architectured reinforcement structure of a building is constructed.
Accordingly, by implementing the architectured reinforcement structure of the present invention, the construction of the concrete structure reinforced by steel frame can be improved, and the connection of the beams and columns can have advantages as follows:
The grouting and tamping of concrete construction is improved, and the phenomena such as hive, segregation, and bleeding can be reduced.
The ability of beam-column joint is improved, for example, the ability of confinement is improved.
Increase the beam-column joint construction speed, convenience, and accuracy.
In addition to better ensure the structural safety, but also saves manpower and schedule.
The present invention provides an architectured reinforcement structure, comprising a plurality of interconnected steel box units, wherein each steel box unit comprises two end plates being disposed at both ends of the steel box unit, each one of the end plates comprises an end plate central opening located at the central region of the end plate and a plurality of end plate peripheral openings located at the peripheral region of the end plate; at least two angle steel bars being disposed between the two end plates and respectively attached thereto, and positioned on side edges of the steel box unit in the direction parallel to a longitudinal axis of the steel box unit; and, at least three side plates being disposed between the two end plates, and configured as lateral planes of the steel box unit by the angle steel bars.
According to one aspect of the invention, the angle steel bar is attached to the end plate further by an angle steel bar connecting piece.
According to one aspect of the invention, the end plate comprises at least a flange perpendicularly protruding the surface circumference of the end plate. And the architectured reinforcement structure of the invention further comprises a joint sleeve configured to inset into the flange of the end plate for joining the end plates of the two adjacent steel box unit, wherein the two adjacent steel box units are joined together by means of welding the joint sleeve with the adjacent end plates in a full-penetration weld manner.
According to one aspect of the invention, the architectured reinforcement structure of the invention further comprises a plurality of reinforcing steel bars, passing through the end plate peripheral openings and extending outwardly from the steel box unit, respectively, wherein the reinforcing steel bar extending out from the end plate peripheral openings can be anchored on an outer surface of the end plate.
According to one aspect of the invention, the side plate further comprises a side plate central opening located at the central region of the side plate, and a plurality of side plate peripheral openings surrounding the side plate central opening, wherein the steel box unit further comprises a plurality of reinforcing steel bars, passing through the side plate peripheral openings and extending outwardly from the steel box unit, respectively. The reinforcing steel bar passing through the side plate peripheral opening can be anchored on an outer surface of the side plate.
According to one aspect of the invention, the steel box unit further comprises a plurality of steel rings, which are hung on the side plate for hooking the reinforcing steel bar.
According to one aspect of the invention, the side plate is a grid steel plate.
By interconnecting multiple steel box units according to the architectured reinforcement structure of the present invention in the X direction, the Y direction, and the Z direction respectively, the architectured reinforcement structure of a building can be constructed.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments will be described in detail with reference to the following drawings in which like reference numerals refer to like elements wherein:
FIGS. 1A and 1B illustrate an embodiment of an architectured reinforcement structure of the present invention;
FIGS. 2A-2C illustrate an embodiment of a beam steel box unit of an architectured reinforcement structure of the present invention;
FIG. 3 illustrates an embodiment of a column steel box unit of an architectured reinforcement structure of the present invention;
FIGS. 4A-4C illustrate an embodiment of connection between a beam column and a steel box unit of the present invention; and
FIGS. 5A and 5B illustrate jointed multiple steel box units of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1A , the present invention presents an architectured reinforcement structure, which is composed of a plurality of interconnected steel box units. According to the present invention, a steel box unit is designed to have various side plates and end plates, so that the steel box unit can be formed as a beam steel box unit 100 , a column steel box unit 200 , and a beam-column joint steel box unit 300 . By interconnecting plural beam steel box unit 100 , column steel box unit 200 , and beam-column joint steel box unit 300 in the X direction, the Y direction, and the Z direction, an architectured reinforcement structure as shown in FIG. 1A can be provided.
Refer to FIGS. 2A-2C . FIGS. 2A-2C illustrate an embodiment of a beam steel box unit of an architectured reinforcement structure of the present invention. A beam steel box unit 100 includes two end plates 110 , two angle steel bars 120 , three side plates 130 , reinforcing steel bars 140 , and steel rings 150 , as shown in FIG. 2A .
The two end plates 110 are disposed at both ends of the beam steel box unit 100 . The end plate 110 comprises an end plate central opening 111 , which is located at the central region of the end plate 110 , and a plurality of end plate peripheral openings 112 , which are located at the peripheral region of the end plate 110 . The aperture size of the end plate central opening 111 is configured to allow concrete to flow through during grouting.
The two angle steel bars 120 are disposed between the two end plates 110 and respectively attached to the two end plates 110 . And, the two angle steel bars 120 are positioned on side edges of the beam steel box unit 100 in the direction parallel to a longitudinal axis of the beam steel box unit 100 .
The three side plates 130 are disposed between the two end plates 110 , and configured as lateral planes of the beam steel box unit 100 by the angle steel bars 120 . By assembling two end plates 110 , two angle steel bars 120 , and three side plates 130 , a box frame is formed to provide not only an over-wrapped steel structure for a beam of a construction, but a systematic mold plate module when grouting concrete.
The reinforcing steel bar 140 passes through the end plate peripheral openings 112 of the beam steel box unit 100 , and extends outwardly from the beam steel box unit 100 . The portion of the reinforcing steel bar 140 protruding out of the end plate peripheral opening 112 not only can pass through adjacent beam steel box unit, but also can butt another corresponding reinforcing steel bar, e.g. directly butting by a steel bar connector 400 , as shown in FIG. 1B , to extend the length required for the beam. Otherwise, the portion of the reinforcing steel bar 140 protruding out of the end plate peripheral opening 112 can be anchored on an outer surface of the end plate 110 by, for example, a T-headed anchor head.
As shown in FIG. 2B , the steel ring 150 can be hung on the side plate 130 and provided to hook the reinforcing steel bar 140 , in order to fixedly position the reinforcing steel bar 140 in the beam and to maintain the spacing between the reinforcing steel bar 140 and the side plate 130 . And, as the beam is under load, the steel ring 150 may also transfer the beam stress between the reinforcing steel bar 140 and the side plate 130 .
The above-mentioned angle steel bar 120 may further connect to end plate 110 by an angle steel bar connecting piece 160 . Moreover, referring to FIG. 2C , the end plate 110 includes at least a flange 113 , protruding perpendicularly out from the circumference of the surface of the end plate 110 . Thus, a joint sleeve 170 can be used to sheathe among flanges 113 of the end plate 110 for the beam steel box unit 100 . And by means of a full-penetration weld manner to affix end plates 110 , end plate 110 ′ of the adjacent beam steel box units 100 with the joint sleeve 170 , two adjacent beam steel box units 100 and 100 ′ are connected. Additionally, the above-mentioned side plate 130 is a grid steel plate thereby the bond strength between the plate and the concrete is improved. Preferably, the above-mentioned side plate 130 is a perforated grid steel plate, thereby the weight of the plate is reduced and its strength and stiffness are improved.
Refer to FIG. 3 . FIG. 3 illustrates an embodiment of a column steel box unit of an architectured reinforcement structure of the present invention. As the illustrated embodiment, the column steel box unit 200 includes two end plates 210 , four angle steel bars 220 , four side plates 230 , reinforcing steel bars 240 , and a steel ring 250 (not shown)
The two end plates 210 are disposed at both ends of the column steel box unit 200 . The end plate 210 includes an end plate central opening 211 located at the central region of the end plate 210 , and a plurality of end plate peripheral openings 212 located at the peripheral region of the end plate 210 , wherein the aperture size of the end plate central opening 211 is configured to allow concrete to flow through during grouting.
The angle steel bars 220 are disposed between the two end plates 210 and respectively attached to the two end plates 210 . And, the angle steel bars 220 are positioned on side edges of the beam steel box unit 200 in the direction parallel to a longitudinal axis of the beam steel box unit 200 .
The side plates 230 are disposed around sides of the column steel box unit 200 , and assembled on two end plates 210 by the angle steel bars 220 . By assembling two end plates 210 , four angle steel bars 220 , and four side plates 230 , a box frame is formed to provide not only an over-wrapped steel structure for a column of a construction, but a systematic mold plate module when grouting concrete.
The reinforcing steel bar 240 passes through the end plate peripheral openings 212 of the column steel box unit 200 , and extends outwardly from the column steel box unit 200 . The portion of the reinforcing steel bar 240 protruding out of the end plate peripheral opening 212 not only can pass through adjacent column steel box unit, but also can butt another corresponding reinforcing steel bar, e.g. directly butting by a steel bar connector 400 , as shown in FIG. 1B , to extend the length required for the column. Otherwise, the portion of the reinforcing steel bar 240 protruding out of the end plate peripheral opening 212 can be anchored on an outer surface of the end plate 210 by, for example, a T-headed anchor head 500 as shown in FIG. 5B .
The steel ring 250 (not shown) can be hung on the side plate 230 and provided to hook the reinforcing steel bar 240 , in order to fixedly position the reinforcing steel bar 240 in the column and to maintain the spacing between the reinforcing steel bar 240 and the side plate 230 . And, as the column is under load, the steel ring 250 may also transfer the column stress between the reinforcing steel bar 240 and the side plate 230 .
The above-mentioned angle steel bar 220 may further connect to end plate 210 by an angle steel bar connecting piece 260 . Moreover, the end plate 210 includes at least a flange 213 , protruding perpendicularly out from the circumference of the surface of the end plate 210 . Thus, a joint sleeve 270 can be used to sheathe among flanges 213 of the end plate 210 for column steel box unit 200 . And by means of a full-penetration weld manner to affix end plates 210 of the adjacent column steel box units 200 with the joint sleeve 270 , the two adjacent column steel box units 200 are connected. Additionally, the above-mentioned side plate 230 is a grid steel plate thereby the bond strength between the plate and the concrete is improved. Preferably, the above-mentioned side plate 230 is a perforated grid steel plate, thereby the weight of the plate is reduced and its strength and stiffness are improved.
Refer to FIGS. 4A-4C . FIGS. 4A-4C illustrate an embodiment of connection between a beam column and a steel box unit of the present invention. The beam-column joint steel box unit 300 includes two end plates 310 , and four side plates 330
The two end plates 310 are disposed at both ends of the beam-column joint steel box unit 300 . As shown in FIG. 4A , based on the structure design, the end plate 310 includes an end plate central opening 311 located at the central region of the end plate 310 , and a plurality of end plate peripheral openings 312 located at the peripheral region of the end plate 310 . Wherein the aperture size of the end plate central opening 311 is configured to allow concrete to flow through during grouting, and the aperture size of the end plate peripheral openings 312 is configured to allow the above-mentioned reinforcing steel bar 240 of the column steel box unit 200 to pass through.
The four side plates 330 are attached to end plates 310 , and are disposed around sides of the beam-column joint steel box unit 300 . The side plate 330 can be alternatively designed based on the position of the architectured reinforcement structure of the present invention. In one aspect, as shown in FIG. 4A , the side plate 330 may include a side plate central opening 331 located at the central region of the side plate 330 , and a plurality of side plate peripheral openings 332 located at the peripheral region of the end plate 330 . Wherein the aperture size of the side plate central opening 331 is configured to allow concrete to flow through during grouting, and the aperture size of the side plate peripheral openings 332 is configured to allow the above-mentioned reinforcing steel bar 140 of the beam steel box unit 100 to pass through. In another aspect, as shown in FIGS. 4B and 4C , the side plate 330 may only include plural side plate peripheral openings 332 , but not side plate central openings 331 .
By assembling two end plates 310 and four side plates 330 , a box frame is formed to provide not only an over-wrapped steel structure for a beam-column joint of a construction, but a systematic mold plate module when grouting concrete.
The above-mentioned end plate 310 can be alternatively designed based on the position of the architectured reinforcement structure of the present invention. The end plate 310 may include a flange 313 , protruding perpendicularly out from the surface of the end plate 310 . Thus, a joint sleeve 370 can be used to sheathe among flanges 313 of the end plate 310 for the beam-column joint steel box unit 300 . And by means of a full-penetration weld manner to affix end plates 310 of the beam-column joint steel box unit 300 and the adjacent end plate 210 of the column steel box units 200 with the joint sleeve 370 , the adjacent beam-column joint steel box unit 300 and column steel box unit 200 are connected together. In addition, the above-mentioned side plate 330 may also include a flange 333 , protruding perpendicularly out from the surface of the side plate 330 . Thus, a joint sleeve 370 can be used to sheathe among flanges 333 of the side plate 330 for the beam-column joint steel box unit 300 . And by means of a full-penetration weld manner to affix side plate 330 of the beam-column joint steel box unit 300 and the adjacent end plate 110 of the beam steel box unit 100 with the joint sleeve 370 , the adjacent beam-column joint steel box unit 300 and beam steel box unit 100 are connected together.
As stated above, by interconnecting multiple beam steel box units 100 , column steel box units 200 , and beam-column joint steel box units 300 in the X direction, the Y direction, and the Z direction respectively, the architectured reinforcement structure of the present invention as shown in FIGS. 5A and 5B can be provided. Furthermore, an architectured reinforcement structure of a building as shown in FIG. 1A can be constructed.
What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the aforementioned embodiments, but one of ordinary skill in the art may recognize that many further combinations and permutations of various embodiments are possible. Accordingly, the described embodiments are intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. | This invention presents a modified reinforced concrete structure, which has a steel structure composed of a beam steel box unit, column steel box unit, and beam-column joint steel box unit with lap jointing reinforced steels. The side plate and/or end plate of the steel box has through holes for concrete flowing therebetween. In this way, the workability of concrete grouting and tamping are improved, and the phenomena of hive, segregation, or floating can be avoided. It can also enhance the performance of beam-column joints (e.g. with better confinement ability, etc.). Applying the invention, the efficiency and accuracy of constructing beam-column joints can be increased, and in addition to better ensure the structural safety, it can also reduce construction manpower and schedule. |
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BACKGROUND
[0001] Conventionally, wells in oil and gas fields are built up by establishing a wellhead housing and, with a drilling blow out preventer (BOP) adapter valve installed, drilling down to produce the borehole while successively installing concentric casing strings. The casing strings are cemented at their lower ends and sealed with mechanical seal assemblies at their upper ends. In order to convert the cased well for production, a production tubing string is run in through the BOP and a tubing hanger at its upper end is typically landed in the wellhead. Thereafter the drilling BOP is removed and replaced by a Christmas tree having one or more production bores containing valves and extending vertically to respective lateral production fluid outlet ports in the wall of the tree.
[0002] The tubing hanger is installed by a hanger running tool and the tool lowers the tubing hanger down the production bore until it lands on top of a stop shoulder. The stop shoulder is created with a decreased inner diameter portion of the housing in which the hanger is landed, which provides a permanent means to stop the lowering of the tubing hanger.
[0003] During subsequent operations, the difference in diameter of inner bore created by the permanent stop shoulder may present an inner diameter that can impede the progress of elements that are intended to be lowered past the stop shoulder. In this case, the utilization of the stop shoulder could present and inner diameter less than the inner diameter that would allow an element such as a workover tool to progress downward through the bore. If no stop shoulder were present, such and impedance would not occur and the maximum inner diameter of the production bore would be available to the operator. In addition, the standard amount of housing required between the production bore and a wellhead casing increases proportionally with the inner diameter of the production bore. If no stop shoulder is present, the amount of material can be decreased, per required standards. The absence of a stop shoulder would create “full” production bore, where the inner diameter of the production bore is limited only by the inner wall of the production bore itself.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more detailed description of the embodiments, reference will now be made to the following accompanying drawings:
[0005] FIG. 1 is a sectional view of a full bore production system showing a production full-bore support casing.
[0006] FIG. 1A shows a detailed sectional view showing a close up of some of the full bore production system components.
[0007] FIGS. 2-8 include sectional views of the full bore production system during installation.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0008] In the drawings and description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
[0009] Referring to FIG. 1 there is shown a standard full bore production system 1 including a wellhead 4 , a BOP adapter 34 , and a hanger running tool 28 . The wellhead 4 is landed on top of a conductor casing 3 . The wellhead 4 controls and monitors flow, temperature, and pressure of the production fluid or gas via a plurality of valves and tubing (not shown) inside of the full bore production system 1 . The BOP adapter 34 is landed atop the wellhead 4 and bolted to wellhead 4 using bolts as shown or any other suitable attachment means.
[0010] A tubing hanger system 5 is lowered through the top of the BOP adapter 34 and landed in position inside the wellhead 4 via a hanger running tool 28 . The tubing hanger system 5 includes a hanger body 8 supporting a production tubing and a load shoulder 12 that includes a load segment 14 . The load shoulder 12 is designed to receive loading that may be transferred during construction and operation of the full bore production system 1 . The load shoulder 12 also includes an upper load sleeve 38 and a lower load sleeve 40 . The load sleeves 38 , 40 move independently of each other and transfer applied loading via free-fall movement of tubing hanger body 8 and a stud force pin 16 respectively. Further, hanger system 5 includes an upper lock ring 36 that is manipulated between a locked and an unlocked position by the movement of a wedge 50 .
[0011] Loading transferred to the tubing hanger system 5 components in the full bore production system 1 may originate from a hanger running tool 28 . The hanger running tool 28 includes a sealed port 70 for fluid communication with the BOP adapter 34 and an outer sleeve 37 . The hanger running tool 28 is “run” by being lowered through the top of the BOP adapter 34 and temporarily landed inside of BOP adapter 34 using load pins 24 , 25 that are manipulated between extended and withdrawn positions per operator discretion as discussed below. Although only two load pins 24 , 25 are shown, it should be appreciated that as many load pins as desired may be used. The hanger running tool 28 , in use, applies pressure force to the full bore production system 1 via a chamber 35 and hydraulic fluid communicated through the pressure port 32 in the BOP adapter 34 .
[0012] In use, a downhole completion is initiated by drilling and completing an oil or gas production well in such a manner that the well can allow proper flow during the period in which the reservoir operates. The full bore production system 1 may be used for completing the well with the tubing hanger system 5 installed to allow communication and control of downhole functions and as a sealing mechanism for the production components that are utilized in the operation of the well.
[0013] The tubing hanger system 5 is positioned and installed by utilizing the hanger running tool 28 to insure proper placement and to keep the tubing and control lines from becoming entangled in the system. The hanger system 5 includes the upper lock ring mechanism 36 , the upper and lower load sleeves 38 , 40 , the outer loading sleeve 37 , a stud force pin 16 , and the load segment 14 mechanism. These elements provide the means for running, setting, locking, and preloading the load segment 14 mechanism without requiring the use of a permanent stop shoulder in the wellhead 4 . This method will also limit the possibility of leakage in the system tubing due to the fact that the load segment mechanism can be run with the tubing hanger system 5 in a single approach—thus limiting the opportunities for potential leakage upon its removal. It should be noted that as shown in FIGS. 1 and 1A , the full bore production system 1 is in the running position configuration.
[0014] FIGS. 2-8 show further installation of the hanger system 5 . Referring to FIG. 2 , at least the load pins 24 , 25 are set into the extended position in the direction of the hanger running tool 28 . (It should be noted that this embodiment could contain more than two load pins.) This movement may be actuated from variant sources, however, the conventional source is through manual operation. The purpose of moving the load pins 24 , 25 , is to locate and temporarily support the hanger system 5 and to provide verification of the elevation of the casing. This setting is known as the run-in position for the full bore production system 1 .
[0015] Referring to FIG. 3 , hydraulic fluid pressure is applied through the pressure port 32 orifice to set and lock the load shoulder 12 . Pressure is applied at pressure port 32 and this pressure load is introduced into the chamber 35 above an annular collar on the inside of the outer sleeve 37 , effecting a hydraulic piston. The increased pressure in the chamber 35 is transferred to the outer sleeve 37 through the collar, shifting the sleeve 37 downward and applying pressure force to the stud force pin 16 . This pressure loading of the stud force pin 16 transfers to the lower load sleeve 40 , causing it and a wedge 41 to move downward. Movement of the wedge 41 relative to the load segment 14 causes the load segment 14 to move in a radially outward motion towards a groove 44 machined into the inner bore of the wellhead 4 until the load segment 14 is set in the groove 44 . Once set, the load segment 14 may receive and support subsequent loading.
[0016] Referring to FIG. 4 , with the load segment 14 extended, the hanger body 8 is supportable using the engagement of the load segment 14 with the groove 44 as a load shoulder. Transfer of the load to the load segment 14 is accomplished by retracting the load pins 24 , 25 while holding the hanger body 8 using the running tool 28 , and then slowly releasing the hanger body 8 . With enough downward force, the hanger body 8 shears a force shear pin 42 located inside of a shear pin housing 48 , allowing the hanger body 8 to continue to move in a downward direction until the hanger body 8 is supported by the load shoulder 12 .
[0017] Referring to FIG. 5 , once the hanger body 8 is landed, the pressure supplied to the system through pressure port 32 is terminated and the running tool 28 is removed.
[0018] Referring to FIG. 6 , an overshot tool 54 and an overpull tool 56 are positioned in the location previously occupied by hanger running tool 28 . It should be appreciated that in the case that the tubing hanger body 8 is adjustable, overpull tool 56 may be used to position the adjustable hanger per the operator's specification and then to subsequently lock the hanger in place.
[0019] Referring to FIG. 7 , once the hanger body 8 is positioned, the overshot tool 54 may be rotated to apply torque to the wedge 50 , which is threaded to the outside of the upper load sleeve 38 . Relative rotation of the wedge 50 to the upper load sleeve 38 drives the wedge 50 downward, applying an outward force to upper lock ring 36 and expanding the lock ring 36 into a groove 51 . The movement of upper lock ring 36 towards the groove 51 allows for movement of the adjustable tubing hanger body 8 per the user's discretion. With the wedge 50 moved downward and the upper locking ring 36 engaged with the groove 51 , the hanger body 8 is considered locked in position. The overshoot tool 54 may now be removed from the system as shown in FIG. 8 .
[0020] Subsequent to installing the full bore system 1 , operations may need to be performed on the well that include removal of the hanger system 5 and the supported production tubing. Removal of the hanger system 5 , including the load shoulder 12 may be performed by unlocking and unsetting the hanger system 5 and then removing the system 5 from the wellhead 4 . When removed, the wellhead 4 offers full bore access for running in tools or elements downhole for performing well operations such as workover procedures. The wellhead 4 thus does not limit the size of elements run into the well to a reduced inner diameter of a permanent load shoulder in the wellhead 4 .
[0021] While specific embodiments have been shown and described, modifications can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments as described are exemplary only and are not limiting. Many variations and modifications are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | A production assembly for controlling production from a well, the assembly including a wellhead that includes a body and a bore through the body. The bore does not include a hanger support shoulder but does include an engagement profile extending into the body. The assembly also includes a tubing hanger assembly installable in the wellhead. The assembly includes a load shoulder including a load segment expandable into supporting engagement with the bore engagement profile. The assembly also includes a tubing hanger and attached production tubing capable of being run in with the load shoulder and supportable on the load shoulder when the shoulder is engaged with the wellhead. |
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FIELD OF THE INVENTION
This invention relates generally to extension ladders and more particularly to extension ladders comprising two separable sections which may readily be coupled together to constitute an extension ladder.
BACKGROUND OF THE INVENTION
In the past various extension ladders comprising separable sections have been provided. Typical are the ladders disclosed in U.S. Pat. No. 1,555,344 to Whitney issued Sept. 29, 1925; Australian Pat. No. 289,370 to Paynter of Mar. 4, 1969 and French Pat. No. 1,252,593 to Roth issued Dec. 19, 1960. In each of these patents the ladders comprise separable base and extension sections which are coupled together at longitudinally spaced locations by means of co-operating rung and slot couplings whereby rungs and extensions of rungs are received in longitudinally extending slots.
These prior art extension ladders all suffer a major disadvantage that to couple the two separable sections of the ladder together requires the two sections to be precisely positioned with respect to each other in longitudinal alignment so that the slot and rung coupling means at the two spaced locations may be concurrently engaged. Suitable positioning of the ladder sections may be extremely difficult particularly by a single person when the ladder sections are heavy or when no suitably flat terrain is available on which to lay both of the ladder sections. When used outdoors, vegetation, mud and snow may catch on the sections or partially block the slots increasing the difficulty of coupling the sections together. Further in frigid wintery conditions protective clothing such as mitts and gloves impair the ability of an individual to precisely locate the ladder sections as is required for coupling.
Servicemen working for utility companies such as hydro electric suppliers, cable television suppliers and telephone companies require ladders for day-to-day use. For example in Canada, telephone company servicemen require almost daily a ladder which can extend to 17 feet. Less frequently they will require a ladder which extends to 21 feet. In the past these servicemen have been provided with a two piece telescoping extension ladder which is 12 feet in length when unextended and may extend to 21 feet. Recently, however, telephone servicemen have been provided with several automobiles of smaller size than previously, with the result that the existing 12 foot ladders are longer than the new automobiles and present a safety hazzard. To overcome this problem new ladders were proposed comprising a telescoping two piece ladder of 10 foot length unextended which may extend to 17 feet. To provide the ladder with the capability to extend 21 feet when necessary a third detachable section has been proposed. The disadvantages of the prior art extension ladders have made the use of known separable extensions unsatisfactory particularly in regard to difficulties in coupling the separable section to the rest of the ladder by a single serviceman in the field. Another disadvantage of the known separable extension ladder is the absence of any provision for positive locking of the separable extension to the rest of the ladder as is required to ensure safe use of the ladder.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to at least partially overcome these disadvantages of the prior art by providing a ladder comprising two separable sections to be coupled together in longitudinally overlapping relation by first coupling means coupling a portion of a first ladder section proximate one end thereof to the second section so as to permit the first ladder section to be rotated with respect to the second ladder section to a position where second coupling means are aligned in position for engagement, preferably with stop means being provided to stop rotation of the first ladder section at a position where the second coupling means are aligned for engagement.
Another object is to provide a ladder comprising two separable sections which is easy to assemble by a single person even under adverse field conditions.
Another object is to provide a ladder comprising two separable sections which provides means to positively lock together the sections when assembled into an extension ladder.
To this end, in one of its aspects the present invention provides a ladder comprising two separable sections, a ladder extension section and a base ladder section to be coupled together in longitudinally overlapping relation to constitute an extension ladder;
each section comprising rails and rungs, portions of each rail of the extension section at the lower end thereof being spaced to be received between rails of the ladder section and having complementary primary slots formed therethrough to slidably receive one rung of the base section therein;
each primary slot having a blind end proximate the lower end of the extension section, the primary slots extending from the blind end longitudinally away from the lower end of the extension section to an open end permitting entrance of the one rung therein; wherein with the one rung received in the primary slots at the blind ends, the extension section being rotatable with respect to the ladder section about the one rung;
first coupling means on the extension section spaced longitudinally from the slot on the remote side of the slot from the lower end of the extension section;
secondly coupling means on the ladder section spaced longitudinally from the one rung on the remote side of the one rung from the lower end of the ladder section;
stop means on one of the extension section and ladder section, wherein with the one rung received in the slots at the blind ends, on rotation of the extension section about the one rung, the stop means stopping rotation of the extension section about the one rung at a position wherein the first and second coupling means are in alignment for coupling,
the first and second coupling means engaging to couple together by sliding the extension section from the position in a substantially longitudinal direction with respect to the ladder section to slide the one rung in the primary slots away from the blind ends, the primary slots being of sufficient longitudinal extension that with the first and second coupling means coupled together the one rung being retained within the primary slot;
the first and second coupling means on coupling preventing further sliding of the extension section in the direction, and, with the first and second coupling means coupled together and the one rung retained within the primary slots, relative rotation of the extension section with respect to the longitudinal section is prevented.
In another of its aspects, the present invention provides a ladder comprising two separable sections, a first section and a second section to be coupled together in longitudinally overlapping relation to constitute an extension ladder with a first end of each section overlapping with the other section and the other, second, end of each section to be remote from the respective other section,
each section comprising rails and rungs, the first end of the first section coupling to the second section by means of complementary primary slots in the rails of one of the first and second sections to slidably receive one rung of the other of the first and second sections;
the primary slot having a blind end and extending longitudinally away from the blind slot directionally away from the first end of the first or second section provided with the primary slot to an open end permitting entrance of the one rung therein; wherein with the one rung received in the primary slots at the blind ends, the first section being rotatable with respect to said second section about said one rung
first coupling means on the first section spaced longitudinally from the one of the primary slots and the one rung provided on the first section on the remote side thereof from said first end of the first section;
second coupling means on the second section spaced longitudinally from the one of the primary slots and the one rung provided on the second section on the remote side thereof from the second end of the second section,
stop means on one of the first section and second section, wherein with said one rung received in the primary slots at the blind ends, on rotation of the first section about the one rung, the stop means stopping rotation of the first section about the one rung at a position wherein the first and second coupling means are in alignment for coupling,
the first and second coupling means engaging to couple together by sliding the first section from the position in a substantially longitudinal direction with respect to the second section to slide the one rung in the primary slots away from the blind ends, said primary slots being of sufficient longitudinal extension that with the first and second coupling means coupled together the one rung being retained within the primary slot;
the first and second coupling means on coupling preventing further sliding of the first section in the direction, and with the first and second coupling means coupled together and the one rung retained within the primary slots relative rotation of the first section with respect to the second section being prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will appear from the following description taken together with the accompanying drawings in which;
FIG. 1 is a pictorial view of an extension ladder in accordance with a first embodiment of the invention shown with two separable ladder sections located relative to each other in a first position to initiate a coupling sequence.
FIGS. 2 and 3 are partial pictorial views of the ladder of FIG. 1 with the two separable ladder sections located relative to each other in second and third positions during a coupling sequence.
FIG. 4 is a partial pictorial view of the ladder of FIG. 1 with the two separable ladder section located relative to each other in a fourth coupled position.
FIGS. 5 and 6 are similar cross-sectional views through section line V--V' of FIG. 4 showing a locking means in an unlocked and locked position, respectively.
FIG. 7 shows a schematic pictorial view of two ladder sections coupled to from an extension ladder in accordance with a second embodiment of the invention similar in many respects to the ladder shown in FIG. 1.
FIGS. 8, 9 and 10 show schematic pictorial views of two ladder sections coupled to form extension ladders in accordance with third, fourth and fifth embodiments of the invention.
FIG. 11 shows a pictorial view of an extension ladder in accordance with a sixth embodiment of the invention in a position similar to that shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is made first to FIG. 1 showing a first preferred embodiment in accordance with the present invention. The extension ladder comprises two seperable ladder sections, a first or extension section 10 and a second or base section 20. Each of the first and second ladder sections have a first end 12 and 22, respectively, and a second end 14 and 24, respectively. The first ends are designated so that as shown in FIG. 4 when the two sections are coupled together to comprise an extension ladder, the first end of each section is the end overlapping with the other section whereas the second end of each section is the end shown to be remote from the respective other section.
Each ladder section comprises rails and rungs with the rails of the first and second sections designated 16 and 26, respectively. The rungs of the first section 10 are designated 18 while the rungs of the second section are generally designated 28 with the exception of the one rung closest to the first end 22 of the second section 20 which is designated 29.
Rails 26 of the second section 20 are shown as parallel, cross-sectionally U-shaped members with an end cap 30 at the first end 22 to be described later. The rails 16 of the first section 10 are shown to comprise two rails portions, 32 and 34, with rail portions 32 closest to the second end 14 of the first section 10 being parallel cross-sectionally U-shaped members similar to rails 26. Rail portions 34 proximate the first end 12 of the first section 10 comprise a pair of hook-like members fixedly secured as, for example, by rivetting to inside surfaces 36 of rail portions 32 and extend longitudinally beyond the ends of rail portions 32.
Rails 26 of the second section are provided spaced the same distance as rail portions 32 of rail 16 of the first section. Rail portions 34 of the first section are spaced so as to be received between rails 26 of the second section.
Each rail portion 34 appears as a hook-like member by reason of primary slots 38 transversely therethrough in the direction of extension of rungs 18. Primary slot 38 extends from a blind end 40 longitudinally with respect to rails 16 away from first end 12 of the first section 10 to a slot opening 42. As best seen in FIG. 3, surfaces 44 of rail portion 34 bordering these slot openings 42 are suitably shaped to assist in guiding rung 29 of the second section 20 into primary slot 38 as is described later.
Primary slot 38 is sized so as to closely receive rung 29 yet to permit rung 29 to enter slot opening 42 and to be slidable longitudinally in the slot to contact and engage blind end 40.
As best seen in FIG. 3, each rail portion 34 is provided with a post 50 which extends transversely outward from the outside surface 48 of rail portion 34. As seen in FIGS. 3, 5 and 6, an internally threaded locking member 56 is provided co-axially on post 50, threadably engaging external threads on the post and with a snap-locking ring 58 preventing withdrawal of the locking member 56 off the outwardmost end of post 50. Locking member 56 has a conical end portion 60 and a handle portion 62 facilitating manual turning of the locking member 56 for a movement axially with respect to post 50 by cooperative engagement of the threaded portion of post 50.
Referring now to FIGS. 2 and 3, end cap 30 on the second section 20 at its first end is provided with a secondary slot 64 extending transversely of the rail therethrough in the direction of extension of rungs 28. Secondary slot 64 extends from a blind end 66 longitudinally of rail 26 towards the first end 22 of the second section (and therefore away from the second end 24 of the second section) to slot opening 68 providing an open end to slot 64.
The end cap extends as a longitudinal extension 70 on one side of slot opening 68 longitudinally farther from second end 24 than on the other side of slot opening 68 for the purpose of acting as a stop means in a manner to be described later.
With the major elements of the first and second sections now defined, the interaction of these elements will now be described with reference to FIGS. 1 to 4 which show successive steps in a sequence of coupling the first section to the second section. For the purpose of illustration, the second section 20 is assumed to stay in one position and the first section 10 is to be moved with respect to the second section 20.
The first section 10 is first moved so that both primary slots 42 will receive rung 29. As shown in FIG. 1, first section 10 is preferably positioned so that surfaces 44 proximate slot opening 42 contact rail 29 of the second member, and then by sliding first section 10 in the direction of arrow A shown in FIG. 1, surface 44 may effectively act as a cam surface to guide rung 29 into slot opening 42. Further sliding in the direction of arrow A permits rung 29 to slide from slot opening 42 through the slot until further relative sliding of the first and second portions is prevented by rung 29 engaging blind ends 40 of primary slot 38 and locating these sections in their relative positions shown in FIG. 2.
With the first and second sections in the position shown in FIG. 2, and with rung 29 maintained in engagement with blind slot 40, the first section may be rotated with respect to the second section about rung 29 in the direction indicated by arrow B until posts 50 engage extensions 70 on the first end 22 of the second section preventing further rotation and resulting in the first and second sections being located in their relative positions shown in FIG. 3. With the locking member 56 being withdrawn towards the outermost end of post 50 as seen in FIG. 5, the upper surface 72 of extension 70 of the second section contacts post 50 to stop rotation at the position shown in FIG. 3.
With the first and second sections in the position shown in FIG. 3, the post 50 is in engagement with extension 70 and post 50 is in a position in alignment for coupling with secondary slot 64 by sliding longitudinally in the direction of arrow C until the first and second sections assume their relative positions shown in FIG. 4. In sliding the first section in the direction of arrow C, post 50 slides longitudinally along the upper surface 72 of extension 70 to enter slot opening 68 and slide along secondary slot 64 until the post engages blind end 66. Concurrently with this sliding, the relative position of rung 29 will be changed with respect to primary slot 38 so as to change from the position shown in FIG. 3 with rung 29 engaging blind end 40 by relative sliding of rung 29 in primary slot 38 away from blind end 40, to a position as shown in FIG. 4, with rung 29 disposed in primary slot 38 at an intermediate location between blind end 40 and slot opening 42.
The longitudinal extent of primary slot 38 is chosen so as to be greater than the longitudinal extent of secondary slot 64 so that when the posts 50 engage blind ends 66 preventing further relative sliding of the first and second sections in direction C, rung 29 will remain disposed within primary slot 38. As is to be appreciated, the relative longitudinal positions of rung 29, slot opening 68, blind end 66 and extension 70 on the second section must be chosen having regard to the relative positioning of post 50, and blind end 40 on the first section. For example, as seen in the figures, the longitudinal distance between blind end 66 and the far side of rung 29 on the second section 20 may be equal to the longitudinal distance between post 50 and blind end 40 on the first section 10 less the longitudinal distance from slot opening 68 to blind end 66 on the second section 20.
With the first and second ladder sections engaged as shown in FIG. 4, the extension ladder is satisfactorily assembled for use. Longitudinal compression of the assembled ladder is prevented with post 50 engaging on blind end 66. With post 50 engaging blind end 66 while rung 29 is disposed in primary slot 38, relative rotation of the first section 10 with respect to the second section 20 is prevented. Preferably also, the ouside surfaces 48 of rail portions 34 may closely engage the inside surfaces of rails 26 of second section 20 to provide additional stability.
The preferred embodiment of FIG. 1 also includes an optional locking mechanism whereby locking member 56 may securely lock post 50 to end cap 30 of the second section. As described and best shown in FIGS. 5 and 6, locking member 56 has a truncated conical end portion 60 co-axially located about post 50. End cap 30 carrying secondary slot 64 is formed at blind end 66 to have a conical recess complementary to conical end portion 60. As seen in FIGS. 5 and 6, blind end 66 proximate the inside surfaces of rail 26 has a diameter marginally larger than that of post 50. As the blind end extends transversely towards the outside surfaces 78 of rails 26 it opens into a conical recess 80 having conical walls 82. Conical recess 80 is co-axial with respect to post 50 when post 50 is engaged with blind end 66.
The operation of the locking mechanism is now described. In coupling the first and second sections together as described by the sequence with reference to FIGS. 1 to 4, the locking member 56 should be screwed to be withdrawn to the outermost end of post 50 so that post 50 may engage and cam on extension 70 to slide into secondary slot 64 and to engage blind end 66. With the first and second sections coupled in their relative positions shown in FIG. 4, then the post 50, locking member 56 and end cap 30 will be in the relative position shown in FIG. 5 being a cross-section through FIG. 4 on section line V--V'. The engagement of post 50 with blind slot 66 will axially align post 50 and conical end portion 60 with respect to conical recess 80 of end cap 30. Turning handle portion 62 of locking member 56 will move locking member 56 from the retracted or unlocked position shown in FIG. 5 to the locked position shown in FIG. 6 engaging conical walls 82. As best seen in FIG. 3, the conical walls 82 extend more than 180° about the conical recess whereby with the complementary conical end portion 60 engaged in conical recess 80, the first and second sections are positively locked together.
The first embodiment of this invention provides two sections for an extension ladder which facilitates easy coupling together of the two sections in assembly into a complete extension ladder. For example, a single individual may lay the second ladder section 20 on the ground. The first ladder section 10 may then be manipulated to the position shown in FIG. 1. With the surfaces 44 near slot opening 42 on the first section serving to cam and guide rung 29 into primary slot 38, the initial engagement of rung 29 into slot 38 does not require precise manual control of the two ladder sections. Once rung 29 is engaged in primary slot 38, by further pulling the first section in direction A as shown in FIG. 1, rung 29 is caused to slide down the primary slot to engage blind end 40. Next, simple manual rotation of the first section about rung 29 until rotation is stopped by post 50 engaging extension 70 will place the two sections in two positions to be slid longitudinally for engagement of post 50 in secondary slot 64 and contact with blind end 66 thereof. Finally, locking member 56 may be manually turned to cause the locking member to enter conical recess 80 and securely lock the two sections together. Thus, as described, the particular embodiment shown in FIG. 1, the first section need only be roughly manipulated into place in order to accomplish a positive coupling of the two sections together. Cooperating slots and grooves on the two sections provide for the adequate relative positioning of the sections for coupling once rung 29 has been positioned to enter primary slot 38.
Reference is now made to FIGS. 7 to 10 which show second, third, fourth and fifth embodiments in accordance with the present invention. In each of FIGS. 7 to 10, two ladder sections are shown, a first ladder section 110 and a second ladder section 120. Throughout FIGS. 7 to 10 like numerals are used to refer to similar elements.
In each of FIGS. 7 to 10, the first and second ladder sections are shown coupled together in a position ready for use as an extension ladder. The first and second sections are coupled together at two longitudinally spaced junctures, as shown in FIGS. 7 to 10, an uppermost juncture at U and a lowermost juncture at L. Each juncture comprises a longitudinally extending slot in the rails of one of the sections and a rung or extension of a rung from the other of the sections to be received in that slot.
As in the case of FIG. 1, the first end 112 and 122 of the first and second sections 110 and 120, respectively, are designated as the end of each section which is in overlapping relation with the other ladder section while the second ends 114 and 124 of the first and second sections respectively are the ends remote from the other section.
The lowermost juncture L of each of the embodiments shown in FIGS. 7 to 10 comprise a primary slot 138 provided in one of the first section and the second section. The primary slot has a slot opening 142 and a blind end 140. Each primary slot extends longitudinally away from the blind end 140 in a direction away from the first end 112 or 122 of the first or second section provided with the primary slot. Adapted to be received in the primary slots 138 is a primary rung 109 or lateral extensions thereof on the other of the first and second sections to that on which the primary slot 138 is provided. One of the primary slots 138 and the primary rung 109 is located sufficiently proximate the first end 112 of the first section that with the primary rung 109 received in the primary slot so as to engage blind end 140, the first section 110 is rotatable with respect to the second section 120 about primary rung 109.
The uppermost juncture U of each of the embodiments shown in FIGS. 7 to 10 comprises a secondary slot 164 provided in one of the first section and the second section. The secondary slot has a slot opening 168 and a blind end 166 and extends longitudinally away from the blind end 166 in a direction away from the second end 114 or 124 of the first or second section provided with the secondary slot. Adapted to be received in the secondary slot 164 is a secondary rung 107 or extension 107' thereof on the other of the first and second section to that on which the secondary slot is provided.
The one of the secondary slot 164 and secondary rung 107 provided on each of the first sections 110 is shown to be located on the rails 116 of the first section spaced longitudinally from the elements of the lower juncture L on the remote side of the lower juncture L from the first end 112 of the first section. Similarly, the one of the secondary slot 164 and secondary rung 107 provided on each of the second section 120 is located on the rails 126 of the second section spaced longitudinally from the element of the lower juncture L on the remote side of the lower juncture L from the second end 124 of the second section.
The coupling sequence of each of the embodiments of FIGS. 7 to 10 is substantially the same as that described with respect to the first embodiment. Firstly, the primary rung 109 is engaged in primary slot 138 and the sections are moved longitudinally with respect to each other so that primary rungs 109 engages the blind end 140 of the primary slot. Secondly, the first section is then rotated about primary rung 109 until rotation is stopped by secondary rung 107 contacting stopping surfaces designated generally as 105 proximate the slot opening 168 of secondary slot 164. Rotation is stopped in a position in which rung 107 is in alignment to enter secondary slot 164 by substantially longitudinal sliding of the two sections. Thirdly, the first section is slid substantially longitudinally with respect to the second section in a direction to move the primary rung 109 away from engagement with blind end 140 whereby secondary rung 107 enters secondary slot 164 and becomes in engagement with blind end 166 thereof preventing further longitudinal sliding of the first section with respect to the second section in that direction. As may be seen in each of FIGS. 7 to 10, with the secondary rung 107 engaging blind end 166 of the secondary slot, the primary rung 109 remains within primary slot 138 so as to prevent relative rotation of the first section 110 with respect to the second section 120.
In discussing the embodiments of FIGS. 7 to 10, the terms upper and lower junctures have been used. It is to be appreciated however that each of the embodiments illustrated may be used in an inverted position from their orientations shown in the figures. Further, in each of FIGS. 7, 8 and 10, the rails 126 of the second section 120 have been shown to be spaced wider than the rails 116 of the first section 110. By the use of suitable rung projections on any of rungs 107 and 109, the rails of the first section may be provided in modified embodiments to be spaced wider than the rails 126 of the second section. Similar changes could be made regarding the embodiment of FIG. 9. For the purpose of clear illustration, the embodiments of FIGS. 7 to 10 has been shown schematically and preferably the inside surfaces of one set of the rails would closely engage the outside surfaces of the other set of the rails to provide additional stability.
Reference is now made to FIG. 11 which shows a sixth embodiment in accordance with the present invention. The embodiment of FIG. 11 is similar in many respects to that of FIG. 1 and like numerals are used to refer to similar elements. The second section 20 of FIG. 11 differs from the second section of FIG. 1 only in the elimination of end cap 30 as shown in FIG. 1 leaving a simple squared end cap 31 on the first end 22 of the second section 20 of FIG. 11. The first section 10 of FIG. 11 is identical to the first section of FIG. 1 with the exception that post 50 has been replaced by a socket means generally designated 90. The socket means 90 comprises a slot-like socket recess 92 sized to permit entry therein of square end cap 31. The socket recess 92 has a blind end provided by end plate 94 and an open end. Near the open end, a stop plate 98 is provided.
The sequence of coupling the embodiment of FIG. 11 is substantially the same as that for FIG. 1. With rung 29 engaging the blind end 40 of primary slot 38, the first section 10 may be rotated about rung 29 until stop plate 98 contacts end cap 31 stopping rotation at a position in which end cap 31 is in alignment for sliding into socket recess 92. The first section is then slid longitudinally with respect to the second section with end cap 31 to slide into socket recess 92 until end cap 31 contacts end plate 94 preventing further longitudinal movement.
Only the first embodiment shown in FIGS. 1 to 4 has been illustrated with a locking mechanism. While the locking mechanism of the first embodiment is preferably, many other locking mechanisms may be used. For example, in the embodiment of FIG. 11, complementary transversely extending holes could be provided through socket means 90 and end cap 31 so that in a coupled position a pin or bolt could be inserted therein to lock the sections together. Further, the pin could be permanently mounted on the socket means 90 and be biased to a locking position by means of a spring, possibly with a cam-like ramp being provided on end cap 31 to permit automatic movement of the biased pin into the hole in the end cap 31 on end cap 31 being slid longitudinally into socket means 90.
Preferably, the ladder sections as shown in all the embodiments of this application may be constructed from fiberglass or fiber reinforced resin. Many other materials are suitable for example wood and aluminum. Suitable frictional engaging means may be provided on the ends of the ladder section to provide frictional engagement with surfaces to be contacted, for example the ground and the side of a building to assist in preventing a ladder from sliding in use. For example, if end cap 30 comprises fiberglass a rigid rubber pad may be attached to the undersurface of extension 70. Possibly this underpad may extend laterally beyond each rail 26 internally thereof to provide increased contact surface and in which case in some embodiments the rubber pad may double as stop means to contact rails 16 and stop rotation thereof at a position for coupling.
Although the disclosure describes and illustrates preferred embodiments of the invention, it is to be understood that the invention is not limited to these particular embodiments. Many variations and modifications will now occur to those skilled in the art. For a definition of the invention reference is made to the appended claims. | A ladder extension is disclosed comprising two separable sections to be coupled together in longitudinally overlapping relation by first coupling means coupling a portion of a first ladder section proximate one end thereof to the second section so as to permit the first ladder section to be rotated with respect to the second ladder section to a position where second coupling means are aligned in position for engagement, preferably with stop means being provided to stop rotation of the first ladder section at a position where the second coupling means are aligned for engagement. The ladder comprises two separable sections which is easy to asemble by a single person even under adverse field conditions and which provides means to positively lock together the sections when assembled into an extension ladder. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of prior copending application Ser. No. 344,290, filed Mar. 23, 1973, now abandoned.
BACKGROUND OF THE INVENTION
A need has long existed in the concrete construction industry for a practical, efficient and convenient column or beam form which is reusable and economical to manufacture and laborsaving.
The prior art has contained some proposals to satisfy this need, and a typical example of the patented prior art is U.S. Pat. No. 3,107,087 issued to C. I. Williams on Oct. 15, 1963. In general, known or proposed devices for this purpose have not been adopted to any significant degree commercially for the simple reason that none has proven to be sufficiently convenient and fool-proof to use particularly by unskilled construction workers, and hence the need for a satisfactory knock-down reusable column or beam form has not been satisfied.
Accordingly, it is the objective of this invention to totally satisfy the above need of the art through the provision of a separable and reusable concrete construction form which is economical to manufacture, extremely durable and long-lasting, easy to assemble by unskilled labor and, in this sense, substantially fool-proof since it cannot be assembled improperly. Among the important features and advantages of the invention over the prior art are the self-squaring ability of the assembled form, its resistance to grout leakage at the corners due to a tight and uniform fit of the components and a superior resistance to bulging or buckling under heavy fluid-induced internal pressure. It is realistically estimated that the customary time involved in the construction of conventional forms on the job site can be reduced by fifty per cent. A great deal of plywood and other material waste is eliminated by the reusable nature of the form. The components of the invention are lightweight and strong and the panels are easily carried and set up in single, double or triple side combinations.
Other features and advantages of the invention will become apparent during the course of the following description.
BRIEF DESCRIPTION OF DRAWING FIGURES
FIG. 1 is a fragmentary perspective view of a knock-down reusable concrete column form embodying the invention.
FIG. 2 is a perspective view of one typical side panel and attached metal parts embodied in the form.
FIG. 3 is an enlarged typical horizontal cross section through the assembled form in the plane of transverse braces and assembly clips, taken on line 3--3 of FIG. 1.
FIG. 4 is a perspective view of a spring steel assembly clip.
FIG. 5 is a fragmentary vertical section taken on line 5--5 of FIG. 3.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts throughout, the numeral 10 designates one of four identical panel sub-assemblies embodied in the assembled form depicted in FIG. 1. Since the panel sub-assemblies are identical a detailed description of one will suffice to describe them all.
Each panel sub-assembly 10 comprises an elongated rectangular plywood body portion 11 preferably formed from commercial 7-ply exterior plywood or equivalent material. Conveniently, the panel sub-assemblies 10 can be constructed in 6 and 8 foot lengths so that joints between longitudinal sections of the form can be staggered around the four sides of the rectangular cross-section assembly. Other panel lengths may be utilized to meet particular needs.
Each plywood panel body portion 11 has rigidly attached to it by riveting or similar fastening means, not shown, a single sturdy 90° metal angle bar 12 which extends continuously along one longitudinal edge of the body portion 11 from end-to-end thereof. One of the two equal width webs of the angle bar 12 lies against the outer face of plywood body portion 11 and the other right angular web abuts the adjacent edge 13 of the plywood as depicted in FIG. 2. This latter angle bar web designated 12' in FIG. 2 projects considerably inwardly of the body portion 11 at right angles thereto.
Somewhat inwardly of and parallel to the opposite exposed longitudinal edge 14 of the plywood body portion 11 a continuous flat longitudinal metal frame bar 15 extends for the full length of the sub-assembly and is fixedly secured to the plywood by riveting or equivalent fastener means, not shown. The bars 12 and 15 are also parallel as well as coextensive lengthwise.
At regular intervals along each panel sub-assembly 10, such as one foot intervals, plural identical transverse hat braces 16 are fixedly secured to the underlying bars 12 and 15 by suitable bolts 17 whose heads are recessed into the inner faces of the plywood panel body portions 11 as indicated at 18 in FIG. 5. These bolts pass through the wooden panels and through the adjacent portions of bars 12 and 15 and also through the opposite side flat flanges 19 of the transverse hat cross-section braces 16, as best shown in FIG. 5. It may be seen that the plural transverse braces 16 which are very rigid structurally tie together the metal bars 12 and 15 at a plurality of points along each form sub-assembly 10. Collectively, these attached metal parts render each panel sub-assembly very rigid and stable and highly resistant to bulging, springing or other deformation under wet concrete pressure loading.
As shown in the drawings, the opposite ends of the transverse braces 16 are beveled or mitered as at 20 to enable the complete assembling of the square cross-section form, as shown in FIG. 1. These mitered end portions 20 project beyond the longitudinal edges 13 and 14 of each panel body portion 11 as is readily apparent in FIG. 3, so that the mitered corners of the four braces 16 at each level on the assembled form project outwardly of the corners formed by metal angle bars 12.
Additionally, each brace 16 on sub-assembly 10 is provided near and equidistantly from its opposite ends and in its outer wall with a pair of slots 21 adapted to receive releasably the inturned terminals 22 of generally L-shaped tempered spring steel assembly clips 23, each clip having a pair of equal length arms 24, see FIG. 4. FIG. 4 shows one of the spring clips 23 in a free or relaxed state wherein the clip is tensioned to hold the arms 24 at an angle of less than 90°. When the clips 23 are applied to the corners of the form during the assembly process as illustrated in broken lines at the lower right hand corner of FIG. 3, each clip will be sprung or tensioned to a right angular shape so that it will tend to snugly embrace the square corner formed by the mitered ends 20 of the adjacent braces 16. Also, as best shown in FIG. 3, the curved terminals 22 of the clips are readily snapped into interlocking engagement with the braces 16 through the slots 21 by slight tapping with a hammer or screwdriver handle. The clips can be readily separated from the assembly when knocking it down by a screwdriver blade. In assembly, the terminals 22 are enclosed inside of the hollow braces 16 to produce a smooth exterior corner as clearly illustrated in FIG. 1. The collective holding power of the numerous spring clips 23 on the assembled form is tremendous so that the form is fully capable of resisting any and all bursting pressures to which it will ever be subjected in practice.
In view of the foregoing structural description of the invention, the manner of assembling and disassembling the form shown in FIG. 1 should be fairly clear. However, the following summary may be given. To start the assembly, a pair of the panel sub-assemblies 10 may be erected to form one square corner of the form. A significant feature of this invention is that the form is self-squaring with a high degree of accuracy as it is assembled. No problem arises in connection with properly pairing the sub-assemblies 10 as they are all identical with no "lefts" or "rights". In assembling one corner of a form, the projecting angle bar web 12' of one sub-assembly 10 is slipped under the end portions of braces 16 of another sub-assembly 10, which end portions are projecting beyond the flat bar 15 of the secondnamed sub-assembly. As shown clearly in FIG. 3, there is a space or slot formed between the end portion of each brace 16 beyond the flat bar 15 and the underlying plywood panel body portion 11. This narrow slot extends continuously across each brace 16 throughout the sub-assembly 10 and the collective slots receive the web or flange 12' of the particular angle bar 12 snugly. When properly in place, the free edge of the web 12' will abut the adjacent longitudinal edge of the flat bar 15 on the other sub-assembly 10 making up the particular corner of the square cross-section form. When the parts are thus slipped into place, the spring clips 23 are applied in the already-described manner and the assembly procedure is completed in substantially the identical manner until the erection of the column form is complete and secure. In the completed assembly, FIG. 1, the exposed edges 14 of the four plywood panel body portions 11 will abut the interior faces of the adjacent plywood panels making up the corners of the form and there are no slots or cavities into which the plywood must be placed or forced during the assembly process. On the completed form, the four corners are completely metal clad to resist injury and the corners are truly square and sufficiently tight to prevent loss of grout and yet not excessively tight so as to resist easy disassembling of the form. At all four corners of the form, after assembly, the projecting edges of webs 12' abut or contact the opposing straight edges of the flat bars 15 as shown in FIG. 1. The corner clips 23 are outermost on the assembly for easy access. The placement of the braces 16 at regular intervals renders the assembled form extremely strong and resistant to bursting pressure. The entire assembling and disassembling process is very simple, requires no particular skill and is economical and labor-saving. Preferably, the lowermost group of braces 16 on the assembled form are no more than about six inches above the base or bottom of the form for maximum strength.
FIG. 3 shows the inclusion in the form assembly of conventional sheet metal chamfering corner elements 25. This is an optional feature of the invention which may be omitted in some cases. FIG. 1 shows the assembly without the elements 25 included.
The column form may be modified to produce a beam form by omitting one sub-assembly 10 and substituting therefor suitable cross bracing means at the open side of the form. Such means are omitted in the drawings, and except for this change, the basic construction of the form is the same in either case.
Another relatively minor feature which may be mentioned is the provision of through openings 26 near the ends of each brace 16 to receive elements of adjustable props or braces, not shown, which may be used to stabilize the erected form. This also is an optional feature and the openings 26 could be omitted and other forms of propping or bracing means to stabilize the upright form can be used.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims. | A concrete construction form embodies separable panels each equipped with attached longitudinal metal frame members and plural transverse braces. Four identical panels with the attached metal components are assembled to form a self-squaring column form which is reusable indefinitely after separation of the panels. The form is secured in the assembled state by a plurality of easily detachable spring steel assembly clips applied to the transverse braces at the four corners of the form. Strength, tightness and a reduction of labor are prime features. |
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional application No. 61/065,383, filed 11 Feb. 2008, the disclosure of which earlier application is incorporated by reference herein and made a part hereof, including but not limited to those portions which specifically appear in this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to sediment barriers. This invention relates to an apparatus and method for controlling water flow, soil erosion and/or sediment flow at, for example, a construction site.
2. Discussion of Related Art
Environmental concerns and federal regulations, such as the Clean Water Act and the accompanying National Pollution Discharge Elimination System (NPDES) Program, require construction sites, including road work projects, to control water flow to stop sediment loss and control soil erosion in and around a construction site.
The typical method currently used for controlling water flow to stop sediment loss and soil erosion is to secure one or more hay bales and/or a silt fence section in and around the construction area. While these barriers are generally effective, both can be easily compromised.
Hay bales, being a natural product, have a tendency to degrade and break down quickly and can become laden with weeds and other contaminants which can cause substantial environmental damage at the construction site. When a hay bale becomes wet, the hay material becomes heavy and bulky, making installation and removal difficult. Because hay bales are an agricultural product, hay bales are susceptible to climatic periods, and may be in short supply and difficult to obtain at a job site at certain times of the year.
Silt fencing can be effectively used at job sites when it is used for its primary purpose of preventing sediment loss. Silt fencing is designed to form a pool of water, which allows sediment to drop out. However, silt fencing is not designed to stand up against relatively high water flows. Silt fencing is susceptible to wind or other forms of weather damage. Generally, a silt fence is stapled to a stake which stuck into the ground and thus high winds or high water flow can rip the fabric from the staple or separate the staple from the stake. Once a silt fence is thus damaged, it is no longer able to protect against sediment loss.
Thus, there is a need for an improved barrier that controls water flow, sediment flow and/or prevents soil erosion in and around construction sites. Desirably, the barrier should be able to maintain integrity over time, by resisting wind, water and other forms weather related damage. There is a need for a barrier that allows construction workers to easily move the barrier to various locations, and not be heavy and bulky to handle, thereby preventing lifting related accidents and saving on freight charges. The barrier should be reusable at various construction sites. Thus, the apparatus should minimize or eliminate the chance of transporting weeds and other contaminants, because of concerns about introducing contaminants at each successive construction site.
SUMMARY OF THE INVENTION
A general object of this invention is to provide an improved barrier to reduce or eliminate soil erosion.
A more specific object of this invention is to overcome one or more of the problems previously described.
This invention relates to an apparatus for controlling water flow, soil erosion and/or sediment flow, such as along a ground surface or other surface. The apparatus includes a dam portion with a water-permeable, sediment impermeable cover enclosing a chamber, and a filler material disposed within the chamber. A rigid supporting structure is attached to the dam portion. A tail portion extends from a bottom edge of the dam portion. The supporting structure secures to the surface to hold the dam portion in an upright position, and the tail portion is disposed at an angle from the dam portion in a direction toward the flow of water.
This invention further provides an apparatus for controlling water flow, soil erosion and/or sediment flow along a surface, including a dam portion with a water-permeable, sediment impermeable cover enclosing a chamber, and a filler material disposed within the chamber. Each of two sleeves can be attached to one of opposing edges of the dam portion. A stake can be disposed through each of the sleeves and a tail portion can extend from a bottom edge of the dam portion. A support structure can be secured to the surface to hold the dam portion in an upright position, and the tail portion can be disposed at an angle from the dam portion, such as in a direction toward the flow of water.
This invention further provides a method for controlling water flow, soil erosion and/or sediment flow across a surface. The method includes providing a sediment barrier including a water-permeable, sediment impermeable cover enclosing a chamber, and disposing a filler material within the chamber. A sleeve can be attached to each of opposing edges of the dam portion, and a stake can be disposed through each of the sleeves. A tail portion can extend from a bottom edge of the dam portion. The sediment barrier can be positioned at an angle, such as perpendicular to a direction of the water flow. The sediment barrier can be secured in place by embedding an end of each of the stakes into the surface and/or extending the tail portion from the sediment barrier along the surface in a direction against the water flow.
In some embodiments, the sediment barrier of this invention has a geotextile cover over a polypropylene core material as a dam portion. The dam portion can be at least partially permeable to water, and impermeable to soil and other sediment, thereby allowing water to filter out undesired soil and other sediment. This invention can be used to pool and filter water, such as a function of the material selected as the cover and the density of the polypropylene core. A geotextile tail portion can extend from the dam portion along a section of the ground in which the barrier is placed. The tail portion can extend upstream against a direction of a flow of water. The tail portion increases the effectiveness of this invention by preventing soil and other sediment from seeping under the dam portion and undermining the purpose of the sediment barrier.
The sediment barrier of this invention can have a pair of supporting structures, such as wooden stakes, to provide vertical support and to anchor the sediment barrier in a position. The supporting structures pass through sleeves which are attached to the dam portion.
The sediment barrier of this invention controls water flow, sediment flow and/or prevents soil erosion in and around construction sites. The apparatus of this invention is able to maintain integrity over time, resisting wind, water and other forms weather related damage. The apparatus of this invention can be lightweight, allowing construction workers to easily move the apparatus to various locations. The apparatus of this invention is reusable at various construction sites and is resistant to weeds and other contaminants, lessening the possibility of introducing contaminants at successive construction sites.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other characteristics and features of this invention will be better understood from the following detailed description taken in conjunction with the drawings, wherein:
FIG. 1 is a perspective view of a sediment barrier, according to one embodiment of this invention;
FIG. 2 is a front view of the sediment barrier as shown in FIG. 1 ;
FIG. 3 is a partial sectional view of the sediment barrier shown in FIG. 1 , taken along line 3 - 3 in FIG. 2 ;
FIG. 4 is a top view of two sediment barriers connected in a staggered formation, according to one embodiment of this invention; and
FIG. 5 is a top view of three sediment barriers connected in a staggered formation, according to another embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-3 illustrate a sediment barrier 10 , according to one embodiment of this invention. The sediment barrier 10 includes or comprises a body or a dam portion 12 and a retainer or a tail portion 14 . In some embodiments of this invention, dam portion 12 includes or comprises a front cover 16 and a back cover 18 . The front cover 16 and/or the back cover 18 can be constructed from one or more higher-flow mono-filament geotextile fabrics, such as known to those skilled in the art of geotextile fabrics, which are generally light-weight, durable and resistant to growth of weeds and/or other contaminants. As used in this specification and in the claims, the term “geotextiles” refers to permeable fabrics which, when used in association with soil, have an ability to separate, filter, reinforce, protect and/or drain. The front cover 16 and/or the back cover 18 can be formed from rectangular shaped sheets, such as shown in FIG. 2 , or from any other suitable shape. The front cover 16 and/or the back cover 18 each is joined at its edges to form at least one pocket 20 , or interior volume, therebetween, and in some embodiments a plurality of pockets 20 , such as shown in FIG. 3 .
The front cover 16 and/or back cover 18 each can be joined along its end and side edges with a seam 22 . The seam 22 can be any suitably durable conventional stitching for fabric. Alternative methods of forming the seam 22 include, but are not limited to, adhesive sealing, heat sealing and/or riveting. In other embodiments, the front cover 16 and/or the back cover 18 each is formed from a single, folded sheet of geotextile fabric which forms or defines the interior volume or pockets 20 . In other embodiments, a separating seam 23 can be utilized to form more than one pocket 20 . The separating seam 23 can be of any suitably durable conventional stitching for fabric.
As shown in FIG. 3 , a core formed of a filler material 24 is positioned within the pocket 20 . The filler material 24 can be permeable to allow water to pass and to prevent soil and other sediment from passing through the filler material 24 . The filler material 24 can be constructed of a three-dimensional polypropylene, but may also be constructed of any other suitable material which can filter, for example sediment and soil from water. In some embodiments of this invention, the filler material 24 is constructed of a polypropylene material having a density from about 0.5 pounds per cubic foot to about 15.0 pounds per cubic foot. As shown in FIGS. 1-3 , according to certain embodiments of this invention, the front cover 16 , the back cover 18 and/or the filler material 24 can form an elliptical or a multi-elliptical shaped dam portion 12 . The dam portion 12 can be formed as any other suitable three-dimensional shape, depending on the need or the intended use.
In some embodiments of this invention, the dam portion 12 comprises two sleeves 26 , each disposed at one of the opposing side edges. Preferably, but not necessarily the sleeves 26 are constructed of the same material as both the front cover 16 and the back cover 18 . The sleeves 26 can be joined to the dam portion 12 using a sleeve seam 28 . Preferably, the sleeve seam 28 is a conventional stitching or other suitable fastener for fabric. Alternative methods for attaching a sleeve at the sleeve seam 28 includes, but is not limited to, adhesive sealing, heat sealing and/or riveting. In other embodiments, the sleeve 26 can be formed of a unitary piece of fabric or sheet material with the front cover 16 and/or the back cover 18 .
The dam portion 12 can be vertically supported with one support structure 30 , or a plurality of supporting structures 30 . The support structure 30 can be positioned within the sleeve 26 . A portion 31 of the support structure 30 can extend beyond the end of the sleeve 26 . As shown in FIGS. 1-3 , the portion 31 extending beyond the sleeves 26 can be embedded in the ground and/or attached to another structure to secure the sediment barrier 10 in the desired position or location. The support structure 30 can be a stake and/or any other suitable support structure, and can be constructed of any suitable material, such as a metal or a plastic.
Extending at an angle from a bottom, a bottom portion and/or a bottom edge of the dam portion 12 is the tail portion 14 , which can also be referred to as a retainer, a flap or an apron. The tail portion 14 can prevent sediment from passing below, by and/or underneath the dam portion 12 , which could undermine the purpose of the sediment barrier 10 . The tail portion 14 can be constructed of the same material or a different material as the front cover 16 and the back cover 18 . In other embodiments, the tail portion 14 can be constructed of an impermeable material, for example to filter water solely by the dam portion 12 . In certain embodiments, the tail portion 14 is fixedly connected to and/or integrated with the dam portion 12 .
Methods of forming the fixed connection include, but are not limited to, sewing with a thread, adhesive sealing, heat sealing and/or riveting. In other embodiments, the tail portion 14 can be detachably connected to the dam portion 12 . Methods of forming the detachable connection include, but are not limited to, buttons, hook and loop fasteners, such as Velcro™ fasteners, and/or zippers. In other embodiments, the tail portion 14 and at least one of the front cover 16 and the back cover 18 is constructed from or integrally formed as a single piece or an integrated piece of fabric.
As shown in FIGS. 1-3 , the tail portion 14 is secured or fixed in position with at least one securing pin 32 inserted into or attachable to the ground. Any number of securing pins can be used, such as two or three pins, for each tail portion 14 . Securing pins 32 are preferably but not necessarily made of metal or plastic. As shown in FIG. 4 , the tail portion 14 can include riveted holes 47 or another suitable structure through which the securing pin 32 can pass. In other embodiments, the securing pins 32 can pierce or puncture through the tail portion 14 . In alternative embodiments, the securing pins 32 are replaced by soil, sand, gravel, bricks and/or any other suitably heavy object. Often, as the sediment barrier 10 is used, sediment will build up on the tail portion 14 and thus further secure or fix the tail portion 14 in position.
In accordance with some embodiments of this invention, the sediment barrier 10 can be used alone or in combination with one or more additional sediment barriers 10 , for example to protect a site.
FIG. 4 shows two sediment barriers 40 assembled according to one embodiment of this invention. FIG. 4 shows a top view of a pair of sediment barriers 40 connected in a staggered formation. Any other staggered configuration is possible. The tail portions 42 of the sediment barrier 40 can include or form one or more slits 34 . Each of the slits 34 is disposed along a side edge 44 of the tail portion 42 . The slits 34 allow the support structure 46 from an adjacent sediment barrier 40 to easily pass through the tail portion 42 , thereby allowing for the staggered relative placement as shown in FIG. 4 , or otherwise, to create an overlapping sediment barrier structure. In other embodiments, the sleeves 26 of adjacent sediment barriers 10 can be configured to accommodate a single shared supporting structure between the sleeves 26 .
Various and alternative configurations are available for the slits 34 according to this invention. For example, each slit 34 can be a simple cut in the fabric of the tail portion 14 , optionally reinforced by threads, such as a button hole, or the slit 34 can be a shaped cut, such as a rectangle shown in FIG. 4 , or other shapes depending on a need, such as depending on the size and shape of the support structure extending therethrough. FIG. 5 illustrates yet another embodiment of this invention, showing the slits 34 as notches 50 cut out from the edges 52 of the tail portions 54 .
To utilize the sediment barriers 40 in FIG. 4 , for example, to protect a water drainage grate 49 from receiving undesirable amounts of sediment, the dam portion 41 can be placed at a general angle, such as generally perpendicular to a water flow direction, shown by arrow 48 , with the tail portions 42 placed upon the ground and extending in a direction against the direction of the water flow and/or the sediment flow 48 . Water can pass through the sediment barrier 40 and into the grate 49 while preventing soil and/or other sediment from passing through and instead to build materials upon the tail portions 42 of each sediment barrier 40 .
Thus, this invention also relates to a method of controlling water flow, soil erosion and/or sediment flow across a surface. The sediment barriers 40 can be desirably aligned, such as generally perpendicular to an expected direction of the water flow and secured in place by embedding an end of each of the stakes 30 into the surface. The tail portions can extend from the sediment barrier 40 along the surface, such as the ground, in a direction against the water flow and/or the sediment, such as shown in FIG. 4 .
An end of a stake of a second sediment barrier 40 can be inserted through the slit 34 in the tail portion of the first sediment barrier 40 , and the second sediment barrier 40 can be secured in place by embedding an end of each of the second stakes into the surface. Construction of an overall barrier structure can be continued by similarly inserting an end of one stake of a third sediment barrier through the slit in the tail portion of the second sediment barrier. In this manner, the sediment barriers of this invention provide the ability to construct an overall barrier structure having the necessary and suitable size and shape for any given site.
Details of the discussed embodiments are given for purposes of illustration and are not to be construed as limiting the scope of this invention. Although only a few exemplary embodiments of this invention are described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. Further, it is recognized that many embodiments may not achieve all of the advantages of some embodiments, yet the absence of a particular advantage shall not be construed to necessarily mean that such an embodiment is outside the scope of this invention. | An apparatus and method for controlling water flow, soil erosion, and/or sediment flow in and around a construction site. The apparatus includes a three-dimensional, water-permeable polypropylene filled geotextile pocket that is secured to the ground with a supporting structure. The apparatus includes a tail portion that is placed flat against the ground, facing upstream against the direction of water flow. The tail portion can be secured with pins that provide protection against movement of the tail portion and reduce an amount of sediment passing under the apparatus. |
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CROSS REFERENCE
[0001] This application claims benefit to U.S. Provisional Application No. 60/458,867 filed on Mar. 28, 2003; International Application No. PCT/GB2004/001084 filed on Mar. 12, 2004; and U.S. Non-Provisional application Ser. No. 10/551,288 filed on Mar. 12, 2004, incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention generally relates to a method for use in subterranean wellbores. More particularly, the invention relates to a method used to measure inflow profiles in subterranean injector wellbores.
[0004] 2. Description of Related Art
[0005] It is important for an operator of a subterranean injector wellbore, such as for an oil or gas well, to determine the inflow profile of the injector wellbore in order to analyze whether all or just certain parts of a specific zone are injecting fluids therethrough. This determination and analysis is useful in vertical, deviated, and horizontal wellbores. In horizontal wellbores, the amount of fluid flowing through a specific zone tends to decrease from the heel to the toe of the well. Often, the toe and sections close to the toe have very little and sometimes no fluid flowing therethrough. An operator with knowledge of the inflow profile of a well can then attempt to take remediation measures to ensure that a more even inflow profile is created from the heel to the toe of the well.
[0006] Thus, there exists a continuing need for an arrangement and/or technique that addresses one or more of the problems that are stated above.
BRIEF SUMMARY OF THE INVENTION
[0007] The invention comprises a method of determining the inflow profile of an injection wellbore, comprising stopping injection of fluid into a formation, the formation intersected by a wellbore having a section uphole of the formation and a section within the formation, monitoring temperature at least partially along the uphole section of the wellbore and at least partially along the formation section of the wellbore, injecting fluid into the formation once the temperature in the uphole section of the wellbore increases, and monitoring the movement of the increased temperature fluid as it moves from the uphole section of the wellbore along the formation section of the wellbore. The monitoring may be performed using a distributed temperature sensing system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is more fully described with reference to the appended drawings wherein:
[0009] FIG. 1 is a schematic illustration of a wellbore utilizing the present invention;
[0010] FIG. 2 is a plot of a geothermal temperature profile along a horizontal wellbore;
[0011] FIG. 3 is a plot showing temperature profiles taken along a wellbore at different points in time, including during injection and while the well is shut-in;
[0012] FIG. 4 is a plot illustrating the movement of a temperature peak along the wellbore and relevant formation; and
[0013] FIG. 5 is a plot of the velocity of the temperature peak of FIG. 4 as it moves along the wellbore and relevant formation.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 is a general schematic of an injector wellbore utilizing the present invention. A tubing 10 is disposed within a wellbore 12 that may be cased or uncased. Wellbore 12 may be a horizontal or inclined well that has a heel 14 and a toe 16 , or a vertical well. The horizontal section of the well may have a liner, may be open-hole, or may have a continuation of tubing 10 therein. Wellbore 12 intersects a permeable formation 18 such as a hydrocarbon formation. A packer 11 may be disposed around the tubing 10 to sealingly separate the wellbore sections above and below the packer 11 .
[0015] Wellbore 12 is an injector wellbore and the tubing 10 thus has injection equipment 20 (such as a pump) connected thereto near the earth's surface 22 . Injection equipment 20 may be connected to a tank 23 containing the fluid which is to be injected into formation 18 . Typically, the fluid is injected by the injection equipment 20 through the tubing 10 and into formation 18 . Tubing 10 may have ports adjacent formation 18 so as to allow flow of the fluid into formation 18 . In other embodiments, a liner with slots disposed in the horizontal section of the well may provide the fluid communication, or the horizontal section may be open hole. Perforations may also be made along formation 18 to facilitate fluid flow into the formation 18 .
[0016] A distributed temperature sensing (DTS) system 24 is also disposed in the wellbore 12 . The DTS system 24 includes an optical fiber 26 and an optical launch and acquisition unit 28 .
[0017] In the embodiment shown, the optical fiber 26 is disposed along the tubing 10 and is attached thereto on the outside of the tubing 10 . In other embodiments, the optical fiber 26 may be disposed within the tubing 10 or outside of the casing of the wellbore 12 (if the wellbore is cased). The optical fiber 26 extends through the packer 11 and across formation 18 . The optical fiber 26 may be deployed within a conduit, such as a metal control line. The control line is then attached to the tubing 10 or behind the casing (if the wellbore is cased). The optical fiber 26 may be pumped into the control line by use of fluid drag before or after the control line and tubing 10 are deployed downhole. This pumping technique is described in U.S. Reissue Pat. No. 37,283, which is incorporated herein by reference.
[0018] The acquisition unit 28 launches optical pulses through the optical fiber 26 and then receives the return signals and interprets such signals to provide a distributed temperature measurement profile along the length of the optical fiber 26 . In one embodiment, the DTS system 24 is an optical time domain reflectometry (OTDR) system wherein the acquisition unit 28 includes a light source and a computer or logic device. OTDR systems are known in the prior art, such as those described in U.S. Pat. Nos. 4,823,166 and 5,592,282, both of which are incorporated herein by reference. In OTDR, a pulse of optical energy is launched into an optical fiber and the backscattered optical energy returning from the fiber is observed as a function of time, which is proportional to distance along the fiber from which the backscattered light is received. This backscattered light includes the Rayleigh, Brillouin, and
[0019] Raman spectrums. The Raman spectrum is the most temperature sensitive, with the intensity of the spectrum varying with temperature, although Brillouin scattering, and in certain cases Rayleigh scattering, are also temperature sensitive.
[0020] Generally, in one embodiment, pulses of light at a fixed wavelength are transmitted from the light source in acquisition unit 28 down the optical fiber 26 . At every measurement point in the optical fiber 26 , light is back-scattered and returns to the acquisition unit 28 . Knowing the speed of light and the moment of arrival of the return signal enables its point of origin along the optical fiber 26 to be determined. Temperature stimulates the energy levels of molecules of the silica and of other index-modifying additives, such as germania, present in the optical fiber 26 . The back-scattered light contains upshifted and downshifted wavebands (such as the Stokes Raman and Anti-Stokes Raman portions of the back-scattered spectrum), which can be analyzed to determine the temperature at origin. In this way, the temperature of each of the responding measurement points in the optical fiber 26 can be calculated by the acquisition unit 28 , providing a complete temperature profile along the length of the optical fiber 26 . In one embodiment, the optical fiber 26 is disposed in a u-shape along the wellbore 12 providing greater resolution to the temperature measurement.
[0021] FIG. 2 shows a graph of the geothermal temperature profile 29 of a generic horizontal wellbore. This profile shows at 30 a gradual increase in temperature as the depth of the well increases, until at 32 a stable temperature is reached along the horizontal section of the wellbore. The geothermal temperature profile is the temperature profile existing in the wellbore without external factors (such as injection). After injection or other external factors end, the wellbore will gradually change in temperature towards the geothermal temperature profile.
[0022] In one embodiment of this invention, in order to determine the inflow profile of a wellbore 12 , the wellbore 12 must first be shut-in so that no injection takes place. The temperature profile of the wellbore 12 changes if there is injection and throughout the shut-in period. FIG. 3 shows these changes.
[0023] Curve 34 is the temperature profile of the wellbore 12 during injection, wherein the temperature is relatively stable since the injected fluid is flowing through the tubing 10 and into the formation 18 .
[0024] Curve 36 represents a temperature profile of the wellbore 12 taken after injection is stopped and the well is shut-in. Curve 36 is already gradually moving towards the geothermal profile 29 . However, section 40 of curve 36 is changing at a much slower rate than the uphole part of the curve 36 because section 40 represents the area of the formation 18 which absorbed the most fluid during the injection step. Therefore, since this area is in contact with a substantial amount of fluid already injected in the formation 18 , this area takes a longer time to heat or return to its geothermal norm. Of interest, peak 42 is present on curve 36 because peak 42 is the area of wellbore 12 found directly before formation 18 (and not taking fluids). Therefore, a substantial temperature difference exists between peak 42 and section 40 .
[0025] Curve 38 represents a temperature profile of the wellbore 12 taken subsequent to the temperature profile represented by curve 36 . Curve 38 shows that the temperature profile is still heating towards the geothermal norm, but that the difference between peak 44 (peak 42 at a later time) and the section 40 are still apparent.
[0026] The object of this invention is to determine the velocity of the fluid being injected across the length of the formation 18 in order to then determine the inflow profile of such formation 18 . The technique used to achieve this is to re-initiate injection after a relatively short shut-in period and track the movement of the temperature peak ( 42 , 44 ) by use of the DTS system 24 .
[0027] FIG. 4 shows four curves representing temperature profiles taken over time. Curve 50 is a profile taken during shut-in, curve 52 is a profile taken after injection is re-started, curve 54 is a profile taken after curve 52 , and curve 56 is a profile taken after curve 54 . For purposes of clarity, the entire temperature profile of the wellbore has not been shown. Curve 50 includes a temperature peak 58 A that represents the temperature peak present during shut-in and found directly uphole of formation 18 . Temperature peak 58 A corresponds to temperature peaks 42 and 44 of FIG. 3 . Once injection is restarted, the slug of heated fluid represented by temperature peak 58 A is essentially “pushed” down the wellbore 12 , as is shown by the temperature peaks 58 B-D in time lapse curves 52 , 54 , and 56 . The temperature peak 58 A-D, as expected, decreases over time once injection is restarted.
[0028] By tracking the movement of the temperature peak 58 A-D down the wellbore 12 (through use of the DTS system 24 ), an operator can determine the velocity of the temperature peak 58 A-D as it moves down the wellbore 12 and the formation 18 over time. As shown in FIG. 5 , the velocity of the temperature peak 58 A-D is then plotted against depth across the length of the formation 18 . This plot shows a constant velocity at 60 immediately prior to the temperature peak reaching the formation 18 , a gradual decrease of velocity at 62 as the temperature peak moves away from the uphole boundary of the formation 18 , and a very low and perhaps zero velocity as the peak nears the downhole boundary of the formation 18 . From this plot, one can determine that the downhole portion of the formation 18 (that closer to the toe 16 ) is not receiving much fluid during injection in comparison to the uphole portion of the formation 18 . With this information, one can provide injection inflow profiles across the formation 18 , which profiles can be shown in percentage form (percentage of fluid being injected along the length of the formation 18 ) or quantitative form (with knowledge or a measurement of the actual surface injection rate). Thus, by monitoring the velocity of a heated slug (temperature peaks 58 A-D) across a formation 18 , the injection inflow profile of a wellbore 12 across a formation 18 may be determined.
[0029] Of importance, the shut-in period required to use the present technique is short in relation to the shut-in periods in some comparable prior art techniques. In some prior art techniques, the area of the formation 18 (see section 40 in FIG. 3 ) and not the area directly uphole of the formation 18 (see peaks 42 and 44 in FIG. 3 ) is monitored during the warmback period (and not the injection period) to determine the inflow profile. However, in wellbores that have been injecting for a long period of time, the area of the formation 18 (see section 40 ) must be monitored for a substantial period of time before the warmback curves begin to move towards the geothermal gradient and the relevant information can be extracted therefrom. With the present technique, the warmback period can be as short as 24 to 48 hours, since the temperature peaks 42 and 44 (used as previously stated) begin to shift towards the geothermal profile much more quickly. Thus, a process that would take weeks or months to complete using the prior art techniques can now be completed in several days using the present technique.
[0030] While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the scope of the invention. | A method of determining the inflow profile of an injection wellbore, comprising stopping injection of fluid into a formation, the formation intersected by a wellbore having a section uphole of the formation and a section within the formation, monitoring temperature at least partially along the uphole section of the wellbore and at least partially along the formation section of the wellbore, injecting fluid into the formation once the temperature in the uphole section of the wellbore increases, and monitoring the movement of the increased temperature fluid as it moves from the uphole section of the wellbore along the formation section of the wellbore. The monitoring may be performed using a distributed temperature sensing system. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority in U.S. Provisional Patent Application No. 62/142,984 filed Apr. 3, 2015, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a mobile hydraulic stage and method for use thereof, and more specifically to a mobile hydraulic stage with removable wall panels and an integrated wireless control via mobile computing device.
2. Description of the Related Art
Mobile performance stages are commonly used for temporary venues, performances, or rallies. Typical mobile performance stages must be assembled on site. Modern mobile stages may come in the form of a trailer, wherein the mobile stage is collapsible to a compact and mobile unit.
Mobile stages are often an economical alternative to erecting a permanent stage at a site. The typical reasons for electing to use a mobile stage include temporary use, cost, and reliability. Cutting the costs of using a mobile stage provides additional incentive for using a mobile stage. The simplest way to cut costs would be to reduce the number of persons and steps required to setup and operate the stage. Costs are also saved when the owner of a mobile stage knows the stage will last. These cost savings can be passed on to customers, increasing the incentive to use one mobile stage over another.
What is needed is a highly transportable stage system with wall panel elements which quickly allow the stage to be transformed from a compact/transportation position to a functional stage position and back.
Heretofore there has not been available a system or method for a mobile hydraulic stage with the advantages and features of the present invention.
SUMMARY OF THE INVENTION
The present invention generally provides a mobile stage which transforms between a first, transport position and a second, deployed position. A primary component of the present invention is a number of modular wall panels which act as a barrier between the interior and the exterior of the stage. This barrier is weather resistant by use of weather stripping in between the panels and additionally serves to protect from unauthorized access to any contents stored inside the stage itself when in transportation mode.
When the stage is set up, the top row of panels are removed and the bottom row of panels serve as handrails (e.g. fall deterrent) along the back edge of the stage. All of the panels are designed to be modular and interchangeable, though the bottom panels also include kick plates to protect the interior of the panels.
The bottom panels are secured to the stage floor by at least two removable bolts (or other connection elements) going through the bottom edge of the panel. There are two identical holes (for either bolts or pins) on the top edge of each of these panels that allow them to be joined to a second row of panels.
The top row of panels have identical bottom edge bolt holes as the bottom panels, however, they are designed with a “track block” at two points on the top edge that allow them to be slid into place within a corresponding “female” track that is part of the roof framing of the stage itself.
The panels could feasibly be designed in such a way as to form a wall/barrier of any suitable size used to cover any open side of a stage, even though the most common use would be to use them along the back edge of a non-symmetric stage design as shown in the figures. Although the top row and bottom row panel designs differ, building a taller wall would simply require additional panels reflecting the bottom panel design. A wall of increased width would require additional top and bottom panels as necessary to construct the wall.
The panels are made from metal square tubing (e.g. aluminum), but the design allows them to be made from virtually any metal as long as the cross section of the material itself is square or rectangular to facilitate horizontal or vertical stacking.
When the stage is in set up and only the lower row of panels are in use, any individual panel can be removed and a staircase or corresponding stage accessory can be placed in the corresponding void.
Typical accessories that could be designed to fit in this void would be stage deck extensions, staircases or an alternative handrail design.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof.
FIG. 1 is a three dimensional isometric view of a preferred embodiment of the present invention in a first position including diagrammatic representation of a wireless mobile device element thereof.
FIG. 2 is a three dimensional isometric view of a preferred embodiment of the present invention in a second position.
FIG. 3 is a three dimensional isometric view of a preferred embodiment of the present invention in a third position.
FIG. 4 is a three dimensional isometric view thereof, featuring an alternative arrangement including a removable stair component.
FIG. 5 is a three dimensional isometric view thereof, featuring an alternative arrangement including a removable screen component.
FIG. 6 is a three dimensional isometric view of a portion of a preferred embodiment of the present invention shown from an interior perspective.
FIG. 7 is a three dimensional isometric view of a portion of a preferred embodiment of the present invention shown from an exterior perspective.
FIG. 8 is a three dimensional isometric view of a portion of a preferred embodiment of the present invention shown from an interior perspective and demonstrating how various components join together.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction and Environment
As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Additional examples include computing devices such as a mobile smart device including a display device for viewing a typical web browser or user interface will be commonly referred to throughout the following description. The type of device, computer, display, or user interface may vary when practicing an embodiment of the present invention. A computing device could be represented by a desktop personal computer, a laptop computer, “smart” mobile phones, PDAs, tablets, or other handheld computing devices. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.
II. Preferred Embodiment Mobile Stage System 2
Referring to the figures in more detail, FIG. 1 shows a mobile stage system 2 primarily including a trailer element 4 with wheels 6 for transporting the stage, and a plurality of lower 10 and upper 8 wall panels forming at least one wall of the stage assembly. FIG. 1 demonstrates the stage in a first, transport position where the walls 12 , roof 14 , and stage cover 16 are collapsed and compact arrangement.
FIG. 2 shows the same arrangement as FIG. 1 with the upper wall panels 8 being removed. These panels (as shown in more detail in FIGS. 6-8 ) fit into tracks or guides (not shown) along the interior edge of the roof 14 . The upper panels 8 hang from or slide into these tracks, and if the stage roof 14 and walls 12 are raised using the risers 22 , the upper panels 8 will rise with the roof 14 and can be taken down from there. Alternatively, the panels could be removed at any time.
FIG. 3 shows the mobile stage system 2 transforming from the transport position to a second, deployed position. Here, the walls 12 and roof 14 are raised up on risers 22 which may be hydraulic arms or some other suitable device. Support legs 20 are deployed beneath the stage to provide additional support. The stage cover 16 and stage floor 18 unfold from the compact transport position and are separated by support towers 24 . Here it can clearly be seen that the lower wall panels 10 provide a base which functions as a hand rail and prevents persons from falling over the edge of the stage while still permitting a view out the rear of the stage if necessary.
FIG. 4 shows how a modular stairway assembly 26 including hand rails could be inserted along the base of the stage into a slot left behind when a lower wall panel 10 is removed. Other devices may be inserted in such gaps as well, including stage extension panels, alternative hand rail assemblies or other desired elements. As shown, the stairway assembly 26 provides back stage access for performers or technicians away from the front stage platform 18 which faces the audience.
FIG. 5 shows a wind screen 28 which may be removably attached to the rear of the stage system 2 for providing a backdrop to the stage to prevent wind, rain, and other elements from entering the stage, to provide privacy to the back stage area, or to provide a screen upon which a projector or other device can project lights, images, videos, or other display elements. The screen 28 may be made of a solid material or a semi-permeable, mesh material or other suitable material. It can be attached to the stage walls 12 and roof 14 using screws, bolts, nails, hooks, hook-and-loop fasteners, or any other suitable non-permanent attachment.
FIG. 6 shows the interior face of an upper wall panel 8 . The panel is generally constructed from a square or rectangular frame 30 made from tube metal and a face plate 32 attached to the exterior face of the panel 8 . Bolt or pin holes 36 are located at the top and bottom edges of the frame 30 and receive bolts or pins for connecting the frame 30 to an adjacent upper 8 or lower 10 wall panel. Additional holes may be located on the sides of the frame for connecting to adjacent panels to the left and right. Other attachment elements could be used, including hooks, screws, hook-and-loop fasteners, straps, or other suitable devices.
FIG. 7 shows the exterior face of the upper wall panel 8 which would be identical to the exterior face of the lower wall panel 10 . As shown in both FIGS. 6 and 7 , weather stripping 34 is placed onto the frame 30 and squeezes between the panels to prevent wind and other elements from penetrating the wall formed by the panel, keeping wind, rain, water, dirt, dust, and other elements from penetrating the wall formed by the panels.
FIG. 8 shows how the upper 8 and lower 10 wall panels may be joined together. In the example as shown, long pins 40 are inserted through the receiver holes 36 of each respective panel and are secured using cotter pins 42 . These could be replaced with bolts or any of the other options discussed previously. The interior face of the lower wall panel 10 differs slightly from the upper panels in that it includes a kick plate 38 for protecting the interior of the face plate 32 from being damaged by feet or equipment.
Referring back to FIG. 1 , the present invention could be deployed using manual power, or it could be set up to include automated features for automatically raising the roof 14 and wall 12 structures using the risers 22 and may also automatically deploy the stage floor 18 and covering 16 . This could be performed using a remotely controlled hydraulic system or electrical system including winches and hydraulic arms. A mobile computing device 44 , such as a computer, touch-screen computer, smart phone, or other computing can be used to control the deployment or compacting of the mobile stage system 2 . The mobile computing device 44 includes a processor 46 , data storage 48 for storing a software application 52 associated with controlling the stage, and a wireless antenna 50 or other communicating element for communicating with a controller 54 associated with the stage. This controller could be a simple processor or computer solely responsible for receiving commands from the mobile computing device 44 and then operating the various devices which raise or lower the stage.
It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects. | A mobile stage which transforms between a first, transport position and a second, deployed position. A number of modular wall panels which act as a barrier between the interior and the exterior of the stage. This barrier is weather resistant by use of weather stripping in between the panels and additionally serves to protect from unauthorized access to any contents stored inside the stage itself when in transportation mode. The wall panels may be selectively remoted and replaced by stairways and other stage components. The upper wall panels are temporarily engaged by a roof of the mobile stage. |
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates a to a switch device and, more particularly, to a switch device with multiple water outputs.
Description of the Related Art
Currently, faucets in kitchen adopt a handle to switch a top and down plate to have different water outputs ranging from two to four different water outputs. However, even the maximal four water outputs are still not enough to meet users' expectation in their daily life. Moreover, because of limited space on the down plate of the switch device, the down plate doesn't have water output, through the switch device connected with different water output hole, and have different water outputs.
SUMMARY OF THE INVENTION
In view of the problems and drawbacks of the prior art, the objective of the present invention is to provides a switch device with multiple water outputs featuring a simple structure, easy control and multiple water outputs.
To achieve the foregoing objective, the switch device with multiple water flow type includes a switch valve, a rotary rod, an engagement ring, a first rotary plate and a second rotary plate.
The switch valve has a top portion and a bottom portion. The top portion has an opening, and the bottom portion has a recess and a hole. The recess is formed in a top surface of the bottom portion. The hole is formed through the bottom portion of the switch valve.
The rotary rod has a top end, a bottom end. The top end is mounted through the opening of the switch valve.
The engagement ring has two toothed rings formed on the bottom end of the rotary rod.
The first rotary plate engages one of the two toothed rings, is mounted inside the recess of the switch valve, and has a spindle, a stem and multiple first holes.
The spindle is formed on a top surface of the first rotary plate and is mounted inside the toothed ring engaging the first rotary plate.
The stem is formed on a bottom surface of the first rotary plate and is mounted through the hole of the switch valve.
The multiple first holes are mounted through the first rotary plate.
The second rotary plate engages the other toothed ring, is mounted inside the recess of the switch valve, and has multiple second holes formed through the second rotary plate.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description of the drawings particularly refers to the accompanying figures in which:
FIG. 1 is a perspective view of a switch device in accordance with the present invention;
FIG. 2 is an exploded perspective view of the switch device in FIG. 1 ;
FIGS. 3-7 are operational top views of a first rotary plate and a second rotary plate switched to provide multiple water outputs;
FIG. 8 is an exploded perspective view of an engagement ring, the first rotary plate and the second rotary plate of the switch device in FIG. 1 ; and
FIG. 9 is a perspective view of the engagement ring of the switch device in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The purpose, construction, features, functions and advantages of the present invention can be appreciated and understood more thoroughly through the following detailed description with reference to the attached drawings.
With reference to FIGS. 1 and 2 , a switch device with multiple water outputs in accordance with the present invention includes a switch valve 1 , a rotary rod 2 , an engagement ring 3 , a first rotary plate 4 and a second rotary plate 5 .
The switch valve 1 has a top portion and a bottom portion. The top portion of the switch valve 1 has an opening 10 and multiple bars 11 . The opening 10 is formed through the top portion. The bars 11 are formed on a bottom surface of the top portion of the switch valve 1 . The bottom portion of the switch valve 1 has a recess 17 and a hole 16 . The recess 17 is formed in a top surface of the bottom portion. The hole 16 centrally formed through the bottom portion of the switch valve 1 .
The rotary rod 2 has a top end and a bottom end, and the top end is mounted through the opening 10 of the switch valve 1 .
With reference to FIG. 9 , the engagement ring 3 is mounted around a periphery of the bottom end of the rotary rod 2 . The engagement ring 3 has an inner toothed ring 301 and an outer toothed ring 302 . The outer toothed ring 302 surrounds the inner toothed ring 301 . An angle at a circular segment of the engagement ring 3 between each adjacent two of the inner toothed ring 301 is defined as an inner deviation angle 303 . An angle at a circular segment of the engagement ring 3 between each adjacent two of the outer toothed ring 302 is defined as an outer deviation angle 304 . Multiple channels 14 are formed through the outer toothed ring 302 and the inner toothed ring 301 , and the bars 11 of the switch valve 1 are mounted in the respective channels 14 to prevent the inner toothed ring 301 and the outer toothed ring 302 from rotating but to keep the inner toothed ring 301 and the outer toothed ring 302 movable up and down along an axial direction of the switch device, and to get the rotary rod 2 fixed.
With reference to FIG. 8 , the first rotary plate 4 has a spindle 13 , multiple first teeth 8 , multiple first water holes 6 and a stem 15 . The spindle 13 is formed on a top surface of the first rotary plate 4 . The first teeth 8 are formed on the top surface of the first rotary plate 4 , are located on a perimeter of the first rotary plate 4 , are spaced apart from each other by a gap, and are arranged around the spindle 13 . The first holes 6 are formed through the first rotary plate 4 and surround the first teeth 8 . Each first hole 6 defines an operation position. An angle at a circular segment of the first rotary plate 4 between each adjacent two of the first teeth 8 is same as the inner deviation angle 303 of the inner toothed ring 301 , and the alternate angle at the circumference and alternate interior angle of two neighbor of the first holes 6 are same. The stem 15 is formed on a bottom surface of the first rotary plate 4 , and is mounted through the hole 16 of the switch valve 1 with a spring 18 mounted around the stem 15 .
With reference to FIG. 8 , the second rotary plate 5 has multiple second teeth 9 , a central hole 12 and multiple second holes 7 . The second teeth 9 are formed on a top surface of the second rotary plate 5 . An angle at a circular segment of the second rotary plate between each adjacent two of the second teeth 9 is same as the outer deviation angle 304 of the outer toothed ring 302 . The central hole 12 is centrally formed through the second rotary plate 5 , and the second holes 7 are formed through the second rotary plate 5 and are located around the central hole 12 . Each second hole 7 defines another operation position. The second teeth 9 are located between the center hole 12 and the second holes 7 .
The spindle 13 and the first teeth 8 are mounted through the central hole 12 for the first rotary plate 4 to be connected with the second rotary plate 5 . The angle at the circumference of two neighbor of the second teeth 9 are alternate interior angle, and the alternate angle at the circumference and alternate interior angle of two neighbor of the second holes 7 are same. The first rotary plate 4 and the second rotary plate 5 are mounted into the recess 17 . Further, the quantity of teeth in the inner toothed ring 301 is the same as that of the first teeth 8 , and the inner toothed ring 301 engages the first teeth 8 . The quantity of teeth in the outer toothed ring 302 is the same as that of the second teeth 9 , and the outer toothed ring 302 engages the second teeth 9 . The quantity of teeth in each of the outer toothed ring 302 and the second teeth 9 doubles that of each of the inner toothed ring 301 and the first teeth 8 .
Embodiment 1
With reference to FIG. 3 , the first teeth 8 of the first rotary plate 1 engage the inner toothed ring 301 . The first rotary plate 4 has three first holes 6 , and two of the first holes 6 located next to each other, which are selected to be open and correspond to two operation positions, are spaced apart from each other by the inner deviation angle, which is 120°. The second teeth 9 of the second rotary plate 2 engage the outer toothed ring 302 . The second rotary plate 5 has six second holes 7 , and four of the second holes 7 located next to one another or at every other second hole 7 , which are selected to be open and correspond to four operation positions, are spaced apart from one another by the outer deviation angle, which is 60°, or double of the outer deviation angle, which is 120°.
Embodiment 2
With reference to FIGS. 4 and 5 , the first teeth 8 of the first rotary plate 1 engage the inner toothed ring 301 . The first rotary plate 4 has three first holes 6 , and two of the first holes 6 next to each other that are selected to be open and correspond to two operation positions are spaced apart from each other by the inner deviation angle, which is 120°. The second teeth 9 of the second rotary plate 2 engage the outer toothed ring 302 . The second rotary plate 5 has six second holes 7 , and five of the second holes 7 next to each other, which are selected to be open and correspond to five operation positions, are spaced apart from one another by the outer deviation angle, which 60°.
Embodiment 3
With reference to FIG. 6 , the first teeth 8 of the first rotary plate 1 engage the inner toothed ring 301 . The first rotary plate 4 has four first holes 6 , and two of the first holes 6 located at every other first hole 6 , which are selected to be open and correspond to two operation positions, are spaced apart from each other by double of the inner deviation angle, which is 180°. The second teeth 9 of the second rotary plate 2 engage the outer toothed ring 302 . The second rotary plate 5 has eight second holes 7 , and six of the second holes 7 located next to each other, which are selected to be open and correspond to six operation positions, are spaced apart from one another by the outer deviation angle, which is 45°.
Embodiment 4
With reference to FIG. 7 , the first teeth 8 of the first rotary plate 1 engage the inner toothed ring 301 . The first rotary plate 4 has four first holes 6 , and three of the first holes 6 located next to each other, which are selected to be open and correspond to three operation positions, are spaced apart from each other by double of the inner deviation angle, which is 90°. The second teeth 9 of the second rotary plate 2 engage the outer toothed ring 302 . The second rotary plate 5 has eight second holes 7 , and three of the second holes 7 located next to one another, which are selected to be open and correspond to three operation positions, are spaced apart from one another by the outer deviation angle, which 45°.
During operation, the rotary rod 2 is pushed to rotate toward the first rotary plate 4 and the second rotary plate 5 to a next operation position. When one of the first holes 6 of the first rotary plate 4 that is open communicates with one of the second holes 7 of the second rotary plate 5 that is open, water then flows out sequentially through the second hole 7 and the first hole 6 .
With reference to FIGS. 3 to 7 , the number of the first holes 6 of the first rotary plate 4 may be three or four, and the inner deviation angle may be 180°, 120°, or 90°. The number of the second holes 7 of the second rotary plate 5 may be six, or eight, and the outer deviation angle may be 120°, 60°, or 45°. Because the number and the inner deviation angle of the first holes 6 and the number and the outer deviation angle of the second holes 7 may be different, embodiment 1 has 4 or 5 kinds of water outputs, embodiment 2 has 4 kinds of water outputs, embodiment 3 has 6 kinds of water outputs, and embodiment 4 has 7 kinds of water outputs. | A switch device with multiple water outputs includes a switch valve, a rotary rod, an engagement ring, a first rotary plate and a second rotary plate. The rotary rod is mounted through an opening of the switch valve. The engagement ring has an inner toothed ring and an outer toothed ring formed on a bottom end of the rotary rod. The first rotary plate and the second rotary plate respectively engage the inner toothed ring and the outer toothed ring, and the both rotary plates have multiple holes. As water entering the holes with different number and deviation angle of the first and second rotary plate selectively communicate with each other, different water outputs can be provided. |
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The invention relates to suspended ceiling grid and, more particularly, to a clip for attaching grid tee ends to wall molding.
PRIOR ART
Suspended ceiling grid is normally made up of inverted tee shaped runners or tees that are arranged in a rectangular open grid pattern. Commonly, the ends of the tees, where they intersect with a wall, are simply laid onto the horizontal leg of a wall angle or wall molding. The vertical leg of the wall molding extends upwardly from the horizontal leg and is concealed by the horizontal leg and installed ceiling tiles. The vertical leg is nailed or screwed to the wall to support the wall molding and, in turn, the ends of the tees. Since the area of the vertical leg of the wall molding is concealed from view when the ceiling is completed, the fasteners used to secure it to the wall are unseen.
U.S. Pat. Nos. 4,715,161, 4,610,562 and 5,046,294 disclose types of clips that are used to attach ends of typical grid tees to wall moldings. U.S. Pat. Nos. 5,195,289 and 5,201,787 show a clip used to secure island trim to grid tees.
SUMMARY OF THE INVENTION
The invention provides a clip useful with suspended ceiling grid for attaching the ends of grid tees to wall angles or molding at selected or specified locations. The clip is arranged to be joined onto the end of the face or flange of a grid tee. The clip includes a formation, concealed in use, that interengages with the hem of a wall angle and to thereby lock the clip into position on the wall angle. In certain disclosed versions, the entire clip is concealed from view so as to yield an uninterrupted smooth finish on the visible portion of the wall angle and associated end of the tee.
In a reversal of roles, the clip can be used to mount the wall molding or its equivalent to the ends of the tees where the ceiling is constructed as an “island”. The clip can, additionally, be configured to telescopically support a tee end during seismic disturbances. Still further, the clip can be arranged to receive a grid tee that, by design, intersects the wall molding at an angle other than a right angle. This variable angle clip can be arranged, as mentioned before, to mount a wall molding or its equivalent in an island-like configuration even where the molding is free form or otherwise non-rectangular at the perimeter of the ceiling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view, looking from above, of a suspended ceiling grid employing the invention;
FIG. 2 is a fragmentary perspective view on an enlarged scale, of a first form of a clip for attaching the ends of grid tees to a wall molding;
FIG. 3 is a front elevational view of the clip of FIG. 2 ;
FIG. 4 is a side view of the clip of FIG. 2 ;
FIG. 5 is a perspective view of a modified form of the clip;
FIG. 6 is a perspective view of another modified form of the clip;
FIG. 7 is a perspective view of still another form of the clip specially suited for service in locales where seismic activity concerns exist;
FIG. 8 is a side elevational view of the clip of FIG. 7 ;
FIG. 9 is a plan view of the clip of FIG. 7 ;
FIG. 10 is a front elevational end view of the clip of FIG. 7 ;
FIG. 11 is a side view of a clip modified in form from that shown in FIGS. 7-10 ;
FIG. 12 is a fragmentary perspective view of a clip of modified form for use in instances where a tee intersects a wall molding at an angle other than 90°;
FIG. 13 is a plan view of the clip of FIG. 12 ;
FIG. 14 is a front end view of the clip of FIG. 12 ; and
FIG. 15 is a side elevational view of the clip of FIG. 12 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , there is shown a portion of a suspended ceiling grid 10 including intersecting tees 11 and a wall angle or wall molding 12 . The tees 11 can be relatively long main tees and relatively short cross tees as is customary. The illustrated tees are of a customary cross-section ( FIG. 2 ) having a lower flange 13 , the underside of which forms the face of the tee visible from below in a room, a vertical stem or web 14 and an upper hollow reinforcing bulb 15 . The wall angle 12 illustrated in the figures has horizontal and vertical legs 17 and 25 of equal length (i.e. lateral width) and are each formed with a hem 16 . Customarily, the wall molding 12 is an elongated roll-formed sheet metal structure having a nominal standardized width.
As discussed hereinbelow, the ends of the tees 11 that overlie the horizontal leg 17 of the wall molding 12 are attached to the wall molding by individual clips 18 , as suggested in FIG. 2 . The clip 18 , preferably formed of sheet metal, has a generally horizontal leg 19 and an integral generally vertical leg 20 . At its end or edge remote from the vertical leg 20 , the horizontal leg 19 includes an integral tongue 21 . The tongue 21 extends substantially across the width of the clip, projects lengthwise a short distance from the horizontal leg, and is bent downwardly so that it forms an obtuse angle with the plane of the horizontal leg. The edges of the horizontal leg 19 are folded in the manner of a hem to form opposed channels 22 . The hems, designated 23 , are open sufficiently and their bight areas, designated 24 , are spaced apart sufficiently from one another to receive the flange 13 of the end of an associated tee 11 with sufficient room to enable the tee flange 13 to be received within the hem formed channels 22 without the application of excessive force. The hems 23 are short enough to permit free passage therebetween of the web 14 . For example, where the face of the flange is typically 15/16″ in width, the distance between the bights 24 can provide a lateral clearance of roughly 1/32″. The vertical distance between the hems 23 and main portion or body proper of the horizontal leg 19 can allow for minimal friction or a slight clearance with the thickness of the tee flange. The main portion of the horizontal leg 19 has a pair of laterally spaced holes 27 and the vertical leg 20 has a similar set of laterally spaced holes 28 .
Ideally, the clip 18 is proportioned so that it snaps in the space included between the two wall molding hems 16 . It can be difficult to precisely form the wall angle 12 so that the hems 16 are precisely open or precisely closed and/or to precisely position the free edges, designated 31 , of the hems 16 . The configuration and proportions of the clip 18 are intended to snap fit into the hem area of the wall molding 12 despite these variations. The tongue 21 , by virtue of its downward inclination is potentially capable of at least partially wedging under the hem 16 of the horizontal wall molding leg 17 . With reference to FIG. 4 , it will be seen that the generally vertical leg 20 is originally formed with a slightly obtuse angle α of say between about 91° and 101° to the plane of the main body portion of the horizontal leg 19 . The clip 18 is enabled to snap into the space occluded by the hem edges 31 by proportioning the clip 18 so that the distance between the free edge of its tongue 21 and a remote edge 36 of its vertical leg 20 , when the clip is in the free state illustrated in FIG. 4 is greater than the distance between the free edges 31 of the wall molding hem 16 . In this situation, when the clip 18 is pressed into the space bounded by the wall molding hem free edges 31 , the tongue 21 will lock against the free edge 31 of the horizontal wall molding leg 17 or will slip under its hem 16 . Similarly, the edge 36 will tightly abut the free edge 31 of the hem 16 on the vertical leg 25 or will snap under this hem 16 . Once the clip 18 is snapped in position so that it bears against the wall molding hem edges 31 or slips under one or both of them, the clip will be frictionally retained in its location. A moderate force can be applied to the clip manually to adjust it along the length of the wall angle 12 .
Ordinarily, the clip 18 can be slipped onto the end of a tee 11 before the clip is installed at a desired location on the wall molding 12 . The clip 18 is installed on the tee by simply slipping or telescoping the clip hems 23 and bights 24 over the lateral extremities of the tee flange 13 enabling these elements to grip the tee and prevent any significant relative movement between the clip and tee apart from telescoping motion along the longitudinal axis of the tee. Where desired, the tee 11 and clip 18 can be completely fixed relative to one another by assembling shallow head rivets or the like through the holes 27 in the main portion 26 of the horizontal clip leg 19 and through corresponding holes in the tee flange 13 , the location and making of which is ordinarily accomplished in the field by the installer. Shallow head fasteners assembled from the visible or face side of the flange 13 through the holes 27 allow these fasteners to exist between the horizontal clip leg 19 and horizontal wall molding leg 17 so that they are concealed from view of an observer looking upwards at a finished ceiling. The clip 18 can be fixed relative to the wall angle or molding 12 by screws, nails, or the like, through one or both of the vertical leg holes 28 and the vertical leg 25 of the wall angle. Fasteners in the clip vertical leg holes 28 , of course, cannot be seen from below the finished ceiling.
Various modified forms of the clip 18 are illustrated in FIGS. 5 through 15 . Elements serving the same or essentially same function as that described above in connection with the clip 18 are designated by the same previously used numerals. Elements having different or supplemental functions are ascribed with a third digit number designation.
FIG. 5 illustrated a clip 118 that is devoid of the vertical leg 20 of the previously described clip 18 . Here, in one approach the length of the clip 118 is such that the distance from the tongue free edge designated 34 to an opposite edge 119 is greater than the distance of a free edge 31 of a wall molding hem 16 (of a horizontal leg 17 ) to the vertical wall molding leg 25 . This extra length between these edges 34 and 119 assures that the tongue 21 will, at least, interfere with the wall molding horizontal leg hem edge 31 or will be caused to slide under it. In either case of interference or fitting below the hem 16 , the tongue 21 will lock the clip 118 in a selected position along the length of a wall molding 12 . The clip 118 is most easily installed by abutting the tongue edge 34 with the wall molding horizontal leg hem edge 31 and then forcing the clip from any inclination downwardly until the edge 119 is adjacent the corner between the horizontal and vertical wall molding legs 17 , 25 . Once the clip 118 is pressed so that its edge 119 is at or adjacent the corner between the wall molding legs 17 , 25 , the clip is frictionally locked in position. In an alternative approach, the distance between the free edge 31 of the tongue 21 and the opposite edge 119 can be the same or less than the distance between the inside edge 31 of the hem 16 of the horizontal wall molding leg 17 and the vertical leg 25 . The clip 118 is attached to a grid tee end with shallow head fasteners through holes 27 and aligned holes in the grid tee flange 13 . Where the holes 27 are not used or are omitted, the clip 118 (as well as other clips disclosed herein) can be locked to the grid tee flange 13 by crimping the hems 23 onto the flange.
Referring to FIG. 6 , a clip 218 differs from the 18 in that it is devoid of the vertical leg 20 , hems 23 , and bights 24 . The clip 218 has an edge 219 corresponding to the edge 119 of the clip 118 of FIG. 5 . The clip 218 is frictionally locked in position when the tongue edge 34 tightly abuts or slips under the wall molding horizontal leg hem free edge 31 and the edge 219 abuts or is adjacent the corner between the horizontal and vertical legs 17 , 25 of the wall molding 12 . Spaced holes 27 enable the clip 218 to be locked to the end of an associated tee 11 when screws, rivets or the like, are located in the holes and holes formed in the tee end.
FIGS. 7-10 illustrate a clip 250 suitable to be used, for instance, where seismic activity may be expected. The clip 250 has an elongated, e.g. 3″ long, horizontal leg 251 . The leg 251 includes a generally planar main body 252 with integral opposed hems 253 and bights 254 along its elongated edges. The hems 253 are open to enable the flange 13 of an end of a tee 11 to freely telescope therein along the longitudinal direction of the tee in the manner of a “trombone”. Like the hems 23 and bights 24 of the clip 18 , the hems 253 and bights 254 are proportioned to allow passage of the tee web 14 therebetween and limit relative motion between the clip 250 and tee 11 to longitudinal motion.
The clip 250 has the geometry of the tongue 21 and relative geometry between the plane of the horizontal leg 19 and vertical leg edge 36 as described in connection with the clip 18 of FIGS. 2 through 4 . Depending on where the end of the tee 11 is positioned, i.e. that dictated by the selected length of the tee, there can be about 1½″ in free telescoping movement in each longitudinal direction of a tee in the event of seismic movement.
FIG. 11 illustrates a side view of a clip 260 similar to the clip 250 of FIGS. 7-10 . The clip 260 differs from the clip 250 in that the tongue 21 is spaced farther from the vertical leg 20 of the subject clip. The clip 260 is provided to work with a seismic wall molding. The distance between the tongue edge 34 and remote edge 36 of the vertical leg 20 is increased to match the corresponding pseudo hypotenuse dimension between the free edges of the hems of the seismic molding.
FIGS. 12 through 15 illustrate another form of a clip 270 for attaching the ends of grid tees to wall angles or similar elements. The clip 270 is an assembly including a base 271 and an arm 272 pivotally joined to the base by a pin or rivet 273 which may be a separate element or integrally formed from one or both the base and arm. The rivet 273 enables the arm 272 to pivot about its axis in a horizontal plane when the clip 270 is in the orientation shown in FIG. 12 . The arm 272 from the rivet or pin 273 has a cross-section like that previously described in connection with the clip 18 of FIGS. 2 through 4 and the other modified clips, the arm including open hems 274 and bights 275 . The clip 270 allows a tee 11 to be attached to a wall molding 12 while intersecting it in the horizontal plane of a leg 276 at an angle other than 90°. It will be seen that the arm 272 can be pivoted about the center of the rivet 273 to permit the arm 272 to receive a tee 11 intersecting the wall molding at an angle from nearly 0° to nearly 180°.
While the clip of FIGS. 12 through 15 is proportioned to work with a wall molding with a horizontal leg of conventional width, this clip can be modified to lengthen the horizontal portion of the base 271 so as to move the tongue 21 further from the vertical leg 20 so as to mate with a relatively wide or seismic wall molding.
Various ones of the disclosed clips can be conveniently used to support a wall molding or a similar structure when the roles of the tees and wall molding are reversed such as in an island ceiling treatment where the perimeter of the ceiling does not abut a wall. The clip 270 permits a wall angle or a similar structure to be supported on tees which intersect at one or more angles other than 90°.
While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention. | A clip for attaching the end of a grid tee to a wall angle. The clip, in various forms, is arranged to frictionally lock between the hem of the horizontal leg of the wall angle and the vertical leg. The clip, typically, has a pair of opposed open hems forming channels in which the flange of the tee end is received to join the tee to the clip. The clip can be elongated horizontally to accommodate movement of the grid during seismic activity. The clip can be used to trim the edges of a ceiling island and can be made to accommodate angular intersections of the grid with a wall or island edge. |
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SUMMARY OF THE INVENTION
A trencher having a new attachment concept for attachment to a tractor, the tractor having a hydraulic system and a 540 r.p.m. takeoff, the trencher having a main frame to which is attached a pivotal boom containing a drive and driven sprocket for an endless chain having cutters to do the cutting thereon, a power takeoff shaft connected to the tractor output shaft for driving a head shaft which, in turn, drives the drive sprocket and also acts as a pivoting axle for the trencher boom and the crumber, the trencher having a creep drive for producing a slow forward movement pushing the tractor forward and hydraulic means including an adjustable flow regulator valve for operating a low speed hydraulic motor for creeping drive, and a 3-position directional control valve to shift the boom and crumber to operative and non-operative position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the present invention;
FIG. 2 is a side view with the trencher in digging position;
FIG. 3 is a perspective view with parts broken away;
FIG. 4 is a perspective view of the hydraulic system;
FIG. 5 is a perspective view of the trencher;
FIG. 6 is an expanded perspective view;
FIG. 7 is a perspective view showing how the boom is anchored and the boom is to be tilted up or down; and
FIG. 8 is a plan view taken in the circle of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
The present invention requires a tractor "T" having a three-point hitch, a minimal hydraulic system, and a 540 r.p.m. power takeoff 24.
The trencher is made up of two basic parts, namely a creep drive and digging mechanism.
The trencher main frame 26 has an upper leg 28, lower leg 30 and rearwardly extending legs 32, 33, a diagonal brace leg 34, and vertical side legs or frames 38, 40.
Extending above the upper leg 28 is an adjustable hydraulic flow regulator 180 and a "tilt" valve 72 in housing 42 supported by a vertical bar 44, the lower end being bolted to the upper leg 28 medially thereof. Also mounted to and lying in back of the upper leg 28 is a hydraulic creep motor 46.
Self-aligning pillow block bearings 48, 50 are bolted each to one of the rear upper surfaces of the lower legs 32, 33 to support a shaft 52 therebetween. A drive sprocket 54 is secured to the shaft medially of its ends.
The power takeoff 24 from the tractor "T" is connected to the telescoping drive shaft 56 through a torque limiter 146 and universal gears 148 to speed reducing gears in gear box 58. The output shaft 57 contains sprocket 55 which is attached by chain 59 to a sprocket 107 mounted to the head shaft 52 to provide power to the drive sprocket 54.
The hydraulic oil is channeled to the flow regulator by hose 45. The flow regulator 180 routes oil through hoses 64, 65 to the creep motor 46 (hereinafter detailed). The creep motor's output shaft is connected through a series of speed reducing sprockets and chains generally indicated by the numeral 66 to the axle 68 of the trencher on which wheeled tires 70 are secured one to each end thereof. Only one is shown in the drawing but the opposite tire should be understood.
By adjusting the oil flow from the regulator 180 in housing 42 (see FIG. 4) to the motor 46, with the transmission of the tractor in neutral, the oil from the regulator 180 to the creep motor 46 will cause the wheels 70 to rotate, pushing the tractor forward ahead of the trencher via sprockets 80, 82, 55, 86, with the sprockets 80, 82 mounted on shaft 88 and the sprocket 86 mounted on the all 68. By regulating the amount of oil from the regulator 180 to the motor 46, this determines the amount of speed or forward movement of the tractor, as will hereinafter be described.
A boom 90 is secured to the head shaft 52 through a pair of plates 92, 94 by four bolts 96 extending through aligned slots 97. The rear ends of the plates 92, 94 are provided with right angled plates 94". Spaced therefrom are a pair of right angled plates 94" anchored to the boom 90 having a threaded aperture to receive bolts 92'. When the bolts 96 are loosened, the bolt 92' may shift the boom to adjust the endless chain 102. A pair of elongated, V-like shaped plates 90", 96' lying longitudinally are welded one to each side of the plates 92, 94 and to the boom mounts 98, 100. The boom mounts 98, 100 are hollow cylinders with appropriate bushings and seals and are secured to the head shaft 52. Apertures in boom mounts 98, 100 are provided with appropriate grease fittings 101'. One end of each of the plates 92, 94 is welded to the inner end of the boom mounts 98, 100, as seen in the drawing (FIG. 4).
An endless chain 102 is placed on the drive sprocket 54 and extends to the rear and is mounted on the idler sprocket 104. A series of cutter blades 103 are removably mounted on the endless chain by bolts 107 and depend from plates 106. The idler sprocket 104 is mounted on an axle between the plates of a longitudinally extending, U-shaped bracket 105 with appropriate bearings. The connector plate abuts the end of boom 90 and is welded thereto.
An auger sprocket 108 is mounted rearwardly of the drive sprocket 54 with appropriate bearings and is pinned to shaft 110 and supported by spaced plates 111 anchored at their lower ends to boom 90 by welding. An I-beam 99 is welded medially to the upper surface of the boom 90 and medially of the sides thereof. The chain 102 rides on the upper surface of the I-beam 99 to support it above the boom. The I-beam 99 extends rearwardly at an angle.
A pair of auger flights 112, 114 are mounted on the shaft 110 so that the earth removed by the cutter blades will be shifted sideways of the trench.
A pair of V-like plates 116, 118 are spacedly mounted on boom mount 98 by welding at its inverted apex with the upper end extending upwardly and provided with a radius. (See FIG. 3.)
A tilt cylinder 120 is pivotally mounted to shaft 122 supported between a pair of upstanding spaced plates mounted on the frame lower leg 30. The free end of the cylinder rod 124 is pivotally mounted between plates 116, 118 by a pin 119. The tilt cylinder is operable by the hydraulic fluid flowing from the tilt valve 72 in housing 42 through hoses 126, 128 to lower or raise the boom 90. The boom may be drawn to vertical position above the shaft 52 based solely on the operation of the tilt valve 72.
The crumber is comprised of a steel beam 130, square in cross-section, positioned above the boom 90 and extending rearwardly thereof. One end is mounted to the plate 118 through an angularly extending bar 134. The bar 134 is bolted at one end to the plate 118 and at the other end welded to a short, horizontal, square bar 135 at right angles and anchored to the front end of the crumber bar 130. Now the bar 130 lies directly over the boom 90. The rear end of the elongated bar 130 has pairs of short plates 136, 138, respectively, pivotally anchored thereto. The other end of the pairs of plates 136, 138 is pivotally anchored to one end of a downwardly extending, square in cross-section bar 140 for a parallelogram action. A curved plate 142 is provided with a pair of spaced, upwardly-extending plates 144, 146', the lower ends of which are welded to the plate 142. The free end of bar 140 is welded between the plates 144, 146' at the forward end thereof. The plates 144, 146 are tapered at their rear ends as at 145. The crumber plate 142 drags along the bottom of the trench dug by the cutter blades 103 on the endless chain 102 to drag forward the loose spoils.
With reference to the attachment of the trencher to the tractor, the trencher attachment is provided with a commercially available spring-loaded Scheid pre-set slip-clutch type radial pin torque limiter 146 and two universal joints 148 connected with the telescopic drive shaft 56 therebetween which is connected at its rear end to the reducing gears in box 58 as aforesaid.
The bolts 96 in slots 97 are for use in adjusting the boom to adjust the chain 102 on the boom and on the upper surface of the I-beam 99 on which it rides between sprockets 54, 108 and 104.
In order to dig a trench wider than six inches, an attachment 150 (FIG. 6) is provided. The bolts 107 are removed from chain plate 106 and the attachment 150 is bolted thereto through the apertures 152 to the lower end of plate 106 and the cutter blades 103 secured by bolts in the apertures 147 to dig a trench eight to twelve inches wide dependent upon the width of the attachment 150. The maximum depth of the trench may be from three feet to six feet depending on the length of the boom selected.
Appropriate mud guards 158 are placed over the tires 70.
When the transmission on the tractor is engaged, an over-running clutch 160 on the trencher axle 68 allows the wheels 70, and the axle 68 to free wheel, thus not turning the reduction sprockets 66.
The three-point attachment comprising the upper rod 162 which has an eye 164 is placed between the arms 166 and bolted. The two side arms 168, 170 are placed on the rods 172 mounted on the side frames 38, 40 through a short plate 174. Due to the complexity of the drawings, only one rod and arm are shown but those not shown are mounted to the side frame 38 in the same manner as rod 172 and arm 174.
When the tractor is in neutral and the PTO shaft is signaled, the head shaft 52 rotates, thereby running the digging chain without affecting the position of the boom or the boom mounts.
To raise the trencher boom 90, the tilt valve port 176 is opened by shifting the handle 175 upwardly to direct the hydraulic fluid to the cylinder 120.
The creep motor 46 is made operable by the hydraulic fluid from the tractor moving through hose 45 to the adjustable flow control 180 through hose 64, to generate power in the creep motor 46, with the excess hydraulic fluid returning to the tractor tank through hose 65 and hoses 43, 22. The adjustment is controlled by a valve screw 182 through handle 184.
When the tractor transmission is in neutral, the creep motor 46 will push the tractor forwardly and pull the trencher forward simultaneously through the gearing heretofore mentioned.
The trencher may be anchored in vertical position by an angularly-extending bar 186 anchored at its lower end to the side leg 38. The bar has a pair of spaced plates 188 anchored one to each side of the upper end of the bar to receive the plate 190 therebetween. The plates 188 and 190 have aligned apertures therein to receive a bolt (not shown).
If the boom is to be kept in a horizontal position, and to relieve the hydraulic system, the plates 188 may be positioned over the upstanding plate 194 on plate 116. The plates 188 and plate 194 have aligned apertures therein and are bolted together. To prevent spoils which may adhere to the blades from flying forward, a protective arcuate shield 192 is provided.
Although but one specific embodiment of this invention is herein shown and described, it will be understood that details of the construction shown may be altered or omitted without departing from the spirit of the invention as defined by the following claims. | A trencher machine for attachment to a tractor movably mounted hydraulically for up and down movement relative thereto, boom means for adjusting the depth of the cut in the soil, boom means pivotally mounted on a support means including cutting means thereon. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to reservoir simulation by computer processing and more particularly to processing data relating to a subsurface reservoir to compress the reservoir simulation grids, and subsequently to decompress the grids for study and analysis of the simulation results.
2. Description of the Related Art
In the oil and gas industries, massive amounts of data are required to be processed for computerized simulation, modeling, and analysis for exploration and production purposes. For example, the development of underground hydrocarbon reservoirs typically includes development and analysis of computer simulation models of the reservoir. A realistic simulation model of the reservoir, and the presence of its fluids, helps in forecasting the optimal future oil and gas recovery from hydrocarbon reservoirs. Oil and gas companies have come to depend on simulation models as an important tool to enhance the ability to exploit a petroleum reserve.
The underground hydrocarbon reservoirs are typically complex rock formations which contain both a petroleum fluid mixture and water. The reservoir fluid content usually exists in two or more fluid phases. The petroleum mixture in reservoir fluids is produced by wells drilled into and completed in these rock formations. Sometimes, fluids such as water and/or gases are also injected into these rock formations to improve the recovery of the petroleum fluids.
Reservoir simulation belongs to the general domain of flow in porous media simulation. However, reservoir simulation normally involves multiple hydrocarbon components and multiple fluid phases in an underground geological formation which is under high pressure and temperature. The chemical phase behavior of these hydrocarbon fluids and the included groundwater has to be taken into account in these simulators.
The simulation models contain volumetric data which describe the specific geometry of the rock formations and the wells, and also reservoir properties data, such as the fluid and rock properties, as well as production and injection history pertaining to the specific reservoirs of the oil or gas field in question. The simulation models are formed by a simulator (known as a reservoir simulator) which is a suite of computer programs run on a data processing system.
The reservoir simulator which runs these models is a computer implemented numerical methodology, or coded algorithms and data constructs of an underlying mathematical model. The mathematical model which represents the physics of fluid movements in these hydrocarbon reservoirs is a system of nonlinear partial differential equations which describe the transient multiple-phase, multiple-component fluid flow, and material balance behaviors in these reservoirs induced by the production and/or injection of fluids, as well as the pressure-volume-temperature (PVT) relationships of the reservoir fluids.
A reservoir simulator simulates the multiphase multicomponent fluid flow and material balance in subterranean reservoirs and the included surrounding porous rock formations by subdividing the volume into contiguous cells, also known as grid blocks. In simulation models, the reservoir is thus organized into a number of individual cells. A cell or grid block is the basic finite volume where the underlying mathematical model is applied. The number of cells varies depends on the resolution needed for the simulation and the size of the reservoirs in question.
For a large reservoir, such as the type known in the industry as a giant reservoir, which may have multi-billion barrels of original oil-in-place (OOIP), the number of grid cells can be in the hundreds of millions to over a billion. This number of cells is required in order to have adequate resolution to represent flow dynamics, formation rock porosity and permeability heterogeneity, and many other geologic and depositional complexities within the reservoir. Simulation of this size reservoir can be termed giga-cell reservoir simulation.
The challenges in hydrocarbon reservoir simulation require the use of the latest technology to maximize recovery in a cost-effective manner. Reservoir simulators such as GigaPOWERS have been described in the literature. See, for example articles by Dogru, A. H. et al., “ A Next - Generation Parallel Reservoir Simulator for Giant Reservoirs ,” SPE 119272, proceedings of the 2009 SPE Reservoir Simulation Symposium, The Woodlands, Tex., USA, Feb. 2-4, 2009 and by Dogru, A. H., Fung, L. S., Middya, U., Al-Shaalan, T. M., Byer, T., Hoy, H., Hahn, W. A., Al-Zamel, N., Pita, J., Hemanthkumar, K., Mezghani, M., Al-Mana, A., Tan, J, Dreiman, T., Fugl, A, Al-Baiz, A., “ New Frontiers in Large Scale Reservoir Simulation ,” SPE 142297, Proceedings of the 2011 SPE Reservoir Simulation Symposium, The Woodlands, Tex., USA, Feb. 21-23, 2011. GigaPOWERS reservoir simulation is capable of fine-scale grid simulation that exceeds a billion-cell barrier for post-processing while utilizing hundreds of GB footprint per scenario.
The total number of simulation runs for a company with a number of hydrocarbon reservoirs and appreciable reserves exceeds multiple tens of thousands per year, and one or more petabytes of high performance storage is required to host these data. For full simulation studies, it is required to maintain and store for subsequent use and analysis all of the simulation visualization data that are represented by the hundreds or thousands gigabytes of reservoir simulations.
Consider the case of a single volumetric grid of 1024 3 grid points (on the order of a billion cells) that is processed by a solver such as GigaPowers. Storing volumetric data alone requires 3 times 1024 3 floats (4 bytes each) for space coordinates (x, y, z). State of the art data formats would imply a memory space or capacity of 12.88 GB for volumetric data alone.
This memory space for volumetric data coordinates is required without even considering the many other properties attached to each cell as a result of simulation, such as oil saturation, water saturation, etc. Serious maintenance issues arise due to the vast file size, such as time delays for I/O, file disk size limitations, and required support for increasing or expanding the available memory space capacity as petroleum engineers and reservoir analysts generate more simulation data on a continuing basis.
SUMMARY OF THE INVENTION
Briefly, the present invention provides a new and improved computer implemented method of compressing reservoir simulation data representative of a subterranean reservoir organized into a three dimensional grid of reservoir cells arranged in a set of layers in a vertical dimension of the three dimensional grid. The computer implemented method according to the present invention selects a layer from the three dimensional grid, and batch compresses the reservoir simulation grid data to a compressed layer file representation. The compressed layer file representation is stored in memory. The steps of selecting, batch compressing and storing are repeated for the set of layers of the three dimensional grid; and a reduced representation is formed of the reservoir from the stored compressed layer file representations of the layers of the three dimensional grid for analysis.
The present invention also provides a new and improved data processing system for compressing reservoir simulation data representative of a subterranean reservoir organized into a three dimensional grid of reservoir cells arranged in a set of layers in a vertical dimension of the three dimensional grid. The data processing system includes a processor which selects a layer from the three dimensional grid; and batch compresses the reservoir simulation grid data to a compressed layer file representation. The data processing system also includes memory which storing the compressed layer file representation. The processor further repeats the steps of selecting, batch compressing and storing for the set of layers of the three dimensional grid. An interface of the data processing system forms a reduced representation of the reservoir from the stored compressed layer file representations of the layers of the three dimensional grid for analysis.
The present invention further provides a new and improved data storage device having stored in a non-transitory computer readable medium computer operable instructions for causing a data processing system to compress reservoir simulation data representative of a subterranean reservoir organized into a three dimensional grid of reservoir cells arranged in a set of layers in a vertical dimension of the three dimensional grid. The instructions stored in the data storage device cause the data processing system to select a layer from the three dimensional grid, and batch compress the reservoir simulation grid data to a compressed layer file representation. The instructions also cause the data processing system to store in memory the compressed layer file representation, and to repeat the steps of selecting, batch compressing and storing for the set of layers of the three dimensional grid. The instructions also cause the data processing system to form a reduced representation of the reservoir from the stored compressed layer file representations of the layers of the three dimensional grid for analysis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the organization of the processing methodology according to the present invention.
FIG. 2 is a functional block diagram of data processing steps for the processing methodology of data compression of hydrocarbon reservoir simulation grids according to the present invention.
FIG. 3 is a schematic diagram of a computer network for data compression of hydrocarbon reservoir simulation grids according to the present invention.
FIG. 4 is a functional block diagram of data processing steps for data compression for individual layers of hydrocarbon reservoir simulation grids according to FIG. 2 .
FIG. 5 is a schematic diagram of the computer network of FIG. 3 configured to perform the data processing steps of FIG. 4 .
FIG. 6 is a functional block diagram of data processing steps for layer by layer data decompression of hydrocarbon reservoir simulation grids according to FIG. 1 .
FIG. 7 is a schematic diagram of the computer network of FIG. 3 configured to perform the data processing steps of FIG. 2 .
FIG. 8 is a functional block diagram of data processing steps for data visualization of hydrocarbon reservoir simulation grids according to FIG. 1 .
FIG. 9 is a schematic diagram of the computer network of FIG. 3 configured to perform the data processing steps of FIG. 8 .
FIG. 10 is an example of a full display of a volume of reservoir simulation input data organized into a three dimensional grid of cells for processing according to the present invention.
FIG. 11 is an example display of a single layer of the reservoir simulation input data of FIG. 10 .
FIG. 12 is a graphical plot of a parametric cubic boundary curve representing an approximation of one side of the layer of FIG. 11 .
FIG. 13 is a graphical plot of the actual data of the side of the layer of FIG. 11 approximated in FIG. 12 .
FIG. 14 is a plot of a smoothed boundary curve formed from data points of the data of FIG. 13 .
FIG. 15 is a representation of four sides of a reservoir layer plotted in parametric space.
FIG. 16 is a plot of corresponding sides of the parameterization of FIG. 15 .
FIG. 17 is a plot of a four sided surface defined with corners and tangent vectors during processing according to the present invention.
FIGS. 18, 19, 20 and 21 are example plots of different levels of compression and surfaces per layer according to the present invention.
FIG. 22 is a schematic diagram illustrating the selection of boundary tangents during processing according to the present invention.
FIG. 23 is a schematic diagram of an example color mapping function applied during processing according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, FIG. 1 illustrates schematically as indicated at A the organization of the computerized processing methodology for data compression of hydrocarbon reservoir simulation grids in accordance with the present invention. The processing is composed of three segments or parts as shown generally in FIG. 1 .
As indicated at C, reservoir simulation grid data is subjected to a compression sequence. Batch compression is performed during segment or stage C, as will be set forth, and compresses reservoir simulation grid data from spatial xyz coordinates of the reservoir to mathematical coefficients. The compression methodology during stage C reads layer by layer a volumetric unstructured grid and computes coefficients layer by layer. The coefficients so obtained represent a main compressed grid file. The grid file is stored in computer memory and can be shared quickly given its relatively small size (in comparison to the original grid file size). The operational sequence of the compression processing C is set forth in FIG. 2 , with the batch compression methodology processing B illustrated schematically in FIG. 4 .
As indicated at stage or segment D in FIG. 1 , the stored compressed grid data is available to be subjected to decompression processing. Processing during decompression stage D opens the main compressed grid file and extracts grid information to evaluate the basic functions and re-generate a surface of interest to a user reservoir analyst or engineer. The operational sequence of the decompression processing D is set forth in FIG. 6 .
During stage or segment V, the decompressed grid data resulting from decompression processing in stage D is subject to visualization processing. Surfaces of interest selected after decompression from the stored compressed grid data are mapped to geometric primitives and displayed to the user at a specified display resolution, in interactive time. The operational sequence of the visualization processing V is set forth in FIG. 8 .
Data Processing Methodology and System
The computerized reservoir grid data processing of the present invention according to FIGS. 1, 2, 4, 6 and 8 is adapted for deployment on a variety of presently available high performance computing or HPC platforms. An example HPC environment for the present invention is a multi-node, multi-CPU, multi-core computer cluster system illustrated at R in a data processing system S of FIG. 3 . More detailed schematic diagrams of the data processing system S showing components or units involved in the processing sequences of FIGS. 4, 6 and 8 are shown in FIGS. 5, 7 and 9 , respectively.
The cluster R of the data processing system S ( FIG. 3 ) is formed of a plurality of computer nodes indicated at 50 operating in parallel under control of one or more cluster terminals or router servers 52 . The computer nodes 50 are provided with reservoir grid data in parallel as indicated by arrows 54 from disk storage 56 under control of cluster terminal server or servers 52 . Original reservoir grid simulation input data is stored in a suitable number of data storage/file servers 56 . The reservoir grid data in disk storage 56 is obtained from long term data storage memory 58 in the form of a suitable number of data storage memory units. The computer system S also includes a number of client work stations such as shown at 60 in FIG. 3 for user reservoir analysts and engineers. The work stations 60 are in data communication with reservoir grid data stored in disk storage 56 over a network, as indicated at 62 .
The cluster terminal 52 operates during performance of the compression processing C under control of program code 64 ( FIG. 5 ) stored in terminal 52 . Similarly, the work station or stations 60 operate during performance of decompression processing D and visualization processing V under control of program code 66 and 68 ( FIGS. 7 and 9 ) stored in each work station or stations. The program codes 64 , 66 and 68 according to the present invention are in the form of non-transitory computer operable instructions causing associated terminal 52 or work station 60 to perform the respective reservoir grid data processing sequences, as will be described.
It should be noted that program codes 64 , 66 and 68 may be in the form of microcode, programs, routines, or symbolic computer operable languages that provide a specific set of ordered operations that control the functioning of associated cluster terminal 52 or work station 60 of the data processing system S and direct its operation. The instructions of program codes 64 , 66 and 68 may be stored in memory of the associated terminal or work station or on a data storage device such as computer diskette, magnetic tape, conventional hard disk drive, electronic read-only memory, optical storage device, or other appropriate data storage device having a non-transitory computer usable medium stored thereon.
Compression
With reference to FIG. 2 , a high-level logic flowchart of a preferred sequence of steps for performing computer-implemented reservoir grid data compression processing C according to the present invention is illustrated schematically. As shown in FIG. 2 , during step 100 of compression processing C the complete reservoir grid of interest is obtained from disk storage 56 after retrieval from long term data storage memory 58 . A layer of interest is the reservoir grid is selected during step 102 for performance during step 104 of the batch compression processing B ( FIG. 4 ) of the layer grid data by the computer cluster R.
During step 106 , a lightweight or reduced data volume footprint representative of the compressed layer grid resulting from batch compression is formed. During step 108 , a determination is made whether all layers of the reservoir grid of interest have been batch compressed. If not, processing returns to step 102 and another layer in the grid is select for batch compression.
If all layers of the grid of interest are indicated to have been processed during step 108 , the layer's compressed parameters are retrieved during step 110 and the compressed parameters are sent during step 112 to storage disk 56 .
The general process of compression implies a one by one transformation of each layer of a large volumetric grid coming from the discretization of an oil/gas reservoir. The final output is a lightweight file containing information about connectivity points and directions. This information in form of a file is then stored in a database on storage disk 56 of frequent access, or to long term storage 58 , and is thereafter accessible to users at work stations 60 as reservoir information for use in day to day operations and for decision making.
The compression process is triggered in batch, possibly automatically right after simulation is over, launched by a user or client with access to a parallel cluster able to leverage the parallel nature of the processing. The processing is highly recursive in the sense that the same computational process is applied to equally divided regions of the layer of interest. A limit in the recursion process would be the size of the original grid, but for general visualization purposes and considering the highly adaptive basis, functions with only a few subdivisions are necessary to achieve a visually fair reconstruction.
Batch Compression
FIG. 4 illustrates a high-level logic flowchart sequence of steps for performing computer-implemented batch compression processing B during step 104 of compression processing C according to the present invention. As indicated at step 120 , for a layer of interest selected during step 102 , the corners of the layer are identified and set as control points.
As an example, a volume data set V of 49×104×69 cells (or about 25,000) reservoir grid cells is shown in shown in FIG. 10 . The volume data set V is represented by 70 layers of 50×105 points. This means the other layers have similar shape and characteristics. The methodology of the present invention compresses the data layer by layer; therefore the first step is to decompose a single layer for compression.
Because of the small size of the image shown in FIG. 10 the seventy layers appear to be generally level or flat horizontal layers. However, an individual layer L shown in FIG. 11 is seen to be significantly arched from a high center portion to four lower corners.
Reservoirs are usually thin in the vertical axis or Z direction of the three dimensional coordinate system, compared to the areal size of the reservoirs. The 70 layers of FIG. 10 are assembled from actual real reservoir simulation data. The single layer L of FIG. 11 is scaled which is typical for reservoir visualization purposes. The layer L has a different scale on the Z axes than the stacked layers of FIG. 10 to emphasize the layer shape and results in the highly curved image of FIG. 11 .
Layer L in FIG. 11 can be seen to have four sides, each of which represents a two dimensional or 2-D surface, as shown in FIG. 12 . Referring to a first side 121 of layer L, it can be seen to be composed of a set of boundary points (as shown schematically in FIG. 13 ) that can be approximated by an appropriately determined parametric cubic boundary curve 122 , as shown in FIG. 14 in superposition with selected boundary points for the side 121 from the set of FIG. 13 .
For the purposes of the present invention, a mathematical representation in the form of a cubic Hermite spline function is utilized to represent the set of boundary points in compressed form. The spline function utilized can be defined with two points P and a tangent m per point. The result is a one dimensional or 1-D function in parameter space t, according to the following expression:
p ( t )=(2 t 3 +3 t 2 +1) p 0 +( t 3 −2 t 2 +t ) m 0 +(−2 t 3 +3 t 2 ) p 1 +( t 3 −t 2 ) m 1
where p 0 and p 1 represent the two points P and m 0 and m 1 represent the two tangents. FIG. 15 is an illustration of each of the four sides of layer L in parametric space u and w.
During step 124 ( FIG. 4 ), a determination of the degree of a compression factor n is made in response to a user query. For a layer side, a reduced representation is found. For example, a tolerance of 1.5 and Error=4 (units) results in 95.2% less data points. This represents a compression ratio of 20:1 per layer. With processing for the level 0 of compression, tangents are subsequently chosen for best fit (in a least square manner) to approximate the given data per layer. Additional levels of compression subdivide the layer to minimize the approximation error. Compression varies depending on topology, and thus each layer model may have a unique compression rate. Level zero of compression accounts for the 4 corner points and approximate tangents directions.
Level one of compression accounts for a subdivision by half in each horizontal direction (x-y plane) of the previous level. In the present example, this results in four new domains, as shown schematically in FIG. 16 .
The selected layer is divided during step 126 into a number of subdomains, as shown in FIG. 16 , and during step 128 one of the domains of the layer being processed is selected. Sub-domains are computed separately according to the compression level selected and then retrieved in order for subsequent decompression (reconstruction) and visualization.
Computation of additional levels of compression can be done in parallel one subdomain per node of the cluster R of the data processing system S. The output of the compression computation is the spatial position of the joint or juncture of sub-surfaces and connectivity information for the subsurface, in order to merge the subsurface junctions together in decompression.
Using the formulation of the one dimensional expression for the problem now that each side can be represented by a mathematical function with fewer points than the whole set of points. This results in significant data storage requirement savings according to the present invention.
The formulation for a single layer side is extended to four parametric curves which describe the four boundaries which form a surface or layer L. The formulation is as follows:
Q
(
u
,
w
)
=
P
(
u
,
0
)
(
1
-
w
)
+
P
(
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1
)
w
+
P
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)
(
1
-
u
)
+
P
(
1
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w
)
u
-
P
(
0
,
0
)
(
1
-
u
)
(
1
-
w
)
-
P
(
0
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1
)
(
1
-
u
)
w
-
P
(
1
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)
u
(
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w
)
-
P
(
1
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1
)
uw
A two dimensional or 2-D surface is thus defined that approximates the layer L based on four corners points and eight tangents with the formulation set forth above. FIG. 17 is a plot of the results obtained, from a four sided surface with four corners and eight tangent vectors, with level 0 of compression, one surface per layer. This is done by using what is known as a Coons patch, with 16 degrees of freedom. Coons' patches, for example, represent a general multi-sided surface definition that allows a curve formulation to be used for a composite surface. It should be understood that other forms of surface patches may be used, as well.
The curve formulation performed during step 122 is general enough to support any type of curve. A simpler form known as Ferguson patch may also be used, which has 12 degrees of freedom, namely 4 corners and 2 tangent vectors. Ferguson patches, for instance, make use of cubic polynomial curves.
FIG. 18 shows schematically a level 1 of compression by equally subdividing a layer into four regions. FIGS. 19, 20 and 21 schematically represent subsequent levels of compression by further dividing the layers by increasing powers of two in order to provide final reconstruction. Different shading in sub regions denotes an independent subdomain of the underlying grid at a higher resolution than the previous subdivision level. During step 130 , approximate tangent vectors at the corners of the layer being processed are selected. This is accomplished by assembling in the computer a suitable surface patch for the layer, based on the assembled sets of compressed data points for the four layer sides.
After visual and error requirements are met surfaces are joined together choosing boundary tangents so that continuity is preserved. Boundary tangents are selected or obtained by computer processing during step 130 as shown in FIG. 22 . There are many conventional alternative techniques to approximate tangents across neighboring pieces of data. An example of one is the use of a general second order function such as a parabola to compute the slope of the middle point as shown in FIG. 22 . It should be understood, as mentioned, that a number of conventional techniques to approximate tangents across neighboring pieces of data may be used for this purpose. The general second order function technique is illustrative.
A color mapping function is then applied during step 132 to the number of elements of the original data set properties (e.g. oil saturation, permeability, pressure, etc.) A 1 through A n , with a new lower number B 1 through B m for the new cells according to the level of compression, as the schematic multivalued function diagram of FIG. 23 indicates.
Color mapping of the type indicated in FIG. 23 is a conventional computer implemented functionality used to visualize a scalar of interest over an underlying grid. A description color mapping methodology and its implementation is presented, for example, at: http://en.wikipedia.org/wiki/Color_mapping.
During step 134 , the control points and tangent vectors and the applied color mapping determined in the cluster R are stored in memory. During step 136 , a determination is made whether all of the n domains of the identified layer have been batch compressed. If not, processing returns to step 126 and another domain is then processed according to steps 126 , 128 , 130 and 132 in the manner described above.
If all of the n domains of the identified layer are indicated to have been processed during step 134 , a layer temporal file with control points and tangents is formed and stored during step 136 in memory.
Decompression
Decompression during the sequence or stage D is the middle step between retrieval and visualization; it opens up and reconstructs the underlying grid. The result is a set of geometric primitives in form of triangles or quadrangles that can be rendered in any modern graphics library such as OPENGL, DIRECTX, COIND3d, VTK, among others.
FIG. 6 illustrates a high-level logic flowchart of a preferred sequence of steps for performing computer-implemented decompression processing D of compression processing C according to the present invention. The decompression processing sequence D is performed in work station 60 under control of decompression operating instructions 66 stored in work station 60 . As indicated at step 140 , the compressed grid reservoir file of interest is retrieved by the work station 60 ( FIG. 7 ) from storage disk 56 .
In step 142 , the number of layers in the reservoir grid is identified. During step 144 , a layer is selected by a user and the control points and tangents resulting from step 136 of compression processing are retrieved. During step 146 , the surface layer is reconstructed by processor 70 of the user work station 60 , and during step 148 , geometric primitives are generated for display or rendition on graphical user interface 72 of the work station 60 .
During step 150 , a determination is made whether all layers of the reservoir grid have completed decompression processing. If not, processing returns to step 144 and another layer is selected and then processed according to steps 146 and 148 in the manner described above. When each identified layer has been decompressed, a temporary file or dataset of geometric primitives is generated during step 152 .
Visualization
Considering the visualization processing sequence V ( FIG. 8 ), during step 160 a user selected compressed or lightweight file of interest in the reservoir is selected and downloaded to work station 60 from disk storage 52 . The processing sequence V is performed by work station 60 under control of visualization routines operating instructions stored in work station 60 . During step 162 , the decompression processing sequence D shown in FIG. 6 is performed in the work station 60 under control of operating instructions 66 stored in memory of work station.
During step 164 , the geometric primitives generated during step 152 ( FIG. 6 ) are loaded into memory of work station 60 for processing. During step 166 , a user selects a scalar field of interest in the reservoir. In step 168 , the selected scalar field is mapped for surface reconstruction, and during step 170 , the reservoir geometric primitives are rendered for display on graphical user interface 72 of the work station 60 .
Rendering of the geometric primitives by graphical user interface 72 allows a client user to select the layer of interest to visualize and the scalar field of interest, e.g. oil saturation, water saturation, pressure, etc. With the present invention, it can thus be seen that due to the small size of the compressed grid file, the user client at the work station 60 is able to download and interact in real time with the grid.
A comparison of data storage reductions P with other well-known algorithms for mesh compression and certain standard computer graphics test models is provided and contrasted with current data in the chart below:
Processing
Model
Gain
Compressing
triceratops
43.800%
Polygon Mesh
cessna
10.500%
Connectivity with
beethoven
27.300%
Degree Duality
sandal
18.700%
Prediction
shark
54.700%
al
17.000%
cupie
28.900%
tommygun
13.500%
cow
19.500%
teapot
32.500%
Binary
wolf
88.889%
Compression
raptor
88.889%
Rates for ASCII
fish
94.118%
Formats
snake
92.308%
horse
90.909%
cat
87.500%
dog
90.010%
Present
Reservoir
95.010%
Invention
Layer
The present invention forms a smooth representation of the reservoir of interest that preserves the data grid shape with significantly less data storage footprint requirements. The present invention thus has less storage memory requirements. Fewer I/O or input/output operations are required when a user is interacting with a compressed grid according to the present invention. The present invention allows faster data retrieval for visualization.
The present invention can thus be seen to provide an effective simulation grid methodology that reduces data footprint. The present invention has the potential to reduce the cost of new storage and retain generated scenarios after completion of simulation studies.
The invention has been sufficiently described so that a person with average knowledge in the field of reservoir modeling and simulation may reproduce and obtain the results mentioned in the invention herein. Nonetheless, any skilled person in the field of technique, subject of the invention herein, may carry out modifications not described in the request herein, to apply these modifications to a determined structure, or in the manufacturing process of the same, requires the claimed matter in the following claims; such structures shall be covered within the scope of the invention.
It should be noted and understood that there can be improvements and modifications made of the present invention described in detail above without departing from the spirit or scope of the invention as set forth in the accompanying claims. | A dense volumetric grid coming from an oil/gas reservoir simulation output is translated into a compact representation that supports desired features such as interactive visualization, geometric continuity, color mapping and quad representation. A set of four control curves per layer results from processing the grid data, and a complete set of these 3-dimensional surfaces represents the complete volume data and can map reservoir properties of interest to analysts. The processing results yield a representation of reservoir simulation results which has reduced data storage requirements and permits quick performance interaction between reservoir analysts and the simulation data. The degree of reservoir grid compression can be selected according to the quality required, by adjusting for different thresholds, such as approximation error and level of detail. The processions results are of potential benefit in applications such as interactive rendering, data compression, and in-situ visualization of large-scale oil/gas reservoir simulations. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to earth and rock boring apparatus, finding particular utility in the formation of vertical shafts to mines or other subterranean installations.
2. Statement of the Prior Art
It has been previously known to provide a plurality of drills supported in a casing within a housing pipe and to rotate both the support and pipes while the drills are free to rotate about their axis. Representative of patented art is U.S. Pat. No. 3,945,445.
SUMMARY OF THE INVENTION
The present invention provides a large diameter earth and rock boring apparatus which eliminates the necessity for driving a drill stem from above ground, and which relies principally upon the mass and weight of the drill assembly for its bore function. The assembly hereof is driven, and is provided with fluid input and exhaust means for evacuation of drilled material.
In presently practiced mining procedures, particularly in certain types of long shaft coal mines, it is necessary as the shaft is extended to provide periodic vertical intercept shafts. Conventionally, the intercept shafts are formed by blasting, drilling and excavation in clam shell buckets and the like. This procedure is not only costly and dangerous, but often results in shafts of irregular form having fragmented, unstable side walls. Also, blasting often causes flooding by disruption of adjacent subterranean water sources, and in that event, the shaft walls must be lined with concrete resulting in additional cost.
The present invention provides a method and means for the construction of shafts of the type described above, embodying the essential characteristic of pulverization of material to be drilled, combination of the pulverized material with a fluid medium to form a slurry, and pumping of the slurry to the surface for disposal.
The apparatus hereof is adapted for operation from the surface thereby avoiding dangers inherent in those devices requiring personnel to be present at the bottom of shaft.
The unit hereof comprises a main body section of tubular form, supported for releasable stationary positioning, a casing with a lower hub supporting free wheeling cutters, and fluid input and exhaust means. The rate of drilling is a function of the weight and mass of the cutting elements, and the rate of motion thereof.
Other and further objects and advantages of the invention will become apparent to those skilled in the art from a consideration of the following specification when read in conjunction with the annexed drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational view taken through a section of drilled shaft, showing earth drilling equipment constructed and assembled in accordance with the teachings of this invention, vertically foreshortened;
FIG. 2 is a sectional view looking down on the cutting component, of the unit shown in FIG. 1;
FIG. 3 is a view similar to FIG. 2, but taken below the drive wheels, and with portions of the base removed for disclosure of details;
FIG. 4 is a horizontal cross sectional view taken to show the jack arrangement;
FIG. 5 is another sectional view looking down, taken below the base to disclose the fluid input and exhaust means, the cutting elements being shown in phantom lines;
FIG. 6 is a foreshortened vertical sectional view taken through the main body tube and casing; and
FIGS. 7a through 7d are schematic views showing sequences of operation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in more detail, the invention finds its principal environment of intended utilization in the formation of a substantially vertical shaft 10 in the earth 12. The shaft 10, as it is formed, has an inside wall 14, and drilling occurs at its bottom 16. The bottom is, during drilling, constantly eroded by the action of the apparatus, commencing from the surface 18 to a desired depth or to an intersection with a tunnel or the like.
The apparatus hereof is generally identified in the drawing by reference character 20. A principal structural and functional component of the unit 20 is an elongated main body tube 22 which is normally vertically disposed when the unit is in use. The main body tube 22 has upper and lower ends 24, 26, an outer side wall 28, and an inside wall 30 defining a bore 32 (FIG. 6). In FIGS. 1 and 4, it will be observed that a plurality of jack assemblies 34 are fixedly secured on the outer side wall 28, each comprising a fixed lateral sleeve 36 with a extensible and retractable rod 38 projecting from its end remote from the main body tube. The rods are connected at the outer ends to elongated abutment members 40 which extend between and interconnect vertically aligned pairs of the jacks. The jack sleeves 36 are rigidified and reinforced by a series of braces 42 which extend back to the main body tube and between one another of the sleeves. The jacks may be hydraulic or otherwise actuated.
Disposed vertically within the main body tube 22 is an elongated, tubular outer casing 44. The casing has a top end portion 46, and an opposite bottom end portion 48, the top and bottom end portions projecting above and below the upper and lower ends 24, 26, respectively, of the main body tube. The casing 44 is rotatably journaled within the bore 32 of the main body tube, as described more fully hereinafter, and has a vertical passageway 50 defined by its interior wall 52.
The bottom end portion 48 of the casing is fixedly connected to a horizontal base member 54. The base member is of optional and variable design, but here is shown as of cruciform shape with a central hub 56 with an opening 58 receiving the casing, and having upper and lower sides 60 and 62. The cruciform configuration provides a pair of diametrically opposite cutter arms 64 and 66, and radially spaced, diametrically opposite pair of drive wheel arms 68 and 70 (FIGS. 2 and 3).
Fitted within the passageway 50 of the outer casing and inwardly spaced therefrom is a tubular exhaust tube 72. The exhaust tube 72 has a lower intake end 74 which projects, as shown in FIG. 6, below the base member 54, and an upper discharge end 76 with a flange 78 for connection to a suitable conduit. Below said base, the lower intake end 74 is integrally joined to a plurality of scavenging tubes 80. The scavenging tubes are hollow, and in fluid communication with the tube 72, and each has an outer vertically depending leg 82 with an enlarged mouth element 84 at its lower extremity.
A fluid input pipe is of reduced diameter relative to the exhaust tube 72, and has a top portion 88 and a bottom portion 90 with an end wall 92. Immediately above the end wall 92, ports 94 are formed in the portion 90 of the pipe 86, and spouts 96 are secured to the pipe about each of said ports. The spouts have downturned nozzles 98 at their ends.
Mounted on the upper side 60 of the base member 54 on said cutter arms 64 is a drive motor 100 with an output gear box 102 or other conventional drive conversion mechanism. On each of the drive wheel arms 68 and 70 of the base is a housing 104 for a worm gear drive (not shown), and shafts 106 from the gear box 102 drivingly engage the same. A driven stub axle 108 extends from each of the housings 104, and a drive wheel 110 with a friction tire 112 is secured thereto. The wheels are driven from the motor 100 to rotate the base by frictional contact of the friction tires. The motor may be of the reversible types so that the direction of the rotation of the unit can be changed.
A cutter motor 114 is mounted on the drive wheel arm 68 above the base, and has a operatively associated output gear 116. On the extremities of the cutter arms 64 and 66 are housings 118 with side worm gear portions 121. Shafts 120 are engaged at one end with the gear drive 116 and at the opposite end within the worm gear portions 121 in driving relation. Vertical drive cutter axles 122 extend from the housings 118 through the base. The plurality of downwardly and outwardly extending legs 124 are radially spaced on each axle, and the legs have upwardly inclined foot portions 126.
The cutting elements 128 hereof each comprises an assembly of disk form plates 130 suitably clamped together in freely rotatable fashion on the respective foot portions 126 of the axles 122. As seen in FIG. 1, the plates are of variable diameter, increasing from inside to out, such that, with the inclination of the foot portions, the peripheral cutting edges of the plates are disposed in contact with the shaft bottom 16.
Means 132 on the outer casing 44 and on the main body tube 22 for energizing the drive and cutter motors is provided. The particular means employed is a variable feature of the invention, and various optional power arrangements are contemplated according to energy availability, terrain and the like. In this illustration, the means 132 comprises a housing 134 secured on a base 136 above a collar 138 on the casing. As shown in FIG. 6, the collar is fixedly secured to the casing, as by a weld, but the base 136 is not, and the casing is free to rotate without the plate. An insulater sleeve 140 is attached to the casing within the housing, and a series of annular electrical contacts 142 are placed thereabout in spaced apart relation. A housing mount rod 144 is secured on the main body tube by gusset plates 146 and a slide bushing 148 in an opening 150 in the base 136 permits vertical sliding movement of the rod therein. The rod however prevents rotation of the base and housing with the casing. A power supply cable 152 extends to a power supply and control station (not shown) located on the surface. A series of stationary contacts 154 within the housing are in sliding engagement with annular contacts 142, and suitable electrical wiring 156 is positioned between the casing and the exhaust tube 72.
In FIGS. 7a through 7d, it is seen that start up involves initial erection of an above ground frame 158 comprising an outter super structure 160 and interior wall 162. The main body tube 22 is initially positioned within the wall confines and the jack assemblies 34 are extended to bring the abutment members 40 into contact with the walls. The exhaust tube 72 is connected to a pump 164 leading to a slurry discharge site, and the input pipe 86 has a pump 166 supplying fluid from a reservoir or other source. This places the cutting elements 128 on the surface as shown in FIG. 7a. Rotation of the casing, base and cutting elements is then instituted by energization of the drive motor 100 resulting in the frictional contact of the tires 112 of the wheels 110. Fluid is introduced into the cutting area and forms a slurry with excavated material, the slurry being then expelled through the tube 72. In FIG. 7b the drilling has progressed to a point near the vertical downward limit of the casing with respect to the main body tube, and shaft formation has occurred to a first depth. At this point, the jacks 34 are retracted and the main body tube lowered to the position shown in FIG. 7c. The jacks are again extended at this point to bring the abutment member into contact partially with the wall 162 and partially with the shaft 14. FIG. 7d shows completion of this cycle and it will be noted that the process of lowering the tube may continue until the desired drill depth is achieved.
It will of course be understood that during operation the cutter drive motors 114 are energized in order to drive the cutters. | Earth drilling equipment includes a main body tube with jacks to releasably support it within a drilled shaft, or within an erected start up shaft. An outer casing is rotatably mounted within the main body tube, and carries a horizontal base on which are driven wheels, and vertical shafts which have cutting elements. Means within the casing for fluid input and evacuation within the drill area is provided to form a slurry of the fluid and excavated material for withdrawal through the casing. As drilling continues, the main body tube is lowered into the shaft.
The cutting elements include plates with cutting edges mounted on individual axles such that the edges are maintained in cutting relation to the area to be drilled. |
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FIELD OF THE INVENTION
[0001] The invention relates to a novel apparatus for use in the door framing industry. Particularly, the apparatus of the invention is an adjustable device which equips a carpenter engaged in framing doors with an adjustable door spreader capable of spreading virtually all doors, thereby saving time and materials by eliminating the need to build a single-use spreader for each door to be framed.
BACKGROUND OF THE INVENTION
[0002] Carpenters use a wide variety of tools to help them with repetitive tasks. Where the construction of a plurality of doors is concerned, one of the critical tasks is spreading the door bucks to the proper spacing prior to securing the doors' sides and the bottom of the bucks to the floor and other securing members of the frame. Ordinarily, a door spreader is fashioned for each door on each new job from wood or other like material, taking time and using materials.
[0003] In the past, several tools designed to mitigate the need for crafting new spreaders on each job have been disclosed, however, they generally are complicated, clumsy, expensive, or insufficiently adjustable to accommodate the requirements of most door-framing jobs. For example, U.S. Pat. No. 5,340,095 discloses a door spreader with myriad moving parts, connections, and clamps, but it has disadvantages in that it requires tools such as wrenches to adjust the spread width. Likewise, U.S. Pat. No. 3,851,868 discloses a spreader employing bolts, magnets, and sliding members which allows for adjustability, but is limited in its ability to accommodate doors of different sizes, because the largest spread it can accommodate is somewhat less than twice the smallest spread owing to the nature of the sliding members. Further, at wider spreads, the device is insufficiently stable because its sliding members are extended to their fullest and are secured by only a single bolt.
[0004] U.S. Pat. No. 5,775,036 discloses a spreader employing grooves and slots to enable spreading of doors in a range likewise limited by the spread of its sliding members to less than twice the smallest range. Additionally, the lateral ends of the spreader are a single size, such that adaptation to a variety of door buck width sizes is not possible without building additional units.
[0005] The art is therefore in need of a superior door spreading apparatus which is useful on a variety of door spread widths and buck sizes, which may be carried by the carpenter to each job and used on the variety of doors in a repetitive fashion such that each door requires only a simple adjustment of the spreader apparatus.
SUMMARY OF THE INVENTION
[0006] The door spreader of the invention satisfies the needs in the art for a spreader which is reuseable on a variety of door framing jobs, which may be carried by individual carpenters to such jobs, and is both inexpensive and particularly well-adapted to its function.
[0007] In one aspect, the invention comprises an adjustable door spreader having (a) a base member comprising a top surface having two longitudinally opposed notches and two longitudinal rails extending upward from opposing edges of the top surface; and (b) a slideable member slideably affixed to the base member and retained thereon by the rails, wherein at least one end of the slideable member has a notch; wherein the door spreader may be adjusted to accommodate a variety of widths separating a first door buck and a second door buck.
[0008] For door bucks whose width of separation is the same as the width of the base member, the slideable member is unextended; the base member's notches engage the first and second door bucks. However, where the desired door bucks' separation width is greater than that of the base member, the slideable member is extended, wherein one notch of the base member engages the first door buck and the notch of the slideable member engages the second door buck.
[0009] The upper surface of the base member optionally has a spline extending longitudinally along the top surface thereof, while the slideable member has a groove extending longitudinally along a lower surface thereof, such that the groove slides along the spline when the slideable member is extended or retracted.
[0010] In another aspect, the door spreader further comprises means for securing the slideable member to the base member at a desired extension length. The means for securing comprises pairs of recesses at desired locations of the base member, at least one pair of holes at a desired location of the slideable member, and locking pins capable of passing through the holes in the slideable member into the recesses of the base member. The locking pins are generally any means capable of passing through the slideable member and into the recesses on the base member, and may be, for example, dowels, pins, bolts, wingnuts, screws, and spring-bolts. Preferably, the locking pins are spring-bolts.
[0011] The adjustable door spreader optionally has measurement indicators, such as engraved or printed dimensions, along the top surface of the slideable member, the upper edges of the rails, the sides of the base member, or any combination thereof. The measurement indicators are optional because the recesses are spread at precise increments. In use, the door spreader is adjusted to these incremental spread widths.
[0012] In another aspect, then, the door spreader may be locked to at least 2 spread widths found in common door frames, and are generally from 24 to 48 inches in 2 inch increments. Any desired increment may be accomplished by spacing the recesses on the slideable member at the desired distance. Preferably, the door spreader may be locked to a variety of common door frame widths, typically in 2 inch increments. Where the base member is 30 inches in its longest dimension, the spread widths are generally variable from 24 inches (using the slideable member only where the slideable member is 24 inches in its longest dimension), 30 inches (using a 30 inch base member with or without the slideable member affixed to the base member, but unextended therefrom), and from 30 to 48 inches in increments of 2 inches. Again, other increments are easily adapted by designing alternative space increments between the recesses on the slideable member.
[0013] In another aspect, the adjustable door spreader has an additional adjustable extension member adjustably affixed to the upper surface of the slideable member, thereby providing an additional extension and allowing the door spreader to function with larger door buck spread widths. The adjustable extension member is affixed to the slideable member with securing means, such as dowels, pins, bolts, wingnuts, screws, and spring-bolts, which pass through holes in the extension member into recesses in the upper surface of the slideable member. Extension of the adjustable extension member is accomplished through releasing the securing means, repositioning the extension member, and securing the adjustable extension member to the slideable member through a second pair of holes in the extension member and into the recesses of the slideable member. For example, a 9 inch extension member allows for additional extension up to 4 inches.
[0014] In one aspect, an adjustable door spreader with a 30 inch base member, a 24 inch slideable member, and a 9 inch extension member may thus be extended to accommodate spread widths of from 24 to 52 inches in increments of 2 inches, or any combination of at least two of such widths.
[0015] In another aspect, an adjustable door spreader with a 24 inch base member, a 20 inch slideable member, and a 7 inch extension member may thus be extended to accommodate spread widths of from 20 to 44 inches in increments of 2 inches, or any combination of at least two of such widths.
[0016] A suitable handle may optionally be positioned and affixed to the upper surface of the slideable member. The handle may be used to carry the door spreader as well to assist in extending the slideable member.
[0017] In another aspect, the notches of the base member and slideable member are adjustable in width, permitting the door spreader to be employed with a variety of door buck widths, as described more fully below.
[0018] The adjustable door spreader may be fabricated from any suitable material known in the art with sufficient rigidity and the ability to be formed into the required dimensions. For example, the base member, slideable member, extension member, and handle are independently made from wood, fiberglass, plastic, PVC, carbon fiber, aluminum, and the like.
[0019] The invention also includes methods for spreading a door frame using any of the embodiments of the adjustable door spreader of the invention.
[0020] These and other features of the invention are exemplified and further described in the Detailed Description of the Invention below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic diagram showing an embodiment of the adjustable door spreader of the invention.
[0022] FIG. 2 is a schematic diagram showing an overhead view of an embodiment of the adjustable door spreader of the invention.
[0023] FIG. 3 is a schematic diagram showing a side view of an embodiment of the slideable member of the invention, with an extension member affixed thereto.
[0024] FIG. 4 is a schematic diagram showing an edge-on view of an embodiment of the adjustable door spreader of the invention.
[0025] FIG. 5 is a schematic diagram showing the base member, the slideable member, and the extension member of an embodiment of the adjustable door spreader of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The door spreader of the invention comprises a base member having a smooth bottom surface, and lateral ends with notches adapted to fit standard door buck widths. The notches may be of a fixed width, or may be adjustable as described below to fit a variety of door buck widths.
[0027] The base member may be used by itself for the smallest door frame sizes, as it is designed to precisely fit the smallest standard door sizes, such as 24 inches or 30 inches. To accommodate larger door spread widths, the base further comprises a longitudinal spline running down the middle of the upper surface, and longitudinal rails running down the sides of the base. These features allow a slideable member having a lower and an upper surface, the lower surface having a groove sized to fit along the spline of the base member, and the slideable member being of width such that it fits within the two rails of the base member. The slideable member has its own set of notches on its longitudinal ends to accommodate the door bucks' width. The carpenter using the spreader simply slides the slideable member along the base member until the desired spread width is achieved.
[0028] The upper surface of the slideable member optionally has an adjustable third member adjustably affixed thereto to allow further extension and additional spreader width.
[0029] Measurement indicators are optionally present on one or more of the upper surface of base member, one or both of the side surfaces of the base member, the upper surface of the slideable member, and the upper surface of the adjustable third member. In one embodiment, the indicators provide markings spaced in intervals of, for example, 2 inches.
[0030] Once the desired spread width is achieved, the width of the spreader is secured by securing means which pass through holes through the entire thickness of the sliding member into recesses in the upper surface of the base member adapted to receive the securing means. Generally, a pair of securing means are used, positioned advantageously in opposition on the slideable member. The securing means may be dowels, pins, bolts, or preferably spring bolts which may be released and secured with a simple twist-and-pull action. The recesses in the upper surface of the base member are positioned such that each will engage a securing means, which have been passed through the holes. In the case of spring bolts, a simple twist-and-pull action recedes the spring bolt from being engaged, allowing the sliding member to slide against the base member, whereupon the desired width is achieved. The spring bolts are then twisted back to reengage the recesses at the desired position, achieving a secure engagement of the sliding and base members at the desired width.
[0031] Thus, in one embodiment of the invention, an adjustable door spreader has (a) a base member comprising a top surface having two longitudinally opposed notches and two longitudinal rails extending upward from opposing edges of the top surface; and (b) a slideable member slideably affixed to the base member and retained thereon by the rails, wherein at least one end of the slideable member has a notch; wherein the door spreader may be adjusted to accommodate a variety of widths separating a first door buck and a second door buck.
[0032] For door bucks whose width of separation is the same as the width of the base member, the slideable member is unextended; the base member's notches engage the first and second door bucks. For example, a base member having a longest dimension of 30 inches accommodates a standard 30 inch door frame, while the slideable member of 24 inches in longest dimension may be used by itself for smaller frames, such as those in smaller closets. However, where the door bucks' separation width is greater than that of the base member, the slideable member is slid within the base member, and extended, wherein one notch of the base member engages the first door buck and the notch of the slideable member engages the second door buck. This allows for spread widths of, for example, 24 inches to 48 inches in desired increments of, for example, 2 inches. In another embodiment, where the base member is 24 inches in width, the door spreader accommodates spreads of 20 to 44 inches.
[0033] The upper surface of the base member optionally has a spline extending longitudinally along the top surface thereof, while the slideable member has a groove extending longitudinally along a lower surface thereof, such that the groove slides along the spline when the slideable member is extended or retracted.
[0034] In one embodiment, the door spreader further comprises means for securing the slideable member to the base member at a desired extension length. The means for securing comprises pairs of recesses at desired locations of the base member, at least one pair of holes at a desired location of the slideable member, and locking pins capable of passing through the holes in the slideable member into the recesses of the base member. The locking pins are generally any means capable of passing through the slideable member and into the recesses on the base member, and may be, for example, dowels, pins, bolts, wingnuts, screws, and spring-bolts. Preferably, the locking pins are spring-bolts, such as those available from McMaster-Carr (e.g., “Pull-Ring” Hand-Retractable Spring Plungers, found in the online catalog at mcmaster.com), and may be made of brass, steel, or the like.
[0035] The adjustable door spreader optionally has measurement indicators, such as engraved or printed dimensions, along the top surface of the slideable member, the upper edges of the rails, the sides of the base member, or any combination thereof.
[0036] In an embodiment of the invention, the door spreader may be locked to at least 2 spread widths found in common door frames, and are generally 24 to 52 inches, in desired increments. Preferably, the door spreader may be locked to all these common door frame widths. Further, the recesses in the base member may be more numerous to allow for locking of the slideable member at additional, less common, widths.
[0037] In another embodiment, the adjustable door spreader has an adjustable extension member adjustably affixed to the upper surface of the slideable member, thereby providing an additional extension and allowing the door spreader to function with larger door buck spread widths. The adjustable extension member is affixed to the slideable member with securing means, such as dowels, pins, bolts, wingnuts, screws, and spring-bolts, which pass through holes in the extension member into recesses in the upper surface of the slideable member. Extension of the adjustable extension member is accomplished through releasing the securing means, repositioning the extension member, and securing the adjustable extension member to the slideable member through a second pair of holes in the extension member and into the recesses of the slideable member. For example, an extension member of 9 inches provides for additional extension of 4 inches.
[0038] In another embodiment, then, the adjustable door spreader with a 30 inch base member may thus be extended to accommodate spread widths of 24 to 52 inches, or any desireable combination of at least two of such widths. Preferably, the door spreader is capable of accommodating all such widths, and may be optionally machined to allow for less common widths in between these standard widths. For example, where a 2 increment is desired, the door spreader accommodates spread widths of 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, and 52 inches. In another embodiment, where the base member is 24 inches long, the door spreader accommodates door buck spread widths of 20 to 44 inches when the slideable member and extension members are utilized. Preferably a 2 inch increment is used, thus allowing for spread widths of 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, and 44 inches.
[0039] A suitable handle may optionally be positioned and affixed to the upper surface of the slideable member. The handle may be used to carry the door spreader as well to assist in extending the slideable member.
[0040] In another aspect, the notches of the base member and slideable member are adjustable in width, permitting the door spreader to be employed with a variety of door buck widths. For example, in one embodiment, the notches, as defined by their protruding sides are 2½ inches wide, but may be adjusted to greater or lesser width by adapting one of the protruding sides defining the notches to be movably adjustable, thereby allowing for door buck widths of from about 1 inch to about 3 inches.
[0041] The adjustable door spreader may be fabricated from any suitable material known in the art with sufficient rigidity and the ability to be formed into the required dimensions. For example, the base member, slideable member, extension member, and handle are independently made from wood, fiberglass, plastic, PVC, carbon fiber, aluminum, and the like. Each of the base member, the slideable member, and the extension member may be constructed from a single piece of material, or may be constructed from separate pieces which, when appropriately joined, formed the respective member. Preferably the door spreader is made of wood or fiberglass.
[0042] The dimensions of the door spreader are chosen for the particular spread of widths intended to be accommodated. Preferably, the door spreader is capable of spreading from 24 inches to 52 inches including a plurality of 2 inch increments thereof, more preferably including a majority of 2 inch increments thereof, more preferably including substantially all 2 inch increments thereof, and most preferably including all 2 inch increments thereof.
[0043] The invention also includes methods for spreading a door frame using any of the embodiments of the adjustable door spreader of the invention. In these methods, the carpenter lays the door spreader between the door bucks and adjusts the door spreader to the desired width, either by using the notches in the base member alone, or by extending the slideable member to a greater width, engaging one of the slideable member's notches with the first door buck and the base member's notch with the other, or by extending the extension member to achieve greater widths than possible with the slideable member alone.
EXAMPLES
[0044] The present invention will be further understood by reference to the following non-limiting examples.
Example 1
Adjustable Door Spreader with 30 Inch Base Member
[0045] With specific reference to the Figures, this Example illustrates an embodiment of the invention wherein the base member is 30 inches in its longest dimension. Made from wood, the door spreader is 30 inches wide, 7 inches across, and 2 inches high (including the height of the rails). The base member ( 1 ) as depicted in FIG. 1 is constructed from ¾ inch thick wood. The rails ( 2 ) are a total of 2 inches high and ½ inch thick, and, as shown in FIG. 4 , at the top ¼ inch of the rails, extend medially ¾ inches from the edge of the base member toward the center of the base member to retain the slideable member ( 4 ) in a flange-like manner, thereby providing a ¼ inch overhanging retaining portion of the rail.
[0046] The notches on the base member ( 3 ) are defined by tongs extending outward from the base member by ¾ inches, though they may alternatively extend outward by ½ inch to about 1 inch. The tongs are each 1¾ inches across. The notches defined by the tongs extended from the base member are therefore 2½ inches across, accommodating door bucks of up to 2½ inches in width.
[0047] The top surface of the base member has a 2 inch across spline ( 6 ), either side of which are recesses ( 7 ), beginning from between about 4 and 6 inches from either end of the base member, preferably between 5 and 5½ inches, and spaced in an interval of every 2 inches. The recesses ( 7 ) are set about 1 inch from the rails in order to match with the pair of holes ( 9 ) in the slideable member.
[0048] The slideable member ( 4 ) depicted in FIG. 3 is 24 inches in width, 5⅞ inches across, and 11/16 inches thick. The slideable member ( 4 ) has notches ( 3 ) such that the space defined by the tongs thereof are of similar width to those of the base member ( 1 ). The thickness of the notches ( 3 ) shown in FIG. 3 may be less than the full thickness of the slideable member ( 4 ), or the notches ( 3 ) may be fully as thick as the slideable member ( 4 ) itself. In this example, a groove matching the dimensions of the spline ( 6 ) (which in this example is ⅛ inch thick) is provided on the lower surface of the slideable member ( 4 ). As depicted in FIG. 5 , the slideable member ( 4 ) has two pairs of recesses towards one end for adjustably affixing the extension member ( 5 ), only one pair of recesses being utilized at a particular time depending on the desired door buck spread width. The slideable member may have three pairs of recesses, 2 inches apart, to allow for adjusting the extension member to extend by 0, 2, or 4 inches. Towards the opposite end of the slideable member, at a position about 2½ inches from the end of the slideable member, is a pair of holes ( 9 ) through which the locking pins ( 8 ) (shown in FIGS. 2 , 3 , and 4 ) are passed, for securing the slideable member ( 4 ) to the base member ( 1 ). The pair of holes ( 9 ) are each set back from the edge of the slideable member by 15/16 inches. The locking pins ( 8 ), after passing through the holes ( 9 ), pass into the recesses ( 7 ) of the base member. A handle ( 10 ) is also provided on the slideable member ( 4 ).
[0049] The extension member ( 5 ) as depicted in FIG. 5 is 9 inches in width, 5½ inches across, and ½ inch thick. It has a notch at only one end, the tongs of which define a space having dimensions as in the notches of the base member and slideable member, although the space defined by the tongs may be less, such as 2¼ inches. Two pairs of holes ( 12 ) are positioned on the extension member ( 5 ) such that it may be affixed to the slideable member ( 4 ) at either an unextended position (see FIG. 2 ), or in an extended position. The affixing is accomplished by means of wingnuts ( 11 ) which pass through the holes ( 12 ) and into the recesses in the slideable member ( 4 ). As shown in the Figures, the extension member ( 5 ) has two pairs of holes for extension purposes, however, if desirable, the extension member ( 5 ) may have additional pairs of holes for additional extension width possibilities. For example, three pairs of holes may be used to accommodate extension by 0, 2, and 4 inches.
[0050] FIG. 1 depicts the fully assembled adjustable door spreader, showing the base member ( 1 ), the slideable member ( 4 ) in unextended position, and the extension member ( 5 ) in unextended position. FIG. 5 depicts the unassembled door spreader, indicating the manner in which it is assembled for use.
[0051] The door spreader is used by placing it between door bucks and adjusting the door spreader so that the notches present in the appropriate member define the desired spread width. For example, a 30 inch spread width is accomplished by merely keeping the slideable member and extension member in unextended positions. A 36 inch spread width is accomplished by releasing the spring-bolts, sliding the slideable member 6 inches, and resecuring the spring-bolts. One notch of the base member abuts one of the door bucks, while one notch of the slideable member abuts (or defines the position) for the other door buck. The door bucks are then affixed to form a door frame of precise desired width. Similarly, a 52 inch spread width may be accomplished by extending the slideable member by 18 inches, and then the extension member to its fully extended position (yielding an additional 4 inches of extension), bringing the total width of the adjusted spreader to 52 inches.
Example 2
Adjustable Door Spreader with 24 Inch Base Member
[0052] This example differs from Example 1 in that the base member ( 1 ) is 24 inches wide, the slideable member is 20 inches wide, and the extension member is 7 inches wide. This example apparatus is capable of spreading from 24 inches to 44 inches.
[0053] It will be apparent to persons skilled in the art that numerous enhancements and modifications can be made to the above described apparatus without departing from the basic inventive concepts. All such modifications and enhancements are considered to be within the scope of the present invention, the nature of which is to be determined from the foregoing description and the appended claims. Furthermore, the preceding Examples are provided for illustrative purposes only, and are not intended to limit the scope of the invention. All references cited herein are expressly incorporated by reference herein. | The invention relates to an adjustable door spreader apparatus for use in the door framing industry. The apparatus equips a carpenter engaged in framing doors with an adjustable door spreader capable of spreading virtually all common door sizes, thereby saving time and materials by eliminating the need to build a single-use spreader for each door to be framed. |
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BACKGROUND OF THE INVENTION
The present invention relates to a toilet-tank discharge valve with a main-valve body that can be lifted off of its face by release-activating an auxiliary valve with an activating mechanism as a consequence of negative water balance in an associated discharge compartment.
A system of this type is known from German No. OS 2,609,138, wherein the top of the main-valve body constitutes the lower limit of a discharge compartment. A water channel with an auxiliary valve in it leads from the discharge compartment into the outlet of the tank. When the full tank is initially activated--release-activated, that is--the auxiliary valve opens. The water flowing out of the discharge compartment generates a negative water balance in it, lifting the main-valve body off of its face.
It has not as yet been possible with discharge valves of this type to discontinue the flushing process once it has been initiated, and every activation results in a complete discharge of the tank.
SUMMARY OF THE INVENTION
In consideration of the constantly increasing need to conserve water, the object of the present invention is to provide a toilet-tank discharge valve of the aforesaid type in which flushing can be discontinued, once initiated, by a second activation. This discontinuance activation is carried out with the existing activating mechanism.
This and other objects are achieved in accordance with the invention by a supplementary auxiliary valve which is associated with the discharge compartment.
The supplementary auxiliary valve, which opens at least briefly as the result of the discontinuance activation of the activating mechanism, produces a positive water balance in the discharge compartment in the sense of the closing of the main-valve body, the positive water balance being maintained until the main-valve body is completely closed.
This system makes it possible to discontinue flushing in advance of the completion thereof and is also easy to operate because the activating forces and strokes can be kept low and because discontinuance is activated in the same way as the release.
In one embodiment of the invention, since the supplementary auxiliary valve has a larger cross-section than the auxiliary valve, it opens as the result of a discontinuance activation and does not close before the auxiliary valve closes.
In this case it is practical to position a shift mechanism in the connection between the activating mechanism and the supplementary auxiliary valve so that a discontinuance activation will shift the supplementary auxiliary valve from whatever limiting position it happens to be in into the opposite limiting position.
It is of course also possible to basically open the supplementary auxiliary valve only briefly as the result of discontinuance activation and to simultaneously extensively restrict the flow through the auxiliary valve with a plug that maintains itself in position until the main-valve body finally closes. This conformation makes it possible to carry out both release activation and discontinuance activation with the same pressure stroke. This not only makes the device easier to operate but also makes it possible to adapt the mechanisms that have long been conventional and that generally operate only in one direction, for the purposes of remote activation.
In one embodiment of the invention the shift mechanism is a binary reduction mechanism with a control arm that determines the direction in which it moves by whatever limiting position it happens to be in, that is mounted in such a way as to rotate on a pivot that can be moved by the activating mechanism, and that has lever arms flexibly mounted on each end and another lever arm flexibly mounted in the middle, with limiting pins on the free end of each lever arm with which are associated fixed catches with an access flank by means of which they can be temporarily secured in position during the relative motion initiated by the pivot and accompanied by temporary flexible deformation of the associated levers. This type of binary reduction mechanism allows comparatively short activating strokes and, even in its unactivated position, can be shifted with especially low forces out of its limiting position. This design for a binary reduction mechanism is considered inventive in itself.
Some embodiments of the invention will now be described by way of example with reference to the drawings, in which
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic section through a discharge valve in the initial position according to the invention,
FIG. 2 illustrates the valve in FIG. 1 during the flushing process,
FIGS. 3 and 4 are schematic drawings of various operating phases of a binary reduction mechanism according to the invention,
FIG. 5 is a schematic section through another embodiment of a discharge valve in the initial position, and
FIG. 6 illustrates the value in FIG. 5 during the flushing process.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate a discharge valve with a activating rod 1 projecting out of the top of the tank. Activating rod 1 is rigidly connected to a valve bell 2 that is supported on the floor of the tank by prestressed lateral springs 3. There is a main-valve body 4 inside valve bell 2 that can be lifted upwards and that blocks both the main valve at the bottom and auxiliary valve 8 in the middle when the tank is full and ready to flush (FIG. 1). The top of main-valve body 4 demarcates in conjunction with valve bell 2 a discharge compartment 6. Auxiliary valve 8, which blocks the water channel between discharge compartment 6 and tank outlet 5, consists of a gasket 8a positioned in main-valve body 4 and of a flange 8b at the bottom of activating rod 1.
A supplementary auxiliary valve 9, consisting of a sealing float 11 that operates in conjunction with a perforation 9b through the wall 9a, is positioned in the upper wall 9a of discharge compartment 6. The free cross-section of supplementary auxiliary valve 9 is larger than that of auxiliary valve 8. Sealing float 11 is positioned on the left arm of a control lever 10 that has a pivot 15 that is rigidly connected to valve bell 2. On the right arm of lever 10 is a tappet 12 that penetrates into discharge compartment 6, and in the middle of the lever a control arm 13.
Control arm 13, which moves in relation to a fixed control housing 14 every time the device is activated, constitutes in conjunction with that housing, a shift mechanism that can consist of a binary reduction mechanism like that to be described subsequently. The shift mechanism shifts control lever 10 out of whatever limiting position it happens to be in and into the opposite limiting position whenever the device is activated. Since control housing 14 does not impede control arm 13 in the unactivated state, control lever 10 will either remain in the limiting position it arrives at subsequent to activation of the device or will shift into the opposite limiting position depending on the direction in which forces are applied to it.
FIG. 1 illustrates the initial position of the discharge valve with the tank full and ready to flush. The main valve and the auxiliary valve 8 are closed. Since activating rod 1 is raised, supplementary auxiliary valve 9 is open and control arm 13 has assumed its right-hand limiting position. When the device is release-activated, control arm 13 will move in relation to control housing 14, which will shift it into its left-hand limiting position. Supplementary auxiliary valve 9 will close and, since auxiliary valve 8 will open simultaneously, the water balance in the discharge compartment will become negative. Main-valve body 4 will be lifted off of its seat and the flushing process will commence. These motions are indicated in FIG. 1 by the arrows.
Sealing float 11 can also be moved without compulsory control into its closure position by shift mechanism including elements 13 and 14. It must accordingly be designed so that it can be carried along in spite of its operating force by the flow imposed by auxiliary valve 8, which is also necessarily applied at supplementary auxiliary valve 9. This process will subsequently be described in greater detail.
FIG. 2 illustrates the same discharge valve subsequent to release activation and during the flushing process. Since the pressure difference acting on supplementary auxiliary valve 9 in the closure direction is maintained, sealing float 11 will remain closed in spite of its operating force. If no discontinuance activation occurs, main-valve body 4 will not close until the tank is empty. Water will then flow in through the supply valve and the level build up again. When the water level rises above sealing float 11, the latter's operating force will restore control lever 10 to the initial position illustrated in FIG. 1 and the tank will be ready to flush again.
With the state illustrated in FIG. 2 as a point of departure, discontinuance activation will again initiate the relative motion between control housing 14 and control arm 13. The latter will accordingly shift back into its right-hand limiting position. Supplementary auxiliary valve 9 will open and tappet 12 will simultaneously force main-valve body 4 downward. This is theoretically unnecessary, serving only to reinforce the closure motion, and can be restricted with no problem to the initial stretch of the closure stroke. Nevertheless, it does ensure that main-valve body 4 will enter the wake of the flushing water as it discharges and that its flotation force will be overcome more reliably by the downward-acting flow forces.
What is decisive for the prior closure of main-valve body 4 is the opening of supplementary auxiliary valve 9. Since the latter's free cross-section is larger than that of auxiliary valve 8, which is still open at this juncture, the necessary positive water balance will occur in discharge compartment 6. This balance will itself be maintained if auxiliary valve 8 and supplementary auxiliary valve 9 close simultaneously with the return stroke of activating rod 1. This is ensured not only by the larger cross-section of supplementary auxiliary valve 9 but also by the admittedly very slight but always present free cross-sections made available by the play space left between main-valve body 4 and valve bell 2. When the return stroke of activating rod 1 is complete, main-valve body 4 will finally close.
It is, however, also possible to do without the perforation 9b through the wall 9a of supplementary auxiliary valve 9, without, that is to say, its free cross-section. In this case, tappet 12, which can be moved into discharge compartment 6 by discontinuance activation, must make main-valve body 4 travel over its complete stroke. A more powerful tappet force will then be necessary because of the lack of hydraulic reinforcement to overcome the lift of main-valve body 4. It is also preferable to adopt shift mechanism including elements 13 and 14 to this design if the pivot 15 that supports control arm 13 is mounted rigidly and control housing 14 in such a way as to move when the device is activated.
Shift mechanism including elements 13 and 14 can be a special binary reduction mechanism for example, which will require a comparatively shorter activating stroke and will exert no forces on control lever 10 in the unactivated state. This mechanism will now be described with reference to FIGS. 3 and 4.
In FIG. 3, the right-hand limiting position of symmetrically designed control arm 13' (which corresponds to the schematically represented arm 13 in FIGS. 1 & 2) is represented with the continuous lines. Its pivot 15' moves relative to the also symmetrical rigid control contours (which correspond to control housing 14 in FIGS. 1 & 2). Lever arms 17, one of which supports right-hand limiting pin 19 and the other left-hand limiting pin 20 at the top, are attached at the ends of control arm 13' at flexible joints 16. The limiting pins operate in conjunction with stationary catches 21 and their access flanks 22. At the upper end of intermediate arm 23 is a limiting pin 24 that operates in conjunction with stationary catches 25 and their access flanks 26. Since the arms with the limiting pins are elastic perpendicular to the plane of projection, the access flanks do not impede them.
When pivot 15' moves down in the direction indicated by the arrow in response to activation of the device, control arm 13' will pivot on its right-hand flexible joint because upward motion will be impeded at that point by the engagement of limiting pin 19 behind catch 21. On the way to the limiting position represented by the broken lines in FIG. 3, the limiting pin 24 on intermediate arm 23 will travel over the access flank 26 of limiting pin 24 and come to rest behind it.
This limiting position is also the initial position for the subsequent return activation stroke and hence for pivot 15' represented by the continuous lines in FIG. 4. Limiting pin 24 will slip up behind catch 25 and lock control arm 13' into the left-hand limiting position. The right-hand limiting pin 19 will be released from catch 21 and spring back into its original position relative to control arm 13'. During the final phase of the return stroke, left-hand 20 will travel over access flank 22, the upper right limiting edge of which will take over the locking of the pivoting position before limiting pin 24 leaves catch 25. The return-stroke limiting position is illustrated in FIG. 4, the left limiting pin resting behind catch 21.
Because of the symmetrical design of the binary reduction mechanism just described, another double stroke will initiate the opposite motion, returning control arm 13' to its original initial position.
The limiting pins will not be impeded by the stationary control contours when the binary reduction mechanism is not activated. Control arm 13' can therefore be pivoted back into its original initial position without reinstating the double stroke by externally applied forces that only have to be powerful enough to overcome the bearing friction of pivot 15' as indicated by the blank arrows in FIG. 4.
The binary reduction mechanism can be re-designed for the present purpose in such a way that control arm 13' is pivoted into its opposite limiting position only by hydraulic forces when the device is release-activated. These hydraulic forces are effective to the extent that the flow initiated by the auxiliary valve when the device is release-activated is also necessarily applied at the supplementary auxiliary valve and moves the sealing float in the closure direction. In order to reinforce this closure motion, which must occur against the operating force of sealing float 11, a stationary catch 18 can be positioned as represented by the dotted line in FIG. 3. It will act on limiting pin 20 and introduce a leftwards pivot on the part of control arm 13'. A simplified shift mechanism of this type can accordingly, in comparison with the complete version of the binary reduction mechanism, do without the right-hand and intermediate control arms as well as the stationary control contours that operate in conjunction with them.
In the embodiment of a discharge valve in accordance with the invention and illustrated in FIGS. 5 and 6, the discontinuance of the flushing process and the reinstatement of the readiness to flush is, although the design is comparable, achieved in a basically different way, with a shift mechanism in particular.
In this embodiment valve bell 2 and activating rod 1 are separate. They are, however, forced together by a compression spring 27 with prestressing that is more powerful than that of prestressed lateral springs 3. The supplementary auxiliary valve 9' leading into discharge compartment 6 consists of a flange 28 on activating rod 1 and of an annular shelf 28a inside valve bell 2 that operates in conjunction with the flange. An auxiliary float 29 is also positioned in the vicinity of discharge compartment 6 on activating rod 1. The outside diameter of the bottom of auxiliary float 29 is slightly longer than that of the interior shelf 30 in the central bore of main-valve body 4.
The device is conventionally release activated. When, during release activation, only the restoration force of lateral springs 3 is overcome and not spring 27, supplementary auxiliary valve 9' will remain closed. The open auxiliary valve provides a negative water balance in discharge compartment 6, and main-valve body 4 opens. These motions are indicated by the arrows in FIG. 5.
FIG. 6 illustrates discontinuance activation, during which the restoration force of spring 27 is used to open supplementary auxiliary valve 9'. The water balance in discharge compartment 6 becomes positive and, in conjunction with the flow forces, which are reinforced in the closure direction, moves main-valve body 4 downward. Main-valve body 4 is followed by auxiliary float 29, which is pressed by hydraulic forces against the annular shelf 30 inside float piston 4, and thus blocks flow through the still open auxiliary valve 8. Thus, the positive water balance will be maintained until final closure of the discharge valve even when supplementary auxiliary valve 9' closes before auxiliary valve 8 during the return stroke of discontinuance activation. This is ensured again by the additional flow cross-sections between the outside diameter of main-valve body 4 and the interior surface of valve bell 2. These cross-sections are definitely larger than the comparatively narrow play space between auxiliary float 29 and activating rod 1.
With the final closure of the discharge valve, auxiliary valve 8 will also be closed. Auxiliary float 29 will, because of its lift, move up because the pressure drop initially affecting it can be compensated through its intermediate play space. The tank will accordingly be ready for the next release activation.
It will of course be evident that the embodiments described herein as examples of the invention represent only a fraction of its potential applications. | A toilet-tank discharge valve has a main-valve body that can be lifted off of its face, by release-activating an auxiliary valve with an activating mechanism, as a consequence of negative water balance in an associated discharge compartment. A supplementary auxiliary valve is associated with the discharge compartment and opens at least briefly as a result of discontinuance activation of the activating mechanism, producing a positive water balance in the discharge compartment until the main-valve body closes. A valve of this type, with an auxiliary valve, makes it possible to discontinue the flushing process ahead of time. A shift mechanism in the connection between the activating mechanism and the supplementary auxiliary valve shifts the supplementary auxiliary valve from whatever limiting position it happens to be in into the opposite limiting position in response to a discontinuance activation. This makes it possible for both release and discontinuation activation to be initiated with uniform pressure strokes. This not only makes the device easier to operate but also makes remote activation possible with simple devices. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device for effecting translational movement of a machine comprising two anchoring elements on which the machine is supported, sometimes on one and sometimes on the other, the machine hauling itself by means of hauling jacks respectively connected to the anchoring elements.
2. Description of the Prior Art
French Pat. No. 1,548,671 describes a device for the translational movement of a mining machine which is hauled by means of two associated jacks on a gripping arrangement having two positions, one of which is a clamping position and the other a sliding position, these two positions being combined with the movements of extension and retraction of the jacks.
In this arrangement the jacks are connected both by their rods and by pipes.
This construction introduces a certain rigidity into the machine.
A main object of the invention is to permit a more flexible construction by eliminating any mechanical connection of the hauling jacks. For this purpose it might be conceivable to retain only the hydraulic connection. However damping effects are evident so that hunting occurs which is detrimental to the correct operation of the arrangement.
A further object of the invention is to eliminate these disadvantages and to permit the construction of a machine in which the jacks can be conveniently accommodated without being governed by their relative spacial dispositions.
Yet another object is to reduce as far as possible the hydraulic connections by flexible pipes, whose disadvantages are well known for machines which have to operate under very severe conditions and are subject to shocks and rock fall, as is the case with mining machines.
SUMMARY
A device for effecting translational movement of a machine includes two anchoring elements operated one at a time, usually alternately; which elements support the machine and are respectively connected to hauling jacks which have cylinders which are interconnected by a hydraulic connection and which have the same effective volume. The hydraulic connection is estabished through a free-piston hydraulic jack which has at least the same effective volume as the interconnected cylinders.
BRIEF DESCRIPTION OF THE DRAWING
An embodiment of the invention will now be described with reference to the accompanying drawing which illustrates a device according to the invention for the translational movement of an ore extraction machine along the ramp of an armoured conveyor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The machine illustrated has two gripping anchoring elements 1 and 2 comprising clamping jaws which engage a ramp 4 and which are hydraulically operated by jacks 5, as illustrated in FIGS. 19, 20 and 21 of French Pat. No. 1,548,671. These clamping elements will hereinafter be referred to as "gripper hands". Each gripper hand consists of a set of single-action jacks 5 and a hook 3 which surrounds the fixed ramp 4. When the jacks 5 are under pressure the gripper hand is clamped to the ramp, thus providing a fixed point. When the jacks 5 are not under pressure the gripper hand can slide on the ramp 4.
In order to haul the machine, two double-action jacks 11 and 21 are provided, which are identical and have pistons 15 and 25 connected by operating rods 13 and 23 to the gripper hands 1 and 2. The hauling jacks 11 and 21 are connected in series by hydraulic connection of cylinders 12 and 22 of small section, that is to say on the sides of the pistons 15 and 25 where the rods 13 and 23 are attached. The hydraulic connection includes a pipe 31.
In the pipe 31 there is connected an intermediate jack 32 having a free piston 33. In each of its end positions the free piston 33 defines in the cylinder of the jack 32 an effective volume which is at least equal to the effective volume of each of the cylinders 12 and 22 of the hauling jacks 11 and 21. The free piston 33 of the intermediate jack 32 is traversed axially by a central sliding rod 34 which acts as an end-of-stroke detector and which carries two stops 35 and 36 near and at a short distance from its ends. This central rod 34 controls an operating distributor 17 by thrust or by a return spring 38. When the larger face of the hauling jack 11 is loaded, oil contained in the cylinder 12 pushes the free piston 33 from left to right in the drawing. In the other chamber of the intermediate jack 32 the oil in turn pushes the piston of the hauling jack 21 in the opposite direction to that of the hauling jack 11. The sliding rod 34 is locked in its end positions by a branch 42 of an operating circuit 41 controlled by the operating distributor 17, which is an inversion distributor. The self-locking abutment force is smaller than the force acting on the free piston 33.
Valves 14 and 24 are located in the pistons 15 and 25 of the hauling jacks 11 and 21, which valves are opened by stops 16 and 26 at the end of the stroke on the side connected to the intermediate jack 32. The valves are also opened at the opposite end of the stroke through their non-return valve effect, thus effecting the additional filling of the useful volume developed by the corresponding hauling jack, so as to make up for variations in volume of hydraulic fluid on each side of jack pistons, thus avoiding the phenomenon of hunting.
When the free piston 33 of the intermediate jack 32 bears against the stop 35 or 36 of the sliding rod 34, the latter reverses the operating distributor 17 which, by means of the operating circuit 41, reverses the oil pressure distributor 42 supplying the hauling jacks 11 and 21.
Th clamping and unclamping of the gripper hands are controlled by hydraulic circuits 51 and 52 which are fed by a pressure line 50 and operated by a distributor 53 which is supplied by a branch 43 of the operating circuit 41. This branch 43 is controlled by a manual reversing selector 54. In order to avoid flexible connections, which are always vulnerable, it is advantageous that the pipes connecting the operating circuits 51 and 52 of the gripper hands 1 and 2 pass axially through the body and operation rod of each of the hauling jacks 11 and 21.
A hauling machine has the two hauling jacks 11 and 21 fixed on its body, with the operating rods connecting the machine to the gripper hands 1 and 2. The arrangement described so far operates in such a way that when one of the hauling jacks is extended the other is retracted, and vice versa. In order to operate the hauling jacks to achieve translational movement of the machine, the jacks are mounted on the machine with the two operating rods directed in the same direction.
The operation of this arrangement will now be described. It is assumed that in a first stage, as a result of control pressure supplied from a circuit 45, the distributor 17 feeds the distributor 42 in the direction applying pressure to the hauling jack 11, and the distributor 53 is supplied in the direction effecting the clamping of the gripper hand 1. The machine is then moved away from the clamped gripper hand 1, while the unclamped gripper hand 2 slides towards the hauling jack 21. When the free piston 33 reaches the stop 36 of the sliding rod 34, its force overcomes the locking force of the rod, the rod 34 then operates the inversion distributor 17, which reverses the supply to the hauling jacks 11 and 21 simultaneously, that is to say then the hauling jack 21 is supplied. Supplies to the gripper hands are also reversed so that the gripper hand 2 is clamped and the hauling jack 21 then hauls itself forwardly, while the gripper hand 1 is unclamped and slides on the ramp. At the same time the circuit 42 again locks the sliding rod 34. It will be seen that as the hauling jacks 11 and 21 are directed in the same direction, as stated, the machine is hauled by alternating extensions in relation to each alternately clamped gripper hand until, on each operation the maximum extension of the active hauling jack is reached. If the manual selector 54 is operated, there is reversal of the clamping and unclamping of the gripper hands in relation to the action of the hauling jacks 11 and 21, and the machine will then be hauled by alternating retractions of the jacks in relation to the clamped gripper hand, which again leads to almost continuous movement of the machine, but in the opposite direction.
The invention has been described in connection with an embodiment relating to a mining machine which has to be hauled along a conveyor, such as an armoured conveyor. It can be applied to other types of self-propelled machines, for example machines which are to be clamped between the walls of a mine working, such as wedge type extraction machines provided with clamping means in the walls. | A hauling device, for example for a mining machine, has two clamping elements which grip on ramps each of which elements is attached to an operating rod of a hauling jack. The jacks are operated alternately, in conjunction with the clamping elements to advance or retract the machine, and the hauling jacks are hydraulically interconnected in a manner to avoid hunting. |
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This application is a continuation application of U.S. patent application Ser. No. 12/452,466, filed May 20, 2010, which is a national stage of PCT/N2008/000158 filed Jul. 3, 2008, and published in English, which has a priority of New Zealand No. 556329 filed Jul. 3, 2007, and New Zealand No. 565118 filed Jan. 15, 2008, hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a panel mount for mounting a panel such as a glass pane.
BACKGROUND
Glass panes are used in buildings for many purposes. Glass panes can offer partitions within offices, showers, as a guard rail around an edge with a drop off, as fencing for a pool and the like.
Such glass panes are normally of a reinforced glass that has substantial impact or break resistance. Post production workability of such glass can be difficult.
Mounting of such glass panes can be cumbersome. The glass panes are heavy. They are inflexible. They can be difficult and time consuming to drill.
Means for mounting glass panes are known. By way of example U.S. Pat. No. 6,434,905, U.S. Pat. No. 4,837,993 illustrate ways in which a glass pane may be mounted. However these means for mounting do not readily lend themselves to the mounting of glass panes that may not necessarily align with the slot that is provided for receiving the glass pane. Alignment of the slot with the glass pane and/or vice versa can be a time consuming exercise. Particularly where for example such glass panes are mounted from a fixed structure of a building to which the brackets themselves need to be secured. The brackets themselves, secured to a fixed structure may not present the slot in the desired orientation to receive and hold the glass pane in its desired position.
WO03/091516 illustrates a device for supporting a glass pane. Such a device may be used in combination with other like devices that are for example mounted in concrete or to concrete to support the glass pane along its edge. Where multiple devices are used, alignment of each device with the glass pane as well as with each other becomes important. Use of the invention of WO03/091516 requires the glass to be drilled. This means that both slot alignment between multiple devices and spacing between devices is necessary to secure a glass pane.
Accordingly it is an object of present invention to provide a panel mount to provide improvements to known means for mounting a panel and/or that has the capacity to accommodate with slight misalignment relative to the desired position of glass to be held and/or that will at least provide the public with a useful choice.
BRIEF DESCRIPTION OF THE INVENTION
In a first aspect the present invention consists in a panel mount for non penetrative fastening of a panel (such as a glass pane), said panel mount comprising:
clamp jaws defining an elongate slot in which an edge of a panel can be received,
a foot for mounting and fastening said clamp jaws to a structure,
at least one of said clamp jaws holding at least two spaced apart threaded fasteners that can be actuated by a user,
at least one clamp member located intermediate of said threaded fasteners and one side of said panel (when received in said slot),
at least one base member of a configuration to be contiguous an edge of the panel when located in said slot, to operatively act as a partial extension of the panel and positioned such that at least one of said threaded fasteners can act thereon (directly or indirectly),
the threaded fasteners, in cooperation with the clamp jaws, capable of operatively clamping said panel to hold it in said slot.
Preferably the base member is of the same width (being in a direction in which the same as force of clamping acts) as the thickness of the panel.
Preferably the foot and the clamp jaws are integrally formed.
Preferably the foot is engaged to the clamping jaws.
In a second aspect the present invention consists in a panel mount for non penetrative fastening of a panel (such as a glass pane), said panel mount comprising.
a housing that includes a slot to receive the edge of a panel, the housing defining a cavity that include at least one opening on at least one side of the slot and at the base of the slot,
a base member positioned in a location to act as an extension of and to be contiguous with the panel at an edge of the panel within said cavity,
an elongate clamp member located in said cavity in a manner to allow it to move in a direction normal to the panel and, via said at least one opening, can effect a clamping force onto the panel in conjunction with resistance to movement of the panel offered by the housing from the other side of the slot,
the clamping force being effected by at least two fasteners carried by the housing, a first fastener that acts to apply a force in a direction normal to the panel onto the elongate clamp member and a second fastener that acts to apply a force in a direction normal to the panel and onto the base member.
Preferably there are two clamp members that each extend on a separate side of the panel (when located in the slot) and that each extend on a separate side of the base member.
Preferably there are two pairs of fasteners each having one fastener on each side of the panel and each fastener of a said pair located to act in opposite directions.
Preferably the panel is retained between the two clamp members upon a tightening of the fasteners.
Preferably a first of the pair of fasteners is located to apply a force acting through the base member.
Preferably a second of the pair of fasteners is located to apply a force acting through the panel and adjacent the edge of the panel when located in the slot.
Preferably a second of the pair of fasteners is located to apply a force onto said clamp members and acting through and normal to the panel and adjacent the edge of the panel when located in the slot.
Preferably a third pair of fasteners is provided that is located to act on the clamp members at a location proximate to the mouth of the slot.
Preferably the cavity includes an opening at the base of the housing to allow the at least one clamp member and base member to be inserted in to the housing.
Preferably said at least one opening of the cavity is an elongate slot.
Preferably said at least one opening of the cavity is at least one hole.
Preferably there is one of said at least one openings for each of the clamping members.
Preferably the base member is substantially of the same thickness as the panel.
Preferably a packer is located between each clamp member and the panel.
Preferably the packer is also located between each clamp member and the base member.
Preferably the fasteners are threaded fasteners.
Preferably the housing includes apertures to receive the fasteners the apertures including an opening to the cavity to allow the fasteners to act (directly or indirectly) onto a respective the clamp member and said base member.
Preferably the slot is a U-shaped slot.
In a further aspect the present invention consists in a panel mount for non penetrative fastening of a panel (such as a glass pane), said panel mount comprising.
a housing that includes a slot to receive the edge of a panel, the housing also including at least one cavity defining an elongate opening to and on each side of the slot,
for each side of the panel, an elongate clamp member located at least in part within said cavity in a manner to allow it to operatively move in a direction parallel to the normal to the panel to effect a clamping force in conjunction with resistance to movement of the panel offered from the other side of the slot by the other elongate clamp member onto the panel
a base member located between the two clamp members and adjacent an edge of the panel and of a configuration to allow the clamp members to also effect a clamping force onto the base member,
the clamping force being effected by at least two pairs of fasteners carried by the housing, each fastener of a pair to apply a clamping force in opposite directions, the first of a pair of fasteners acting to apply a clamping force passing through the base member and a second of a pair of fasteners to apply a clamping force passing through the panel adjacent an edge of the panel when located within the slot.
In still a further aspect the present invention consists in a panel mount for non penetrative fastening of a panel (such as a glass pane), said panel mount comprising:
clamp jaws defining an elongate slot in which an edge of a panel can be received, a foot for mounting and fastening said clamp jaws to a structure, at least one of said clamp jaws carrying at least one threaded fastener that can be actuated by a user, including when said foot is fastened to said structure, the threaded fastener(s) of said at least one clamp jaw, in cooperation with the other clamping jaw, capable of operatively clamping said panel to hold it in said slot, irrespective of any non-parallel disposition of the plane of said panel to the elongate direction of said slot.
Preferably each clamp jaw carries at least one threaded fastener that can be actuated by a user, including when said foot is fastened to said structure, the threaded fastener(s) of each clamping jaw, in cooperation with the or each other threaded fastener, capable of operatively clamping said panel to hold it in said slot, irrespective of any non-parallel disposition of the plane of said panel to the elongate direction of said slot.
Preferably said foot includes a means to fasten, to fasten to or with said structure.
Preferably there is at least one pair of clamp jaws.
Preferably each clamp jaw defines an elongate rectilinear slot.
Preferably a mouth opening is defined by the distal ends of each slot and through which part of said panel can enter said slot.
Preferably said clamp jaws are, at their proximal end, engaged to said foot.
Preferably said foot is a foot plate positioned so that the elongate slot extends in a direction normal to the plane of said foot plate.
Preferably said threaded fasteners are engaged to said clamp jaws to move in a direction lateral to the elongate direction of said slot (and preferably normal to the plane of the panel).
Preferably said threaded fasteners can extend into said slot.
Preferably an intermediate member is located between a or all said threaded fasteners and, when in situ, said panel.
Preferably said intermediate member is a protective member that prevents direct contact of said threaded fasteners with said panel.
Preferably said intermediate member is a planar member or elongate member that extends parallel to the elongate direction of the slot.
Preferably a said intermediate member is located at each side of said slot, each intermediate member to be reacted on by a or the threaded fasteners held by one of the clamp jaws.
Preferably each said intermediate member extends from said distal end of each said clamp jaw to or towards the opposite end of said slot.
Preferably each said threaded fastener is located in a threaded hole passing through a respective clamp jaw.
Preferably the slot defined by said clamp jaws terminates short of the foot at a slot base.
Preferably said base is able to engage with an edge of said panel.
Preferably said threaded fasteners can be actuated by a user when the panel mount is fastened to the fixed structure.
Preferably the panel mount is one that is used as part of a glass pane incorporating balustrade system.
Preferably the panel mount is one that is used as part of a glass pane defined wall.
Preferably said slots are open sided.
In a further aspect the present invention consists in a method of mounting a panel (such as a glass pane) relative a fixed structure, comprising:
securing, in a spaced apart configuration to a fixed structure, at least two panel mounts as claimed in any one of the preceding claims in a condition wherein their slots are substantially in alignment,
inserting a panel into the slot of each panel mount,
holding the panel in the desired position,
adjusting the threaded fasteners to clamp said panel in place in said desired position.
In a further aspect the present invention consists in a panel defined wall, partition or fence or panel including balustrade system wherein a panel is edge supported by at least one panel mount as herein before described.
In still a further aspect the present invention consists in a panel mount as herein described with reference to any one of the drawings.
Preferably the means to fasten is an aperture passing through said foot to allow a fastener to pass there through and secure said panel mount to said structure.
Preferably the means to fasten is a fastener that projects in a direction away from said elongate body to pass into an aperture of said structure and secure said panel mount to said structure.
Preferably the structure is a floor, beam, bearer or pad.
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements and features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
As used herein the term “and/or” means “and” or “or”, or both.
As used herein “(s)” following a noun means the plural and/or singular forms of the noun.
The term “comprising” as used in this specification means “consisting at least in part of”. When interpreting statements in this specification which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as “comprise” and “comprised” are to be interpreted in the same manner.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred form of the present invention will now be described with reference to the figures in which:
FIG. 1 illustrates a panel mount,
FIG. 2 illustrates a front view of the panel mount that also includes the shroud,
FIG. 3 is a front view of the clamping jaws,
FIG. 4 is a front view of the shroud,
FIG. 5 is a plan view of the foot,
FIG. 6 is a front view of the packing,
FIG. 7 is a side view of FIG. 4 ,
FIG. 8 is a front view of part of a panel mount illustrating a panel in situe,
FIG. 9 is a front view of a pane supported by a plurality of panel mounts,
FIG. 10 shows a variation of the foot shape of the mount,
FIG. 11 shows a cross-sectional view of the panel mount with the housing and the clamping members,
FIG. 12 shows a front view of the panel mount illustrating the movement of the clamping members into the opening of the housing,
FIG. 13 illustrates the panel mount of the present invention,
FIG. 14 illustrates the clamping members and the base members,
FIG. 15 shows the front view of the panel mount together with the bracket,
FIG. 16 illustrates the bracket mounted on a fixed structure and FIGS. 17 a - d show other variations.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 there is shown a first version of a panel mount 1 . It is shown partially exploded, and absent of a shroud that may be used. With reference to FIG. 2 the preferred shroud 2 is shown.
With reference to FIG. 1 , the panel mount 1 includes clamping jaws 3 , 4 . The clamping jaws define a slot 6 therebetween. The slot 6 is an elongate slot that in the preferred mode of use extends vertically. The slot, at the distal ends 8 , 9 of the clamp jaws 3 , 4 presents a mouth opening 10 into and through which an edge of a glass pane can be received.
Whilst in this form the panel mount as herein described is designed for use with a glass pane, it will be appreciated by a person skilled in the art that other forms of building panels may be used in combination with panel mounts of the present invention. The present invention lends itself particularly suitable for use with a glass pane since the invention does not require for holes to be drilled through the glass pane for the purposes of mounting of the glass pane by the panel mount.
The slot receives the glass pane by passing the pane through the mouth 10 . However the slot also includes side openings to allow sliding location of the glass pane therethrough. The slot from its mouth 10 to its base 11 is preferably of a length that stops short from the foot 12 .
The foot 12 can mount the panel mount to a fixed structure. The clamp jaws 3 , 4 are preferably directly engaged and supported by the foot 12 . The panel mount may be made as a unitary member or alternatively may be fabricated from several members. Where it is fabricated, the jaws 3 , 4 may for example be welded to the foot 12 .
The clamp jaws 3 , 4 are preferably of a unitary body as for example shown with reference to FIG. 3 . The unitary body 13 includes a base portion at where the clamp jaws 3 , 4 are affixed to or from which the foot 12 extends. As can be seen the base 11 of the slot does not extend to the proximal end 14 at where the foot 12 is fixed. The distance D defines the separation of the bottom edge of a glass pane, to the floor where for example the foot 12 is to be mounted.
The foot 12 includes means 16 , for fastening the foot to a fixed structure of a building. The means 16 in the preferred form are apertures through which a penetrative fastener can extend for securing the foot to the fixed structure. Such penetrative fasteners may be screws, dyna bolts, or other, selected for suitable use with the materials of the fixed structure to which the panel mount is to be mounted.
Alternative means to fasten the foot 12 to the fixed structure may be provided. The foot 12 may include rods to be cast into a suitable material such as concrete or resin. The foot may be a stud or footing as shown in FIG. 10 to be set into concrete or resin.
One and preferably each of the clamp jaws 3 , 4 includes at least one aperture 20 to receive a threaded fastener 21 . As can be seen in FIG. 1 , each clamp jaw includes 2 apertures to each receive a threaded fastener. In the preferred form apertures are provided for each clamp jaw 3 , 4 . The threaded fasteners may be otherwise disposed to, or from the jaws.
Each threaded fastener can be actuated by a user by for example using a tool such as a screw driver or allen key. In the most preferred form the threaded fasteners are grub screws. The fasteners may extend into the slot to operatively engage with a pane that is received in the slot. Alternatively the threaded fasteners may actuate an intermediate member that engages directly against the pane. However it may be that the threaded fasteners may make direct contact with the pane, or each may have a shoe to contact the panel.
In FIG. 1 , intermediate members 30 are shown. The intermediate members 30 are for example packers or spacers that are positioned intermediate of a pane in the slot and each of the threaded fasteners. They may be strips of a material such as a metal or plastic that is provided at each of the sides of the slot as shown in FIG. 1 . They may be flexible so as to deflect when the threaded fasteners are moved to engage thereon. The packers may be of a material (or include a material) that has a high coefficient of friction with the material of the panel.
With reference to FIG. 8 , there is illustrated part of the panel mount of the present invention. The width “W” of the slot is greater than the thickness “T” of the pane 33 . The width “W” is sufficient to allow for at least some misalignment of the pane 33 to occur with the elongated direction of the slot 6 . When affixed to a fixed structure the slot may not be presented in a position that perfectly aligns with the position that the pane 33 is desired to be in. Misalignment can be accommodated by the slot 6 due to the size of the slot being larger than the thickness of the pane. With the use of the threaded fasteners the pane, despite not being perfectly aligned within the slot, can still be clamped through the cooperation of the threaded fasteners with each other.
In use, the panel mount is firstly mounted to a fixed structure in a position that is, as best as possible, provided to present the slot in alignment with the desired position of the pane 33 . A pane is then inserted into the slot 6 and held in its desired position. A person can then actuate the threaded fasteners 21 so as to clamp the pane 33 and hold it in the slot.
Once the pane is secured, a shroud 2 may be positioned over the clamp jaws 3 , 4 so as to obscure these from sight. The shroud 2 preferably also includes a slot that may be of a size smaller than the slot 6 . The slot of the shroud 2 may be of a width “W-2” that is smaller than the width “W” of the slot 6 . The slot of the shroud may be of a flexible nature so that it can be at least to some extent compliant to a misaligned positioning of the panel 33 in the slot 6 . The shroud 2 may also cover the foot or part of the foot 12 .
The shroud may include apertures therethrough to allow for a tool to reach the threaded fasteners that are carried by the clamp jaws 3 , 4 . The shroud may be permanently affixed to the clamping jaws and/or the foot. The construction can improve the strength of the mount.
Alternatively the shroud may not include such apertures.
With reference to FIG. 9 there is shown a pane 33 supported by 3 panel mounts relative to a fixed structure 36 .
The mount can more conveniently receive and secure panels and can also allow for subsequent adjustment to occur without needing to remove the mount from the structure. It also does not require the panel to be machined, such as by drilling, to become secured.
FIGS. 11-14 show another form of a panel mount. The panel mount comprises a housing 50 which is or can be affixed to a fixed structure such as a deck in similar(s) as described above.
The housing 50 is preferably of a unitary construction and includes a slot 71 between two clamp jaws 100 and 101 , to receive a pane 33 . When a pane 33 is inserted into the slot 71 , the edge of the pane may rest on the base of the slot 70 . As shown in FIG. 11 , the slot may not extend to the base end of the housing. The housing 50 includes a cavity 65 extending from the underside of the housing 50 to or towards the top of the housing 50 . The cavity is of a shape to receive intermediate members 30 . The housing is preferably made of stainless steel. Alternatively, other metals with similar mechanical properties may be used.
The intermediate members preferably comprise two side clamp members 60 , 61 and a base member 62 in between the side clamp members 60 , 61 . The height of the base member 62 may be smaller than the clamp members 60 , 61 . When inserted in the cavity 65 of the housing, it may be contiguous the underside of the base of the slot 70 of the housing. The thickness of the base member “X” is preferably equal to the thickness of the pane “T”. This is to ensure that the side clamp members 60 , 61 will provide an even distribution of clamping force on the pane 33 prior to being set. The side clamp members can move laterally relative the pane 33 within the cavity 65 .
The width “W” of the slot of the housing is preferably greater than the thickness “X” of the base member to accommodate panes of various thickness.
The side clamp members 60 , 61 are preferably equal in size and dimensions, although different dimensions may be used. The side clamp members 60 , 61 should preferably fit the cavity 65 with a sufficient allowance that enables the side clamp members 60 , 61 to move laterally in the direction towards and away from the pane 33 .
Since the side clamping members are separate members, this allows panes of various nominal thickness (but limited by the width “W” of the slot) to be accommodated by simply varying (for example by substitution) the thickness “X” of the base member without changing the dimensions of the side clamp members to, 61 .
The side clamp members 60 , 61 , and base member 62 are instrumental in providing the clamping forces on the pane.
The two side clamp members 60 , 61 , and base member 62 are preferably made of stainless steel. Alternatively, other types of metal for example aluminium or other materials providing a similar amount of strength may be used. They are substantially rigid.
The housing 50 includes apertures to receive threaded fasteners. Each of the apertures is threaded to receive a threaded fastener. The apertures extend substantially through the side walls (e.g. the clamp jaws 100 and 101 ) of the housing to the cavity of the housing. In the most preferred embodiment, the housing includes three pairs of apertures, each pair of aperture on the opposite sides of the housing. In the most preferred embodiment, one pair of apertures located to allow fasteners to act at the base member 62 , one pair just above and acting on the side clamp members 60 , 61 , and preferably one pair at or towards the upper end of the housing also acting on the side clamp member 60 , 61 . Each pair of apertures are preferably aligned to evenly distribute the clamping force provided by the threaded fasteners on the intermediate members. More than 3 pairs of apertures may be used to provide more rigidity.
The threaded fasteners are actuated by a user for example using a tool such as a screwdriver or allen key and provide the clamping force required to clamp the panel. The threaded fasteners are preferably grub screws, but other fastening devices may alternatively be employed.
As shown in FIG. 11 , packers 30 , are preferably interposed between the intermediate members 60 , 61 , 62 and the panel. The packers may be inserted between the opposite sides of the base member 62 adjacent to the side clamp members 60 , 61 . The packer 30 serves to adequately grip the panel 33 and provides protection for the hard or abrasive side clamp members. Preferably, packers may be made of cork-rubber composite, neoprene, synthetic based rubber of polypropylene. They may be made of material which has a high coefficient of friction with the material of the panel to adequately grip the panel. They are preferably elastic to accommodate any warping and uneven surfaces of the panel. Alternatively, no packer may be interposed.
The mechanics of clamping of the panel will now be explained. As shown in FIG. 11 , the slot of the housing 50 receives the panel by passing the pane through the mouth of the slot 71 to eventually rest on the upper side of the base of the slot 70 of the housing (or on the base member 62 ). The side clamp members 60 , 61 , and base member 62 , preferably inserted into the cavity 65 from the underside of the housing can be manually put and/or kept in place. The side clamp members 60 , 61 may abut against the top end of the cavity wall and the base member 62 may abut the underside of the base of the slot 70 of the housing.
Clamping forces on the panel are generated by the tightening of the threaded fasteners. The ends of the fasteners cause the side clamp members 60 , 61 to move laterally (as shown in the direction of the arrow in FIG. 11 ) in the direction of the panel thereby making direct or indirect contact with the panel. This is shown in FIG. 11 where the threaded fasteners are screwed in the direction of the arrow shown. The clamp members 60 , 61 also enable the panel to be easily aligned to a desired position by adjusting of the threaded fasteners. Alternatively, the side clamp members 60 , 61 can be moved comply with the position of the panel.
Preferably, the width “W” of the slot of the housing 50 is greater than the thickness “X” of the base member 62 (which corresponds to the thickness of the panel). This can then allow for misalignment of the panel with the elongated direction of the slot 70 of the housing to be accommodated. This also allows the panel to be adjusted or aligned to a desired position. It also allows panels of various nominal thickness to be used by simply changing the thickness of the base member 62 .
In a preferred form, the positioning of the apertures allows the lower two pairs of threaded fasteners, when tightened, to provide most of the clamping forces on the panel. This allows the upper pair of threaded fasteners to be tightened less than the lower two pairs of threaded fasteners or alternatively to be sufficiently tightened without the use of a tool. Since the upper pair of threaded fasteners provides less clamping forces on the panel, the lateral stresses on the panel near the mouth of the slot of the housing are reduced. Also, the lateral stress on the housing at its upper region is reduced meaning that less deformation of the housing will occur.
The panel mount may also be mounted on a bracket 80 . This is shown in FIGS. 15 and 16 . The housing 50 may be affixed to the bracket 80 by directly engaging the underside of the housing 50 with one end of bracket 80 . Conventional means for affixing the housing 50 to the bracket 80 may be used such as for example a threaded fastener. The bracket 80 may be mounted on a fixed structure 75 for example a deck.
The bracket 80 includes at least an opening 81 to receive at least one fastener 84 to enable the bracket 80 to be mounted to a fixed structure 75 . Preferably, the opening 81 is an elongate slot to receive fasteners to secure the bracket to the structure in a direction perpendicular to the panel. Alternatively, the opening 81 may be at least one aperture to receive a fastener FIGS. 17 a - d show other variations. | This invention is a panel mount for non penetrative fastening of a panel (such as a glass pane). The panel mount has clamp jaws defining an elongate slot in which an edge of a panel can be received. A foot is provided for mounting and fastening the clamp jaws to a structure. At least one of the clamp jaws carries at least one threaded fastener that can be actuated by a user, including when the foot is fastened to the structure. The threaded fastener(s) of the at least one clamp jaw, in cooperation with the other clamping jaw, is capable of operatively clamping the panel to hold it in the slot, irrespective of any non-parallel disposition of the plane of the panel to the elongate direction of the slot. |
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CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] This invention relates to doors for pets, for example a door to allow the pets egress from or entry into a dwelling.
[0007] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0008] Pet doors of various kinds for cats and dogs are widely available. The doors for cats are usually called “cat flaps”.
[0009] Pet doors are adapted to be fitted in a lower portion of a wall or of an existing full-sized door. The pet door may consist simply of a flap, often being transparent so that the animal can see where it is going, and being hung from a horizontal axis to swing against the force of gravity when pushed by an animal. Alternative structures are mounted to swing about a vertical axis, but since they do not have gravity to bring the door/flap back to a closed position, they require springs to bias the door/flap to its neutral closed position. Also available are flexible transparent flaps, where the top of the flexible flap is held in fixed position and the animal bends the flap to make an entry or exit.
[0010] A simple latch may be provided for holding the door/flap at its neutral closed position so as to prevent movement of the door/flap in either direction or in just one direction. In the latter case, the latch may be arranged so as to allow entry but not egress or alternatively to allow egress but not entry.
[0011] The problem with such simple constructions is that, depending upon the position of the latch, any animal of the size to fit through the opening may gain entry or egress. In order to prevent passage of unwanted stray animals, pet doors have been designed with magnetically operable latches. The latch, powered by battery, is operable only when a magnetic tag (or in other operations an electrical loop) is detected. In simple mechanisms, any magnetic tag of adequate field strength will unlock the latch.
[0012] More sophisticated constructions have been designed in an attempt to allow selective operation of a door by a selected animal with the appropriate tag.
[0013] Pets commonly carry a subdermal identification coded tag. GB2376977 of Duerden, suggests transmitting a radio frequency signal at intervals to cause a signal to be transmitted by the standard passive coded subdermal identification tag carried by an animal, detection by a pet door of the retransmitted signal being adapted to open a pet door latch if the identification tag matches a code in memory. It is doubtful whether the Patentee had given any serious thought as to how the system could be put into effect. This prior proposal gives no detail as to how to effectively couple a transmitter or receiver at the pet door to a passive subdermal tag so as to get any useful received signal or how to discriminate between the millions of such tags in existence. In practice such subdermal tags can only be “read” by an interrogation coil placed on the skin immediately above the subdermal tag. If the tag has moved, in general it cannot be located. The poor coupling between an aerial associated with a pet door and the conventional subdermal tag, as well as the high energy requirements for a system based on utilizing such tags to control a pet door, makes a system of the kind proposed in GB2376977 unworkable.
[0014] GB1187383 of National Research Development Corporation is concerned with a somewhat different use, namely controlling access to different feeding spaces in a cow byre for different cows, in which each cow has a tag with a characteristic frequency effective to allow access only to its dedicated feeding space.
BRIEF SUMMARY OF THE INVENTION
[0015] In contrast to the prior art and in accordance with a first aspect of this disclosure, a pet door unit is adapted to allow entry to and egress from a dwelling of an animal. The pet door unit includes a pet door provided with a latch means, the pet door being mounted for movement to allow passage of the animal therepast when the latch means is disabled. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0016] The pet door unit comprises:
an animal detector for detecting an animal apparently seeking passage past the pet door; a controller allowing selection of a permitted passage condition via the pet door, the permitted passage condition being selected from entry to the dwelling but not egress, egress from the dwelling but not entry, both entry to and egress from the dwelling, and neither entry to nor egress from the dwelling; and a selective latch disabler for selectively disabling said latch means to allow passage past the pet door; the disabler being coupled to the controller to disable the latch means in accordance with the selected permitted passage condition when the animal detecting means detects an animal seeking entry or seeking egress.
[0020] The term “latch means” as used herein is to be understood to mean any arrangement for latching a pet door. This may be a single latch or separate latches for respectively preventing entry and egress.
[0021] In a second and alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling of an animal, the pet door unit including a pet door provided with latch means, the pet door being mounted for movement to allow passage of the animal therepast when the latch means is disabled. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow controlled entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0022] The pet door unit further comprises:
a clock; a controller coupled to the clock and including a selector for selecting a permitted entry period in which the animal is allowed entry to the dwelling, and a permitted exit period in which the animal is permitted egress from the dwelling; an animal detector coupled to the controller for detecting whether an animal appears to be seeking entry or egress via the pet door; and a selective latch disabler for selectively disabling said latch means to allow passage past the pet door, the disabler being coupled to the controller to disable the latch means to allow entry when the animal detector detects an animal seeking entry during said permitted entry period, and also to disable the latch means to allow egress when the detecting means detects an animal seeking egress during said permitted exit period.
[0027] In a third alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling of a plurality of animals, each animal being provided with a detectable tag identifying the particular animal, the pet door unit including a pet door provided with latch means, the pet door being mounted for movement to allow passage of the animal therepast when the latch means is disabled. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow controlled entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0028] The pet door unit comprises:
a clock; a controller coupled to the clock and including a selector for selecting, for each said tag, a permitted entry period in which the animal associated with that tag is allowed entry to the dwelling, and a permitted exit period in which the animal associated with that tag is permitted egress from the dwelling; an animal detector coupled to the controller for detecting whether an animal appears to be seeking entry or egress via the pet door; a tag detector adapted to detect the presence of a said tag in a region adjacent the pet door; and a selective latch disabler for selectively disable said latch means to allow passage therepast, the disabler being coupled to the controller to disable the latch means to allow entry at a time when both the tag detector detects a tag and the animal detector detects an animal seeking entry during said permitted entry period for that tag, and also to disable the latch means to allow egress when both the tag detector detects a tag and the animal detector detects an animal seeking egress during said permitted exit period for that tag.
[0034] The tag may be detected by infra-red detection, magnetic detection, or inductive loop detection.
[0035] The animal detector may comprise two reed switches, each having a closed state and an open state, operable by a magnet carried by the pet door. The pet door has a central median position, the pet door, when latched, being movable through a first minor distance from the central median position in a direction into the dwelling by an animal pushing the pet door from outside in that direction. The arrangement of reed switches and magnet is such that the open or closed state of a first of the two reed switches is changed by movement of the pet door through the said first minor distance. The pet door, when latched, is movable through a second minor distance from the central median position in a direction out of the dwelling by an animal pushing the pet door from inside in that direction. The arrangement of reed switches and magnet is such that the open or closed state of the second of the two reed switches is changed by movement of the door through the second minor distance.
[0036] In a fourth alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling of a plurality of permitted animals, each animal being provided with a detectable tag, the tags being the same or different. The pet door unit includes a pet door provided with latch means, the pet door being mounted for movement to allow passage of the animal therepast when the latch means is disabled. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow controlled entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0037] The pet door unit comprises:
a tag detector operatively adapted to detect the presence in a region adjacent the pet door of a tag identifying a permitted animal; and a latch disabler for disabling said latch means for the pet door to allow permitted passage therepast to an animal bearing a tag so detected, said disabler being operable within a selected period of permitted passage associated with the said tag, the period of disablement of the latch means before it is enabled again allowing passage of the animal bearing the detected tag past the pet door.
[0040] The pet door unit has a power saving mode in which the tag detector and the latch disabler remain inactive and the door remains latched, and an active mode in which the tag detector is operable and in which the latch disabler is also operable if a tag associated with a permitted animal is detected by the tag detector during a period of permitted passage associated with the tag.
[0041] The pet door unit further comprises an animal detector separate from the tag detector for detecting whether an animal appears to be seeking passage via the pet door, the animal detector being adapted to initiate the active mode when an animal's presence is detected and the pet door unit is in power saving mode.
[0042] In this case, the animal detector may comprise one or more reed switches, each reed switch having a closed state and an open state and being operable by a magnet carried by the pet door. The pet door has a central median position. The pet door, when latched, is movable through a first minor distance from the central median position in a direction into the dwelling by an animal pushing the pet door from outside in that direction. The arrangement of the one or more reed switches and the magnet is such that the open or closed state of the or a first of the reed switch(es) is changed by movement of the pet door through the first minor distance. The pet door, when latched, is movable through a second minor distance from the central median position in a direction out of the dwelling by an animal pushing the pet door from inside in that direction. The arrangement of the one or more reed switches and the magnet is such that the open or closed state of the or a second of the reed switch(es) is changed by movement of the pet door through the first minor distance.
[0043] In all the above units, where two reed switches are employed, preferably the two reed switches are mounted alongside each other in proximity to an edge of the pet door. Each reed switch is generally tubular in configuration to define a longitudinal direction, and one reed switch is displaced relative to the other in its longitudinal direction into the dwelling, while the other reed switch is displaced relative to the one in its longitudinal direction out of the dwelling. The magnet comprises a magnet mounted in said edge so that in the central median position of the pet door the magnet is effective to close both reed switches, movement of the pet door through the first minor distance by being pushed from outside being effective to move the magnet to a position in which it opens said one reed switch. Movement of the pet door through the second minor distance by being pushed from inside is effective to move the magnet to a position in which it opens the other reed switch.
[0044] Opening detection means may be provided to detect whether the pet door has been opened subsequent to the latch means being disabled. Means are preferably provided to delay at least one of initiation of the active mode and operation of the animal detector when, on a predetermined number n of occasions within a set period, an animal has been detected by the animal detector as apparently seeking passage via the pet door without subsequent opening of the pet door being detected by the opening detection means. As explained in the detailed description hereinbelow, this feature helps to preserve battery power with a diffident cat or in windy conditions where false indications that an animal is present at the pet door might occur.
[0045] According to a fifth alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling for at least one animal, the pet door unit including a pet door provided with latch means. The pet door is mounted for movement to allow passage of the animal therepast when the latch means is disabled, the pet door having a central median position in which it is latched. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow controlled passage via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0046] The pet door unit further comprises:
a latch disabler for disabling said latch means to allow passage of an animal; and a latch enabler for enabling the latch means to re-latch the pet door after an animal has passed therepast and the pet door has returned to its central median position, and including a door position detector for detecting whether the door is located in its central median position.
[0049] The disabler may be controllable to allow passage for the animal in a selected entry or egress direction.
[0050] The door position detector preferably comprises one or more reed switches, each reed switch having a closed state and an open state and being operable by magnet means carried by the pet door. The arrangement of the one or more reed switches and the magnet is such that the open or closed state of a first of the reed switch(es) is changed by movement of the pet door from the central median position into the dwelling. The arrangement of the one or more reed switches and the magnet is such that the open or closed state of a second of the reed switch(es) is also changed by movement of the pet door from the central median position out of the dwelling.
[0051] Preferably there are two reed switches, namely said first reed switch and said second reed switch. The two reed switches are mounted alongside each other in proximity to an edge of the pet door, each reed switch being generally tubular in configuration to define a longitudinal direction, and one reed switch being displaced relative to the other in its longitudinal direction into the dwelling, while the other reed switch is displaced relative to the one in its longitudinal direction out of the dwelling. The magnet comprises a magnet mounted in said edge so that in the central median position of the pet door the magnet is effective to close both reed switches. Movement of the pet door from the central median position into the dwelling is effective to move the magnet to a position in which it opens said one reed switch, and movement of the pet door from the central median position out of the dwelling being effective to move the magnet to a position in which it opens said other reed switch.
[0052] In a sixth alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling for an animal, the pet door unit including a pet door that is mounted for movement to allow passage of the animal therepast. The pet door has a central median position. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0053] The pet door unit further comprises:
an electrically operable determinator for determining in which direction the animal last passed the pet door and adapted to provide an indication whether the animal is likely to be within the dwelling or outside, the determinator including an opening detector adapted to detect that the door has been opened by at least a predetermined amount indicative of an animal having passed the pet door.
[0055] Preferably, the electrically operable determinator comprises: a direction of movement detector for determining, when the pet door leaves its central median position, in which direction it moves; and an extent of movement detector comprising a reed switch having a closed state and an open state and being operable by magnet means carried by the pet door; the arrangement of the reed switch and the magnet being such that the open or closed state of the reed switch is changed by a movement of the pet door from the central median position in either direction sufficiently for the animal to have passed therepast.
[0056] A clock may also be provided, together with means for recording the time of last passage of an animal past the pet door.
[0057] In a seventh alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling for a plurality of animals, each provided with a detectable tag with a different identity. The pet door unit includes a pet door that is mounted for movement to allow passage of the animal therepast, the pet door having a central median position. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow controlled entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0058] The pet door unit further comprises:
a tag detector adapted to detect the identity of a tag in a region adjacent the pet door; an animal passage determinator for determining that an animal has passed the pet door and in which direction; and a store coupled to said determinator for storing, for a particular passage via the pet door, the direction detected by the determinator and the identity of the tag as detected by said tag detector.
[0062] That an animal has passed the door and in which direction can be detected in various ways, including infra-red detectors mounted on either side of the door. However, the determinator preferably comprises: a direction of movement detector for determining, when the pet door leaves its central median position, in which direction it moves; and an extent of movement detector comprising a reed switch having a closed state and an open state and being operable by a magnet carried by the pet door. The arrangement of the reed switch and the magnet is such that the open or closed state of the reed switch is changed by a movement of the pet door from the central median position in either direction sufficiently for the animal to have passed therepast.
[0063] The pet door may further comprise a clock, and a recorder coupled to the clock for recording for each of said tags both the time and direction of last passage of the animal associated with that tag past the pet door.
[0064] In a preferred arrangement, the pet door is mounted for rotation on a pivot about a horizontal or vertical axis, and said extent of movement detector comprises a magnet located on the door at one axial end of the pivot to rotate therewith. The reed switch is mounted in a fixed position in confronting relation to the magnet.
[0065] The direction of movement detector may comprise one or more reed switches, each reed switch having a closed state and an open state and being operable by a co-operating magnet carried by the pet door. The arrangement of the one or more reed switches and the magnet is such that the open or closed state of one of the reed switch(es) is changed by one of movement of the pet door from the central median position into the dwelling and movement of the pet door from the central median position out of the dwelling.
[0066] In a preferred arrangement, the direction of movement detector comprises two reed switches mounted alongside each other in proximity to an edge of the pet door, each of said two reed switches being generally tubular in configuration to define a longitudinal direction. One reed switch is displaced relative to the other in its longitudinal direction into the dwelling, while the other reed switch is displaced relative to the one in its longitudinal direction out of the dwelling. The co-operating magnet comprises a magnet mounted in said edge so that in the central median position of the pet door the magnet is effective to close both reed switches, movement of the pet door from the central median position into the dwelling being effective to move the magnet to a position in which it opens said one reed switch. Movement of the pet door from the central median position out of the dwelling is effective to move the magnet to a position in which it opens said other reed switch.
[0067] In all the above arrangements in different aspects, where a pair of reed switches are employed, the two reed switches are preferably connected in series across a source of electric potential by a first reed of a first one of said two reed switches being connected to a first reed of the second one of said two reed switches in a circuit providing first and second inputs on first and second lines. The first line is connected to a second reed of said first one of the two reed switches, and the second line is connected both to the first reed of said first one of the two reed switches and to the first reed of the second one of said two reed switches. Detection of the potential of the second reed of the second one of the two reed switches on the first line indicates that both reed switches are closed and the pet door is in its median central position. Detection of the potential of the second reed of the first one of the two reed switches on the first line and the potential of one of the second reeds of the two reed switches on the second line indicates that the pet door has moved, the direction being determined by which of the two potentials is present on the second line. Detection of the potential of the second reed of the first one of the two reed switches on the first line and a potential other than those of the two second reeds on the second line indicates that the pet door is open.
[0068] In an eighth alternative aspect, a method of recording movement of an animal past a pet door to determine whether the animal is within or outside a dwelling provided with the pet door and the time interval since the animal last passed through the pet door comprises the steps of:
providing the animal with an interrogatable passive tag; transmitting an interrogation signal receivable by a said tag in a vicinity close to the pet door, said transmitting step being triggered by an animal seeking passage through the pet door; determining from which side of the door the animal was seeking passage; determining from said interrogation signal whether the tag has been identified, and, if so, disabling the latch for a period sufficient for the animal to make passage past the pet door; and determining whether the pet door has in fact opened sufficiently for passage of the animal during the period in which the latch was disabled, and if so, recording the time and direction of such passage.
[0074] Although the embodiment of pet door unit described in detail hereinbelow is adapted for electrical detection of tags worn by permitted animals, other arrangements are possible. For the purpose of some aspects of this disclosure, it is not necessary that animals wear any tag at all. In some cases, detection of the presence of an animal or a permitted animal may be by infrared, by magnetic coupling or, as in the arrangement described in detail below by decoding the modulation of an interrogation signal caused by coded tags worn by the animals. Each tag may then comprise a coil to couple with a coil of the pet door unit, a capacitor and a binary coded microchip. In electrical systems, coupling to a passive tag worn by an animal is inductive, and improved coupling will achieve better results.
[0075] In an eighth alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling of a plurality of permitted animals, each animal being provided with a tag detectable by inductive coupling with a coil mounted on the pet door unit, the tags being the same or different. The pet door unit includes a pet door provided with latch means, the pet door being mounted for movement to allow passage of the animal therepast when the latch means is disabled. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow controlled entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall.
[0076] The pet door unit further comprises:
a tag detector, including said coil, operatively adapted to detect the presence in a region adjacent the pet door of a said tag identifying a permitted animal; and a latch disabler for disabling the latch means to allow permitted passage past the pet door to an animal bearing a tag so detected, said disabler being operable within a selected period of permitted passage associated with the said tag, the period of disablement of the latch means before it is enabled again allowing passage of the animal bearing the detected tag past the pet door.
[0079] The coil circumextends about the perimeter of the pet door and is diverted from the periphery of the pet door below the pet door to a position adjacent the lower edge of the pet unit to enhance coupling with a tag attached to the collar of an animal and hanging beneath its neck.
[0080] The latch mechanism of the detailed embodiment of pet door unit described in detail with reference to the accompanying drawings is believed novel in itself. Accordingly, in a ninth alternative aspect, a pet door unit is adapted to control entry to and egress from a dwelling of one or more permitted animals. The pet door unit includes a latchable pet door that is mounted for movement to allow passage of an animal therepast when its latch is disabled. The pet door unit is adapted to be fitted in one of: a lower portion of an existing door or window to allow controlled entry or egress via the pet door when the existing door or window is closed, and a lower portion of a wall. The latch comprises a latch member constrained to move in a generally vertical direction into and out of engagement with the pet door to latch it and unlatch it, and being provided with drive means therefor, comprising an electric motor and a rotatable drive rod coupled to the said motor. The drive rod is coupled to turn a wheel provided with an eccentrically mounted pin, the latch member including an elongate through slot, the longitudinal direction of the slot being generally horizontal. The pin is constrained to slide in said slot, whereby rotation of the drive rod by the motor is effective to rotate the wheel so that its pin slides in the horizontal slot, causing the latch member to be raised or lowered depending on the direction of rotation of the motor.
[0081] The drive rod maybe coupled to turn a second wheel mounting an opaque sector plate adapted to occlude a light sensor to provide an indication of the position of the latch. One or both of the wheels may be coupled to the drive rod via a worm drive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0082] An embodiment is hereinafter more particularly described, by way of example only, with reference to the accompanying drawings.
[0083] FIG. 1 is an overall perspective view of a pet door unit with a housing cover omitted to show internal parts, and with other parts omitted fro clarity.
[0084] FIG. 2 is an enlarged cross-sectional view illustrating the latch mechanism.
[0085] FIG. 3 is a cross-sectional view similar to FIG. 2 with the latch plate omitted to show otherwise hidden parts.
[0086] FIG. 4 is a much enlarged partial perspective view of a corner of part of the unit adjacent one corner of the pet door, with parts omitted for clarity.
[0087] FIG. 5 is a schematic view of a reed switch.
[0088] FIGS. 6 and 7 are schematic circuit diagrams of reed switch circuits.
[0089] FIG. 8 is a much enlarged partial perspective view of the unit adjacent one end of the pet door pivot.
[0090] FIGS. 9 and 10 are logic diagrams of use in explaining operation of preferred embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0091] Pet doors are commonly sold as a unit to be fitted through a lower portion of an existing door intended for human use, so as to allow entry and egress for pets via the pet door when the existing door is closed.
[0092] FIG. 1 is an overall perspective view of an embodiment of a pet door unit comprising a pet door proper (here a vertically mounted flap adapted to turn on a horizontal axis), associated housing, latch and control mechanisms. Flap 1 is mounted in a housing 3 , suitably moulded of plastics, which includes a generally tubular section or tunnel 4 , here of generally square cross-section, which is adapted to pass through a correspondingly shaped, but slightly larger, opening formed through the lower portion of an existing door or window to allow mounting of the pet door therein. Main portion 5 of the housing fits flush against and is fixed to the inner side of the existing door, which may be of any conventional construction, including glass, pvc, metal and wood, or window. There may be a further face plate or housing portion (not shown) that fits over the tunnel 4 and flush against the outer side of the existing door or window to provide a neat appearance. It will be understood that main portion 5 is fitted with a cover (omitted to allow the mechanism to be seen) which has a central opening therein corresponding to the shape of and slightly larger than the flap 1 .
[0093] It will be appreciated that, provided the tunnel is long enough or a bespoke tunnel is formed, the pet door unit may, alternatively, be fitted through a wall rather than an existing door. However, for the purpose of this description, it is assumed that the unit is fitted to an existing door.
[0094] The pet door unit is provided with a latch mechanism 6 , generally indicated and operated by battery power from a stack of batteries 7 under control of a processor 8 , which may have one or more indicators or buttons 9 and/or an LCD screen 10 adapted to present instructions and/or information in alpha-numeric form.
[0095] As explained in detail below, the latch mechanism in this case comprises a single latch plate that operates to latch the door against opening in either direction. In alternative arrangements, there may be an individual latch on either side of the door, one serving to prevent entry, and the other serving to prevent egress.
[0096] In the illustrated arrangement, latch mechanism 6 comprises an electric motor 11 , the spindle 12 of which is adapted, via a coupling 13 , to rotate a drive rod 14 (best shown in the enlarged views of FIGS. 2 and 3 ) mounted for rotation in bearings 15 , 16 , 17 and 18 . Coupling 13 comprises a first disc 19 mounted on spindle 12 and having a plurality (here two) of projections 20 extending parallel to the spindle axis from forward face 21 of disc 19 . Projections 20 are received in through openings 22 in a second disc 23 mounted on one end of drive rod 14 . Projections 20 are enabled to slide in the axial direction in through openings 22 so as to accommodate any tolerance or movement between drive rod 14 and spindle 12 in the axial direction of the drive rod. The bearings 15 , 16 , 17 and 18 may be formed of first bearing parts integrally moulded with housing main portion 5 and second bearing parts that cooperate with the first and are integrally moulded in the cover (not shown) for main housing portion 5 . Drive rod 14 may be a simply pushed into the first bearing parts of bearings 15 , 16 , 17 and 18 before the cover is fitted to complete the bearings. It is prevented from moving by any substantial distance in its axial direction by lands 24 . Drive rod 14 mounts a worm 25 which is adapted to drive a cog wheel 26 . Cog wheel 26 mounts an eccentric pin 27 which is adapted to slide within a slot 28 formed in a latch plate 29 . Latch plate 29 is constrained to slide vertically within slots 30 , 31 formed in face 32 of main housing portion 5 .
[0097] As can be seen from FIG. 3 , from which latch plate 29 has been omitted, slots 30 , 31 each have a cranked configuration so as to define lower portions 30 a, 31 a which are separated from each other by a greater distance than upper portions 30 b and 31 b of the slots. Latch plate 29 has projections 33 , 34 that extend sideways from a lower portion of the latch plate 29 and mount pins (not illustrated) adapted to be guided in lower portions 30 a and 31 a of the slots. The face of latch plate 29 opposite that illustrated in FIG. 2 carries two further guide pins (not illustrated) which are guided in the upper portions 30 b and 31 b of the slots. Thus, as drive rod 14 turns and cog wheel 26 rotates driven by worm 25 , eccentric pin 27 is allowed to slide in slot 28 , and this causes the latch plate 29 to slide vertically upwards or vertically downwards, depending upon the direction of rotation of the drive rod, guided in slots 30 and 31 . Latch plate 29 has an upper end bifurcated to form two separate latch members 35 , 36 adapted to engage in blind openings formed in the lower edge of flap 1 .
[0098] Drive rod 14 mounts a second worm 37 adapted to drive a cog wheel 38 mounting a semi-circular sector plate 39 formed of a non-transparent material and adapted to occlude a light sensor 40 to provide an indication to processor 8 as to whether latch plate 29 is in its raised position to provide latching engagement with flap 1 , or not.
[0099] The above described latch mechanism is believed novel in itself and may be employed regardless of whether or not the system cooperates with passive tags worn by animals, as explained below. While this latch mechanism is preferred in the embodiment of pet door unit described in detail below, it will be understood that other forms of latch mechanism may be substituted in alternative embodiments.
[0100] A variety of different systems are currently employed to detect an animal at or close to a pet door for controlling its operation. Many of the novel features described herein and embodied in the specific embodiment of pet door unit illustrated in the accompanying drawings will find utility in pet door units operating on different systems of detection, including infra-red detectors.
[0101] However, in the preferred arrangement, one or more pets associated with the household in which the illustrated pet door has been mounted in a door to allow entry and egress for those pets are each provided with a passive tag comprising a binary coded microchip and an oscillatory circuit including a pick-up coil. Different tags are given different binary codes. The pet door is provided with a coil of wire (omitted for clarity) adapted to transmit an interrogation signal at a high frequency to interrogate the binary code in exactly the same fashion as subdermal pet identification tags are “read” through the skin by placing an interrogator coil on the skin surface.
[0102] It is explained below how it is possible to enhance coupling between the coils to get useful results. The resultant modulation of the waves of the interrogation signal by different amounts for “0”s and for “1”s in the binary code, as energy is transferred to the pick-up coil of the tag via an inductive link between the coils, enables the processor 8 to determine the binary code of the tag from the interrogation signal. Thus, processor 8 may be pre-programmed to enable it to determine whether a tag so detected identifies a pet permitted to enter or permitted to exit. That recognition of permission may then cause the latch mechanism to be driven to release the latch and allow entry or egress as the case may be. The processor 8 and latch mechanism 6 thus act as a latch disabling means when a permitted tag is detected. Because a plurality of pets may be given tags with different binary codes, this enables the system to control entry and exit of a plurality of different pets within the same household whose windows of opportunity for entry and exit may be set to be different from each other.
[0103] This feature is believed novel in itself in pet doors and may be employed independently of other features disclosed herein.
[0104] The present embodiment of pet door unit enables the entry and exit of a number of different pets to be controlled with entry and exit windows that may be different from each other.
[0105] For the system to work efficiently, a reliable inductive link must be created between the pet door coil and the coil in the tag worn by the pet. Since the tag will suitably be mounted on the animal's collar, it is likely to be positioned close to the pet door when the animal is seeking entry or egress, and beneath the animal's neck. A channel 41 is defined in the face of main portion 5 of the housing to accommodate the pet door coil (not shown). The coil must obviously run around the perimeter of flap 1 . It will be noted, however, that, beneath the flap, channel 41 is diverted from the periphery of the flap 1 to as low as possible a position 42 adjacent the rim of main portion 5 of housing 3 . By this means, the maximum possibility for inductive coupling between the pet door coil and the coil of an animal's tag coil hanging beneath its collar is created, and thus the maximum opportunity for a permitted tag to be detected. The coil preferably operates at a frequency of 125 kHz.
[0106] Latches operable by tags worn by pets have been provided in pet doors previously with coils running around the periphery of the flap proper. However, as far as presently aware, it has never previously been suggested to divert the pet door coil from the periphery of the flap to the lowest possible position within the pet door unit beneath the flap so as to achieve maximum coupling with a tag hanging from the collar of a pet approaching the pet door. The better the inductive coupling, the more reliable is the system, whatever form of tag is employed, and the need for repeated interrogations before entry or egress is allowed can be reduced. The present novel coil geometry is applicable to both the present binary coded microchip tags and to other more conventional tags adapted to operate a pet door latch via an inductive link.
[0107] If an interrogation signal were provided continuously, the batteries 7 would very soon run down. Indeed, a structure of the kind described would simply not be workable without a main electricity supply in place of batteries. However, a system has been devised which allows for conservation of battery power.
[0108] As explained below, the presently described embodiment causes the processor 8 to generate an interrogation signal when a pet is present at the pet door. This is possible because animals, especially cats, habitually push the door/flap before trying to make passage past it. It has been found that the fact that the door/flap has been pushed, and from which side, can readily be determined by the provision of appropriate reed switches. Preferably, as shown, two reed switches 43 , 44 are mounted adjacent a corner of the door/flap, and best shown in the greatly enlarged view of FIG. 4 .
[0109] A reed switch RS (see FIG. 5 ) commonly comprises two magnetic contacts C 1 and C 2 within a glass or ceramic tube T filled with a protective gas. When a magnet comes close to the reed switch RS by displacement or by rotation, so that one out of the two contacts C 1 and C 2 becomes magnetized to be more “North” than the other, the two contacts will be attracted to each other to complete an electric circuit through the switch. Otherwise, the contacts C 1 and C 2 separate and the circuit opens.
[0110] As can be seen, in particular from FIG. 4 , reed switches 43 and 44 are mounted beneath flap 1 adjacent one corner thereof. Although the two reed switches are mounted essentially in the same horizontal plane they are mounted both skew rather than normal to the vertical plane of the flap and staggered relative to each other so that one reed switch 43 extends beyond the flap 1 when it hangs in its vertical position in the direction of the exterior (the tunnel 4 side of the flap) while the other reed switch 44 is displaced slightly in the other direction, namely into the dwelling side of the cat flap in use.
[0111] The edge of flap 1 adjacent the two reed switches 43 and 44 carries a magnet adapted to operate those reed switches.
[0112] The magnet is preferably aligned with the edge of the flap. When the flap is in its medial central position, both reed switches are off-set from the medial position in opposite directions. This means that for each reed switch, one of its reeds will be more exposed to the magnet than the other, causing attraction between its reeds, so that the switch is closed. Thus, when the flap is exactly in its median central position, both switches will be closed. However, when, for example, a cat approaches the cat flap from the exterior (tunnel 4 ) side, its habit will generally be to push with its paw against the flap. This causes the flap to move slightly (the latch is designed to allow small movements even when latched). This causes a displacement of the magnet in the edge of the flap so that it now magnetises both reeds of switch 44 equally. When the door is unlatched, and moves further, the magnet first closes reed switch 44 as the effect on the two reeds of that switch again become unbalanced. As it moves even further, it will cease to have any substantial differential effect on the reeds of either switch, so that both will be open.
[0113] Thus noting the pattern of opening or closing of the two reed switches of the described arrangement, enables the system to tell not only from which side a cat is seeking to open the flap when it is latched, but also whether the flap then opens after being unlatched.
[0114] Thus, the arrangement of the two reed switches 43 and 44 enables the system to know whether the flap is at rest, whether a cat is attempting to make entry, whether a cat is attempting to make egress and whether the flap is open. The logical information is set out in Table 1 below.
TABLE 1 Reed 44 Reed 43 Information Flap is at rest Closed Closed Flap at rest, do nothing saving power Flap moved from Closed Open short Flap moved from inside. If cats are inside time allowed out then start looking for tag. When tag found, if that tag is allowed out, then open lock Flap moved from Open short Closed Flap moved from outside. If cats are outside time allowed in then start looking for tag. When tag found, if that tag is allowed in, then open lock Flap open Open Open Do not lock the flap until flap closed Flap closed Closed Closed When both reeds open, lock can be shut, as flap is in the centre. The flap is locked as soon as is possible to stop other cats getting in or out
[0115] The two reed switches 43 and 44 may be linked to processor 8 by a simple circuit such as that shown in FIG. 6 in which an input on line L 1 indicates that reed R 1 is closed and an input on line L 2 indicates that reed R 2 is closed. However, it is preferred to employ the alternative circuit of FIG. 7 which employs only a single power connection and uses essentially half the power that would be required for the circuit of FIG. 6 , and involves a modified logic.
[0116] The alternative logic involved with this circuit is explained in Table 2.
TABLE 2 Input L1 Input L2 Flap is at rest Ground voltage Input not used Flap moved Positive voltage - If ground voltage, reed R2 open. start looking at If positive voltage, reed R1 open Input L2 Flap open Positive voltage Not positive or ground Flap closed Ground voltage Input not used
[0117] Other arrangements are also possible. Thus if the magnet is vertically aligned to present a pole to the switches, then when the flap is centrally located in its median vertical plane, the magnet will cause both reed switches 43 and 44 to be closed. Pushing the flap from the exterior (tunnel 4 ) side may cause the flap to move to displace the magnet in the edge of the flap sufficient to disengage reed switch 43 while leaving reed switch 44 engaged. Conversely, when a cat approaches the flap from the dwelling side with, pushing the flap slightly may cause just sufficient movement of the magnet in the edge of the flap to disengage reed switch 44 while leaving reed switch 43 engaged.
[0118] In this construction, further movement on unlatching the door will result in movement of the magnet out of reach of both reed switches so that both will be open.
[0119] The use of the two reed switches, as discussed above allows the system to know whether an animal is seeking to enter or to leave the dwelling, which information can be used to control a latch, and also to know whether the door subsequently opens after being unlatched. Thus, regardless of whether any tags are fitted to the household pets, the two reed switch arrangement may be used to trigger unlatching while keeping the latch otherwise closed. A four-way control of the latch becomes possible, namely: open for entry and closed for egress; closed for entry and open for egress; closed both ways; and open both ways.
[0120] However, it is preferred to use the knowledge of attempted use, and from which side, in a more sophisticated control system employing tags. This is explained with reference to the logic diagrams of FIGS. 9 and 10 .
[0121] The system employs a programmable processor, preferably a PIC 16F627a or PIC 16F870 processor, the processor being operated from a microchip of the read/write analogue front end type for 125 kHz RFID base station. A suitable such microchip is sold by E M Micro Electronic under the designation EM4095.
[0122] The tags for permitted animals must first be calibrated to the processor. This is achieved by the following routine:
1. Press the “tag” button (for example button 49 ) for a set period (say 5 seconds). 2. The display flashes. 3. The tag is moved close to the flap. 4. That an interrogation signal from the processor and the pet door coil has detected the presence of the tag is indicated by the flashing slowing down. 5. The binary code of the particular tag is then stored in the processor by pressing a “set” button (such as button 50 ). 6. Steps 1 to 5 are repeated for up to 7 further tags.
[0129] For each said tag, periods for allowed entry and for allowed egress must be programmed into the processor following a menu set in the processor. The individual tags, after having their digital code stored in the processor, must then be fitted to the collars of individual pets such as cats. Thereafter, the system operates essentially as shown in the logic flow diagram of FIG. 9 .
[0130] The default setting 51 , or “waiting stage”, runs the system in power-saving mode, consuming very little power from the batteries. In that power saving mode, the system checks periodically at step 52 whether either of the reed switches 43 or 44 has operated (is open). If the switch has operated, the system checks at 53 whether the cat in question is trying to enter or leave the dwelling, this being determined, as explained above, by switches 43 and 44 . If a cat is trying to come in, then, at step 54 , a check is made whether, at the particular time, any of the permitted cats is allowed to come in. If the answer is “no”, then the system is returned to its waiting power-saving mode 51 . If the answer is “yes”, then the system looks for a tag at step 55 .
[0131] As explained above, looking for a tag involves sending out an interrogation signal via the pet door coil. At step 56 , the system determines whether any permitted tag is detected. If no permitted tag is detected, then, at step 57 , a check is made whether a predetermined number of seconds have elapsed since the system started looking for a tag. If it has not, then the system recycles to look for a tag again. If the predetermined period has elapsed and no permitted tag has been detected, then the system assumes that it is a stray cat that is trying to get in, and the system remains locked and returns to its power-saving mode 51 . If a tag is detected at step 56 , then a check is made at step 58 whether the tag so detected identifies a cat that is allowed, at the particular time, to go in. If that detected tag does not have permitted entry at the time in question, the system returns to its waiting power-saving mode 51 . However, if the detected tag is associated with a cat that does have permission to enter at the time in question, the flap is unlocked at step 59 by energizing motor 11 to rotate drive rod 14 , and so cause latch plate 29 to move downwardly to release the flap.
[0132] A check is made at step 60 whether the flap has been opened, this check being made by reed switches 43 , 44 , as explained above, subsequent to being unlocked. If the flap has not been opened, then a check is made at step 61 to see whether a predetermined number Y of seconds has elapsed since the flap was unlocked. If it has not, then, after a short interval, the system checks again at step 60 whether the flap has been opened. If at check 61 the period of Y seconds has elapsed since the flap was unlocked, then the system moves to step 62 . Also at step 60 , if the flap has been opened, then the system passes to step 62 . In this step 62 , the system checks whether the flap is in its centre position. This is also determined by the two reed switches 43 and 44 . If both are closed then the flap is in its medial central vertical position. If the flap is not in its centre position then, after a brief delay, the system checks again at step 62 whether the flap is in its centre position. If the flap has been opened and the flap has returned to its medial central position as detected at step 62 , it is safe to lock the flap again in step 64 and return the system to its waiting mode 51 .
[0133] Essentially identical steps will be followed (Right-hand side of FIG. 9 ) if it was determined at step 53 that the cat was trying to get out. Processor 8 has a clock and may thus record successful passage of the cat past the pet door (“Yes” at step 60 ) and the direction (Step 53 ) of passage.
[0134] With the system described above and adopting the logic shown in FIG. 9 , problems may still occur in conditions where the wind is sufficient to repeatedly move the flap, or where a cat is particularly diffident in using the flap and repeatedly pushes the flap before actually making passage therepast. In either of these conditions, this will result in high power usage. In the standard system of FIG. 9 , if (say) the flap is pushed every 10 seconds by a cat or moved every 10 seconds by the wind, the system would go flat using standard size A batteries in around 4 hours. Of course it is unlikely that a cat that is locked out would try repeatedly to get in for 4 hours in any one go but even trying for 3 minutes every day, this would have the effect of reducing a standard 9 months battery life down to just 2 to 3 months. The protocol illustrated in the logic diagram of FIG. 10 overcomes these problems and in practical examples, has been shown to save up to 94% of the battery life. Use of the protocol of FIG. 10 , even with a cat that repeatedly pushes the flap for 3 minutes every day, will have the effect of reducing battery life from the standard 9 month period by only as little as 10 days.
[0135] As will be appreciated, the protocol of FIG. 10 applies at step 55 of the FIG. 9 logic. The system is requested at 65 to look for a tag as a result of the answer “yes” being achieved at step 54 . At step 66 , the system checks whether it has looked for a tag 5 times in the last 20 minutes and not unlocked the flap. If the answer is “yes”, then the system moves straight to step 67 and looks for a tag for up to ¼ second on and ¼ second off up to two times. It then waits for 10 seconds at step 68 if it did not find a tag, and then moves on to step 51 . However, if the answer at step 66 is “no”, so that the system has not looked for a tag 5 times within the past 20 minutes without unlocking the flap, then the system moves to step 69 , and asks whether it has looked for a tag in the past 30 seconds without unlocking the flap. If the answer to this is “yes”, then the system moves to step 70 , and looks for a tag for up to ¼ second on and ¾ second off for up to 6 times before moving to step 51 . However, if the answer at step 69 is “no”—the system has not looked for a tag in the last 30 seconds without unlocking the flap—then the system moves to step 71 , and looks for a tag for up to ¼ seconds, and then to step 72 if it did not find a tag, and looks for a tag for up to ¼ second on and 1¼ second off for up to 5 times before moving to step 51 of the FIG. 9 logic.
[0136] With this protocol, the system will still be able to find a tag quickly except in the circumstance where a succession of false positives have recently occurred, and even in this situation the maximum time that a cat that does have permission to come in may have to wait will be 10 seconds. Thus, a balance is struck between efficiency and power saving.
[0137] Even after the latch has opened, a cat may simply push the flap but not make an entry past it. This may show up as an indication at stage 60 that the flap has opened. By use of a further reed switch in our preferred embodiment, as now explained with reference to FIGS. 1 and 8 , it can be told for certain whether a cat has passed through the pet door. In this arrangement, the door consists of a flap 1 mounted for rotation about a horizontally extending axis defined by respective pivots 45 and 46 . A third reed switch 47 is fixedly mounted in confronting relation with a magnet 48 that is mounted on one pivot 46 so as to be rotatable with the flap. Magnet 48 is aligned so that the North-South alignment of its poles is at right angles to the longitudinal direction of the reed switch 47 when the flap 1 hangs vertically in which condition the switch is closed providing an input to processor 8 . Rotation of the flap through an angle of (say) 45° or more, corresponding to passage of an animal through the pet door past the flap, will rotate the magnet by the same substantial angle and cause the switch to open. However, movement of the flap only by a small angle is not sufficient to open the reed switch. Thus, the system is enabled to know whether a pet has actually passed through the flap rather than merely pushed the flap from one side, and then retreated. Since the system already knows through reed switches 43 and 44 from which side the animal was coming, this means that the system knows at any time whether a particular pet has passed through the pet door and so is either inside the dwelling or outside.
[0138] As the processor includes a clock, it may be programmed to store the time of last passage through the pet door for any tag, and in which direction. A pet owner can thus tell whether a particular pet has been out for a prolonged period and may therefore be missing.
[0139] In a household that has only a single pet, this third switch, coupled with the double reed switch to tell from which direction the animal was approaching the door, provides information whether the animal is in or out, regardless of whether it is wearing a tag or not; and this may be coupled with a time stamp for each (or the last) opening of the door to provide passage.
[0140] Other arrangements for telling whether the door has opened sufficiently for an animal to pass therepast are also feasible. These may include infra-red detectors on either side of the door, or a system in which switches are operated by the door at predetermined angles of opening indicative of an animal passing the door.
[0141] The illustrated embodiment has a flap hung from a horizontal axis. The invention in all its aspects is equally applicable to doors mounted to swing on a vertical axis. In such an arrangement, the reed switches 43 , 44 may be located adjacent the edge of the door away from its axis, or along either the upper or lower edges of the door at a position away from that axis. The same principle may be applied to arrangements in which the flap is fixed at its top edge, but is formed of flexible material that is displaceable by an animal passing the pet door and then returns to its original medial central position. In this case, the reed switches 43 , 44 may be located, as in the illustrated embodiment adjacent the lower edge of the flap.
[0142] The detailed description of operation of the illustrated embodiment refers to cats. The systems disclosed herein will work equally well for a pet door designed to be used by dogs. Unlike cats, dogs tend to be more positive in approaching a pet door. Whereas a cat will usually push at the door with its paw with a noticeable delay before it actually passes through the door, dogs tend to push straight into the door with an expectation that it will open for them. Nevertheless, the moment a dog pushes into the door, this will cause one of the reed switches to open. This brings the system out of its power-saving mode. The logic steps may be adjusted to be performed at a rapid rate so that a permitted dog hardly notices a delay before the latch is released and the door yields to their push. | A pet door unit allowing entry to and egress from a dwelling of an animal includes a pet door provided with a latch. The pet door is mounted for movement to allow passage of an animal when the latch is disabled. The pet door unit includes an animal detector for detecting an animal seeking passage past the pet door. A controller allows selection of a permitted passage condition. A disabler selectively disables the latch. Other arrangements described include systems for controlling entry and exit for different animals in different time frames, systems that detect an animal by a tag carried by the animal, systems that detect a door, systems that detect whether an animal has actually passed through the door and in which direction, and systems that record time and direction of passage, a preferred coil geometry for tag detection, and a preferred latch. |
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TECHNICAL FIELD
[0001] The present invention relates generally to equipment utilized and operations performed in conjunction with a subterranean well and, in an embodiment described herein, more particularly provides a metal seal for downhole tools.
BACKGROUND
[0002] Metal seals are sometimes used to seal between structures in well tools, and in equipment used in other environments. However, several problems are frequently encountered when metal seals are used. For example, metal seals require very smooth and clean surfaces to seal against, and most metals can only be elastically deformed to a limited extent (which thereby limits the biasing force available from elastically deforming a metal seal), etc.
[0003] Elastomeric and other types of nonmetal seals may provide the ability to seal against irregular and unclean surfaces, and may provide sufficient resilient biasing force for urging the seals against the surfaces. However, nonmetal seals tend to degrade rapidly when used in dynamic configurations, i.e., where the seal must contact a moving surface while sealing against a pressure differential, or where the seal loses contact with the surface while the pressure differential still exists across the seal.
[0004] Therefore, it may be seen that improvements are needed in the art of sealing devices.
SUMMARY
[0005] In carrying out the principles of the present invention, a sealing device is provided which solves at least one problem in the art. One example is described below in which the sealing device includes both a metal seal and an elastomer seal. Another example is described below in which elastomer seals are used to energize metal seals in response to pressure differentials in different directions.
[0006] In one aspect of the invention, a sealing device is provided. The sealing device includes at least one metal seal. A nonmetal seal may be used to bias the metal seal in a radial direction in response to a pressure differential applied to the sealing device.
[0007] In another aspect of the invention, a well tool is provided which includes a housing assembly and a closure member. A sealing device is used for sealing between the housing assembly and closure member. The sealing device includes at least one metal seal and at least one nonmetal seal. Both of the metal and nonmetal seals contact one of the housing assembly and closure member when the closure member blocks flow through the housing assembly.
[0008] A method of sealing between a housing assembly and a closure member is also provided by the invention. The method includes the steps of: providing a sealing device including at least one metal seal and at least one nonmetal seal; applying a pressure differential across the sealing device while the sealing device seals between the housing assembly and the closure member; and displacing the closure member to relieve the pressure differential. The metal seal continues to seal against the pressure differential until the nonmetal seal no longer seals between the housing assembly and the closure member.
[0009] These and other features, advantages, benefits and objects of the present invention will become apparent to one of ordinary skill in the art upon careful consideration of the detailed description of representative embodiments of the invention hereinbelow and the accompanying drawings, in which similar elements are indicated in the various figures using the same reference numbers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic partially cross-sectional view of a well system embodying principles of the present invention;
[0011] FIG. 2 is an enlarged scale cross-sectional view of a closure mechanism of a flow control device in the well system;
[0012] FIG. 3 is a further enlarged scale cross-sectional view of a sealing device for use in the closure mechanism;
[0013] FIG. 4 is an enlarged scale cross-sectional view of an alternate configuration of the closure mechanism; and
[0014] FIG. 5 is a further enlarged scale cross-sectional view of an alternate configuration of the sealing device for use in the closure mechanism of FIG. 4 .
DETAILED DESCRIPTION
[0015] It is to be understood that the various embodiments of the present invention described herein may be utilized in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in various configurations, without departing from the principles of the present invention. The embodiments are described merely as examples of useful applications of the principles of the invention, which is not limited to any specific details of these embodiments.
[0016] In the following description of the representative embodiments of the invention, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used for convenience in referring to the accompanying drawings. In general, “above”, “upper”, “upward” and similar terms refer to a direction toward the earth's surface along a wellbore, and “below”, “lower”, “downward” and similar terms refer to a direction away from the earth's surface along the wellbore.
[0017] Representatively illustrated in FIG. 1 is a well system 10 which embodies principles of the present invention. In the well system 10 , a tubular string 12 (such as a production tubing string) is positioned in a wellbore 14 lined with casing 16 . The tubular string 12 includes well tools 18 , 20 .
[0018] The well tool 18 is a packer, and the well tool 20 is a flow control device (such as a valve or choke). The packer provides an annular seal between the tubular string 12 and the casing 16 , and the flow control device regulates fluid communication between the interior of the tubular string and an annulus 22 formed between the tubular string and the casing. The flow control device includes a closure mechanism 24 which is operated to regulate flow.
[0019] At this point, it should be reiterated that the invention is not limited to any of the details of the well system 10 described herein. For example, it is not necessary for the invention to be used in a wellbore, in a well tool, in a cased wellbore, in a flow control device, in a tubular string, etc. The closure mechanism 24 could, as another example, be used in a hydraulic setting device of the packer 18 , or could be used in another type of well tool. Thus, it should be clearly understood that the well system 10 is only a single example of a wide variety of uses for the principles of the invention.
[0020] Referring additionally now to FIG. 2 , an enlarged scale cross-sectional view of a portion of the well tool 20 is representatively illustrated. In this view it may be seen that the closure mechanism 24 includes a tubular closure member 26 which is displaced relative to a housing assembly 28 to thereby regulate flow through openings 30 in the housing assembly.
[0021] To completely block flow through the openings 30 , the closure member 26 engages a sealing device 34 . The sealing device 34 operates to provide a seal between the closure member 26 and the housing assembly 28 to thereby prevent flow through the openings 30 .
[0022] In one important feature of the sealing device 34 , both metal seals 32 a, 32 b and nonmetal seals 36 a, 36 b are included in the device. These seals 32 a, 32 b, 36 a, 36 b contact and seal against the closure member 26 when the closure member is in the position depicted in FIG. 2 . However, it will be appreciated that the sealing device 34 could be carried on, and displace with, the closure member 26 , so that the seals 32 a, 32 b, 36 a, 36 b could contact and seal against the housing assembly 28 when the closure member is in the position depicted in FIG. 2 , if desired.
[0023] Note that a separate seal 38 is shown sealing between the sealing device 34 and the housing assembly 28 . However, it will be appreciated that this seal 38 could be incorporated into the sealing device 34 , if desired. For example, the nonmetal seals 36 a, 36 b could extend further radially outward into sealing contact with the housing assembly 28 , and/or a seal could be formed by metal to metal contact between the housing assembly and an outer ring 40 of the device 34 .
[0024] Referring additionally now to FIG. 3 , a further enlarged cross-sectional view of the sealing device 34 is representatively illustrated. In this view it may be more clearly seen that the metal seals 32 a, 32 b each include an inclined beam or arm 42 a, 42 b extending between a seal surface 44 a, 44 b and the ring 40 . It may also be seen that each of the nonmetal seals 36 a, 36 b includes a generally wedge-shaped portion 46 a, 46 b positioned between the ring 40 and a respective one of the arms 42 a, 42 b.
[0025] The metal seals 32 a, 32 b are preferably made of strong, durable and resilient metals, such as Inconel 718, 13-chrome steel, etc. The nonmetal seals 36 a, 36 b are preferably made of high temperature and well fluid resistant, strong and elastomeric materials, such as NBR, HNBR, fluoroelastomers, etc. Non-elastomeric materials, such as PEEK, etc., may additionally or alternatively be used in the nonmetal seals 36 a, 36 b. It should be clearly understood that any metal materials may be used for the metal seals 32 a, 32 b, and any nonmetal materials may be used for the nonmetal seals 36 a, 36 b, in keeping with the principles of the invention.
[0026] Note that the nonmetal seals 36 a, 36 b are not necessary for the sealing device 34 to seal between the housing assembly 28 and the closure member 26 . The sealing device 34 could be provided without the nonmetal seals 36 a, 36 b, in which case the metal seals 32 a, 32 b would still provide sealing engagement with the closure member 26 . Use of the nonmetal seals 36 a, 36 b is preferred when a bubble-tight sealing engagement is required.
[0027] When the closure member 26 engages the sealing device 34 as depicted in FIG. 2 , the seal surfaces 44 a, 44 b contact the outer surface of the closure member and the arms 42 a, 42 b are deflected radially outward somewhat. This deflection causes elastic deformation of the arms 42 a, 42 b, resulting in a biasing force being applied by the arms to the seal surfaces 44 a, 44 b. Note that the seal surfaces 44 a, 44 b have small ridges formed thereon to concentrate this radial biasing force on a relatively small area, thereby increasing the contact pressure between the seal surfaces and the outer surface of the closure member 26 . It should be understood, however, that use of the small ridges is not required on the seal surfaces 44 a, 44 b.
[0028] The nonmetal seals 36 a, 36 b are also radially compressed between the ring 40 and the outer surface of the closure member 26 . In this manner, a seal surface 48 a, 48 b on each nonmetal seal 36 a, 36 b is biased into sealing contact with the outer surface of the closure member 26 .
[0029] Deflection of the arms 42 a, 42 b as described above will compress the wedge portion 46 a, 46 b of each nonmetal seal between the ring 40 and the respective arm. If the nonmetal seals 36 a, 36 b are made of a resilient material, this compression will result in a radial biasing force being applied to each arm, thereby further biasing the seal surfaces 44 a, 44 b into contact with the outer surface of the closure member 26 .
[0030] When a pressure differential 50 is applied across the sealing device 34 in an upward direction as depicted in FIG. 3 , the wedge portion 46 b of the lower nonmetal seal 36 b will be further compressed between the ring 40 and the arm 42 b of the lower metal seal 32 b. This compression of the lower wedge portion 46 b will result in a further radial biasing force being applied to the arm, thereby further biasing the lower seal surface 44 b into contact with the outer surface of the closure member 26 .
[0031] When a pressure differential 52 is applied across the sealing device 34 in an downward direction as depicted in FIG. 3 , the wedge portion 46 a of the upper nonmetal seal 36 a will be further compressed between the ring 40 and the arm 42 a of the upper metal seal 32 a. This compression of the upper wedge portion 46 a will result in a further radial biasing force being applied to the arm, thereby further biasing the upper seal surface 44 a into contact with the outer surface of the closure member 26 .
[0032] Thus, it will be appreciated that each of the sealing surfaces 44 a, 44 b is radially biased into metal to metal sealing contact with the outer surface of the closure member 26 due to: 1) elastic deformation of the respective arm 42 a, 42 b, 2) compression of the respective wedge portion 46 a, 46 b between the ring 40 and the respective arm due to deformation of the arm, and 3) compression of the respective wedge portion 46 a, 46 b due to the pressure differential 50 or 52 . This results in reliable metal to metal sealing between the metal seals 32 a, 32 b and the outer surface of the closure member 26 .
[0033] If, however, the seal surfaces 44 a, 44 b or the outer surface of the closure member 26 should become damaged, so that metal to metal sealing therebetween cannot be achieved, sealing contact between the nonmetal seals 36 a, 36 b and the closure member may still be possible.
[0034] In another important feature of the sealing device 34 , note that, as the closure member 26 displaces upward from its closed position depicted in FIG. 2 , sealing contact with the closure member is progressively removed from the lower nonmetal seal 36 b, then the lower metal seal 32 b, then the upper metal seal 32 a, and then the upper nonmetal seal 36 a. This means that, if the differential pressure 50 or 52 is applied against the sealing device 34 when the closure member 26 displaces upward, the pressure differential across the lower nonmetal seal 36 b will be relieved while the other seals 32 a, 32 b, 36 a maintain sealing contact with the closure member. This prevents damage to the seal 36 b from excessive flow when the pressure differential 50 or 52 is relieved.
[0035] When the closure member 26 eventually displaces upward sufficiently far that it no longer is in sealing contact with the upper nonmetal seal 36 a, and the pressure differential across this seal is thus relieved, the closure member will still be contained within a closely fitted sleeve 66 in which the openings 30 are formed, thereby preventing damage to the seal from excessive flow.
[0036] As the closure member 26 displaces downward from its open position in which flow is permitted through the openings 30 , the pressure differential 50 or 52 may be applied when the closure member sealingly engages the sealing device 34 . The pressure differential 50 or 52 will first be applied to the upper nonmetal seal 36 a while the closure member 26 remains within the closely fitted sleeve 66 , thereby preventing damage to the seal from excessive flow. Next, in succession, the closure member 26 sealingly contacts the upper metal seal 32 a, the lower metal seal 32 b, and the lower nonmetal seal 36 b.
[0037] It may now be fully appreciated that the sealing device 34 provides significant benefits in performing the sealing function in the closure mechanism 24 of the well tool 20 . For example, the metal seals 32 a, 32 b provide for metal to metal sealing between the closure member 26 and the housing assembly 28 , the metal seals are resiliently biased into sealing contact in multiple ways (including an increased biasing force as the differential pressure across the sealing device 34 increases), and the nonmetal seals 36 a, 36 b provide for additional sealing capability in the event that metal to metal sealing cannot be achieved. Pressure differentials from either direction across the sealing device 34 can be sealed against, without damage to the seals 32 a, 32 b, 36 a, 36 b, whether the closure member 26 displaces to close or open while the pressure differential exists.
[0038] Referring additionally now to FIG. 4 , an alternate configuration of the closure mechanism 24 is representatively illustrated. This alternate configuration of the closure mechanism 24 includes an alternate configuration of the sealing device 34 , which is depicted in a further enlarged cross-sectional view in FIG. 5 .
[0039] The sealing device 34 as illustrated in FIG. 5 is similar in some respects to the sealing device of FIG. 3 , in that it includes multiple metal seals 54 a, 54 b with respective seal surfaces 56 a, 56 b and inclined beams or arms 58 a, 58 b extending between the seal surfaces and a ring 60 .
[0040] The sealing device 34 of FIG. 5 also includes multiple nonmetal seals 62 a, 62 b positioned between the metal seals 54 a, 54 b. A wedge portion 64 a, 64 b of each respective nonmetal seal 62 a, 62 b is positioned between a respective one of the arms 58 a, 58 b and the ring 60 .
[0041] A difference between the nonmetal seals 62 a, 62 b and the nonmetal seals 36 a, 36 b described above is that the seals 62 a, 62 b are formed as a single, integral element, rather than as separate elements. Indeed the nonmetal seals 62 a, 62 b could be formed as a single seal, if desired. Furthermore, as discussed above for the nonmetal seals 36 a, 36 b, use of the nonmetal seals 62 a, 62 b is not required in the sealing device 34 of FIGS. 4 & 5 .
[0042] As with the configuration of FIGS. 2 & 3 , the seal surfaces 56 a, 56 b of the metal seals 54 a, 54 b are radially biased into sealing contact with the outer surface of the closure member 26 due to elastic deformation of the arms 58 a, 58 b and resulting compression of the wedge portions 64 a, 64 b of the nonmetal seals 62 a, 62 b between the arms and the ring 60 . However, further biasing forces applied to the arms 58 a, 58 b due to differential pressure across the sealing device 34 occurs somewhat differently in the alternate configuration of FIGS. 4 & 5 .
[0043] When the closure member 26 is in its closed position as depicted in FIG. 4 , the pressure differential 50 will cause the wedge portion 64 a of the nonmetal seal 62 a to further compress between the arm 58 a and the ring 60 , thereby applying a biasing force to the arm and further biasing the seal surface 56 a against the outer surface of the closure member. When the pressure differential 52 is applied across the sealing device 34 , the wedge portion 64 b of the nonmetal seal 62 b will be further compressed between the arm 58 b and the ring 60 , thereby applying a biasing force to the arm and further biasing the seal surface 56 b against the outer surface of the closure member.
[0044] As the closure member 26 displaces upward from its closed position depicted in FIG. 4 , sealing contact with the closure member is progressively removed from the lower metal seal 54 b, then the lower nonmetal seal 62 b, then the upper nonmetal seal 62 a, and then the upper metal seal 54 a. This means that, if the differential pressure 50 or 52 is applied against the sealing device 34 when the closure member 26 displaces upward, the pressure differential across the nonmetal seals 62 a, 62 b will be relieved (after the pressure differential is relieved across the lower metal seal 54 b ) while the upper metal seal 54 a maintains sealing contact with the closure member. This prevents damage to the seals 62 a, 62 b from excessive flow when the pressure differential 50 or 52 is relieved.
[0045] When the closure member 26 eventually displaces upward sufficiently far that it no longer is in sealing contact with the upper metal seal 54 a, and the pressure differential across this seal is thus relieved, the closure member will still be contained within the closely fitted sleeve 66 , thereby preventing damage to the seal from excessive flow.
[0046] As the closure member 26 displaces downward from its open position in which flow is permitted through the openings 30 , the pressure differential 50 or 52 may be applied when the closure member sealingly engages the sealing device 34 . The pressure differential 50 or 52 will first be applied to the upper metal seal 54 a while the closure member 26 remains within the closely fitted sleeve 66 , thereby preventing damage to the seal from excessive flow. Next, in succession, the closure member 26 sealingly contacts the upper nonmetal seal 62 a, the lower nonmetal seal 62 b, and the lower metal seal 54 b.
[0047] It will be appreciated that the sealing device 34 in the configuration of FIGS. 4 & 5 provides similar benefits to those of the configuration of FIGS. 2 & 3 . For example, the metal seals 54 a, 54 b provide for metal to metal sealing between the closure member 26 and the housing assembly 28 , the metal seals are resiliently biased into sealing contact in multiple ways (including an increased biasing force as the differential pressure across the sealing device 34 increases), and the nonmetal seals 62 a, 62 b provide for additional sealing capability in the event that metal to metal sealing cannot be achieved. Pressure differentials from either direction across the sealing device 34 can be sealed against, without damage to the seals 54 a, 54 b, 62 a, 62 b, whether the closure member 26 displaces to closed or open positions while the pressure differential exists.
[0048] Sealing devices constructed in accordance with the principles of the invention should be capable of sealing against 15,000 psi differential pressure at 325-400° F. in a static condition (no movement of the closure member relative to the housing assembly), and should be capable of reliably sealing against 1500-5000 psi during opening and closing of the closure member.
[0049] Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the invention, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to the specific embodiments, and such changes are contemplated by the principles of the present invention. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims and their equivalents. | A metal to metal seal for downhole tools. A sealing device includes a metal seal. A nonmetal seal may be used to bias the metal seal in a radial direction in response to a pressure differential applied to the sealing device. A well tool includes a housing assembly, a closure member and the sealing device. Both of the metal and nonmetal seals contact a selected one of the housing assembly and closure member when the closure member blocks flow through the housing assembly. A method of sealing between the housing assembly and closure member includes the step of displacing the closure member to relieve the pressure differential, the metal seal continuing to seal against the pressure differential until the nonmetal seal no longer seals between the housing assembly and the closure member. |
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RELATED APPLICATION
The application is a continuation application of U.S. patent application Ser. No. 10/925,267, filed Aug. 24, 2004 now U.S. Pat. No. 7,301,473, which application is incorporated herein by reference.
TECHNICAL FIELD
The application relates generally to a telemetry system for data communications between a downhole drilling assembly and a surface of a well. In particular, the application relates to a receiver for an acoustic telemetry system.
BACKGROUND
During drilling operations for extraction of hydrocarbons, a variety of communication and transmission techniques have been attempted to provide real time data from the vicinity of the bit to the surface during drilling. The use of measurements while drilling (MWD) with real time data transmission provides substantial benefits during a drilling operation. For example, monitoring of downhole conditions allows for an immediate response to potential well control problems and improves mud programs.
Measurement of parameters such as weight on bit, torque, wear and bearing condition in real time provides for more efficient drilling operations. In fact, faster penetration rates, better trip planning, reduced equipment failures, fewer delays for directional surveys, and the elimination of a need to interrupt drilling for abnormal pressure detection is achievable using MWD techniques.
Currently, there are four major categories of telemetry systems that have been used in an attempt to provide real time data from the vicinity of the drill bit to the surface; namely, acoustic waves, mud pressure pulses, insulated conductors and electromagnetic waves.
With regard to acoustic waves, typically, an acoustic signal is generated near the bit and is transmitted through the drill pipe, mud column or the earth. It has been found, however, that the very low intensity of the signal which can be generated downhole, along with the acoustic noise generated by the drilling system, makes signal detection difficult. Reflective and refractive interference resulting from changing diameters and thread makeup at the tool joints compounds the signal attenuation problem for drill pipe transmission. Such reflective and refractive interference causes interbit interference among the bits of data being transmitted.
In a mud pressure pulse system, the resistance of mud flow through a drill string is modulated by means of a valve and control mechanism mounted in a special drill collar near the bit. This type of system typically transmits at one bit per second as the pressure pulse travels up the mud column at or near the velocity of sound in the mud. It is well known that mud pulse systems are intrinsically limited to a few bits per second due to attenuation and spreading of pulses.
Insulated conductors or hard wire connection from the drill bit to the surface is an alternative method for establishing downhole communications. This type of system is capable of a high data rate and two-way communication is possible. It has been found, however, that this type of system requires a special drill pipe and special tool joint connectors that substantially increase the cost of a drilling operation. Also, these systems are prone to failure as a result of the abrasive conditions of the mud system and the wear caused by the rotation of the drill string.
The fourth technique used to telemeter downhole data to the surface uses the transmission of electromagnetic waves through the earth. A current carrying downhole data signal is input to a toroid or collar positioned adjacent to the drill bit or input directly to the drill string. When a toroid is utilized, a primary winding, carrying the data for transmission, is wrapped around the toroid and a secondary is formed by the drill pipe. A receiver is connected to the ground at the surface where the electromagnetic data is picked up and recorded. It has been found, however, that in deep or noisy well applications, conventional electromagnetic systems are unable to generate a signal with sufficient intensity to be recovered at the surface.
In general, the quality of an electromagnetic signal reaching the surface is measured in terms of signal to noise ratio. As the ratio drops, it becomes more difficult to recover or reconstruct the signal. While increasing the power of the transmitted signal is an obvious way of increasing the signal to noise ratio, this approach is limited by batteries suitable for the purpose and the desire to extend the time between battery replacements. These approaches have allowed development of commercial borehole electromagnetic telemetry systems that work at data rates of up to four bits per second and at depths of up to 4000 feet without repeaters in MWD applications. It would be desirable to transmit signals from deeper wells and with much higher data rates which will be required for logging while drilling, LWD, systems.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention may be best understood by referring to the following description and accompanying drawings which illustrate such embodiments. The numbering scheme for the Figures included herein are such that the leading number for a given reference number in a Figure is associated with the number of the Figure. For example, a system 100 can be located in FIG. 1 . However, reference numbers are the same for those elements that are the same across different Figures. In the drawings:
FIG. 1 illustrates a system for drilling operations, according to some embodiment of the invention.
FIG. 2 illustrates a repeater along a drill string, according to some embodiments of the invention.
FIG. 3 is a timing diagram of an acoustic signal received across a number of symbolic intervals, according to some embodiments of the invention.
FIG. 4 illustrates a receiver for an acoustic telemetry system, according to some embodiments of the invention.
FIG. 5 illustrates a flow diagram for operations of a receiver for an acoustic telemetry system, according to some embodiments of the invention.
FIG. 6 illustrates an on-off key-based receiver for an acoustic telemetry system, according to some embodiments of the invention.
FIG. 7 illustrates a flow diagram for operations of an OOK receiver, according to some embodiments of the invention.
FIG. 8 illustrates a frequency shift key-based receiver for an acoustic telemetry system, according to some embodiments of the invention.
FIGS. 9A-9B illustrate a flow diagram for operations of an FSK receiver, according to some embodiments of the invention.
FIG. 10 illustrates a phase shift key-based receiver for an acoustic telemetry system, according to some embodiments of the invention.
FIGS. 11A-11B illustrate a flow diagram for operations of a PSK receiver, according to some embodiments of the invention.
DETAILED DESCRIPTION
Methods, apparatus and systems for an acoustic telemetry receiver are described. In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure the understanding of this description.
While described with reference to transmitting downhole data to the surface during measurements while drilling (MWD), embodiments of the invention are not so limited. For example, some embodiments are applicable to transmission of data from the surface to equipment that is downhole. Additionally, some embodiments of the invention are applicable not only during drilling, but throughout the life of a wellbore including, but not limited to, during logging, drill stem testing, completing and production. Further, some embodiments of the invention can be in other noisy conditions, such as hydraulic fracturing and cementing.
As further described below, embodiments of the invention attempt to minimize cross correlation between/among the different symbols to allow for the identification of the symbols. Embodiments of the invention allow for a more robust data recovery of acoustic telemetry through tubulars under various noisy conditions. Additionally, embodiments of the invention allowed for an increased data rate of acoustic telemetry through tubulars while maintaining reliable data recovery. Embodiments of the invention may remove intersymbol interference. This removal of intersymbol interference allows for correlation of a symbol with a database of acquired symbols to determine a value of a symbol.
FIG. 1 illustrates a system for drilling operations, according to some embodiments of the invention. A system 100 includes a drilling rig 102 located at a surface 104 of a well. The drilling rig 102 provides support for a drill string 108 . The drill string 108 penetrates a rotary table 110 for drilling a borehole 112 through subsurface formations 114 . The drill string 108 includes a Kelly 116 (in the upper portion), a drill pipe 118 and a bottom hole assembly 120 (located at the lower portion of the drill pipe 118 ). The bottom hole assembly 120 may include a drill collar 122 , a downhole tool 124 and a drill bit 126 . The downhole tool 124 may be any of a number of different types of tools including Measurement While Drilling (MWD) tools, Logging While Drilling (LWD) tools, etc.
During drilling operations, the drill string 108 (including the Kelly 116 , the drill pipe 118 and the bottom hole assembly 120 ) may be rotated by the rotary table 110 . In addition or alternative to such rotation, the bottom hole assembly 120 may also be rotated by a motor (not shown) that is downhole. The drill collar 122 may be used to add weight to the drill bit 126 . The drill collar 122 also may stiffen the bottom hole assembly 120 to allow the bottom hole assembly 120 to transfer the weight to the drill bit 126 . Accordingly, this weight provided by the drill collar 122 also assists the drill bit 126 in the penetration of the surface 104 and the subsurface formations 114 .
During drilling operations, a mud pump 132 may pump drilling fluid (known as “drilling mud”) from a mud pit 134 through a hose 136 into the drill pipe 118 down to the drill bit 126 . The drilling fluid can flow out from the drill bit 126 and return back to the surface through an annular area 140 between the drill pipe 118 and the sides of the borehole 112 . The drilling fluid may then be returned to the mud pit 134 , where such fluid is filtered. Accordingly, the drilling fluid can cool the drill bit 126 as well as provide for lubrication of the drill bit 126 during the drilling operation. Additionally, the drilling fluid removes the cuttings of the subsurface formations 114 created by the drill bit 126 .
The drill string 108 may include one to a number of different sensors 151 , which monitor different downhole parameters. Such parameters may include the downhole temperature and pressure, the various characteristics of the subsurface formations (such as resistivity, density, porosity, etc.), the characteristics of the borehole (e.g., size, shape, etc.), etc. The drill string 108 may also include an acoustic telemetry transmitter 123 that transmits telemetry signals in the form of acoustic vibrations in the tubing wall of the drill sting 108 . An acoustic telemetry receiver 115 is coupled to the kelly 116 to receive transmitted telemetry signals. One or more repeaters 119 may be provided along the drill string 108 to receive and retransmit the telemetry signals. The repeaters 119 may include both an acoustic telemetry receiver and an acoustic telemetry transmitter configured similarly to the acoustic telemetry receiver 115 and the acoustic telemetry transmitter 123 .
FIG. 2 illustrates a repeater along a drill string, according to some embodiments of the invention. In particular, FIG. 2 illustrates one embodiment of the repeaters 119 . As shown, the repeaters 119 may include an acoustic telemetry transmitter 204 and an acoustic sensor 212 mounted on a piece of tubing 202 . One skilled in the art will understand that acoustic sensor 212 is configured to receive signals from a distant acoustic transmitter, and that the acoustic telemetry transmitter 204 is configured to transmit to a distant acoustic sensor. Consequently, although the acoustic telemetry transmitter 204 and the acoustic sensor 212 are shown in close proximity, they would only be so proximate in a repeater 119 or in a bi-directional communications system. Thus, for example, the acoustic telemetry transmitter 123 might only include the acoustic telemetry transmitter 204 , while the acoustic telemetry receiver 115 might only include sensor 212 , if so desired.
The following discussion centers on acoustic signaling from acoustic telemetry transmitter 123 near the drill bit 126 to a sensor located some distance away along the drill string. Various acoustic transmitters are known in the art, as evidenced by U.S. Pat. Nos. 2,810,546, 3,588,804, 3,790,930, 3,813,656, 4,282,588, 4,283,779, 4,302,826, 4,314,365, and 6,137,747, which are hereby incorporated by reference. The transmitter 204 shown in FIG. 2 has a stack of piezoelectric washers 206 sandwiched between two metal flanges 208 , 210 . When the stack of piezoelectric washers 206 is driven electrically, the stack 206 expands and contracts to produce axial compression waves in tubing 202 that propagate axially along the drill string. Other transmitter configurations may be used to produce torsional waves, radial compression waves, or even transverse waves that propagate along the drill string.
Various acoustic sensors are known in the art including pressure, velocity, and acceleration sensors. The sensor 212 preferably comprises a two-axis accelerometer that senses accelerations along the axial and circumferential directions. One skilled in the art will readily recognize that other sensor configurations are also possible. For example, the sensor 212 may comprise a three-axis accelerometer that also detects acceleration in the radial direction. A second sensor 214 may be provided 90 or 180 degrees away from the first sensor 212 . This second sensor 214 also preferably comprises a two or three axis accelerometer. Additional sensors may also be employed as needed.
In some embodiments, the acoustic telemetry receiver receives an acoustic signal across a number of different symbolic intervals. In some embodiments, the acoustic telemetry receiver subtracts the tail of the acoustic signal of a previous symbolic interval from the acoustic signal of a current symbolic interval. To help illustrate, FIG. 3 is a timing diagram of an acoustic signal received across a number of symbolic intervals, according to some embodiments of the invention. FIG. 3 illustrates a timing diagram 300 for a first symbol 304 A that is represented by a solid line and a second symbol 304 B that is represented by a dashed line. The first symbol 304 A is received by the acoustic telemetry receiver in a symbolic interval 302 A. The second symbol 304 B is received by the acoustic telemetry receiver in a symbolic interval 302 B. As shown, a tail 306 A of the symbol 304 A carries over into the symbolic interval 302 B, thereby causing intersymbol interference with the symbol 304 B. A tail 306 B of the symbol 304 B carries over into a subsequent symbolic interval. Some embodiments of the invention may subtract the tail from the symbol for a previous symbolic interval from the symbol for the current symbolic interval to reduce the intersymbol interference.
Different embodiments of an acoustic telemetry receiver are now described. Such embodiments may be different embodiments of the acoustic telemetry receiver 115 . In particular, FIGS. 4 and 5 illustrate an embodiment of the acoustic telemetry receiver 115 and an embodiment of the operations thereof, respectively. FIGS. 6 and 7 illustrate an on-off key-based embodiment of the acoustic telemetry receiver 115 and an embodiment of the operations thereof, respectively. FIGS. 8 and 9 illustrate frequency shift key-based embodiment of the acoustic telemetry receiver 115 and an embodiment of the operations thereof, respectively. FIGS. 10 and 11 illustrate a phase shift key-based embodiment of the acoustic telemetry receiver 115 and an embodiment of the operations thereof, respectively.
FIG. 4 illustrates a receiver for an acoustic telemetry system, according to some embodiments of the invention. In particular, FIG. 4 illustrates a receiver 400 that includes a correlation logic 402 and a detection logic 404 . The correlation logic 402 is coupled to receive a telemetry signal. For example, the telemetry signal may be an acoustic signal that is propagated along a drill string. The correlation logic 402 may perform one to a number of correlations to stored telemetry signals to determine degrees of correlation. The output of the correlation logic 402 is coupled to the input of the detection logic 404 . The detection logic 404 may determine the symbol within the telemetry signal based on the degrees of correlation. The output of the detection logic 404 may be the symbolic values. Such symbolic values may represent communications (such as communications from downhole).
One embodiment of the operations of the receiver 400 is now described in more detail in conjunction with a flow diagram 500 of FIG. 5 . In particular, FIG. 5 illustrates a flow diagram for operations of a receiver for an acoustic telemetry system, according to some embodiments of the invention.
In block 502 , a telemetry signal that is transmitted along a transmission channel (having a transmission channel characteristic) is received. With reference to the embodiment of FIG. 4 , the correlation logic 402 receive the telemetry signal. In some embodiments, the correlation logic 402 may receive this signal during drilling operations. The telemetry signal may be an acoustic signal (that is transmitted from an acoustic telemetry transmitter downhole) along the drill string 108 . The transmission channel characteristic may include the different physical characteristics of the drill sting (including, length, thickness, shape, number of sections of drill pipe that is part of the drill string, etc.). Control continues at block 504 .
In block 504 , the telemetry signal is correlated to a first stored telemetry signal that includes the transmission channel characteristic to output a first degree of correlation. With reference to the embodiment of FIG. 4 , the correlation logic 402 performs this correlation. The correlation logic 402 may compare the signals and output a degree of correlation that may be a value indicative of such comparison. In some embodiments, logic (not shown in FIG. 4 ) may also remove intersymbol interference from the received telemetry signal prior to this correlation. Such operations are described in more detail below. The first stored telemetry signal may be one of a number of stored telemetry signal (such as from a library of signals) that is stored. This library of signals may be generated during an approximately noise free environment (such as when drilling operations are not being performed).
For example, the acoustic telemetry transmitter may generate a sequence of different symbols that are received by the receiver 400 during a period when no drilling operations are performed. The received symbols include the different characteristics of the drill string. In particular, the received symbols include the distortions made thereto as a result of the characteristics of the drill string. Control continues at block 506 .
In block 506 , the telemetry signal is correlated to a second stored telemetry signal that includes the transmission channel characteristic to output a second degree of correlation. With reference to the embodiment of FIG. 4 , the correlation logic 402 performs this correlation. Control continues at block 508 .
In block 508 , the telemetry signal is marked as a particular symbolic value based on the first degree of correlation and the second degree of correlation. With reference to the embodiment of FIG. 4 , the detection logic 404 marks the telemetry signal. The detection logic 404 may mark this telemetry signal based on either or both of the degrees of correlation. For example, if the telemetry signal received may be one of two symbols, the detection logic 404 may mark the telemetry signal as a first symbol if the first degree of correlation is above a maximum threshold and if the second degree of correlation is below a minimum threshold. In other words, the telemetry signal may be marked as a given symbol base on the correlation with one stored telemetry signal and the lack of correlation with a second stored telemetry signal. A more detailed description of such correlation comparisons is provided below.
While the flow diagram 500 illustrates the correlation with two stored telemetry signals, embodiments of the invention may correlate with a lesser or greater number of such signals. For example, the received telemetry signal may be correlated with any of a number of the signals stored in a library of signals.
FIG. 6 illustrates an on-off key-based receiver for an acoustic telemetry system, according to some embodiments of the invention. In particular, FIG. 6 illustrates an on-off key (OOK) receiver 600 that includes a bandpass filter 608 , a switch 610 , a tail subtract logic 612 , a timing recovery logic 614 , a training logic 615 , a correlation logic 618 , a memory 619 and a detection logic 620 .
The bandpass filter 608 receives an on-off key (OOK) signal 602 . The switch 610 receives a tail signal 604 . The tail signal 604 is a tail from a previous timing interval for a tone pulse. The training logic 615 receives a training OOK signal 601 . The training logic 615 is coupled to the memory 619 . The memory 619 is coupled to a first input of the correlation logic 618 and a first input of the timing recovery logic 614 . An output from the bandpass filter 608 is coupled to a first input of the tail subtract logic 612 and a second input of the timing recovery logic 614 .
The timing recovery logic 614 may determine the time of the symbolic interval. In some embodiments, the output of the timing recovery logic 614 peaks after the received input most closely matches the shape of the training pulse 617 . While the timing recovery logic 614 may be any of a number of different timing circuits, in some embodiments, the timing recovery logic 614 is an early-late-gate correlation timing circuit.
An output of the switch is coupled to a second input of the tail subtract logic 612 . An output of the tail recovery logic is coupled to a third input of the tail subtract logic 612 , a second input of the correlation logic 618 and a detection logic 620 . An output of the tail subtract logic 612 is coupled to a third input of the correlation logic 618 .
An output of the correlation logic 618 is coupled to a second input of the detection logic 620 . The output of the detection logic 620 is an output signal 622 of the OOK receiver 600 . The output signal 622 is coupled an input of the switch 610 .
One embodiment of the operations of the OOK receiver 600 is now described in more detail in conjunction with a flow diagram 700 of FIG. 7 . In particular, FIG. 7 illustrates a flow diagram for operations of an OOK receiver, according to some embodiments of the invention.
In block 702 , a training tone pulse for an OOK signal during a training period is determined. With reference to the embodiment of FIG. 6 , the training logic 615 may make this determination. For binary signaling, the OOK signal 602 may be a tone pulse over a symbolic interval for data “one” and a gap over a symbolic interval for data “zero”. Accordingly, the training OOK signal 601 may be a sequence of approximately identical widely spaced tone pulses sent by the acoustic telemetry transmitter 123 . In particular, the sequence of tone pulses is widely spaced such that there is no interference between the pulses. The training logic 615 may receive the training OOK signal 601 during an approximately noise free operating environment. For example, the drill string 108 is not in motion to turn/move the drill bit (as is typical during normal drilling operations). The training logic 615 may store these trained tone pulses into the memory 619 . As further described below, the correlation logic 618 may correlate these trained tone pulses with the acoustic signals received during normal drilling operations. Additionally, the timing recovery logic 614 may determine the time of the symbolic interval during this training period. Control continues at block 704 .
In block 704 , an OOK signal is received during a current symbolic interval during normal operations. With reference to the embodiment of FIG. 6 , the bandpass filter 608 may receive the OOK signal 602 . Normal operations may include drilling operations or operations related thereto (e.g., trip operations, etc.). The location of the current symbolic interval may be based on the timing of such interval (received from the timing recovery logic 614 ). Control continues at block 706 .
In block 706 , a bandpass filter operation is performed on the OOK signal in the current symbolic interval. With reference to the embodiment of FIG. 6 , the bandpass filter 608 may perform this bandpass filter operation. The OOK signal 602 is bandpass filtered to remove any out-of-band noise. Such out-of-band noise may be introduced into the OOK signal 602 by the multiple joints along the drill string 108 , drilling operations (such as the noise from the drill bit), etc. Control continues at block 708 .
In block 708 , a determination is made of whether the previous symbol is a tone pulse. With reference to the embodiment of FIG. 6 , the switch 610 makes this determination. As shown, the output from the detection logic 620 is inputted into the switch 610 . This output is an indication of whether the symbol is a tone pulse (representing a first value, such as a binary one) or a non-tone pulse (representing a second value, such as a binary zero). Accordingly, the switch 610 may make this determination based on the output from the previous symbolic interval. Upon determining that the previous symbol is a non-tone pulse, there is no need to subtract a tail of this symbol from the current symbol because there is no intersymbol interference. Therefore, control continues at block 712 , which is described in more detail below. In one such embodiment, the switch 610 does not input the tail signal 604 (which is representative of a tail of a tone pulse) into the tail subtract logic 612 . Upon determining that the previous symbol is a tone pulse, the switch 610 may input the tail signal 604 into the tail subtract logic 604 . Additionally, upon determining that the previous symbol is a tone pulse, control continues at block 710 .
In block 710 , the tail of symbol in a previous symbolic interval is subtracted from the symbol in the current symbolic interval to generate a corrected symbol for the current symbolic interval. With reference to the embodiment of FIG. 6 , the tail subtract logic 612 may perform this operation. The tail subtract logic 612 may subtract the tail signal 604 from the symbol in the current symbolic interval. Returning to FIG. 3 , for the symbolic interval 302 B, the tail 306 A of the first symbol 304 A (which has carried over into the symbolic interval 302 B) is subtracted therefrom. Accordingly, the symbol 304 B remains in the symbolic interval 302 B. Control continues at block 712 .
In block 712 , the corrected symbol is correlated with the training tone pulse. With reference to the embodiment of FIG. 6 , the correlation logic 618 correlates the corrected signal with the training tone pulse. The correlation logic 618 may perform this correlation by multiplying the corrected signal by the training tone pulse to generate a multiplied output. Control continues at block 714 .
In block 714 , a determination is made of whether the correlation is above a threshold. With reference to the embodiment of FIG. 6 , the detection logic 620 may make this determination. The detection logic 620 may make this determination by determining if the multiplied output is greater than the threshold. In some embodiments this threshold is a configurable value that may be set based on the environment of operation. For example, a drilling operation may have a lower threshold value in comparison a drill stem test operation.
In block 716 , upon determining that the correlation is above a threshold, the corrected symbol is marked as a tone pulse. With reference to the embodiment of FIG. 6 , the detection logic 620 marks the corrected symbol as a tone pulse. Therefore, if the tone pulse is defined as a binary one, the corrected symbol is marked as a binary one. Control continues at block 720 , which is described in more detail below.
In block 718 , upon determining that the correlation is not above a threshold, the corrected symbol is marked as a non-tone pulse. With reference to the embodiment of FIG. 6 , the detection logic 620 marks the corrected symbol as a non-tone pulse. Therefore, if the non-tone pulse is defined as a binary zero, the corrected symbol is marked as a binary zero. Accordingly, data communications from downhole may be interpreted in light of a sequence of symbols received. Control continues at block 720 .
In block 720 , the value of the corrected symbol is stored. With reference to the embodiment of FIG. 6 , the detection logic 620 may store this value into a memory (not shown) internal or external to the OOK receiver 600 . Such value may then be further processed to interpret the communications based on such symbols. Additionally, the detection logic 620 may store this value into a memory within the switch 610 . Accordingly, for the subsequent symbolic interval, the switch 610 may or may not input the tail signal 604 into the tail subtract logic 612 depending on whether this symbol was a tone pulse or a non-tone pulse, respectively (as described in block 708 ). Control continues at block 704 , where another OOK signal is received for the subsequent symbolic interval.
FIG. 8 illustrates a frequency shift key-based receiver for an acoustic telemetry system, according to some embodiments of the invention. In particular, FIG. 8 illustrates a frequency shift key (FSK) receiver 800 that includes a bandpass filter 802 , a f 1 timing recovery logic 810 , a f 2 timing recovery logic 812 , a switch 814 , a training logic 815 , a tail subtract logic 816 , a f 1 correlation logic 818 , a memory 819 , a f 2 correlation logic 820 and a detection logic 824 .
The training logic 815 receives a training OOK signal 801 . The training logic 815 is coupled to the memory 819 . The memory 819 is coupled to a first input of the f 1 timing recovery logic 810 , a first input of the f 2 timing recovery logic 812 , a first input of the f 1 correlation logic 818 and a first input of the f 2 correlation logic 820 .
The bandpass filter 808 receives a FSK signal 802 . The switch 814 receives a T(f 1 ) signal 804 and a T(f 2 ) signal 806 . The T(f 1 ) signal 804 and the T(f 2 ) signal 806 are tails from a previous timing interval for a first data representation and a second data representation, respectively. An output of the bandpass filter 808 is coupled to a first input of the tail subtract logic 816 , a second input of the f 1 timing recovery logic 810 and a second input of the f 2 timing recovery logic 812 . An output of the switch 814 is coupled to a second input of the tail subtract logic 816 . An output of the f 1 timing recovery logic 810 is coupled to a second input of the f 1 correlation logic 818 . An output of the f 2 timing recovery logic 812 is coupled to a second input of the f 2 correlation logic 820 . The output of the tail subtract logic 816 is coupled to a second input of the f 1 correlation logic 818 and to a second input of the f 2 correlation logic 820 . An output of the f 1 correlation logic 818 and an output of the f 2 correlation logic 820 are coupled as inputs into the detection logic 824 . The output of the detection logic 824 is an output signal 826 of the FSK receiver 800 . The output signal 826 is coupled to a third input of the switch 814 .
One embodiment of the operations of the FSK receiver 800 is now described in more detail in conjunction with a flow diagram 900 of FIGS. 9A-9B . In particular, FIGS. 9A-9B illustrate a flow diagram for operations of an FSK receiver, according to some embodiments of the invention.
In block 902 , a training tone pulse at a first frequency and a training tone pulse at a second frequency for a FSK signal during a training period are determined. With reference to the embodiment of FIG. 8 , the training logic 815 may make this determination. For binary signaling, the FSK signal 802 may be a tone pulse over a symbolic interval at a first frequency for data “one” and a tone pulse over a symbolic interval at a second (different) frequency for data “zero”. Accordingly, the training FSK signal 801 may be a sequence of approximately identical widely spaced tone pulses at a first frequency and a sequence of approximately identical widely spaced tone pulses at a second frequency sent by the acoustic telemetry transmitter 123 . In particular, the sequence of tone pulses at the first and second frequencies is widely spaced such that there is no interference between the pulses. The training logic 815 may receive the training the FSK signal 801 during an approximately noise free operating environment. For example, the drill string 108 is not in motion to turn/move the drill bit (as is typical during normal drilling operations). The training logic 815 may store these trained tone pulses into the memory 819 . As further described below, the f 1 correlation logic 818 , and the f 2 correlation logic 820 may correlate these trained tone pulses with the acoustic signals received during normal drilling operations. Additionally, the f 1 timing recovery logic 810 and the f 2 timing recovery logic 812 may determine the current symbolic interval for the first frequency and the second frequency during this training period. Control continues at block 904 .
In block 904 , a FSK signal is received during a current symbolic interval during normal operations. With reference to the embodiment of FIG. 8 , the bandpass filter 808 may receive the FSK signal 802 . Normal operations may include drilling operations or operations related thereto (e.g., trip operations, etc.). The location of the current symbolic interval may be based on the timing of such interval (received from the f 1 timing recovery logic 810 and the f 2 timing recovery logic 812 ). Control continues at block 906 .
In block 906 , bandpass filter operations are performed on the FSK signal in the current symbolic interval with regard to the first frequency and the second frequency. With reference to the embodiment of FIG. 8 , the bandpass filter 808 may perform this bandpass filter operation. The FSK signal 802 at the first frequency may have a different bandpass region in comparison to the FSK 802 signal at the second frequency. Accordingly, the bandpass filter 808 may perform the bandpass operation at the first frequency separate from the bandpass operation at the second frequency for the FSK signal 802 . Control continues at block 908 .
In block 908 , a determination is made of whether the previous symbol is at the first frequency. With reference to the embodiment of FIG. 8 , the switch 814 may make this determination. As shown, the output signal 826 from the detection logic 824 is inputted into the switch 814 . The output signal 826 is an indication of whether the symbol is a tone pulse at the first frequency or a tone pulse at the second frequency (representing a first value, such as a binary one, or a second value, such as a binary zero, respectively). Accordingly, the switch 814 may make this determination based on the output from the previous symbolic interval.
In block 910 , upon determining that the previous symbol is at the first frequency, the tail of a symbol at the first frequency is subtracted from the symbol in the current symbolic interval to generate a corrected symbol for the current symbolic interval. With reference to the embodiment of FIG. 8 , the tail subtract logic 816 may perform this operation. The switch 814 may input the T(f 1 ) signal 804 (which is a tail at the first frequency) into the tail subtract logic 816 if the previous symbol is at the first frequency. The tail subtract logic 816 may subtract the T(f 1 ) signal 804 from the symbol in the current symbolic interval. Control continues at block 914 , which is described in more detail below.
In block 912 , upon determining that the previous symbol is not at the first frequency (rather the second frequency), the tail of a symbol at the second frequency is subtracted from the symbol in the current symbolic interval to generate a corrected symbol for the current symbolic interval. With reference to the embodiment of FIG. 8 , the tail subtract logic 816 may perform this operation. The switch 814 may input the T(f 2 ) signal 806 (which is a tail at the second frequency) into the tail subtract logic 816 if the previous symbol is at the second frequency. The tail subtract logic 816 may subtract the T(f 2 ) signal 806 from the symbol in the current symbolic interval. Control continues at block 914 .
In block 914 , the corrected symbol is correlated with the training tone pulse at the first frequency to generate a first correlated output. With reference to the embodiment of FIG. 8 , the f 1 correlation logic 818 may correlate the corrected signal with the training tone pulse at the first frequency. The f 1 correlation logic 818 compares the corrected signal with the training tone pulse at the first frequency to determine the correlation there between. Control continues at block 916 .
In block 916 , the corrected symbol is correlated with the training tone pulse at the second frequency to generate a second correlated output. With reference to the embodiment of FIG. 6 , the f 2 correlation logic 620 may correlate the corrected signal with the training tone pulse at the second frequency. The f 2 correlation logic 620 compares the corrected signal with the training tone pulse at the second frequency to determine the correlation there between. Control continues at block 918 .
In block 918 , the second correlated output is subtracted from the first correlated output to generate a subtracted output. With reference to the embodiment of FIG. 6 , the detection logic 624 may perform this subtraction. Control continues at block 920 .
In block 920 , a determination is made of whether the polarity of the subtracted output is positive. With reference to the embodiment of FIG. 6 , the detection logic 624 may make this determination.
In block 922 , upon determining that the polarity of the subtracted output is positive, the corrected symbol is marked as a “data one.” With reference to the embodiment of FIG. 6 , the detection logic 624 may mark the corrected symbol. Control continues at block 926 , which is described in more detail below.
In block 924 , upon determining that the polarity of the subtracted output is not positive, the corrected symbol is marked as a “data zero.” With reference to the embodiment of FIG. 6 , the detection logic 624 may mark the corrected symbol. Control continues at block 926 .
In block 926 , the value of the corrected symbol is stored. With reference to the embodiment of FIG. 6 , the detection logic 624 may store this value into a memory (not shown) internal or external to the FSK receiver 600 . Such value may then be further processed to interpret the communications based on such symbols. Additionally, the detection logic 624 may store this value into a memory within the switch 614 . Accordingly, for the subsequent symbolic interval, the switch 614 may input the T(f 1 ) signal 604 or the T(f 2 ) signal 606 depending on whether this symbol was at a first frequency or a second frequency, respectively (as described in blocks 910 and 912 ). Control continues at block 904 , where another FSK signal is received for the subsequent symbolic interval.
FIG. 10 illustrates a phase shift key-based receiver for an acoustic telemetry system, according to some embodiments of the invention. In particular, FIG. 10 illustrates a phase shift key (PSK) receiver 1000 that includes a bandpass filter 10010 , a switch 1010 , a tail subtract logic 1012 , a timing recovery logic 1014 , a training logic 1015 , a memory 1019 , a (phi-1) correlation logic 1028 , a (phi-2) correlation logic 1030 and a detection logic 1034 .
The training logic 1015 receives a training PSK signal 1001 . The training logic 1015 is coupled to the memory 1019 . The memory 1019 is coupled to a first input of the timing recovery logic 1014 , a first input of the (phi-1) correlation logic 1028 and a first input of the (phi-2) correlation logic 1030 .
The bandpass filter 1008 receives a PSK signal 1002 . The switch 1010 receives a T(phi-1) signal 1004 and a T(phi-2) signal 1006 . The T(phi-1) signal 1004 and the T(phi-2) signal 1006 are tails from a first data representation and a second data representation, respectively.
An output of the bandpass filter 1008 is coupled to a first input of the tail subtract logic 1012 and an input of the timing recovery logic 1014 . An output of the switch 1010 is coupled as a second input of the tail subtract logic 1012 .
A first output of the timing recovery logic 1014 is a timing signal for the first phase, which is a second input of the (phi-1) correlation logic 1028 . A second output of the timing recovery logic 1014 is a timing signal for the second phase, which is a second input of the (phi-2) correlation logic 1030 .
An output of the tail subtract logic 1012 is coupled to a third input of the (phi-1) correlation logic 1028 and to a third input of the (phi-2) correlation logic 1030 . An output of the (phi-1) correlation logic 1028 is coupled to a first input of the detection logic 1034 . An output of the (phi-2) correlation logic 1030 is coupled to a second input of the detection logic 1034 . The output of the detection logic 1034 is an output signal 1036 of the PSK receiver 1000 . The output signal 1036 is coupled to an input of the switch 1010 .
One embodiment of the operations of the PSK receiver 1000 is now described in more detail in conjunction with a flow diagram 1100 of FIGS. 11A-11B . In particular, FIGS. 11A-11B illustrate a flow diagram for operations of a PSK receiver, according to some embodiments of the invention.
In block 1102 , a training tone pulse at a first phase and a training tone pulse at a second phase for a PSK signal during a training period are determined. With reference to the embodiment of FIG. 10 , the training logic 1015 may make this determination. For binary signaling, the PSK signal 1002 may be a tone pulse over a symbolic interval at a first phase for data “one” and a tone pulse over a symbolic interval at a second (different) frequency for data “zero”. In some embodiments, the first phase is shifted approximately 180 degrees relative to the second phase.
The training PSK signal 1001 may be a sequence of approximately identical widely spaced tone pulses at a first phase and a sequence of approximately identical widely spaced tone pulses at a second phase sent by the acoustic telemetry transmitter 123 . In particular, the sequence of tone pulses at the first and second phases is widely spaced such that there is no interference between the pulses. The training logic 1015 may receive the training the PSK signal 1001 during an approximately noise free operating environment. The training logic 1015 may store these trained tone pulses into the memory 1019 . As further described below, the (phi-1) correlation logic 1028 and the (phi-2) correlation logic 1030 may correlate these trained tone pulses with the acoustic signals received during normal drilling operations. Additionally, the timing recovery logic 1014 may determine the current symbolic interval for the first phase and the second phase during this training period (as described above). Control continues at block 1104 .
In block 1104 , a PSK signal is received during a current symbolic interval during normal operations. With reference to the embodiment of FIG. 10 , the bandpass filter 1008 may receive the PSK signal 1002 . The location of the current symbolic interval may be based on the timing of such interval (received from the timing recovery logic 1014 ). Control continues at block 1106 .
In block 1106 , bandpass filter operations are performed on the PSK signal in the current symbolic interval with regard to the first phase and the second phase. With reference to the embodiment of FIG. 10 , the bandpass filter 1008 may perform these bandpass filter operations. Control continues at block 1108 .
In block 1108 , a determination is made of whether the previous symbol is at the first phase. With reference to the embodiment of FIG. 10 , the switch 1010 may make this determination. As shown, the output signal from the detection logic 1034 is inputted into the switch 1010 . This output signal is an indication of whether the symbol is a tone pulse at the first phase or a tone pulse at the second phase (representing a first value, such as a binary one, or a second value, such as a binary zero, respectively). Accordingly, the switch 1010 may make this determination based on the output from the previous symbolic interval.
In block 1110 , upon determining that the previous symbol is at the first phase, the tail of a symbol at the first phase is subtracted from the symbol in the current symbolic interval to generate a corrected symbol for the current symbolic interval. With reference to the embodiment of FIG. 10 , the tail subtract logic 1012 may perform this operation. The switch 1010 may input the T(phi-1) signal 1004 (which is a tail at the first phase) into the tail subtract logic 1012 if the previous symbol is at the first phase. The tail subtract logic 1012 may subtract the T(phi-1) signal 1004 from the symbol in the current symbolic interval. Control continues at block 1114 , which is described in more detail below.
In block 1112 , upon determining that the previous symbol is not at the first phase (rather the second phase), the tail of a symbol at the second phase is subtracted from the symbol in the current symbolic interval to generate a corrected symbol for the current symbolic interval. With reference to the embodiment of FIG. 10 , the tail subtract logic 1012 may perform this operation. The switch 1010 may input the T(phi-2) signal 1006 (which is a tail at the second phase) into the tail subtract logic 1010 if the previous symbol is at the second phase. The tail subtract logic 1012 may subtract the T(phi-2) signal 1006 from the symbol in the current symbolic interval. Control continues at block 1114 .
In block 1114 , the corrected symbol is correlated with the training tone pulse at the first phase to generate a first correlated output. With reference to the embodiment of FIG. 10 , the (phi-1) correlation logic 1028 correlates the corrected signal with the training tone pulse at the first phase. The (phi-1) correlation logic 1028 compares the corrected signal with the training tone pulse at the first phase to determine the correlation there between. Control continues at block 1116 .
In block 1116 , the corrected symbol is correlated with the training tone pulse at the second phase to generate a second correlated output. With reference to the embodiment of FIG. 10 , the (phi-2) correlation logic 1030 correlates the corrected signal with the training tone pulse at the second phase. The (phi-2) correlation logic 1030 compares the corrected signal with the training tone pulse at the second phase to determine the correlation there between. Control continues at block 1118 .
In block 1117 , a determination is made of whether the correlation for the first phase (the first correlated output) is above a maximum first phase threshold. With reference to the embodiment of FIG. 10 , the detection logic 1034 may make this determination. Upon determining that the correlation for the first phase is not above the maximum first phase threshold, control continues at block 1121 , which is described in more detail below.
In block 1118 , upon determining that the correlation for the first phase is above the maximum first phase threshold, a determination is made of whether the correlation for the second phase (the second correlated output) is below a minimum second phase threshold. With reference to the embodiment of FIG. 10 , the detection logic 1034 may make this determination. Accordingly, in some embodiments, both correlation outputs (for the two different phases) may be analyzed in the determinations related to whether the corrected symbol is at the first phase (shown in blocks 1117 / 1118 ). However, embodiments of the invention are not so limited as either one of the correlations alone may be used in this determination. Upon determining that the correlation for the second phase is not below the minimum second phase threshold, control continues at block 1121 , which is described in more detail below.
In block 1120 , upon determining that the correlation for the second phase is not below the minimum second phase threshold, the corrected symbol is marked as a symbol representing the first phase. With reference to the embodiment of FIG. 10 , the detection logic 1034 may mark the corrected symbol. Therefore, if the symbol for the first phase is defined as a binary one, the corrected symbol is marked as a binary one. Control continues at block 1128 , which is described in more detail below.
In block 1121 , upon determining that the correlation for the first phase is not above the maximum first phase threshold or that the correlation for the second phase is not below a minimum second phase threshold, a determination is made of whether the correlation for the second phase (the second correlated output) is above a maximum second phase threshold. With reference to the embodiment of FIG. 10 , the detection logic 1034 may make this determination. Upon determining that the correlation for the first phase is not above the maximum first phase threshold, control continues at block 1126 , which is described in more detail below.
In block 1122 , upon determining that the correlation for the second phase is above a maximum second phase threshold, a determination is made of whether the correlation for the first phase (the first correlated output) is below a minimum first phase threshold. With reference to the embodiment of FIG. 10 , the detection logic 1034 may make this determination. Accordingly, in some embodiments, both correlation outputs (for the two different phases) may be analyzed in the determinations related to whether the corrected symbol is at the second phase (shown in blocks 1121 / 1122 ). However, embodiments of the invention are not so limited as either one of the correlations alone may be used in this determination. Upon determining that the correlation for the first phase is not below the minimum first phase threshold, control continues at block 1126 , which is described in more detail below.
In block 1124 , upon determining that the correlation for the second phase is above the maximum second phase threshold and that the correlation for the first phase is below a minimum first phase threshold, the corrected symbol is marked as a symbol representing the second phase. With reference to the embodiment of FIG. 10 , the detection logic 1034 may mark the corrected symbol. Therefore, if the symbol for the second phase is defined as a binary zero, the corrected symbol is marked as a binary zero. Control continues at block 1128 , which is described in more detail below.
In block 1126 , upon determining that the correlation for the second phase is not above the maximum second phase threshold or that the correlation for the first phase is not below a minimum first phase threshold, the corrected symbol is marked as undefined. With reference to the embodiment of FIG. 10 , the detection logic 1034 may mark the corrected symbol. Therefore, if based on the correlation outputs and the thresholds the detection logic 1034 cannot determine whether the corrected symbol is a symbol representing either of the phases, the corrected symbol is set as undefined. For example, the correct symbol may be undefined because of an excessive amount of noise in the system. In some embodiments, if N number of corrected symbols are set as undefined in a predefined period, the PSK receiver 1000 may set an alarm and/or reboot and re-determine the training tone pulses for the first phase and the second phase. In some embodiments, if N number of corrected symbols are consecutively set as undefined, the PSK receiver 1000 may set an alarm and/or reboot and re-determine the training tone pulses for the first phase and the second phase. Control continues at block 1128 .
In block 1128 , the value of the corrected symbol is stored. With reference to the embodiment of FIG. 10 , the detection logic 1034 may store this value into a memory (not shown) internal or external to the PSK receiver 1000 . Such value may then be further processed to interpret the communications based on such symbols. Additionally, the detection logic 1034 may store this value into a memory within the switch 1010 . Accordingly, for the subsequent symbolic interval, the switch 614 may input the T(phi-1) signal 1004 and a T(phi-2) signal 1006 depending on whether this symbol was at a first phase or a second phase, respectively (as described in blocks 1110 and 1112 ). Control continues at block 1104 , where another PSK signal is received for the subsequent symbolic interval. In some embodiments, these different thresholds (e.g., the maximum first threshold, the maximum second threshold, the minimum first threshold and the minimum second threshold) are configurable values that may be set based on the environment of operation.
While the flow diagrams 700 , 900 and 1100 illustrate the generation of the training pulses during an initial training period, such training may be subsequently re-executed. For example, the tails generated during training may be affected by different physical characteristics of the drill string (e.g., the length). In particular, after a given time of drilling operations, the drill string may be physically altered because of the stresses applied thereto during such operations. Additionally, the physical characteristics may be altered by the removal or addition of a section of drill pipe on the drill string. Accordingly, if a section of the drill string is removed or added, the training may be re-executed. The training may also be re-executed after a given time of drilling operations (e.g., 100 hours of operation).
Moreover, while described with reference to an OOK signal, a FSK signal and a PSK signal, embodiments of the invention are not so limited. Any of a number of different types of signaling can be used that allows for different symbols. For example, symbols may be different shaped envelopes, different levels and/or different chirp pulses that represent different values.
In the description, numerous specific details such as logic implementations, opcodes, means to specify operands, resource partitioning/sharing/duplication implementations, types and interrelationships of system components, and logic partitioning/integration choices are set forth in order to provide a more thorough understanding of the present invention. It will be appreciated, however, by one skilled in the art that embodiments of the invention may be practiced without such specific details. In other instances, control structures, gate level circuits and full software instruction sequences have not been shown in detail in order not to obscure the embodiments of the invention. Those of ordinary skill in the art, with the included descriptions will be able to implement appropriate functionality without undue experimentation.
References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
Embodiments of the invention include features, methods or processes that may be embodied within machine-executable instructions provided by a machine-readable medium. A machine-readable medium includes any mechanism which provides (i.e., stores and/or transmits) information in a form accessible by a machine (e.g., a computer, a network device, a personal digital assistant, manufacturing tool, any device with a set of one or more processors, etc.). In an exemplary embodiment, a machine-readable medium includes volatile and/or non-volatile media (e.g., read only memory (ROM), random access memory (RAM), magnetic disk storage media, optical storage media, flash memory devices, etc.), as well as electrical, optical, acoustical or other form of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.).
Such instructions are utilized to cause a general or special purpose processor, programmed with the instructions, to perform methods or processes of the embodiments of the invention. Alternatively, the features or operations of embodiments of the invention are performed by specific hardware components which contain hard-wired logic for performing the operations, or by any combination of programmed data processing components and specific hardware components. Embodiments of the invention include software, data processing hardware, data processing system-implemented methods, and various processing operations, further described herein.
A number of figures show block diagrams of systems and apparatus for an acoustic telemetry receiver, in accordance with some embodiments of the invention. A number of figures show flow diagrams illustrating operations for an acoustic telemetry receiver, in accordance with some embodiments of the invention. The operations of the flow diagrams are described with references to the systems/apparatus shown in the block diagrams. However, it should be understood that the operations of the flow diagrams could be performed by embodiments of systems and apparatus other than those discussed with reference to the block diagrams, and embodiments discussed with reference to the systems/apparatus could perform operations different than those discussed with reference to the flow diagrams.
In view of the wide variety of permutations to the embodiments described herein, this detailed description is intended to be illustrative only, and should not be taken as limiting the scope of the invention. For example, embodiments of the invention are described in reference to correlations between two different values based on different attributes (phase, frequency, etc.). However, embodiments of the invention are not so limited. Embodiments of the invention may correlate among N number of different values based on a number of different attributes. For example, the pulses may be on multiple frequencies, multiple phases and/or multiple channels. Accordingly, these different pulses may have each have a training pulse for correlations during the acoustic telemetry operations. What is claimed as the invention, therefore, is all such modifications as may come within the scope and spirit of the following claims and equivalents thereto. Therefore, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | One embodiment includes a method comprising receiving an acoustic signal that is propagated along a drill string. The method also includes correlating the acoustic signal to a first stored acoustic signal representing a first symbol, wherein the first stored acoustic signal is acquired from a propagation along the drill string in an approximately noise free environment. |
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[0001] We, Karsten Buhr, a citizen of Germany, residing at Willroth, Germany, Stefan Abresch, a citizen of Germany, residing at Dierdorf, Germany, Thomas Lehnert, a citizen of Germany, residing at Oberraden, Germany, Guenter Haehn, a citizen of Germany, residing at Koenigswinter, Germany, and Cyrus Barimani, a citizen of Germany, residing at Koenigswinter, Germany have invented a new and useful “Ejector Unit For A Road Milling Machine Or The Like”. This application claims priority from German Patent Applications No. 10 2009 014 730.6-25 and No. 10 2009 014 729.2-25, both filed Mar. 25, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an ejector unit, in particular for a road milling machine, having an ejector that comprises a conveying surface.
[0004] 2. Description of the Prior Art
[0005] Road milling machines usually comprise a milling tube on whose surface are mounted a plurality of bit holders. The bit holders are usually part of a bit holder changing system that also encompasses a base part. The base part is welded onto the surface of the milling tube, and replaceably receives the bit holders. The bit holder serves for mounting of a cutting bit, usually a round-shaft cutting bit, as known e.g. from published German patent application DE 37 01 905 C1. The bit holders are arranged on the surface of the milling tube so as to yield spiral-shaped helices. The helices proceed from the edge region of the milling tube and rotate toward the center of the milling tube.
[0006] The respective helices that proceed from the oppositely located edge regions therefore meet at the center of the milling tube. One or more ejectors are also then arranged in this region. The helices convey to the ejectors the material removed by the cutting bits. The ejectors then transport it out of the working region of the milling tube.
[0007] The ejectors are subject to severe abrasive attack, and must therefore be regularly checked and replaced. For this, the ejector welded onto the milling tube must be detached and a new one welded on. Attention must be paid to the exact positioning and alignment of the ejector in order to achieve ideal discharge performance. This replacement work in the confined working area of the milling tube is laborious.
SUMMARY OF THE INVENTION
[0008] It is an object of the invention to make available an improved ejector unit and ejector that enable simple machine maintenance.
1. The Ejector Unit
[0009] The ejector unit includes an ejector replaceably mountable on a carrying part. This results in a tool system in which the ejector can be easily and quickly replaced in the event of damage or wear. Work is thereby considerably simplified, and machine downtimes can be considerably reduced.
[0010] According to a preferred variant embodiment of the invention, provision can be made that the ejector is mountable on the carrier in at least two different operating positions.
[0011] The ejectors can be used in one operating position until the wear limit is reached. The ejector is then brought into the next operating position and can then be used further. This results in a service life for the ejector that is considerably extended as compared with usual ejectors.
[0012] Provision can be made in this context that in order to change the operating positions, the ejector is installed having been rotated 180 degrees. What is exploited here is the recognition that the ejector wears substantially on its region facing away from the milling tube. Once the wear state has been reached there, the ejector is detached and is reinstalled having been rotated 180 degrees. The ejector service life can thereby be considerably extended, ideally in fact doubled. In order to lose as little time as possible when changing the operating positions of the ejector, and to make installation unequivocal, provision can be made that the ejector and the holder form a mechanical interface that enables reversible installation of the ejector.
[0013] Secure mounting of the ejector on the carrier part results from the fact that the ejector comprises a mounting receptacle and/or a mounting extension, and that the ejector is connected indirectly or directly to the carrier by means of one or more mounting elements.
[0014] One conceivable inventive alternative is such that the ejector is braced in planar fashion on a support surface of the carrier by means of a mounting side, that the ejector comprises a securing extension and/or a securing receptacle, and that the securing extension engages into a securing receptacle of the carrier and/or a securing extension of the carrier engages into the securing receptacle of the ejector. The mutually interengaging connection of the securing extension and securing receptacle creates a positively engaged connection through which processing forces can be dissipated in load-optimized fashion. This becomes possible in particular when provision is made that the positively engaged connection impedes or blocks any offset of the ejector with respect to the carrier transversely to the feed direction.
[0015] In the context of the ejector unit according to the present invention, provision can be made that the carrier comprises a mounting foot onto which is shaped a support part, and that the mounting foot comprises a mounting surface extending substantially in the feed direction. By means of the mounting surface, the carrier can be positioned correctly on the milling tube and mounted thereon, in particular welded on.
[0016] The carrier can be produced in simple fashion as an economical component.
[0017] If provision is made that the mounting foot is widened with respect to the support part in or oppositely to the feed direction, a load-optimized geometry then results. The transition region between the support part and the mounting foot is exposed to large bending stresses in the tool insert. Widening decreases the material stresses at that point.
[0018] According to a preferred variant embodiment of the invention, provision can be made that the ejector comprises a conveying surface that is arranged substantially transversely to the feed direction of the ejector unit, and is embodied in hollowed fashion, in particular recessed in scoop-like fashion, at least locally in a direction opposite to the tool feed direction. This hollowed conformation enables a geometry that improves the discharge rate.
[0019] If provision is made that one or more depressions are introduced into the conveying surface, material removed during tool use can become deposited in the depressions. A “natural” wear protection layer forms there.
[0020] According a variant of the invention, provision can be made that at least one screw receptacle is used as a mounting receptacle, and that the screw receptacle opens, toward the front side of the ejector, into a screw head receptacle in which a screw head of a mounting screw is at least locally nonrotatably receivable. Rapid and problem-free ejector replacement is possible with the screw connections. Countersunk or partly countersunk reception of the screw head prevents abrasive attack on the countersunk head region. In addition, loosening of the screw at this point is prevented.
[0021] If the conformation of the ejector is such that one or more shaped-on stiffening ribs are arranged on the rear side facing away from the conveying surface, a sufficiently rigid ejector can then be designed with little material outlay.
[0022] A preferred variant of the invention is such that the mounting side comprises a convex mounting portion for contact against a concave receiving portion of a carrier. This results in a surface connection between the carrier and the ejector through which processing forces can be reliably dissipated even in the event of asymmetrical force application to the conveying surface.
[0023] If provision is made that the carrier holds the ejector in such a way that the conveying surface extends with a slight inclination with respect to the feed direction, the discharge performance can then be optimized. It has been shown that particularly good performance is achieved with an inclination setting in an angle range of +/−20 degrees. Surprisingly, an optimum is obtained at a negative inclination angle, specifically at an inclination of 5 to 15 degrees opposite to the feed direction.
[0024] An additional improvement in ejector service life is achieved by the fact that at least one wear protection element, made of a material more wear-resistant than the conveying surface, is arranged in the region of the conveying surface; provision can be made in particular that the wear protection element is constituted by a hard-material element or by a hardfacing.
2. The Ejector
[0025] The ejector comprises a mounting side, facing away from its conveying surface, having a support surface. With this mounting side, the ejector can be placed onto a component mounted on the milling tube, for example onto a carrying part welded thereon. By way of the support surface of the carrying part, the loads occurring during tool use are reliably dissipated at least in part. The ejector is equipped with a mounting receptacle or mounting extension, so that it is replaceably mountable. In this fashion it can easily be changed in the event of damage or wear.
[0026] According to a preferred variant embodiment of the invention, provision can be made that the conveying surface of the ejector is arranged transversely to the feed direction of the ejector unit, and is at least locally embodied in concave fashion or is assembled, in the hollowed region, from line segments and/or curve segments. The concave or hollowed conformation enables a scoop-like geometry that improves the discharge rate.
[0027] To allow the ejector to be reliably braced on a carrying part, provision can be made that at least one protruding securing extension, or a recessed securing receptacle, is arranged on the side facing away from the conveying surface. Transverse forces that occur can then be transferred, in particular, in positively engaged fashion from the ejector into the carrying part. This is possible in particular when provision is made that by means of the at least one securing extension or the at least one securing receptacle, any displacement of the ejector in a plane transverse to the feed direction can be limited in positively engaged fashion.
[0028] Provision can be made according to the present invention that the screw receptacle is guided through the securing extension or securing receptacle. The carrying part is then utilized for a sufficient clamping length of the mounting screw.
[0029] A preferred configuration of the invention is such that the mounting side is embodied in such a way that the ejector is installable in different operating positions. The ejector can, in particular, be embodied in mirror-symmetrical fashion, or can be embodied in the region of a mounting side in such a way that it enables installation reversibly in two different operating positions. Also conceivable is an ejector that enables three or four different operating positions.
[0030] This is based on the recognition that the ejector becomes worn substantially on its region facing away from the milling tube. Once the worn state is achieved there, the ejector is removed and put back on having been rotated, for example, 180 degrees.
[0031] A preferred configuration of the invention is such that the mounting side comprises a convex or crowned or spherical mounting portion for contact against a concave or hollowed receiving portion of a carrier. This connection creates a large connecting surface that ensures good energy transfer even when the conveying surface is asymmetrically loaded. A further improvement in service life is achieved by the fact that at least one wear protection element, made of a material more wear-resistant than the conveying surface, is arranged in the region of the conveying surface. In this context, provision can be made in particular that the wear protection element is constituted by a hard-material element, for example carbide or ceramic, or by an applied coating, for example a hardfacing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The invention will be further explained below with reference to an exemplifying embodiment depicted in the drawings, in which:
[0033] FIG. 1 is a front view of a milling drum of a road milling machine;
[0034] FIG. 2 is a side view of the milling drum according to FIG. 1 ;
[0035] FIG. 3 shows the view according to FIG. 2 , enlarged and with a slightly modified depiction;
[0036] FIG. 4 is a perspective front view of an ejector unit;
[0037] FIG. 5 is a perspective rear view of the ejector unit according to FIG. 4 ;
[0038] FIG. 6 is a perspective rear view of a carrier of the ejector unit according to FIG. 5 ;
[0039] FIG. 7 is a front perspective view of the carrier according to FIG. 6 ;
[0040] FIG. 8 is a perspective front view of an ejector of the ejector unit according to FIG. 4 ;
[0041] FIG. 9 is a perspective rear view of the ejector according to FIG. 8 ;
[0042] FIG. 10 is a perspective rear view of a second embodiment of an ejector unit having an ejector and a carrier; and
[0043] FIG. 11 is a perspective front view of the arrangement according to FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0044] FIG. 1 shows a milling drum having a cylindrical milling tube 10 onto whose drum surface 10 . 1 are welded a plurality of base parts 11 of bit holder changing systems. Base parts 11 carry replaceable bit holders 12 . A cutting bit 13 , specifically a round-shaft cutting bit, is replaceably received in each bit holder 12 . Base parts 11 are arranged with respect to one another so that they form a helix, specifically a transport helix. The helix rotates, proceeding from the side of milling tube 10 on drum surface 10 . 1 , toward the milling tube center formed between the two sides. For better clarity, only some of the bit holder changing systems are depicted in FIGS. 1 and 2 . Dashed lines that represent the center longitudinal axis of cutting bits 13 are shown as substitutes for the bit holder changing systems (not shown). As is evident from these lines, multiple transport helices are located on either side of the milling tube center.
[0045] The transport helices meet in pairs in the region of the milling tube center. As is evident from FIG. 1 , at least one respective ejector unit is arranged there. FIG. 3 , as compared with the depiction in FIG. 2 , does not show the bit holder changing systems, redirecting attention to the ejector unit. As is evident from this depiction, the ejector unit is constituted by a carrying part 30 and an ejector 20 .
[0046] FIGS. 4 and 5 show the ejector unit in isolation.
[0047] Firstly the design of carrying part 30 will be explained with reference to FIGS. 6 and 7 . Said part comprises a mounting foot 31 that forms on its underside a mounting surface 33 . With this, carrying part 30 can be placed onto drum surface 10 . 1 and welded at the sides. Shaped onto mounting foot 31 is an upwardly projecting support part 35 that forms a rear side 36 . Mounting foot 31 is widened by means of an extension 32 over rear side 36 , so that it forms a wide mounting surface 33 having a large support spacing. The widened cross section produced by extension 32 furthermore brings about a reinforcement of the highly stressed transition region between mounting foot 31 and carrying part 35 . A further widening of mounting surface 33 is achieved with a front-side protrusion 34 that, like extension 32 , extends over the entire width of carrying part 30 . Carrying part 30 comprises on the front side a support surface 37 that extends over the front side of carrying part 35 and also over part of mounting foot 31 . This embodiment of support surface 37 enables strength-optimized bracing of ejector 20 . Two receptacles 37 . 1 , 37 . 2 are inset into support surface 37 . The two receptacles 37 . 1 , 37 . 2 are recessed into support surface 37 so that they form trough-like hollows.
[0048] Ejector 20 will be explained below with reference to FIGS. 8 and 9 . It is embodied in plate-shaped fashion as a drop forged part, and is therefore particularly rigid. Ejector 20 comprises a front-side conveying surface 21 .
[0049] Said surface is equipped with recesses 21 . 1 , 22 . Located between recesses 21 . 1 are ribs that are at an angle to the vertical and are thus inclined toward the center of the ejector. The recesses receive removed material during operational use, thus forming a “natural” wear protector. A particularly good conveying rate is furthermore achieved by the fact that conveying surface 21 is embodied in concave, and thus scoop-shaped, fashion. Recess 22 comprises two oblique surfaces 22 . 1 that are at an angle to conveying surface 21 and assist the conveying action.
[0050] Located between the two recesses 22 is a thickened extension 23 that receives two screw receptacles 29 embodied as through holes. Screw receptacles 29 transition on the front side into hexagonal screw head receptacles 29 . 1 .
[0051] FIG. 9 shows the rear side of ejector 20 . As is evident from this depiction, rib-like securing extensions 26 . 1 , 26 . 2 project from ejector 20 on the rear side. Securing extensions 26 . 1 and 26 . 2 are adapted, in terms of their arrangement and dimensioning, to the arrangement and shape of receptacles 37 . 1 and 37 . 2 of carrier 30 . Screw receptacles 29 are guided through securing extension 26 . 1 .
[0052] As is further evident from FIG. 9 , stiffening ribs 27 are arranged in the rear-side corner regions of ejector 20 . Said ribs are connected to the horizontal securing extension 26 , thus yielding optimum energy dissipation.
[0053] In order to mount ejector 20 , it is placed with its rear side onto support surface 37 of carrier 30 . Securing extensions 26 . 1 , 26 . 2 then engage into the corresponding receptacles 37 . 1 , 37 . 2 . This results in a crosswise splining that prevents any displacement of ejector 20 with respect to carrier 30 in the axial and radial direction of milling tube 10 . By way of this splined connection, large portions of the forces occurring during tool use can be dissipated.
[0054] Screw receptacles 29 , 36 . 1 of ejector 20 and of carrier 30 are in alignment, so that mounting screws 24 (see FIGS. 4 and 5 ) can be inserted through them. The screw head of mounting screws 24 is accommodated in screw head receptacle 29 . 1 , where it is held nonrotatably. Preferably self-locking nuts 28 can be screwed onto mounting screws 24 , and ejector 20 can thus be secured on carrier 30 .
[0055] It is chiefly the radially projecting region of ejector 20 that wears during tool use. As is evident from FIGS. 8 and 9 , ejector 20 is embodied symmetrically with respect to the center transverse plane. When the wear limit is reached, it can therefore be removed and put back on having been rotated 180 degrees.
[0056] FIGS. 10 and 11 show a further variant embodiment of an ejector unit according to the present invention. Said unit once again encompasses an ejector 20 and a carrier 30 . Ejector 20 again possesses a hollowed conveying surface 21 that faces in the processing direction, the hollow being recessed concavely in a direction opposite to the processing direction. Facing away from conveying surface 21 , ejector 20 comprises on its rear-side mounting side 25 a mounting extension 20 . 1 . The latter protrudes in block fashion oppositely to the processing direction. It possesses two screw receptacles that can be arranged in alignment with screw receptacles of carrier 30 .
[0057] Mounting screws 24 can be passed through the screw receptacles, and nuts 28 can be threaded onto their threaded studs. Ejector 20 is thereby fixedly braced against a support surface 37 of carrier 30 . As is evident from the drawings, ejector 20 is equipped in the region of mounting side 25 with cutouts 20 . 2 . Upper cutout 20 . 2 receives the heads of mounting screws 24 and thus protects them, behind conveying surface 21 , from the abrasive attack of the removed material. Lower cutout 20 . 2 extends in skirt fashion over carrier 30 and protects it there. Ejector 20 is symmetrical with respect to the central transverse axis, and can therefore be mounted reversibly in two operating positions, rotated 180 degrees, on carrier 30 .
[0058] FIG. 3 is an end view of the milling tube 10 which can also be referred to as a milling drum 10 . The milling drum 10 rotates in the feed direction indicated by the arrow V. The milling drum rotates about an axis indicated by the + in the center of the milling drum in FIG. 3 . Directions generally parallel to the rotational axis may be referred to as axial directions and directions extending generally radially outward from the axis may be referred to as radial directions. Both the axial and radial directions can be considered to be generally transverse to the feed direction V.
[0059] The ejector 20 seen in perspective in FIGS. 8 and 9 , and in end view in FIG. 3 , can be described as being generally rectangular in shape having a width which extends in a generally radial direction and a length extending in a generally axial direction. The conveying surface 21 of the ejector 20 may be described as generally forward facing or as facing in the working direction V.
[0060] As best seen in FIG. 3 , the carrier 30 may support the ejector 20 at an angle α to a radius of the milling drum, which angle may be in a range of +/−20 degrees, and more preferably a negative angle from about −5 degrees to about −20 degrees. | The invention relates to an ejector unit, in particular for a road milling machine, having an ejector that is replaceably mounted on a carrier. In one aspect the ejector is curved in a scoop-like fashion. In another aspect the ejector is reversible upon the carrier to allow the ejector to be reversed after one wear surface is worn, thus presenting a new second wear surface. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of co-pending application Ser. No. 13/878,599, filed Apr. 10, 2013, which is a United States National Stage application of International Application no. PCT/US2012/047125, filed Jul. 18, 2012. The entire disclosures of these prior applications are incorporated herein by this reference.
TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to equipment utilized in conjunction with operations performed in subterranean wells and, in particular, to a reclosable multi zone isolation tool for isolating an upper zone from a lower zone in a subterranean wellbore and a method for use thereof
BACKGROUND OF THE INVENTION
Without limiting the scope of the present invention, its background will be described with reference to producing multiple hydrocarbon bearing subterranean zones in a well, as an example. It is common to encounter hydrocarbon wells that traverse more than one separate subterranean hydrocarbon bearing zone. In such wells, the separate subterranean hydrocarbon bearing zones may have similar or different characteristics. For example, the separate subterranean hydrocarbon bearing zones may have significantly different formation pressures. Even with the different pressures regimes, it may nonetheless be desirable to complete each of the multiple zones prior to producing the well. In such cases, it may be desirable to isolate certain of the zones from other zones after completion.
For example, when multiple productive zones that have significantly different formation pressures are completed in a single well, hydrocarbons from a high pressure zone may migrate to a lower pressure zone during production. It has been found, however, that this migration of hydrocarbons from one zone to another may decrease the ultimate recovery from the well. One way to overcome this fluid loss from a high pressure zone into a lower pressure zone during production and to maximize the ultimate recovery from the well is to initially produce only the high pressure zone and delay production from the lower pressure zone. Once the formation pressure of the high pressure zone has decreased to that of the lower pressure zone, the two zones can be produced together without any loss of reserves. It has been found, however, that from an economic perspective, delaying production from the lower pressure zone while only producing from the high pressure zone may be undesirable.
A need has therefore arisen for an apparatus that provides for the isolation of separate zones traversed by a wellbore. A need has also arisen for such an apparatus that does not required delayed production from a lower pressure zone during production from a high pressure zone. Further, a need has arisen for such an apparatus that does not allow fluid loss from a high pressure zone into a lower pressure zone if both zones are produced at the same time.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises an apparatus and method that provides for the isolation of separate zones traversed by a wellbore. In addition, the apparatus and method of the present invention do not required delayed production from a lower pressure zone during production from a high pressure zone. Further, the apparatus and method of the present invention enable simultaneous production from multiple zones without fluid loss from a high pressure zone into a lower pressure zone.
In one aspect, the present invention is directed to an apparatus for isolating a first zone from a second zone in a subterranean wellbore. The apparatus includes an outer tubular and an inner tubular disposed within the outer tubular forming a substantially annular flow path therebetween that is in fluid communication with the first zone. The inner tubular defines a central flow path therein that is in fluid communication with the second zone. A sleeve having at least one seal disposed on an inner surface thereof is positioned in the annular flow path to control fluid flow therethrough. The sleeve is axially movable relative to the outer tubular and the inner tubular between a closed position wherein the seal engages an outer surface of the inner tubular and an open position wherein the seal engages an outer surface of the outer tubular. A mandrel is slidably disposed within the inner tubular and coupled to the sleeve. The mandrel is operable to shift the sleeve between the open position and the closed position responsive to changes in pressure within the central flow path.
In one embodiment, a collet assembly is coupled to the sleeve to selectively prevent shifting of the sleeve relative to the outer tubular when the sleeve is in the open position and when the sleeve is in the closed position. In another embodiment, the sleeve has a plurality of seals disposed on the inner surface thereof such that the seals engage the outer surface of the inner tubular in the closed position and the outer surface of the outer tubular in the open position. In some embodiments, the outer tubular includes an extension that forms a substantially annular pocket such that the at least one seal engages the outer surface of the extension in the open position.
In certain embodiments, the mandrel forms at least a portion of the inner tubular. In one embodiment, the mandrel and the inner tubular define an actuation chamber operable to receive pressure from within the central flow path to bias the mandrel in a first direction relative to the inner tubular and shift the sleeve from the closed position to the open position. In another embodiment, an equalization pathway is disposed within the annular flow path to selectively prevent operation of the sleeve from the closed position to the open position.
In some embodiments, a lock assembly is positioned between the mandrel and the inner tubular that selectively prevents movement of the mandrel in the second direction relative to the inner tubular when the sleeve is in the open position. In these embodiments, the lock assembly may include a spring operated lug support and at least one lug such that the lug support props the lug radially outwardly to create interference with the inner tubular. Also, in these embodiments, the mandrel may include at least one reclosing port operable to receive pressure from within the central flow path, when the sleeve is in the open position, to release the lock assembly and to bias the mandrel in the second direction relative to the inner tubular, thereby shifting the sleeve from the open position to the closed position.
In another aspect, the present invention is directed to an apparatus for isolating a first zone from a second zone in a subterranean wellbore. The apparatus includes an outer tubular and an inner tubular disposed within the outer tubular forming a substantially annular flow path therebetween that is in fluid communication with the first zone. The inner tubular defines a central flow path therein that is in fluid communication with the second zone. The outer tubular includes an extension that forms a substantially annular pocket. A sleeve having at least one seal disposed on an inner surface thereof is positioned in the annular flow path to control fluid flow therethrough. The sleeve is axially movable relative to the outer tubular and the inner tubular between a closed position wherein the seal engages an outer surface of the inner tubular and an open position wherein the seal engages an outer surface of the extension of the outer tubular. A mandrel is slidably disposed within the inner tubular and is coupled to the sleeve. The mandrel is operable to shift the sleeve between the open position and the closed position responsive to changes in pressure within the central flow path. The mandrel and the inner tubular define an actuation chamber operable to receive pressure from within the central flow path to bias the mandrel in a first direction relative to the inner tubular and shift the sleeve from the closed position to the open position. The mandrel includes at least one reclosing port operable to receive pressure from within the central flow path when the sleeve is in the open position to bias the mandrel in a second direction relative to the inner tubular and shift the sleeve from the open position to the closed position.
In a further aspect, the present invention is directed to a method for isolating a first zone from a second zone in a subterranean wellbore. The method includes disposing a multi zone isolation tool within the wellbore in a closed position, the tool including an inner tubular defining a central flow path and an outer tubular defining an annular flow path with the inner tubular, the annular flow path in fluid communication with the first zone, the central flow path in fluid communication with the second zone; maintaining the tool in the closed position while treating the second zone by equalizing pressure in the central flow path and the annular flow path; operably coupling a tubing string with the inner tubular; varying the pressure in the central flow path; biasing a mandrel slidably disposed within the inner tubular in a first direction; shifting a sleeve having at least one seal disposed on an inner surface thereof and coupled to the mandrel from the closed position wherein the seal engages an outer surface of the inner tubular to an open position wherein the seal engages an outer surface of the outer tubular; aligning a fluid diverter with at least one reclosing port of the mandrel; varying the pressure in the central flow path; biasing the mandrel in a second direction; and shifting the sleeve from the open position to the closed position.
The method may also include selectively preventing shifting of the sleeve when the sleeve is in the open position and when the sleeve is in the closed position with a collet assembly coupled to the sleeve, selectively preventing movement of the mandrel in the second direction when the sleeve is in the open position with a lock assembly positioned between the mandrel and the inner tubular, propping the lug radially outwardly with a spring operated lug support to create interference with the inner tubular, releasing the lock assembly and/or pressurizing an actuation chamber disposed between the mandrel and the inner tubular.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 is a schematic illustration of a completion system including a multi zone isolation tool of the present invention;
FIGS. 2A-2D are cross sectional views of successive axial sections of a multi zone isolation tool of the present invention in the closed position;
FIGS. 3A-3D are cross sectional views of successive axial sections of a multi zone isolation tool of the present invention in the open position; and
FIGS. 4A-4D are cross sectional views of successive axial sections of a multi zone isolation tool of the present invention in the open position with a fluid diverter positioned therein.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.
The present invention provides improved methods and tools for completing and separately producing individual hydrocarbon zones in a single well. The methods can be performed in either vertical or horizontal wellbores. The term “vertical wellbore” is used herein to mean the portion of a wellbore in a producing zone, which is substantially vertical, inclined or deviated. The term “horizontal wellbore” is used herein to mean the portion of a wellbore in a producing zone, which is substantially horizontal. Since the present invention is applicable in vertical, horizontal and inclined wellbores, the terms “upper and lower” and “top and bottom” as used herein are relative terms and are intended to apply to the respective positions within a particular wellbore while the term “levels” is meant to refer to respective spaced positions along the wellbore. The term “zone” is used herein to refer to separate parts of the well designated for treatment and/or production and includes an entire hydrocarbon formation or separate portions of the same formation. As used herein, “down,” “downward” or “downhole” refer to the direction in or along the wellbore from the wellhead toward the producing zone regardless of the wellbore's orientation toward the surface or away from the surface. Accordingly, the upper zone would be the first zone encountered by the wellbore and the lower zone would be located further along the wellbore. Tubing, tubular, casing, pipe liner and conduit are interchangeable terms used herein to refer to walled fluid conductors.
Referring initially to FIG. 1 , a multi zone isolation tool of the present invention is disposed within a cased wellbore that is generally designated 10 . Wellbore 10 is illustrated intersecting two separate hydrocarbon bearing zones, upper zone 12 and lower zone 14 . For purposes of description, only two zones are shown but it is understood that the present invention has application to isolate any number of zones within a well. As mentioned, while wellbore 10 is illustrated as a vertical cased well with two producing zones, the present invention is applicable to horizontal and inclined wellbores with more than two producing zones and in uncased wells.
A completion string disposed within wellbore 10 includes upper and lower sand screen assemblies 16 , 18 that are located proximate to zones 12 , 14 , respectively. Wellbore 10 includes a casing string 20 that has been perforated at locations 22 , 24 to provide fluid flow paths into casing 20 from zones 12 , 14 , respectively. The completion string includes production tubing 26 , packers 28 , 30 and a crossover sub 32 to enable fluid flow between the interior of the completion string and annulus 34 . The completion string also includes multi zone isolation tool 36 of the present invention. As explained in greater detail below, tool 36 functions to connect lower sand screen assembly 18 and production tubing 26 via a first flow path. Tool 36 also functions to selectively isolate and connect upper sand screen assembly 16 to annulus 34 via a second flow path. Thus, tool 36 selectively isolates zone 12 and zone 14 and allows zones 12 , 14 to be independently produced.
Referring next to FIGS. 2A-2D , therein is depicted a more detailed illustration of an embodiment of a multi zone isolation tool of the present invention that is generally designated 100 . Tool 100 includes a substantially tubular outer housing assembly 102 that is formed from a plurality of housing members that are securably and sealingly coupled together by threading, set screws or similar technique. In the illustrated embodiment, housing assembly 102 includes an upper housing member 104 , a first upper intermediate housing member 106 , a second upper intermediate housing member 108 having a housing extension 110 , a housing coupling 112 , a sleeve housing member 114 that forms a substantially annular pocket 116 with housing extension 110 , a lower intermediate housing member 118 , a housing coupling 120 and a lower housing member 122 . It is to be understood by those skilled in the art that even though a particular arrangement of housing members is depicted and described, other arrangements of housing members are possible and are considered within the scope of the present invention.
Disposed within housing assembly 102 is an inner tubular assembly 124 that is formed from a plurality of tubular members that are securably and sealingly coupled together by threading, set screws or similar technique. In the illustrated embodiment, tubular assembly 124 includes an upper tubular member 126 having a polished bore receptacle 128 , a first upper intermediate tubular member 130 having a radially expanded region 132 , a second upper intermediate tubular member 134 having a lower shoulder 136 , a first intermediate tubular member 138 , a second intermediate tubular member 140 , a first lower intermediate tubular member 142 having a profile 144 , a second lower intermediate tubular member 146 and a lower tubular member 148 . It is to be understood by those skilled in the art that even though a particular arrangement of tubular members is depicted and described, other arrangements of tubular members are possible and are considered within the scope of the present invention.
Slidably disposed within tubular assembly 124 is a mandrel assembly 150 that is formed from a plurality of mandrel members that are securably and sealingly coupled together by threading, set screws or similar technique. In the illustrated embodiment, mandrel assembly 150 includes an upper mandrel member 152 including a profile 154 and a plurality of reclosing ports 156 , an intermediate mandrel member 158 that carries one or more lugs 160 and a lower mandrel member 162 including a plurality of opening ports 164 . It is to be understood by those skilled in the art that even though a particular arrangement of mandrel members is depicted and described, other arrangements of mandrel members are possible and are considered within the scope of the present invention.
Disposed between tubular assembly 124 and mandrel assembly 150 is a lug support sleeve 166 and a spring 168 . Together, lug support sleeve 166 , spring 168 and lugs 160 may be referred to as a lock assembly. Near their lower ends, tubular assembly 124 and mandrel assembly 150 define an actuation chamber 170 that is in fluid communication with opening ports 164 of mandrel assembly 150 . Together, tubular assembly 124 and mandrel assembly 150 define a central flow path 172 that extends between the upper and lower ends of tool 100 . As such, at least portions of mandrel assembly 150 may be considered as part of tubular assembly 124 in the section between tubular member 130 and tubular member 134 . As previously described with reference to FIG. 1 , central flow path 172 is in fluid communication with lower sand screen assembly 18 and therefore lower zone 14 .
Together, housing assembly 102 and tubular assembly 124 define a substantially annular flow path 174 . As previously described with reference to FIG. 1 , annular flow path 174 is in fluid communication with upper sand screen assembly 16 and therefore upper zone 12 . Disposed within annular flow path 174 is a sleeve 176 that has a plurality of seals 178 disposed on the inner surface thereof. In the illustrated embodiment, sleeve 176 is threadably coupled to a collet assembly 180 . Near its lower end, sleeve 176 is securably coupled to mandrel assembly 150 via a threaded connector held in position by a pin 182 that extends through one of three radially expanded sections of mandrel assembly 150 (only one being visible in the figures). Each of the radially expanded sections extends approximately thirty degrees in the circumferential direction such that the flow of fluid through annular flow path 174 is not prevented by the radially expanded sections. Also disposed within annular flow path 174 is an equalization pathway depicted as control line 184 that extends between tubular member 130 and tubular member 146 .
The operation of tool 100 will now be described with reference to FIGS. 2A-2D and 3A-3D . Tool 100 is initially run into the wellbore as part of the completion string with housing assembly 102 preferably forming a portion of the tubular string that extends to the surface. The completion string is the positioned at the desired location, such as that depicted in FIG. 1 . Initially, tool 100 is in its closed position as depicted in FIGS. 2A-2D wherein sleeve 176 is in its lower position with seals 178 engaging an outer sealing surface of tubular member 130 such that fluid flow through annular flow path 174 is prevented. In this configuration, treatment or other operations requiring fluid flow and pressure fluctuations downhole of tool 100 are performed through central flow path 172 . Even though pressure fluctuations are occurring in central flow path 172 and are communicated to actuation chamber 170 and therefore to a lower piston area of mandrel assembly 150 , operation of tool 100 is prevented. Specifically, annular flow path 174 and central flow path 172 are in fluid communication with one another above tool 100 . In addition, the pressure in annular flow path 174 above sleeve 176 is communicated to an upper piston area of mandrel assembly 150 via control line 184 that serves as a pathway to equalize pressure across mandrel assembly 150 .
After treatment or other operations to the lower zone or zones are complete, the lower zones may be plugged off and a tubing string may be stabbed into polished bore receptacle 128 of tubular assembly 124 . In this configuration, annular flow path 174 and central flow path 172 are no longer in fluid communication with one another above tool 100 . Now, increased pressure within central flow path 172 is communicated to actuation chamber 170 via opening ports 164 . This pressure acts on the lower piston area of mandrel assembly 150 and urges mandrel assembly in the uphole direction. Mandrel assembly 150 is threadably coupled to sleeve 176 and sleeve 176 is threadably coupled to collet assembly 180 . As best seen in FIG. 2B , collet assembly 180 selectively prevents upward movement of sleeve 176 and mandrel assembly 150 until the pressure exerted on the lower piston area of mandrel assembly 150 exceeds a predetermined value sufficient to radially inwardly retract the collet fingers of collet assembly 180 , to pass through a downwardly facing shoulder 186 of housing assembly 102 .
When the predetermined value is reached and the collet fingers of collet assembly 180 are radially retracted, sleeve 176 and mandrel 150 shift in the uphole direction to the position depicted in FIGS. 3A-3D . As illustrated, collet assembly 180 reengages with housing assembly 102 in annular recess 188 . Sleeve 176 is in its upper position partially disposed within annular pocket 116 of housing assembly 102 with seals 178 engaging an outer sealing surface of housing extension 110 . In this configuration, fluid communication between annular flow path 174 and the upper zone is allowed, enabling, for example, production from the upper zone into annular flow path 174 . Importantly, in this configuration, seals 178 are protected from fluid flow or any abrasive materials therein as seals 178 are sealingly engaged with the outer sealing surface of housing extension 110 and out of the flow path. As such, seals 178 are not susceptible to damage during production from the upper zone or other fluid flow operations therethrough. Also, in this configuration, downhole movement of mandrel assembly 150 is prevented as spring 168 has urged lug support sleeve 166 under lugs 160 which are now aligned with and interfere with profile 144 of tubular member 142 , as best seen in FIG. 3C .
Referring additionally to FIGS. 4A-4D , if it is desired to return tool 100 from the open position to the closed position, a fluid diverter 190 may be run downhole on a conveyance that is depicted as wireline 192 and positioned within tool 100 . Fluid diverter 190 includes a latch assembly 194 that is operable to engage profile 154 of mandrel assembly 150 . Once engaged, a discharge port 196 of fluid diverter 190 is in fluid communication with reclosing ports 156 of mandrel assembly 150 . In this configuration, fluid pressure above seals 198 of fluid diverter 190 in central flow path 172 is routed to chamber 200 , which is in fluid communication with reclosing ports 156 via discharge port 196 . The fluid pressure then acts on a lower piston area of lug support sleeve 166 which compresses spring 168 and unprops lugs 160 , as best seen in FIG. 4C .
The fluid pressure from chamber 200 now acts on an upper piston area of mandrel assembly 150 and urges mandrel assembly 150 downhole. As best seen in FIG. 4B , collet assembly 180 selectively prevents downward movement of sleeve 176 and mandrel assembly 150 until the pressure exerted on the upper piston area of mandrel assembly 150 exceeds a predetermined value sufficient to radially inwardly retract the collet fingers of collet assembly 180 , to pass through an upwardly facing shoulder of annular recess 188 of housing assembly 102 . When the predetermined value is reached and the collet fingers of collet assembly 180 are radially retracted, sleeve 176 and mandrel 150 shift in the downhole direction to the position depicted in FIGS. 2A-2D . As illustrated, collet assembly 180 is now repositioned below downwardly facing shoulder 186 of housing assembly 102 , thereby selectively preventing upward movement of sleeve 176 and mandrel assembly 150 . Sleeve 176 is now repositioned in its lower position with seals 178 engaging an outer sealing surface of tubular member 130 . In this configuration, fluid flow through annular flow path 174 is prevented and tool 100 has been returned to its closed configuration. The processes of opening and reclosing tool 100 can be repeated as required to enable independent and selective production from the upper and lower zones.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | An apparatus for isolating a first zone from a second zone in a subterranean wellbore. The apparatus includes an outer tubular and an inner tubular disposed within the outer tubular forming an annular flow path therebetween that is in fluid communication with the first zone. The inner tubular defines a central flow path that is in fluid communication with the second zone. A sleeve having at least one seal is positioned in the annular flow path and is axially movable relative to the inner and outer tubulars between a closed position wherein the seal engages the inner tubular and an open position wherein the seal engages the outer tubular. A mandrel is slidably disposed within the inner tubular and is coupled to the sleeve. The mandrel is operable to shift the sleeve between the open position and the closed position responsive to changes in pressure within the central flow path. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 arising from an application for A Personal Computer with an Easy Assembly Structure earlier filed in the Korean Industrial Property Office on Jun. 14, 1995 and there duly assigned Ser. No. 15756/1995. Also, this application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §120 arising from an U.S. application Ser. No. 08/652,969 now issued as U.S. Pat. No. 5,823,644 on Oct. 20, 1998 and filed on May 24, 1996 in which the instant application is a divisional application thereof.
FIELD OF THE INVENTION
The present invention relates to a personal computer, and more particularly to a main body case structure that is easy to assemble and disassemble, so that it becomes easier for a user to manipulate, and simpler for a manufacturer to make.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,083,589 for a Vehicle Security System to Palmerino discloses a vehicle security system where the user pushes a push button to overcome a spring bias. This causes a piece monolithically integrated with the push button to translate in the same direction as the push button. An inclined surface on the monolithic piece of the push button, in contact with a second member, slides the second member by camming action, in a direction perpendicular to the direction of travel of the push button.
U.S. Pat. No. 2,648,561 for a Push Button Latch to Landon discloses a similar device as the one depicted in Palmerino. In Landon, a button is pushed, overcoming the resilient force of a spring bias, causing a member monolithically integrated to the push button to translate in the same direction as the push button causing an inclined plane located on the monolithic push button piece to move in the same direction as the push button. This inclined plane remains in contact with a second member, causing, by camming action, the second member to translate in a direction perpendicular to the first member and against a spring bias on the second member. The translation in the second member caused by the depression of the button on the first member frees a latch monolithically integrated on the second member from an aperture in a chassis part, allowing for the disassembly of the chassis.
U.S. Pat. No. 1,944,450 for a Sash Control for Sliding Windows to Myers describes a window sash control. In Myers, a push button is depressed, causing a monolithically integrated member to cam with a latch bar forcing the latch bar to pivot downward in a direction perpendicular to the push button motion and opposite the spring bias on the latch bar. By forcing the latch bar to pivot downward, a layer of weatherstripping is disengaged.
U.S. Pat. No. 2,221,095 for a Door Locking and Latching Mechanism to Jacobi describes a door locking and latching mechanism. In Jacobi, a push button feature is disclosed. When the push button is depressed, the member monolithically integrated with the push button travels in the same direction as the push button. A rotatable latch, in contact with the push button member, is rotated against a spring bias because of the force of the push button member. This rotation of the latch member against spring bias causes a hook, monolithically integrated to the pivotable latch member, to rotate out from an aperture of the structure allowing for the door to open.
U.S. Pat. No. 5,321,962 for an Injector/Ejector Latch Lock Mechanism to Ferchau et al. illustrates a sliding safety mechanism that prevents the operation of an unlatching mechanism on a computer console. A security lock prevents a trigger from rotating preventing a handle pivotably mounted on the chassis from unlatching the chassis parts preventing the disassembly of the chassis.
U.S. Pat. No. 2,893,773 for a Latch and Detent Assembly to Clifton describes a latch with a detent assembly for a door. The detent prevents the unauthorized unlatching of the door.
U.S. Pat. No. 5,213,382 for a Locking Mechanism for Refuse Container to Dawdy et al. discloses a locking mechanism where a control bar is pivotably mounted and contains a tab section having an aperture. A locking bar also contains a tab with an aperture. When the control bar is rotated to the latched position, the tabs of the control bar and the locking bar as well as the respective apertures align. A padlock may be inserted through the two holes when aligned preventing the subsequent unlatching of the container.
The above button operated latches have not been used in computer cases because of the availability of a less expensive alternatives, such as using screws. In the past, it was generally a service technician, rather than an operator, that opened computer cases. As a service technician would work on many computer cases in a single day, the service technician was equipped with specialized equipment to open and close a computer case and to fix the equipment. Today, it is more common for an operator to be required to open and close a computer case. Since an operator opens a computer case only occasionally, it is much more cumbersome for the operator to possess and use tools to accomplish this task. Thus, the latch mechanism would facilitate the opening and closing of the computer case for such an operator.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a main body case of a personal computer which enables convenient assembling and disassembling and increases assembling efficiency which, as a result, improves productivity of the main body of the computer in the manufacturing process.
It is yet another object to provide a mechanism for disassembling of a computer case that requires a user to simply depress a button while pulling the cover unit off the base unit of the chassis.
It is still another object to provide a mechanism for assembling a computer case by simply sliding together top and bottom assembly members.
It is still yet another object to provide a detent mechanism that prevents the inadvertent disassembly and opening of a computer case by providing a mechanism for preventing a button from being depressed.
It is also an object to provide a security mechanism by providing for the use of a padlock to prevent the inadvertent opening and disassembly of a computer case.
These and other objects may be achieved by a personal computer having a bottom plate member where the components of the computer are mounted, and first and second plates erected respectively at front and rear portions of the bottom plate and monolithically integrated to the bottom plate, and a front-upper cover assembly including a front cover portion forming the front side of the computer and an upper cover portion covering upper, left, and right sides of the computer, thus completing the external appearance of the computer. In addition to the above enclosure, a push button operated locking mechanism is fixedly attached to the front upper cover assembly for engaging and disengaging the bottom plate assembly. Pushing the button causes, by camming action, a catching member to rotate, causing a hook on the catching member to rise from a catching edge of an aperture located on the first plate of the bottom plate assembly. The case also includes a sliding detent mechanism, which allows a knob, slidably attached to the front upper cover assembly near the button, to slide up to the button, causing a protruding tab on the knob to be inserted into a cavity in the button, thus preventing the button from being depressed and thus preventing the inadvertent disassembly and opening of the computer case. Lastly, the case includes a security mechanism having a tab, monolithically integrated with the front upper cover assembly and containing a first aperture for a padlock to lock onto at the extremity of the tab, so that when the tab is slid into a second aperture in the second plate of the bottom plate assembly, a padlock can lock onto the first aperture thus preventing the removal of the tab from the second aperture thus preventing the inadvertent and unwanted disassembly, separation, and opening of the computer case.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of this invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
FIG. 1 is a drawing which shows the conventional computer case;
FIG. 2 is an exploded perspective view of a computer case assembly in accordance with the principles of the present invention;
FIG. 3A is a sectional view showing a guide pin on the front cover connected to a guide hole of the first plate of the bottom plate member in accordance with principles of the present invention;
FIG. 3B is a sectional view showing a guide pin of the rear flange of the front upper cover assembly connected to a guide hole in the second plate of the bottom plate member in accordance with principles of the present invention;
FIG. 4 is a fragmentary sectional perspective view showing the locking mechanism of principles of the present invention;
FIG. 5 is a sectional view showing the latched state of the locking mechanism in accordance with principles of the present invention;
FIG. 6 is a sectional view showing the unlatched state of the locking mechanism in accordance with principles of the present invention;
FIG. 7 is a fragmentary sectional perspective view showing the assembly structure of the front and upper cover for purpose of showing the slidable detent mechanism according to the first embodiment of the present invention;
FIG. 8 is a sectional view illustrating the locked state of a security mechanism according to a second embodiment of the present invention; and
FIG. 9 is a sectional view illustrating the unlocked state of a security mechanism according to the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A personal computer generally has a main body that contains a central processing unit, a memory unit, an auxiliary storage device, an input device such as a keyboard, and an output device such as a monitor. The main body completely encapsulates these components. Because the main body is generally not made of one monolithic piece, the case of the main body is formed by the assembly of a plurality of parts. The main body case of the personal computer is composed of a bottom plate on which various computer parts are mounted, an upper cover for covering and protecting the computer parts which are placed on the bottom plate, a front cover which decorates the front of the main body, and side and rear plates.
A conventional computer case as shown in FIG. 1. The assembly of the main body case is achieved by fixing the front cover 100 to the front part of the upper cover 102 so that they are formed integrally in one body as upper cover assembly 101, and then by combining the upper cover assembly 101 with the bottom plate assembly 105 made up of a bottom plate 104, a rear panel 106, and a front panel (not shown). The combining of upper cover assembly 101 with bottom plate assembly 105 is achieved by screwing rear plate 106, erected from the rear end of the bottom plate assembly 105, into screw holes 108 formed on rear flange 107 of upper cover assembly 101, by means of screws 110. Thus, assembly of a conventional computer case involves screwing together two monolithic units.
As a result, if a user wants to open the conventional computer case for interior repair or installation, the whole upper cover assembly 101 needs to be removed from bottom plate assembly 105. The drawback of the conventional computer case is that all the screws need to be loosened and screwed back in when assembling and disassembling the case. This is an inconvenient process as it is time consuming and creates a risk of losing screws. In addition, since every screw should be driven one by one in assembling the main body at the manufacturing process, productivity is greatly reduced due to the decrease of assembling efficiency.
FIG. 2 is an exploded perspective view of computer case 203 assembly according to the preferred embodiment of the present invention. As with conventional computer case 103, the present invention achieves complete encapsulation of the computer components by joining together two monolithically integrated parts, bottom plate member 120 and front upper cover assembly 130. Unlike the conventional computer case, the present invention does not use screws or tools to assemble or disassemble the computer case.
Bottom plate member 120 is a monolithically integrated part that contains bottom plate 122, first plate 124 in the front, and second plate 126 in the rear. The computer components are mounted on bottom plate 122. Front upper cover assembly 130 is a separate monolithically integrated part that contains front cover 134, upper cover 135, left side 138, right side 139, and rear flange 136 extending around the periphery of the rear side. When computer case 203 is assembled, front cover 134 is placed in front of first plate 124 making first plate 124 invisible to an external observer. Meanwhile, rear flange 136 is obscured to an outside observer by second plate 126 when computer case 203 is assembled.
When assembling computer case 203, in order to provide for a snug fit between bottom plate member 120 and front upper cover assembly 130, guide pins 16 on front upper cover assembly 130 are positioned to fit inside guide holes 12 in bottom plate member 120. During assembly of computer case 203, at least one guide pin 16 of front cover 134 of front upper cover assembly 130 is positioned to slide into corresponding guide hole 12 of first plate 124 of bottom plate member 120. See FIG. 3A in conjunction with FIG. 2. Simultaneously, at least one guide pin 17 of rear flange 136 of front upper cover assembly 130 is positioned to slide into corresponding guide hole 14 of second plate 126 of bottom plate member 120. See FIG. 3B in conjunction with FIG. 2. The result is a tight, snug fit between front upper cover assembly 130 and bottom plate member 120.
Separate from the guide pins and guide holes already discussed, a locking mechanism for latching front upper cover assembly 130 to bottom plate member 120 is provided. Supporting member 18 for supporting pivotable latching member 20 is mounted on either the left or right side of the inside of front cover 134. Button member 22 for operating pivotable latching member 20 is shown in FIG. 4. Supporting member 18 includes plane portion 24 and side walls 32 and 34, and is fixed to bosses 28 projecting from the inside of the front cover 134 by means of fixing screws 26. Through hole 30 is formed in the central part of plane portion 24 of supporting member 18, and through which the front portion of pivotable latching member 20 is inserted. The size of through hole 30 is such that front projecting portion 50 of pivotable latching member 20 can vertically move to some degree.
Pivotable latching member 20 is rotatably fixed to the lower part of supporting member 18 between side walls 32 and 34. See FIG. 2. Pivotable latching member 20 includes plane portion 36 and side walls 38 and 40. The lower front portion of side walls 38 and 40 of pivotable latching member 20 are hinged to side walls 32 and 34 of supporting member 18 by means of hinge member 43. Elastic member 42 which upwardly forces the front end portion of pivotable latching member 20 is made up of a coil spring having winding parts 46 and 48 and connecting part 44 between winding parts 46 and 48, as shown in FIG. 2. Hinge member 43 passes through winding parts 46 and 48 while connecting part 44 is positioned near front projecting portion 50 of pivotable latching member 20. Connecting part 44 elastically supports the upper side of the front projecting portion 50. The free ends of elastic member 42 are elastically supported on a lower edge of through hole 30 of plane portion 24 of supporting member 18. Side walls 38 and 40 are upwardly concaved to form hooks 52 and 54 in the rear portion of pivotable latching member 20. Hooks 52 and 54 latch onto edge 57 of aperture 56 in first plate 124 of bottom plate member 120.
Button member 22 for operating pivotable latching member 20 includes plane part 58 formed out of a rectangular shaped member in which catching groove 64 is formed to catch protrusion 62 of plane portion 36 of pivotable latching member 20. Button member 22 also includes button 60 located at an opposite end from plane part 58. See FIG. 2. Coil spring 66 biases button member 22 and button 60 outward while flange 70 surrounding button 60 prevents button member 22 from being ejected by coil spring 66 from case 203. Flange 70 is positioned just inside front cover 134, and since flange 70 is bigger than aperture 92, flange 70 succeeds in holding button member 22 in place inside aperture 92, thus preventing button member 22 from being ejected. Button member 22 is assembled so that plane part 58 passes through slot 68 formed on side wall 32 of supporting member 18, and so that catching groove 64 catches protrusion 62. Catching groove 64 is bounded by a catching edge 65 on the side of groove 64 furthest from button 60, and by inclined edge 63 on the side of groove 64 closest to button 60. When button member 22 is outwardly retracted, catching edge 65 of groove 64 catches protrusion 62 of pivotable latching member 20. When button 60 is pressed, inclined edge 63 of catching groove 64 of plane part 58 of button member 22 cams with protrusion 62 of pivotable latching member 20, causing the front portion of pivotable latching member 20 to rotate downward against the resilient force of elastic member 42. Rotation against the bias of elastic member 42 causes hooks 52 and 54 in the rear of pivotable latching member 20 to rise from edge 57 of aperture 56 of first plate 124 of bottom plate member 120, allowing front upper cover assembly 130 to be separated from bottom plate member 120. See FIG. 6. While button 60 is pressed, front upper cover assembly 130 can be removed from bottom plate member 120 by simultaneously pulling on front cover 134. This will cause guide pins 16 and 17 to withdraw from guide holes 12 and 14 respectively, separating front upper cover assembly 130 from bottom plate member 120. See FIG. 6.
Assembly of computer case 203 is achieved by first attaching the electronic computer components to bottom plate 122 of bottom plate member 120. Next, front upper cover assembly 130 is placed over bottom member 120 so that front cover 134 extends in front of first plate 124. Guide pins 16 and 17 are now aligned with guide holes 12 and 14 respectively, while pivotable latching member 20 is aligned with aperture 56. Front cover 134 and second plate 126 are squeezed together causing front cover 134 to move closer to first plate 124. As this occurs, guide pins 16 and 17 are inserted into guide holes 12 and 14 respectively while hooks 52 and 54 of pivotable latching member 20 cams with edge 57 of aperture 56 of first plate 124 of bottom member 120, causing the rear portion of pivotable latching member 20 to rotate upward while the front portion of pivotable latching member 20 rotates downward, causing hooks 52 and 54 of pivotable latching member 20 to slide into aperture 56 and to engage with edge 57 of bottom member 120, thus automatically latching front upper cover assembly 130 to bottom member 120.
FIG. 7 illustrates a first embodiment of this invention, showing a detent feature for button 60. The detent mechanism according to this embodiment consists of a monolithically integrated unit, called locking knob 76, slidably attached to slide groove 80 of front cover 134 of front upper cover assembly 130. Locking knob 76 can slide vertically along slide groove 80 of front cover 134 just beneath aperture 92, where button 60 protrudes. Locking knob 76 contains catching protrusion 74 on the upper side, and a gripping protrusion 78 on the lower side. Catching protrusion 74 extends upward parallel to the direction of sliding of locking knob 76, while gripping protrusion 78 extends outward, parallel to the direction of travel of button member 22. Inside gripping protrusion 78 is ball 84, and elastic member 82 to push ball 84 inside. Because ball 84 is always supported elastically on the inside of slide groove 78, ball 84 can prevent locking knob 76 from sliding downward inadvertently. Underneath the middle portion of button 60 is socket 72 which accommodates catching protrusion 74 when locking knob 76 is slid upwards towards button 60. Accordingly, after assembly of computer case 203, if locking knob 76 is raised, then catching protrusion 74 is inserted into socket 72, preventing button 60 from being pressed down.
FIG. 8 and FIG. 9 portray the second embodiment showing a security mechanism applicable to the present invention. In the second embodiment, locking tab 86 protrudes rearward from rear flange 136 of front upper cover assembly 130. Aperture 88 is positioned on second plate 126 of bottom plate member 120, so that locking tab 86 can be inserted into aperture 88 during assembly. Aperture 87 located near the rearward extremity of locking tab 86, allows padlock 90 to attach to tab 86 after tab 86 has been inserted through aperture 88. Padlock 90 prevents the inadvertent withdrawal of tab 86 from aperture 88, thus preventing the separation of front upper cover assembly 130 from bottom plate member 120.
In conclusion, bottom plate member 120 and front upper cover assembly 130 are assembled as shown in FIG. 2, and there is no need to use screws or tools when assembling the present invention. Therefore, the present invention achieves convenient assembling and disassembling and can increase assembling efficiency and improve productivity in the manufacturing process.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | The present invention is a personal computer case that is easy to assemble and disassemble. The computer case can be separated into two members, the first covering the top, front, right and left sides of the case, and the second covering the bottom, front, and rear sides of the case. A push button operated latch enables one member to become detached from the other member, allowing the case to be opened, without requiring the use of screws or special tools. The push button contains a slidable detent feature that can prevent the button from being depressed, thus preventing the inadvertent disassembly, separation, and opening of the computer case. The case contains a security feature that involves attaching a padlock to a tab portion of one member that is slid through a hole in the other member. With the padlock attached, the tab can not be retracted from the hole, thus preventing the unwanted separation of the two members. |
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FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a bedroom cabinet, and more specifically, to a unit type bedroom cabinet which is optimum to provide a flophouse facility comprising a number of individual rooms on the floor of an existing building.
There have been heretofore proposed unit type bedroom cabinets used as a flophouse requiring no bath room or a flophouse for taking a nap. This bedroom cabinet is designed so that it has a floor area at least approximately equal to an area of a bed, has a height such that a user can erect the upper half of his body on the bed, and has the circumference completely shut off from the outside except a doorway. Such a bedroom cabinet can be carried afer it has been assembled and completed and can be simply installed for workmen's quarters or a stadium in a site of construction. In this case, since of course a plurality of bedroom cabinets can be arranged in a plane on the floor of the building and one bedroom cabinet can be stacked on the other, many workmen can be received in a limited floor area for rest. Fixing one's eyes upon this advantage, an attempt has been also made to provide a flophouse in which a number of bedroom cabinets as described above are installed for users to take a nap at at low charges.
DESCRIPTION OF THE PRIOR ART
Such a bedroom cabinet is disclosed, for example, in U.S. Pat. No. 4,395,785 invented by the inventor of the present application. This bedroom panel is assembled in the box-shape by six single layer panels, that is, a bottom panel, a ceiling panel, a front panel, a back panel, a left side panel and a right side panel. The front panel is provided with an opening for an exit, and the bottom panel has a mat thereon. Within the cabinet are projectingly provided an inclined portion which serves as a backrest when a user sits on the mat, a box for accommodating therein a TV receiver, and a box used for accommodating therein an interphone or a radio receiver. The box for a TV receiver can be provided at an upper corner within the cabinet, thus posing no problem, but the box for an interphone is provided at a lower position to which user is easily accessible. Thus, if a protruded portion is provided at the lower portion of the cabinet, a dwelling area is reduced through that amount. The bedroom cabinet is composed of single layer panels and a vent is provided on the panel which serves as a side wall surface. Therefore, the side wall portion is likely to be decreased in strength and in addition there has been encountered a problem in terms of sound-proof.
In this case, there is an idea such that the box is projected from the outer peripheral surface of the cabinet so as not to narrow the dwelling area. However, the provision of a portion projected from the outer periphery of the cabinet makes it necessary to provide a clearance through that projected portion and in addition deteriorates an external appearance, where a plurality of cabinets are stacked or installed adjacent to each other.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to overcome these disadvantages noted above with respect to conventional bedroom cabinets and provide a bedroom cabinet in which the external surfaces thereof are formed to be flat.
It is a further object of the invention to provide a bedroom cabinet in which shelves for accommodating therein a user's belongings and a box for accommodating therein devices such as an interphone can be provided within the cabinet without being projected therein and without being projected from the outer periphery of the bedroom cabinet.
In accordance with the present invention, there is provided a bedroom cabinet formed into a box-shape by a hexahedron consisting of four side surfaces, an upper surface and a lower surface, comprising an outer casing composed of upper and lower outer casings, the upper outer casing having front and rear side portions, left and right side portions and an upper surface portion integrally formed, the front side portion being formed with a notch portion corresponding to the upper half of an exit, the lower outer casing having front and rear side portions, left and right portions and a lower surface portion integrally formed, the front surface portion being formed with a notch portion corresponding to the lower half of the exit; an inner casing positioned within the outer casing and comprising a front surface panel, a back panel, left and right side panels, a ceiling panel and a bottom panel, the front surface panel having an opening in communication with the notches of the upper and lower outer casings and having an area approximately equal to the exit, the bottom panel having a mat thereon, wherein a peripheral edge at the lower end of the upper outer casing and a peripheral edge at the upper end of the lower upper casing are respectively formed with outwardly projected flanges, and the outer casing is assembled in such a way that the flange of the upper outer casing is brought into abutment with the flange of the lower outer casing.
The bedroom cabinet of the present invention is of the dual construction comprising the outer casing and the inner casing, and therefore it is excellent in mechanical strength. In addition, by providing a clearance is formed between the outer casing and the inner casing a box in which electric devices such as an illuminating instrument, an interphone or the like is mounted or a box which serves as a shelf for accommodating therein a user's belongings can be formed in this clearance, and therefore such boxes will not be projected within the cabinet and from the outer periphery of the outer casing. Accordingly, the dwelling area can be effectively utilized, and since the external surfaces of the cabinet are formed to be flat, a plurality of bedroom cabinets can be closed stacked or installed adjacent to each other. The clearance between the outer and inner casings used to form a box can house therein wirings or the like for interior electric devices.
The present invention further provides a bedroom cabinet wherein a clearance between an outer casing and an inner casing is formed over the whole periphery, and spacer members are interposed in the clearance in a suitably spaced relation, the spacer member being formed with a venting groove. Thereby, an uniform air flowpassage is formed in the outer periphery of the inner casing whereby natural ventilation within a room can be carried out smoothly, and sound-proofing effect can be also increased.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing one embodiment of a bedroom cabinet in accordance with the present invention.
FIG. 2 is a front view in longitudinal section of the bedroom cabinet of FIG. 1.
FIG. 3 is a sectional view taken on line 3--3 of FIG. 2.
FIG. 4 is a sectional view taken on line 4--4 of FIG. 2.
FIG. 5 is a perspective view showing the bedroom cabinet of FIG. 1 in an exploded form.
FIG. 6 is a perspective view, in an exploded form, showing a joint between an upper outer housing and a lower outer housing.
FIG. 7 is a front view in longitudinal section showing a further embodiment of the present invention.
FIG. 8 is a sectional view taken on line 8--8 of FIG. 7.
FIG. 9 is a perspective view showing a part of a spacer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of a bedroom cabinet of the present invention shown in FIGS. 1 through 6 will be described. A bedroom cabinet has an upper outer housing 11 and a lower outer housing 12 which are integrally formed of a fiber reinforced plastic (FRP) or the like. The upper outer housing 11 has an upper surface portion 13, a back surface portion 14, left and right side surfaces 15 and a front portion 16, the front portion 16 being formed with a notch portion 18 for forming the upper half of an exit 17. The lower outer housing 12 has a lower surface portion 9, a back surface portion 20, left and right side surfaces 21 and a front portion 22, the front portion 22 being formed with a notch portion 23 for forming the lower half of the exit 17. The upper surface portion 13 and back surface portion 14 of the upper outer housing 11 and the lower surface portion 19 and back surface portion 20 of the lower outer housing 12 are respectively formed with a plurality of recesses 24 having a required width, and the recess 24 in the upper surface portion 13 of the upper outer housing 11 is formed with a number of venting through-holes 25 in a suitably spaced relation. A peripheral edge at the lower end of the upper outer housing 11 and a peripheral edge at the upper end of the lower outer housing 12 are respectively formed with horizontally outwardly projecting flanges 26, 27 so that when the upper outer housing 11 is placed on the lower outer housing 12, these flanges 26, 27 are placed in abutment with each other.
The upper and lower outer housings 11 and 12 are internally provided with an inner casing 2 comprising a front panel 31, a back panel 32, a right side panel 33, a left side panel 34, a ceiling panel 35 and a bottom panel 36, totalling to six panels. The front panel 31 positioned on the side of the exit 17 is provided with an opening 37 corresponding to the exit 17, as shown in FIGS. 4 and 5. One surface adjacent to the opening 37 is formed with a box 40 in which an illuminating device 38 or an interphone 39 is mounted and a box 42 in which a device 41 such as a clock or a radio receiver is mounted. These boxes 40 and 42 are formed to be projected outwardly. Upper and lower ends of the front panel 31 are inwardly bent to form a flange 43 on which is mounted a curtain rail 45 for a curtain 44 to block the exit 17. The back panel 32 is formed with boxes 46 and 47 similar to the boxes 40 and 42 and a box 48 constituting an accommodating shelf, as shown in FIGS. 2 through 5, and is formed at its lower portion with a plurality of vent holes 49. These boxes are also formed to be projected outwardly. It is noted that the boxes 46 and 47 can be also used for installation of devices which cannot be accommodated within the boxes 40 and 42 on the front panel 31 or can be used as arranging shelves. The right side panel 33 has a shelt 52 for accommodating therein a TV receiver 51, as shown in FIGS. 2 through 5, and the shelf 52 is formed to be projected inwardly. The left side panel 34 is formed with an inclined portion 53 which is useful as a backrest when a user rests in the bedroom cabinet, as shown in FIGS. 2, 4 and 5, and a cushion 54 is stuck to the surface of the inclined portion. The ceiling panel 35 has for example expanded styrol and urethane laminated to provide sound-proofing effect. The ceiling panel 35 is formed with a number of vent holes 55 in a suitably spaced relation. Finally, the bottom panel 36 is formed with a rim 57 used to fix a mat 56, as shown in FIGS. 2, 3 and 5. The box 48 of the back panel 32 is provided with a plurality of shelt plates 58 and an accommodating section with a door 59 that may be used for a locker or the like. Of course, this box 48 can be used as a mere box with the shelf plates 58 and the door 59 removed.
While adjacent end edges of each of the panels 31 to 36 are connected and fixed by seals 60, it should be noted that the seal 60 is not always necessary but a fit-in type groove can be formed in each end edge so that they are connected by said groove.
Next, assembling of the bedroom cabinet will be described. First, the lower half of the inner casing composed of the panels 31 to 36 connected and fixed as described above is received into the lower outer casing 12. It is of course at this time that the inner casing is fitted into the lower outer casing 12 in such a way that the notch portion 23 of the front portion 12 of the lower outer casing 12 is registered with the lower half of the opening 37 of the front panel 31. Next, the upper outer casing 12 is fitted in such a way that the notch portion 18 thereof is registered with the upper half of the opening 37 of the front panel 31, and the flange 26 is brought into abutment with the flange 27 of the lower upper casing 12. These two flanges 26 and 27 are resiliently held by a clip member 61 formed from a resilient metal plate, as shown in FIG. 6 in detail. Preferably, a recess 62 is formed in portions of the flanges 26 and 27 held by the clip member 61 to prevent the clip member 61 from being deviated in a lateral direction. An ornamental web 63 formed of an expansible material such as rubber or synthetic resin is wound so as to cover the flanges 26 and 27. This web 63 is formed at its inner surface with an escape groove 64 for the flanges 26 and 27, and on both ends thereof are mounted hooks 65 to be engaged with the end edge of the exit 17. The hook 65 is secured to be web 63 by inserting and locking a screw 67 to a stop plate 66 provided on the rear surface of the end of the web 63 therethrough. The exit 17 with which the hook 65 is engaged by superposition of the notches 18 and 23 of the upper and lower outer casings 11 and 12 and the opening 37 of the front panel 31, and an edge frame 68 formed of an elastic material is mounted so as to bridge over both peripheral edges of the notches 18, 23 and opening 37. Thus, the hook 65 is passed over the edge frame 68.
Articles such as a TV receiver 51 are mounted within the thus assembled bedroom cabinet. In this case, if various electric devices such as a TV receiver 51, an interphone 39 and the like are mounted under the condition that the inner casing is fitted and fixed within the lower outer casing 12, wiring work to the outside of the inner casing can be achieved easily.
As shown in FIGS. 2 to 5, in the above-described embodiment, a sheet 71 to cover the mat 36 is in the form of a web in which both ends thereof are wound by winding rollers 72 and 73, a dirty sheet 71 can be wound on one roller by rotating the winding rollers 72 and 73 in one direction. The sheet 71 is pressed against the mat by keep members 74 and 75 provided in the neighbourhood of each of the winding rollers 72 and 73.
Next, a second embodiment of the bedroom cabinet of the present invention shown in FIGS. 7 through 9 will be described. The same elements in this embodiment as those in the above-described first embodiment bear the same reference numeral, the details of which will not be described. In the second embodiment, the desired clearance over the approximately entire portion is provided between the upper and lower outer casings 11, 12 and the inner casing composed of six panels 31 to 36.
That is, the upper and lower outer casings 11 and 12 are formed to be somewhat large or the inner casing is formed to be somewhat small, whereby a clearance over the approximately entire portion can be formed between the outer casings 11, 12 and the inner casing. Spacer members 77 each having a vent groove 76 are interposed and locked between the inner surfaces of the upper and lower outer casings 11, 12 and the panels 31 to 36 opposed to the upper and lower inner surfaces thereof. The spacer member 77 can be different in strength depending on the position disposed. That is, the spacer member 77 interposed between the lower surface 19 of the lower outer casing 12 and the bottom panel 36 is subjected to the approximately entire load of six panels 31 to 36, loads of various devices provided and the user's weight, and therefore, it is formed of a material having a great strength. On the other hand, the spacer member 77 interposed between the upper surface 13 of the upper outer casing 11 and the ceiling panel 35 can be supported under the condition that the celing panel 35 is suspended to maintain its clearance, and therefore, a small strength thereof will suffice. Further the spacer members 77 respectively interposed between the side, front and back surfaces of the outer casings 11, 12 and the side panels 33, 34, the front panel 31 and the back panel 32 may have an intermediate strength between the spacer member between the uper surface portion 13 and the ceiling panel 35, and the spacer member between the lower surface portion 19 and the bottom panel 36.
As described above, in the second embodiment, a spacer member 77 having the required strength is interposed between the outer casings 11, 12 and the interior body to form a clearance in communication as a whole. This clearance acts as an intake and exhaust passage in communication with the vent hole 49 and with the vent hole 55 of the ceiling panel 35 and also serves as a sound-proofing wall. In this second embodiment, an inclined portion 53 is provided on the right side panel 33 and a box 52 for a TV receiver is provided on the left side panel 34. An illuminating device 38, an interphone 39 and a device 41 are mounted on the boxes 46 47 of the back panel 32. | A bedroom cabinet having a floor area at least approximately equal to an area of a bed and a height such that a user can erect the upper half of his body on the bed. This cabinet is composed of two layers, that is, an outer casing and an inner casing, the outer casing being divided into an upper casing and a lower casing, and a recess serving as an accommodating shelf for electric devices and a user's belongings is provided in the side wall of the inner casing so as to be projected outwardly. This projection of the recess is projected into a clearance between the outer casing and the inner casing, and the projection of the recess is formed so as not to be further projected from the outer periphery of the outer casing, the clearance being used as a wiring passage for electric devices and as vent passage for ventilation. |
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BACKGROUND OF THE INVENTION
This invention relates generally to automatically opening doors. More particularly, the present invention relates to apparatus for testing the door controller and door sensors of an automatic door system.
Automatic door systems of a type which are automatically operable for initiating an opening sequence upon sensing the motion or the presence of traffic at the doorway or receiving a command from a push plate, card reader, mat or other operation initiating device are now commonplace. A number of automatic door systems employ infrared sensors to initiate the door opening sequence. The sensors sense traffic approaching the doorway by detecting changes in received active or passive infrared radiation. Infrared sensors also function as safety devices to ensure that the doors do not inadvertently close.
Some conventional door applications employ multiple sensor units. For example, an approach sensor unit may be positioned at each side of the door to sense approaching traffic. The approach sensors may be conventional microwave field distortion devices or active infrared motion sensing devices. For one-way doors, a single approach sensor may be positioned to detect traffic approaching from the approved direction. A threshold or safety sensor may be positioned to cover the threshold area. Such safety sensors are conventionally presence sensing devices such as pulsed infrared beams.
The controller for the automatic door system must be capable of performing sophisticated signal processing. The controller typically must open the door upon receipt of an appropriate signal from an approach sensor, hold the door open for a predetermined period of time or until the safety sensor no longer senses a presence in the threshold area, and close the door. It should be noted that because of the movement of the doors, the controller and sensors which are employed in the automatic door system must take into account the movement of the door itself. In addition, the sensor and controller must accommodate changes in the background environment.
Periodically, the automatic door system must be tested to ensure that the doors will operate as required. In the event of a component or system failure, testing is also required to troubleshoot and repair the system. With the increasing complexity of the control systems and the sensors, the equipment required to perform such testing has grown in complexity and expense.
SUMMARY OF THE INVENTION
Briefly stated, the invention in a preferred form is a device for testing automatic door systems which has a test circuit, including a display, a micro-controller, a memory for storing data and a test program, and a control switch for controlling operation of the test program by the micro-controller. The test device is installed by connecting the data and power connector of the controller and the data connector of the sensors to the test circuit. A selector switch on the test device is moveable between first and second positions. When the selector switch is in the first position, it completes a data path between the test circuit and the controller and blocks the exchange of data between the sensors and the test circuit and the first connector. When the selector switch is in the second position, it completes a data path between the test circuit and the second connector and blocks the exchange of data between the controller and the test circuit and the second connector.
The automatic door system provides power to the test device via its connection with the controller. The test circuit includes a first voltage comparator for monitoring the automatic door system power and the display comprises an LED for indicating the status of the automatic door system power. A second and third voltage comparator of the test circuit are used to monitor the voltage of the controller and sensor clock lines and data lines during testing. The display also includes an alphanumeric indicator for displaying the test results.
When the test device is installed between the controller and the sensors, the first voltage comparator senses the controller voltage and lights the LED if the sensed voltage is above a predetermined value. The test device micro-controller then prompts the test personnel to place the selector switch in the first position to test the controller. Pressing the control switch steps the micro-controller through the test program such that the second voltage comparator monitors first the voltage of the controller clock line and then the third voltage comparator monitors the data line and provides an indication on the alphanumeric indicator whether or not the sensed voltage is above or below a predetermined minimum value. Next the micro-controller is directed to monitor the signals on the clock line and the data line and provide an indication whether or not the sensed signals correspond to signals which are stored in the memory, thereby completing the testing of the controller.
The micro-controller then prompts the test personnel to move the selector switch to the second position. Pressing the control switch continues to step the micro-controller through the test program such that the second and third voltage comparators monitor the voltage of the sensor clock line and data line and provides an indication on the alphanumeric indicator whether or not the sensed voltage is above or below a predetermined minimum value.
The software then directs the micro-controller to test each sensor. The micro-controller establishes communication with a designated sensor and causes the sensor emitter to emit a signal into a detection zone. If an object is within the zone, the sensor detector detects a return signal. The micro-controller then provides an indication on the alphanumeric indicator whether or not the sensor detector detects the return signal. If the detector is not receiving a return signal, the test personnel places an object in the zone. The sensor performance is satisfactory if the indication changes to show that the detector is now receiving the return signal. If the detector is receiving a return signal, the test personnel covers the emitter or the receiver. The sensor performance is satisfactory if the indication changes to show that the detector is no longer receiving the return signal.
It is an object of the invention to provide a new and improved device and method for testing an automatic door system.
It is also an object of the invention to provide a new and improved device for testing an automatic door system which device has an efficient construction.
It is further an object of the invention to provide a new and improved method of testing an automatic door system which method is simple and takes a minimum of time.
Other objects and advantages of the invention will become apparent from the drawings and specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings in which:
FIG. 1 is a schematic diagram of a test device in accordance with the present invention installed in an automatic door system;
FIG. 2 is a top plan view of the test device of FIG. 1;
FIG. 3 is a cross-section view of the test device taken along line 3--3 of FIG. 2;
FIG. 4 is a schematic diagram of the test device of FIG. 1;
FIGS. 5a, 5b and 5c are a flow diagram illustrating the operation of the test device of FIG. 1;
FIG. 6 is a flow diagram illustrating a first optional test performed by the test device of FIG. 1; and
FIG. 7 is a flow diagram illustrating a second optional test performed by the test device of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings wherein like numerals represent like parts throughout the several figures, an automatic door test device in accordance with the present invention is generally designated by the numeral 10. The test device 10 is interposed between the controller 12 and the sensors 14 of an automatic door system, as shown in FIG. 1. In a preferred embodiment, the test device 10 is a hand-held unit which is removed after the testing is complete. Alternatively, the test device 10' may be permanently installed in the automatic door system.
With reference to FIGS. 2 and 3, the hand-held test device 10 includes a housing 16 having externally accessible fiber optic or electrical connectors 18 for connecting the device 10 to the automatic door system. For example, a test device 10 for use with a Stanley Access Technologies Sentrex 3™ automatic door system will include a first connector 17 for connecting to the sensor Flex Link™ cable 19 and a second connector 21 for connecting to the controller TB2 connector 23. The test device includes two externally-visible indicators, an LED 20 and a four digit alphanumeric display 22. The operators for a two-position selector switch 24 and a push-button switch 26 extend through the housing 16 and are externally accessible.
A circuit board 28 mounted within the housing 16 includes an electrical circuit 30 which is electrically connected to the connectors 18, the LED 20, the alphanumeric display 22, the selector switch 24 and the push-button switch 26. The electrical circuit 30 includes a micro-controller 32 and a memory 34 for storing test data and control programs. The memory 34 may be integral with the micro-controller 32 or comprise one or more separate memory units. Preferably, the test device 10 receives its power from the automatic door system and does not require an internal power supply. As a personnel and equipment safety precaution, power to the automatic door system is secured until the test device 10 has been completely installed.
The electrical circuit 30 includes a first voltage comparator 36 which monitors the power supply voltage and lights the LED 20 when the power being received by the test device 10 is above a preset level. The LED 20 will not turn on if the voltage is below the value required to supply the automatic door system sensors 14. The value of the preset voltage level may be adjusted with a potentiometer to accommodate the range of sensors 14 that may be used by the automatic door system.
With reference to FIGS. 2 and 3, the test device 10 may be used to test either the automatic door system controller 12 or the automatic door system sensors 14, but not both at the same time. The micro-controller 32 is programmed to sequentially test the automatic door system controller 12 first and the sensors 14 second. Consequently, the micro-controller 32 will scroll a "SWITCH TO MICRO" message 38 across the alphanumeric display 22, indicating that the two-position selector switch 24 should be toggled to the micro-controller position. This action selects the automatic door system controller 12 for testing and isolates the data signals from the sensors 14. Such isolation is required to isolate failures between the controller 12 and the sensors 14.
The push-button switch 26 is used to step the test device 10 through the various tests. With reference to the operational diagram of FIGS. 5a-5c as employed for a Sentrex 3™ automatic door system, pressing 40 the push-button switch 26 causes a second voltage comparator 42 portion of the circuit 30 to monitor 44 the voltage on the controller clock line. The micro-controller 32 will send a signal to the display to indicate whether the clock line voltage (V2) is above (V20K) 46 or below (V2NG) 48 a predetermined minimum level. Pressing 50 the push-button 26 steps the micro-controller to monitor 52 the data line voltage with the third voltage comparator 53. The micro-controller will send a signal to the display to indicate whether the data line voltage (V3) is above (V30K) 54 or below (V3NG) 56 a predetermined minimum level. If either V2NG 48 or V3NG 56 is displayed, the controller 12 is defective.
Pressing 58 the push-button 26 again steps the micro-controller 32 to monitor 60 the signals on the clock and data lines. If the signals being sent by the automatic door system controller correspond to correct signals, the micro-controller will send a signal to the display to indicate that the controller communications are good (CMOK) 62. If the signals do not correspond to correct signals the micro-controller will send a signal to the display to indicate that the controller communications are no good (CMNG) 64. On the completion of this test, pressing 66 the push-button 26 will cause the micro-controller to scroll a "SWITCH TO SENSOR" message 68 across the alphanumeric display 22, indicating that the two-position selector switch 24 should be toggled to the sensor position.
The test device 10 may optionally perform two additional tests on the automatic door system controller 12. With reference to FIG. 6, the micro-controller 32 can be programmed to send a signal 118 which is equivalent to the "operate" signal which is normally transmitted by the automatic door system sensors 14. If the signal is accepted 120 by the controller 12, the micro-controller 32 will send a "OPER" signal 122 to the display 22. With reference to FIG. 7, the micro-controller 32 can be programmed to send a signal 124 which is equivalent to the "stall" signal which is normally transmitted by the automatic door system sensors 14. If the signal is accepted 126 by the controller 12, the micro-controller 32 will send a "STAL" signal 128 to the display 22.
Toggling the selector switch 24 to the sensor position will isolate the data signals of the controller 12 from the test device 10 and allow the test device 10 to test the sensors 14. Pressing 70 the push-button switch 26 causes the second voltage comparator circuit 42 to monitor 72 the voltage on the sensor clock line. The micro-controller 32 will send a signal to the display 22 to indicate whether the clock line voltage (V2) is above (V20K) 74 or below (V2NG) 76 a predetermined minimum level. Pressing 78 the push-button 26 steps the micro-controller 32 to monitor 80 the sensor data line voltage with the third voltage comparator 53. The micro-controller will send a signal to the display 22 to indicate whether the data line voltage (V3) is above (V30K) 82 or below (V3NG) 84 a predetermined minimum level. If either V2NG 76 or V3NG 84 is displayed, either the Flex-Link™ cable is shorted or a sensor 14 is defective.
After verifying that the voltages are correct, the push-button switch 26 is pressed 86 to initiate a test 88 of each individual sensor. For each sensor 14, the test comprises a first part where the micro-controller 32 sends a first data signal 90 addressing a specific sensor. When communication with the sensor 14 has been established, the micro-controller 32 sends a second data 92 signal directing the sensor 14 to output a specific zone pattern 94 for detecting the presence of a person/object 96. When the sensor 14 initiates output of the zone pattern 94, an object 96 may or may not be within the zone 94. If the sensor 14 detects the presence of an object 96, the micro-controller 32 will send a "SXON" signal 98 (where "X" is the sensor number) to the display 22 to indicate the presence of an object detection signal from the sensor 14. Conversely, if the sensor 14 does not detect the presence of an object 96, the micro-controller 32 will send a "SXNC" signal 100 to the display 22 to indicate the absence of an object detection signal from the sensor 14.
The sensor 14 is tested by attempting to change the status of the object detection signal. That is, if the "SXNC" signal 100 is being displayed, the operator will introduce an object 96, such as his hand, into the zone 94. If the sensor 14 is operating satisfactorily, the sensor receiver 102 will receive a return signal 104 from the object 96 and thereby sense the presence of this object 96 and send a signal to the test device 10. Upon receipt of this signal, the micro-controller 32 sends a "SXON" signal 98 to the display 22. Conversely, if the "SXON" signal 98 is being displayed, the operator will cover the emitter lens 106 or receiver 102. Since the receiver 102 will no longer receive a return signal 104 from the object 96 in the zone 94, it will appear as if the object 96 has been removed from the zone 94. Consequently, the sensor 14 will cease sending a signal to the test device 10 and the micro-controller 32 will send the "SXNC" signal 100 to the display 22. Pushing 108 the push-button switch 26 will cause the test device to advance to the next sensor 110. When the micro-controller 32 determines 112 that all of the sensors 14 have been tested, pushing 114 the push-button 26 will cause the micro-controller 32 to display a "END" message 116 on the alphanumeric display 22.
It should be appreciated that the test device 10' may be permanently installed in the automatic door system. Since the controller 12 and the sensors 14 must be isolated from each other during testing, a permanently installed test device 10' must include controls and circuitry for inserting the test device 10' between the controller 12 and the sensors 14 during testing and for removing the test device 10' when testing is complete so that the sensors 14 may once again communicate with the controller 12.
It should also be appreciated that the test device 10 is simple to manufacture and operate, resulting in low acquisition and operating costs. The installation and removal of the portable test device 10 of the subject invention is relatively easy to accomplish and does not require complex tools or training to accomplish. In addition, use of the test device 10, 10' requires only the operation of two switches 24, 26. The test results are obtained by observation of a single LED 20 which is either on or off and an alphanumeric display 22 which provides easily understood four digit test result messages.
It should be further appreciated that the test data and control program stored in memory 34 may be customized for each type and manufacture of automatic door system. For example, the program described above is for a standard Sentrex 3™ automatic door system. Consequently, the program includes information on each sensor 14 and component of the controller 12 to ensure that they are properly tested. The test data includes normative data for comparison to the parameters which are sensed by the test device 10, 10' when the sensors 14 and controller 12 are tested. The program and test data also include steps and data necessary to transmit "operate" and "stall" signals to the controller 12 and the first and second data signals for testing the sensors 14.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A test device for testing automatic door systems has a test circuit including a display, a micro-controller, a memory for storing data and a test program, and a control switch for controlling operation of the test program by the micro-controller. The test device is installed by interposing the test circuit between the controller and sensors of the automatic door system. A selector switch on the test device is moveable between first and second positions. When the selector switch is in the first position, it completes a data path between the test circuit and the controller and blocks the exchange of data between the sensors and the test circuit and the first connector. When the selector switch is in the second position, it completes a data path between the test circuit and the second connector and blocks the exchange of data between the controller and the test circuit and the second connector. Pushing the control switch steps the micro-controller through the test program to individually test the controller and each of the sensors. |
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This is a continuation (FILE WRAPPER) of application Ser. No. 07/558,828 filed July 27, 1990.
BACKGROUND OF THE INVENTION
The present invention relates to the field of bridge construction, and more particularly, the construction of precast segmental bridges, especially those having multiple bridge spans, wherein successive bridge segments are positioned and attached to existing bridge components.
Precast segmental bridges are known and commonly used throughout the world as a means to forge roadways through mountainous terrain or across rivers and other natural barriers. Such bridges are typically constructed in accordance with the following sequence: First, a series of upright piers are formed along the bridge span. Thereafter, cantilevered bridge sections are built out from each pier by successively mounting the precast segments to previously completed bridge components and post-tensioning the segments thereto. The cantilevered bridge sections are built out from each pier in a symmetrical fashion so that the piers are not subjected to undue bending loads. When the cantilever sections are complete, the ends thereof are post-tensioned together to form a continuous bridge deck. Typically, two such bridge spans are constructed to accommodate the two directions of travel. These spans run generally side-by-side, but need not be parallel (horizontally or vertically) nor at the same elevation.
Prior techniques employed in the construction of precast segmental bridges have relied on use of a single piece of equipment able to erect one deck at a time, starting from one end and finishing at the other end of the bridge. In the case where several decks were erected, the piece of equipment had to be repeatedly used, or two or more pieces of equipment were used simultaneously. Both options added significant time and expense to bridge construction.
The most frequently used techniques in the past involve the use of a launching girder resting on top of the deck under construction. Such techniques have been used, for example, at Rio-Niteroi Bridge, Brazil where four (4) launching girders (two at each end of the bridge) were used simultaneously to build two (2) parallel decks at the same elevation. Similarly, at Chillon Viaducts, Switzerland, a single launching girder was used to build two parallel decks, at different elevations, with each deck being built independently, one after the other.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a construction system for erecting precast segmental bridges wherein a minimum number of construction components are required and wherein construction time is dramatically reduced for multi-span segmental bridges.
It is a further object of the present invention to provide a construction system for simultaneously constructing multi-span segmental bridges wherein the spans are not elevationally parallel.
It is a further object of the present invention to provide a construction system for multi-span segmental bridges wherein the bridge spans are not horizontally parallel.
It is a further object of the present invention to provide a construction system for multi-span segmental bridges wherein the bridge spans are of differing elevation.
It is a further object of the present invention to provide a construction system for multi-span segmental bridges wherein the lateral spacing between the spans is varied.
The present invention is accordingly directed to a construction system for multi-span segmental bridges which may be embodied in a pair of independent trusses positioned above the outer bridge spans. The trusses to provide a path for a transverse gantry having a trolley and winch system for successively lifting and transporting bridge segments for connection on a plurality of bridge spans. In accordance with one aspect of the invention, there may be provided a first independent longitudinal truss positioned over a first bridge span, a second independent longitudinal truss positioned over a second bridge span, a gantry movably mounted on the trusses, the gantry having a first leg mounted to the first truss and a second leg mounted to the second truss, a gantry drive for controllably driving the gantry along the trusses, a transverse trolley movably mounted on the gantry, the trolley being drivable along the gantry in a direction generally transverse to the longitudinal trusses, the trolley including a winch for lifting and carrying bridge components to be positioned along at least one bridge span, the trolley being selectively positionable over each of the bridge spans, and supports for mounting the longitudinal trusses to bridge components disposed along each of the bridge spans.
DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation view of a construction system in accordance with the present invention showing the positioning of the system for construction of bridge components from a first bridge pier adjacent a completed bridge span portion.
FIG. 2 is a cross-sectional view taken along line 2--2 in FIG. 1 showing the construction equipment of FIG. 1 transporting a bridge segment for connection to a bridge span section.
FIG. 3 is a side-elevational view of a pendulum leg portion of the construction system of FIG. 1.
FIG. 3a is a side-elevational view of an alternative pendulum leg portion of the construction system of FIG. 1.
FIG. 3b is a detailed side view of a pivotal connection in the pendulum leg portion of the construction system of FIG. 1.
FIG. 4 is a side-elevational view of a side-elevational view of a fixed leg portion of the construction system of FIG. 1.
FIG. 4a is a detailed side view of a pivotal connection in the fixed leg portion of the construction system of FIG. 1.
FIG. 4b is a detailed plan view of a transverse beam positioning connection in the fixed leg portion of the construction system of FIG. 1.
FIG. 5 is a detailed side-elevational view of a lifting trolley portion of the construction system of FIG. 1.
FIG. 5a is a detailed front-elevational view of a lifting trolley portion of the construction system of FIG. 1.
FIG. 6 is a detailed diagrammatic view of a longitudinal truss and associated roller support assemblies of the construction system shown in FIG. 1.
FIG. 7 is a detailed side-elevational view of a truss roller support assembly of the construction system of FIG. 1.
FIG. 8 is a detailed cross-sectional view of the truss roller support assembly of FIG. 7 taken along line 8--8 of FIG. 7.
FIG. 9 is a detailed cross-sectional view of the truss roller support assembly of FIG. 7 taken along line 9--9 of FIG. 7.
FIG. 10 is a detailed cross-sectional view of the truss roller support assembly of FIG. 7 taken along line 10--10 of FIG. 7.
FIG. 11 is a detailed side-elevational view of a gantry roller support assembly of the construction system of FIG. 1.
FIG. 12 is a detailed cross-sectional view of the gantry support roller assembly of FIG. 11 taken along line 12--12 of FIG. 11.
FIG. 13 is a detailed cross-sectional view of the gantry support roller assembly of FIG. 11 taken along line 13--13 of FIG. 11.
FIG. 14 is a detailed cross-sectional view through the longitudinal stabilizing member shown in FIGS. 3 and 3a.
FIG. 15 is a detailed cross-sectional view of the gantry support roller assembly of FIG. 11 taken along line 15--15 in FIG. 11.
FIGS. 16a-1 is a sequential diagrammatic view of the launching sequence of the construction system of FIG. 1.
FIG. 17a is a diagrammatic side-elevation view of a construction system in accordance with the present invention in a pre-launch position.
FIG. 17b is a diagrammatic plan view of one truss portion of the construction system of FIG. 17a in the pre-launch position.
FIG. 17c is a diagrammatic plan view of another truss portion of the construction system of FIG. 17a in the pre-launch position.
FIG. 18a is a diagrammatic side elevation view of the construction system of FIG. 17a following the first launching stage.
FIG. 18b is a diagrammatic plan view of one truss portion of the construction system of FIG. 18b following the first launching stage showing transverse positioning of the truss to accommodate bridge span curvature.
FIG. 18c is a diagrammatic plan view of another truss portion of the construction system of FIG. 18b following the first launching stage showing transverse positioning of the truss to accommodate bridge span curvature.
FIG. 19a is a diagrammatic side-elevation view of the construction system of FIG. 17a following the second launching stage.
FIG. 19b is a diagrammatic plan view of one truss portion of the construction system of FIG. 17b following the second stage of launching showing additional transverse positioning of the truss to accommodate bridge span curvature.
FIG. 19c is a diagrammatic plan view of another truss portion of the construction system of FIG. 17b following the second stage of launching showing additional transverse positioning of the truss to accommodate bridge span curvature.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1, a pair of generally side-by-side completed bridge sections 2 and 4 are cantilevered from bridge piers 6 and 8, respectively to terminations 10 and 12. The terminations 10 and 12 extend to the approximate center of the bridge spans defined by the piers 6 and 8 on one side, and the adjacent piers 14 and 16 on the other side of the spans, respectively. Partially completed cantilevered bridge span sections 18 and 20 extend from the piers 14 and 16, respectively, toward the end terminations 10 and 12 of the previously completed bridge sections 2 and 4. As shown, the partially completed cantilevered bridge section 18 includes precast concrete segments 18a-18h. Shown in phantom are the positions where subsequent precast segments 18i-18n will be positioned. The remaining gap between the bridge segment 18n and the termination 10 of the previously completed bridge section 2 will be filled with a final precast segment 18o. Similar partially completed cantilevered bridge sections 22 and 24 extend from the other side of the bridge piers 14 and 16. The section 22 includes segments 22a-22o which will bring the bridge section 22 in contact with yet another bridge section or with existing roadway. The respective sections 18a-18o-and 22a-22o are alternatively attached to the pier 14 to provide a symmetrical section build up to avoid placing unnecessary bending loads on the pier 14. The bridge sections extending from the pier 16 are mounted in similar fashion. Each precast segment is attached to existing bridge components using well known post-tensioning techniques.
The precast segments to be affixed to the bridge sections 18 and 20, and 22 and 24, are conveniently transported and positioned for attachment using a construction system 30 now to be described. The construction system 30 includes, generally, a pair of longitudinal trusses 40 and 40a and a rolling gantry 50. The longitudinal truss 40 is supported at one end thereof adjacent the termination 10 of the completed bridge section 2 using a mounting support 60. The longitudinal truss 40 is supported at the approximate mid-span thereof on the pier 14 using the mounting support 70. Additional mounting supports 80 and 90 may be provided as the partially completed bridge section 22 is constructed. A similar mounting arrangement is provided for the longitudinal truss 40a. The rolling gantry 50 includes roller assemblies 100 and 100a that are rollably mounted to the top of the longitudinal trusses 40 and 40a, respectively. A gantry drive (to be described) provides motive power to drive the rolling gantry 50 along the longitudinal trusses 40 and 40a. The precast bridge segments are typically delivered to a location adjacent the completed bridge terminations 10 and 12, as shown in FIG. 1, where they are picked up by the rolling gantry 60 and transported for attachment to the partially completed bridge sections 18, 20, 22, and 24. The longitudinal range of the rolling gantry 50 is shown in phantom line representation at the ends of the trusses 40 and 40a.
Referring now to FIG. 2, the longitudinal trusses 40 and 40a are mounted, respectively, on the support assembly 60 and its adjacent bridge span counterpart 60a. The support assemblies 60 and 60a include corresponding transverse beam assemblies 110 and 110a. The beam assemblies 110 and 110a include a transverse steel beam section 112 and 112a supported on the completed bridge sections 2 and 4, respectively, using hydraulic jacks 114 and 116, and 114a and 116a, which are mounted to the bottom of the transverse beam sections 112 and 112a, respectively. In addition, one or more shims 118 and 118a may be used to adjust the height of the beams sections. The transverse beam section 112 and 112a are secured to the bridge sections 2 and 4 using steel tie-downs 120 and 122, and 120a and 122a, respectively. The transverse beam sections 112, 112a may be of conventional double I-beam construction having a pair of webs 124, 124a and upper and lower flanges 126, 126a and 128, 128a, respectively.
The support assemblies 60 and 60a further include roller assemblies 130 and 130a, respectively. The roller assembly 130 includes a pair of roller units 132 and 134, while the roller assembly 130a includes roller units 132a and 134a. The support assemblies 60 and 60a further include a jack 136 and 136a for transversely positioning the roller units 132, 134 and 132a, 134a, respectively, with respect to the transverse beam sections 112 and 112a. The transverse jacks 136 and 136a are mounted to the upper flange 126 and 126a of the transverse beam sections 112 and 112a using lock downs 138 and 138a, respectively. As shown in phantam, the roller units 132 and 134 can be transversely repositioned by activating the hydraulic jack 136. The same holds true for the roller units 132a and 134a, except that the hydraulic jack 136a is used. As discussed below, such transverse positioning is used to pivot the longitudinal trusses 40 and 40a in order to accommodate horizontal bridge span curvature.
Still referring to FIG. 2, the horizontal truss 40 is configured in a general three-sided arrangement that includes an upper compression flange 140 that itself includes lower and upper flanges 142 and 144, respectively and a plurality of intermediate webs 146, shown in more detail in FIG. 12. As further described below, the upper flange 144 provides a roller bearing surface for the gantry 50. The longitudinal truss 40 further includes a pair of lower tension flanges. The first lower flange, 150, itself includes an upper flange 152, a lower flange 154 and intermediate web members 156, shown in more detail in FIG. 9. As discussed hereinafter, the lower flange 154 provides a lower bearing surface for the longitudinal truss 40. The longitudinal truss 40 further includes a second lower flange section 160 which itself includes an upper flange 162, a lower flange 164 and intermediate web members 166. Like the lower flange 154, the flange 164 also provides a lower bearing surface for the horizontal truss 40. The horizontal truss 40a is of similar construction and includes similar components 140a-166a whose arrangement and function are the same as the corresponding components 140-160 of the horizontal truss 40. The horizontal trusses 40 and 40a further include leg elements 170 and 180, and 170a and 180a, respectively.
Still referring to FIG. 2, the rolling gantry 50 is rollably mounted on the horizontal trusses 40 and 40a on the roller assemblies 100 (described in detail hereinafter). The gantry 50 further includes a fixed leg assembly 200 and a pendulum leg assembly 210, both of which are joined by ball joint connections to the roller assemblies 100. The rolling gantry 50 further includes a transverse truss assembly 220 that is generally fixedly connected at one end to the fixed leg 200 and is pivotally connected through a ball joint connection at its other end to the pendulum leg 210. Rollably mounted on the transverse truss assembly 220 is a lifting trolley assembly 240 that includes a winch assembly 260, a spreader beam 280 for carrying precast segments and a roller assembly 300 which is rollably mounted on the upper portion of the transverse truss assembly 220. The lifting trolley assembly further includes a traveling crane 310 and a power drive (not shown) providing motive power to drive the lifting trolley assembly 240 along its transverse drive path. The range of positions of the lifting trolley assembly 240 is shown in phantom line representation at the ends of the truss assembly 220.
Referring now to FIGS. 3 and 3a, the pendulum leg assembly 210 of the rolling gantry 50 is shown in greater detail. As shown therein, the transverse truss assembly 220 of the rolling gantry 50 includes a pair of transverse trusses having a single upper flange 222 and 222b, respectively. Each of the flanges 222 and 222b includes upper and lower flanges and intermediate web sections, with the upper flange providing an upper roller bearing surface for the roller assembly 300 of the lifting trolley 240. The individual trusses of the transverse truss assembly 220, further include a pair of lower flanges 224 and 224b, each having respective upper and lower flanges and an intermediate web section. The upper and lower flanges 222 and 224, and the upper and lower flanges 222b and 224b are joined by a series of intermediate truss members 226 and 226b, respectively. Moreover, each of the bottom flanges 224, 224, and 224a, 224a are joined by a longitudinally extending stabilizing beam 228.
As shown in FIG. 3b, the upper flanges 222, 222b of the transverse truss assembly 220 include at the ends thereof lower extensions 320, 320b, having attached thereto lugs 330, 330b. The lugs 330, 330b are joined by ball joint connections 340, 340b to the legs of the pendulum leg assembly 210. Thus, the ball joint 340 pivotally connects the lug 330 to the pendulum legs 350 and 360. Similarly, the ball joint 340a pivotally joins the lug 330a to the legs 350a and 360a. The ball joint connections 340 and 340a themselves are pivotally connected to a stabilizing member 370 through ball joint connections 380 and 380b, as shown in FIG. 3. Thus, the pendulum leg assembly 210 is free to pivot about a generally longitudinal axis as well as twist about a transverse axis and a vertical axis, independently of the transverse truss assembly 220.
Still referring to FIG. 3, the pendulum legs 350 and 360 extend downwardly to a longitudinal stabilizing member 390 and are joined thereto with ball joint connections 400. Similarly, the pendulum legs 350b and 360b extend downwardly to the longitudinal stabilizing member 390 and are connected thereto through ball joint connections 400b. The longitudinal stabilizing member 390 is in turn fixedly mounted to the gantry roller assemblies 100.
Referring now to FIG. 3a, the pendulum leg assembly 210 is shown with a leg extension added thereto to accommodate changes in elevation differential between the longitudinal trusses 40 and 40a. Thus, the pendulum legs 350 and 360 extend to and are fixedly connected to vertical leg extension members 410 and 420. Similarly, the pendulum leg members 350b and 360b extend to and are fixedly connected to the vertical leg extension members 410 and 420a. The legs 410, 420 and 410b, 420b are stabilized by diagonal stabilizing members 430 and 430b, and horizontally stabilizing members 432 and 432b, respectively. The vertical leg extension members 410 and 420 are pivotally connected to the longitudinal stabilizing member 390 with ball joint connections 440. Similarly, the vertical leg extension member 410a and 420b are pivotally connected to the longitudinal stabilizing member 390 with ball joint connections 440b.
Referring now to FIGS. 2 and 3, the gantry roller assemblies 100 have pivotally connected thereto a launching frame assembly 450 which is used to connect the rolling gantry 50 to a truss support assembly 60 such that the gantry drive system can be used to longitudinally translate the trusses 40 and 40a while the rolling gantry 50 remains fixedly positioned, as discussed in greater detail below. The launching frame assembly 450 includes a pair of launching frame legs 460 and 470 joined to respective roller assemblies 100 through ball joint connections 480. The launching frame legs 460 and 470 are connected at their lower extremity to a lock down assembly 500. The lockdown assembly 500 includes a longitudinal support member 505 to which the launching frame legs 460 and 470 are fixedly connected. Pivotally mounted to the ends of the longitudinal support member 505 are a pair of pivoting lock members 510 that are pivotable from an unlocked position to a locked position wherein the lock members 510 engage the upper flange 126 of the transverse truss support beam 112. The lock members are secured thereto with a pair of pin members 515 such as bolts or the like, extending through the lock members and the longitudinal support member 505. In the unlocked position, the launching frame assembly 450 may be pivoted up and away from the transverse support beam 112 to facilitate unrestricted gantry movement.
Referring now to FIG. 4, the fixed leg assembly 200 of the rolling gantry 50 is shown. At the fixed leg end of the rolling gantry transverse truss assembly 220, the upper flanges 222 and 222a include shoulders 520 and 520b, respectively, at the ends thereof. Horizontal stabilizing members 522 and 524 extend between the shoulders 520 and 520b, and fixed legs 550 and 570, respectively. The fixed leg 550 is fixedly connected at one end to the shoulder 520 and is pivotally connected at its other end to a longitudinal stabilizing beam 390a extending between a pair of gantry roller assemblies 100a. The pivotal attachment between the fixed leg 550 and the stabilizing beam 390a is provided by a ball joint connection 560. The shoulder 520b extending from the transverse truss flange 222b is pivotally connected to the second fixed leg 570 through a pin connection 580, shown in greater detail in FIG. 4a. The fixed leg 570 is pivotally attached at its other end to the longitudinal stabilizing beam 390a through a ball joint connection 560b. As further shown in FIG. 4b, the fixed leg 570 is connected to the lower flange member 224b of the gantry flange assembly 220, and the stabilizing members 524, through a jack assembly 590 to provide for transverse position adjustment of the fixed leg 570 with respect to the rolling gantry transverse truss assembly 220. This connection accommodates twisting movement of the fixed leg assembly 220 due to pivoting of the longitudinal truss 40a during launching. Thus, during truss launching, the jack assembly 590 is loosened to allow the fixed leg 570 to freely pivot about the pivotal connection 580. The jack assembly 590 is retightened when the longitudinal truss launching sequence is complete.
Referring now to FIGS. 5 and 5a, the lifting trolley assembly 240 is shown in greater detail. Thus, the winch assembly 260 includes a power winch drive 600 and a block and tackle system 610. The block and tackle system includes upper and lower blocks 612 and 614, respectively. A precast segment to be transported for attachment to a bridge under construction is pivotally connected to the spreader beam 280 using a pair of link members 620. The links 620 are pivotally connected to the top of the spreader beam with a pin connection 630. The link members 620 are pivotally connected to the top of a precast segment with a ball joint connection 640 and an associated mounting lug 650.
As shown in FIG. 5a, the spreader beam 280 is pivotally connected to the lower block 614 of the block and tackle systems 610 through the intermediary of a connecting link 660. The connecting link 660 is pivotally connected to the spreader beam 280 through a pin connection 670 arranged in a slot (not shown) in the spreader beam 280 to provide for transverse adjustment of the spreader beam. The link 660 is mounted to the lower block 614 of the block and tackle system 610 through a bearing assembly 680 that permits rotation of the link 660 with respect to the block. Thus, the precast segment can be manipulated in a plurality of positions for alignment with and placement on previously constructed bridge components.
Still referring to FIGS. 5 and 5a, the winch drive 600, which may be a hydraulic planetary winch as conventionally known, is mounted on a longitudinally extending support beam 690 which is attached to a pair of roller units 700 and 700b, respectively of the roller assembly 300. The roller units 700 and 700b each include a pair of support beams 710 and 710b, respectively, the roller units 700 further include two roller pairs 720 and 730 mounted between the roller units support beam 710. Similarly, the roller unit 700b includes roller pairs 720b and 730b mounted to the roller unit support beam 710b. The roller unit 700 is further provided with a pair of transverse rollers 740 that engage the side of the transverse truss flange 222. Similarly, the roller unit 700b includes a pair of transverse rollers 740b that engage the side of the transverse truss flange 222b. The roller pairs 720 and 730 of the roller unit 700 engage the top of the transverse truss flange 222. Similarly, the roller pairs 720b and 730b engage the top of the transverse truss flange 222b. The roller units 700, 700b are powered for transverse movement along the transverse truss flanges 222, 222b through translation power units 750, 750a, as shown in FIG. 5. Operation of the lifting trolley assembly 240 is directed by a human operator from the traveling crane cab 310.
Referring now to FIGS. 6-10, the details of the longitudinal truss support assembly 60 will now be described. It is understood that the following discussion pertaining to the longitudinal truss 40 applies with equal force to the longitudinal truss 40a, unless otherwise indicated, since the respective components of each assembly are virtually the same. Referring now to FIG. 6, the lower flanges 150 and 160 of the longitudinal truss 40 are rollably mounted for longitudinal translation on the roller units 132 and 134 of the truss support assembly 60.
Referring now to FIG. 7, the roller unit 132 and lower truss flange 150 are shown in detailed side-elevation, it being understood that the components of the roller unit 134 and the lower truss flange 160 are the same. The roller unit 132 includes a central roller assembly 800 having a longitudinal row of transversely extending pin rollers 810 mounted thereon. The pin rollers 810 provide elevational support for the lower roller bearing surface 154 of the lower truss flange 150, which is supported directly thereon.
Referring now to FIG. 9, it will be observed that the rollers 810 are free-floating on underlying rollers 812 which are in turn supported on a steel support member 814. The support member 814 is mounted on a neoprene pad 816 to provide a shock absorbing support medium for the longitudinal truss 40. It will further be observed that the roller unit 132 is supported on a thin sheet of polytetrafluoroethylene (TFE) material 817 and a thin sheet of stainless steel 818 disposed over the upper flange 126 of the transverse beam 112. This enables the roller unit 132 to be easily transversely repositioned on the transverse support beam 112.
The roller unit 132 further includes two pairs of guide rollers 820 (see FIG. 10). The guide rollers 820 positively engage the top of the lower flange 154 of the truss flange 150 in order to positively restrain the truss 40 against lifting forces such that the truss 40 remains in contact with the support assembly 60 at all relevant times. In this regard, and referring now to FIGS. 7 and 10, it will be observed that the roller unit 160 is affirmatively locked in place on the transverse support beam 112 with a pair of pivotable locking arms 840 that engage the lower surface of the upper flange 126 of the transverse beam 112. The locking arms 840 are pivotally connected to the roller unit 132 with pin connections 860. The locking arms 840 may be secured in a locked position and in an unlocked position with a locking pin 870 disposed in an appropriate one of the locking apertures 880 in the roller unit 132. As shown in FIGS. 7 and 8, the roller unit 132 further includes opposing pairs of transverse rollers 890 that positively engage the sides of the lower flange 154 of the truss flange 150 so as to affirmatively restrain the truss 40 against transverse movement.
Referring now to FIGS. 11-15, the gantry roller assemblies 100 will now be described. In this regard, it is understood that only the roller unit associated with the longitudinal truss 40 is referenced since the roller unit associated with the longitudinal truss 40a is of substantially identical construction. The roller unit 100 includes opposing pairs of rollers 900 that positively and rollably engage the upper bearing surface 144 of the upper longitudinal truss flange 140. The roller unit 100 further includes a pair of lower tension wheels disposed between the upper and lower flanges 144 and 142, respectively, of the longitudinal truss flange 140. The tension wheels 910 prevent the roller unit 100 from becoming detached from the horizontal truss flange 140. The roller unit 100 further includes opposing pairs of guide wheels 920 that engage the sides of the upper flange 144 of the horizontal truss flange 140 to laterally restrain the rolling 100 thereon. The upper flange 144 of the horizontal truss flange 140 further has mounted thereon a longitudinally extending rack 930. As shown in FIG. 3, the longitudinal stabilizing member 390 has mounted thereon a translation drive unit 940, having a pinion gear 960 meshingly engaged with the rack 930. The translation drive unit 940 powers the roller units 100, and hence the rolling gantry 40 for longitudinal travel along the longitudinal truss. As shown in FIGS. 11, 13 and 15, the pivoting leg 350 and its associated ball joint connection 400, as well as the launching leg 460 and its associated ball joint connection 480, mount to the roller unit 100. FIG. 14 shows the pivotal connection 400 of the pivotal leg 360 to the longitudinal stabilizing member 390.
Referring now to FIGS. 16a-16e, the operation and launching of the above-described construction system will now be described, it being understood that the following discussion of longitudinal truss 40 applies also to longitudinal truss 40a. The truss 40 has rollably attached thereto three support assemblies 60, 70 and 80. The truss 40 initially rests on two transverse truss support assemblies 60 and 70. The rearward support assembly 60 is mounted to a previously constructed bridge section or existing roadway, and the intermediate support assembly 70 is mounted on the pier of the bridge cantilever to be erected. If the pier segment is cast in place, the support assembly 70 rests directly on the pier segment itself. If the pier segment is a precast unit, the support assembly 70 rests on a temporary frame (not shown). The support assemblies 60 and 70 conveniently position the longitudinal truss 40 above the bridge deck so that the truss does not interfere with the placement of individual segments. As previously indicated, the support assemblies 60 and 70 provide a positive vertical connection between the concrete deck and the longitudinal truss 40 for compression and direct bearing and tension by the intermediary of the rollers. The intermediate support assembly 70 located on the pier from which the next bridge cantilever is to be constructed also includes a locking system (not shown) to provide longitudinal stability of the truss 40 against longitudinal horizontal forces. The locking system could conveniently include restraining pins extending through the lower flanges 156 and 166 of the beams 150 and 156, or other restraining apparatus. The support assemblies 60 and 70 further provide for transverse positioning of the longitudinal trusses 40 and 40a to accommodate bridge span curvature and possible variations in distance between the bridge spans.
During bridge construction, the precast bridge segments are typically trucked to the end of the previously completed cantilever, where they are picked up by the lifting trolley 240 on the rolling gantry crane 50. It would also be possible to pick up the bridge segments from other locations on the ground or water over which the bridge span extends. The rolling gantry crane 50 delivers the precast segment to the end of the cantilever under construction where the segment is positioned and post-tensioned to the structure.
Starting from the pier 14, the segments are placed to extend symmetrically therefrom. As shown in FIGS. 16b through 16e, after a certain number of paired segments are placed, the forward support assembly 80 is progressively positioned toward the forward end of the truss 40 to effectively reduce the cantilever length of the truss and allow the gantry 50 to carry segments to the end of the concrete deck cantilever without relying on stay cables as is conventionally done.
The launching of each truss is done in two (2) steps. First, after the back span 18 has been closed and the continuity post-tensioning tendon stressed, the support assembly 80 is mounted at the end of the cantilever as shown in FIG. 16e. The rolling gantry 50, which provides the longitudinal force to move the truss 40 through its own moving mechanism, is tied down on the center support assembly 70 and acts as a fixed drive point. The support member 60 is loosened from the bridge deck. The longitudinal truss 40 is then longitudinally translated until its front-end reaches the pier "A" as shown in FIG. 16f. The second longitudinal truss 40a is thereafter moved in the same way.
Following the first launching step, the support assembly 70 is moved to the end of the cantilever 22. A temporary support "T," see FIG. 16g, is then tied to the bridge deck behind the support assembly 660 at the pier 70. The support assembly 80 is moved to and installed on the pier "A." The support assembly 60 is then moved to and mounted on to the end of the cantilever 22, while the support assembly 70 as well as the temporary support T, are detached from the bridge deck, as shown in FIG. 16h. The rolling gantry crane 50 is then moved and tied down to the support assembly 80 located at the Pier "A."
As shown in FIG. 16i, the longitudinal truss 40 is launched forward again until its approximate center reaches the support assembly 80 on the pier "A," from which new bridge cantilever construction is to commence. The second longitudinal truss 40a is moved in the same way. The support assembly 70 is then moved to and attached to the pier "A," the support assembly 80 is released therefrom, and the temporary support T is removed from the truss 40. Othering launching sequences would also be possible in accordance with the teachings herein.
Referring now to FIGS. 17-19b, the procedure for launching under conditions where the bridge span has horizontal curvature is shown. When the bridge span has a horizontal curvature, the trusses 40 and 40a must be transversely repositioned during launching to follow the bridge center line. This is done on a support assembly which is away from the rolling gantry crane 50. Thus, at the support assembly on which the gantry legs are secured, there is only a rotation of the truss with regard to the gantry. This change of geometry is accommodated by the ball joints connecting the pendulum leg assembly 210 to the transverse truss assembly 220, and the pin joint and translational adjustment providing relative twist between the fixed leg assembly 200 and the transverse truss assembly 220.
Starting from the position shown in FIGS. 17a, 17b and 17c, the longitudinal trusses 40 and 40a are sequentially launched during the first launching stage to the truss position shown in FIGS. 18a, 18b and 18c. At that point, the rolling gantry crane is positioned at the support assembly 60 and the trusses 40 and 40a are additionally supported at mid-span by the support assembly 70 and at the forward ends thereof by the support assembly 80 located on pier "A," from which the next succeeding cantilever bridge section will be constructed. At this point, the trusses 40 and 40a occupy Position 1 shown in FIGS. 18b and 18c. The trusses 40 are then rotated about the support assembly 60 to Position 2, shown in FIGS. 18b and 18c. Rotation of the longitudinal trusses is accomplished by first rotating the truss associated with the pendulum leg assembly 210 of the rolling gantry 50. Before the second truss can be rotated, the jack assembly 590 on the fixed leg assembly 200 of the rolling gantry 50 is loosened. The second truss is then rotated. At that time, the leg 570 of the fixed leg assembly pivots about its connection 580. At this point, the rolling gantry transverse truss assembly 220 is still oriented approximately perpendicularly to the original orientation of the longitudinal trusses. To reorient the transverse truss assembly 220 perpendicularly with respect to the newly rotated longitudinal trusses, the pendulum leg assembly 210 or the fixed leg assembly 200, which ever is the further from the forward end of the longitudinal trusses, is moved longitudinal forwardly until laterally adjacent the opposing gantry leg assembly, with respect to the longitudinal truss ends. Stage two launching brings the longitudinal trusses 40 and 40a to Position 1 shown in FIGS. 19a, 19b and 19c. At that point, the rolling gantry crane 50 has been positioned at the support assembly 70 located on the next successive pier "A." The longitudinal trusses are then rotated about that point to Position 2 shown in FIGS. 19b and 19c. Other truss rotational sequences would also be possible in accordance with the teachings herein.
It is to be noted that the above described construction system easily accommodates many geometric variations between the bridge spans. Thus, when the bridge decks are at different elevations, the length of the pendulum leg assembly 210 can be varied to keep the gantry crane 50 horizontal or within a preferred transverse slope range, which may, for example be in a range of about +/- 5° from horizontal. Thus, an extension may be added to the pendulum leg as the elevation of one bridge span changes with regard to the other. When the bridges are not horizontally parallel, the pendulum leg will twist with respect to the transverse truss assembly to accommodate the horizontal change in distance between the bridge spans. Moreover, the pivotal connection between the pendulum leg assembly 210 and the transverse truss assembly 220 enables the pendulum leg assembly to pivot while enabling the transverse truss assembly to remain substantially transversely oriented. In the event that the bridge spans are not elevationally parallel, the gantry translation drive units 940 are synchronized by controlling the flow of hydraulic fluid in each motor thereof through the control of a digital processing unit (not shown) that evaluates and compares the relative travel of each gantry leg. The synchronization prevents one side from moving faster than the other where the vertical loads and longitudinal grades of the two longitudinal trusses are different. Any twisting that would otherwise be imparted to the gantry trusses due to the longitudinal trusses being non-elevationally parallel is alleviated by means of the pivotal connections between the transverse truss assembly and the pendulum leg assembly.
Accordingly, a construction system for fabricating precast segmental bridges has been shown and described. It is understood that the foregoing description and accompanying illustrations are merely exemplary and are no way intended to limit the scope of the invention, which is defined solely by the appended claims and their equivalents. Various changes and modifications to the preferred embodiments should be apparent to those skilled in the art. Such changes and modifications could be made without departing from the spirit and scope of the invention. Accordingly, it is intended that all such changes and modifications be covered by the appended claims and equivalents. | A bridge construction system includes a first independent longitudinal truss positioned over a first bridge span, a second independent longitudinal truss positioned over a second bridge span, a gantry movably mounted on said trusses, the gantry having a first leg mounted to the first truss and a second leg mounted to the second truss, the gantry being drivable along the first and second trusses, a gantry drive for controllably driving the gantry along the trusses, a transverse trolley movably mounted on the gantry, the trolley being drivable along the gantry in a direction generally transverse to the longitudinal trusses, the trolley including a winch for lifting and carrying bridge components to be positioned along the bridge spans over which the longitudinal trusses are mounted, the trolley being selectively positionable over each of the bridge spans, and supports for mounting the longitudinal trusses to bridge components disposed along each of the bridge spans. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 11/752,751, filed May 23, 2007, which is a divisional of U.S. application Ser. No. 10/891,622, filed Jul. 15, 2004, now U.S. Pat. No. 7,239,132, which is a divisional of Ser. No. 10/276,203, filed Nov. 12, 2002, now U.S. Pat. No. 6,815,945, and further claims a right of priority based upon PCT Application No. PCT/EP01/05157, filed 7 May 2001 and German Application No. 200 08 413.5 filed 7 May 2000, all of which are hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a detection system for sensing an object in motion relative to a container, especially tubular in design, whereby at least one magnetic unit is associated with the container and/or object, generating as well as measuring magnetic fields, and at least one evaluation device is connected to the magnetic units and serves to receive sensing signals from the magnetic units.
[0004] A detection system of this type is described in U.S. Pat. No. 3,103,976. That particular detection system is used in locating pipes, and especially pipe ends to be joined, in underwater drilling and similar operations. A guide tube, serving as a container extending between a topside derrick and a frame section anchored on the sea bottom, is equipped on its outside with a coil as the magnetic unit generating a magnetic field and with each two search coils respectively mounted above and below the first coil and serving as the magnetic-field measuring magnets. Electric cables connect these various coils with a topside evaluation unit within the derrick. The magnetic-held-generating coil produces a magnetic field inside the guide tube essentially along the longitudinal axis of the tube. That magnetic field also permeates the two magnetic-field-measuring coils. If and when within the guide tube a drill rod, tool, pipe or the like is shifted, the magnetic field in these measuring coils will change as a function of the position of the moving object, leading to a corresponding induction in these coils. It is thus possible to determine when the object concerned has reached one of these magnetic-field-measuring coils or for instance the blowout valve located on the sea bottom.
[0005] That earlier detection system, however, is essentially limited to sensing the position only of the forward end of the moving object, with the positional detection accuracy being determined by its distance from the coils which are mounted along the longitudinal axis of the guide tube, by the coil width in the longitudinal direction, and similar factors.
BRIEF SUMMARY OF THE PREFERRED EMBODIMENTS
[0006] It is the objective of this invention to provide an improved detection system of the type first above mentioned, the improvement consisting in the ability, in simple fashion and with a relatively high degree of accuracy, to determine not only the position of the object relative to the container in the longitudinal direction but also its position in the transverse direction relative to the container.
[0007] In conjunction with the characteristic features specified within the main concept of the claims, this is accomplished in that the magnetic units produce a maximum magnetic flux essentially perpendicular to the direction of relative movement between the object and the container. This causes a change in the magnetic field and in the magnetic flux when the object is close enough to the container that both are located within the magnetic field of the magnetic-field-generating magnetic unit. At the same time, given this position of the object and the container relative to each other, there will be a change in the magnetic field in the direction perpendicular to the relative movement, thus yielding for the evaluation device additional information on the position of the object and the container perpendicular to the direction of relative movement.
[0008] According to this invention, the functionality of the detection system does not depend on whether the container, for instance tubular in design, is stationary while the object moves relative to it, or vice versa, for as long as at least the moving part contains a magnetic element which triggers a corresponding change in the magnetic field between the magnetic units.
[0009] In oil-drilling or similar operations, it may be advantageous in this context if in particular the tubular container constitutes the aforementioned guide tube and the object is the part that moves relative to that tube. The latter should consist of, or contain, a magnetic material at least at the point which is to serve for the detection of the position and orientation of the object relative to the container. That point could for instance be the forward end of the object.
[0010] An object of this type typically moves within the container so that the corresponding magnetic units can be advantageously mounted in an inside area of the container. On the other hand, if the moving object consists of a non-magnetic material while the container is provided with a magnetic element in an appropriate location, the corresponding magnetic units may equally well be mounted on an outside surface of the object. It is also possible, for facilitated access, to position the magnetic units on an outside surface of the container with the generated magnetic field extending through the wall and into the interior of the container.
[0011] In one possible, simple configuration for the precise capture of the moving object the magnetic units are arranged along at least one orientational plane perpendicular to the direction of relative movement. For example, multiple magnetic units may be arranged in a circular array or in some other way depending on the cross-sectional shape of the container, with the possibility of mounting the magnetic units, with equidistant spacing from one another, in the circumferential direction of the container.
[0012] So as not to limit the detection of the object to essentially one such plane, magnetic units may be mounted perpendicular to the direction of relative movement in evenly spaced planar increments. This permits capture in each of these staggered planes as well as detection between these planes by means of suitably interconnected magnetic units.
[0013] Depending on the design of the magnetic unit, it is possible for such a magnetic unit to be switchable between magnetic-field generation and magnetic-field sensing. This can take place even during the course of a measurement. Evidently, such switchability of the magnetic units involves variable polarity of the magnetic units, variable magnetic-field intensity or the like.
[0014] A simple design example of a magnetic-field-generating magnetic unit can be implemented in the form of a permanent magnet.
[0015] For an expanded range of possibilities in object detection per the above, a magnetic unit may be constituted of an electrically powered coil which provides a simple way to permit operation both for magnetic-field generation and magnetic-field measurement. A coil also allows for easy variation of the magnetic-field intensity or polarity and the generation of alternating fields.
[0016] A magnetic-field-measuring unit that is at once precise, simple and inexpensive may be in the form of a magnetic-field sensor and in particular a Hall element. Magnetic-field sensors of that type can be installed, in simple fashion and at low cost, in arrays of the desired density and configuration for instance on the inside of the container.
[0017] Of course, a suitably designed magnetic unit can also detect magnetic attenuation instead of measuring the magnetic field or magnetic flux.
[0018] For an amplification of the magnetic field and thus of the magnetic flux perpendicular to the direction of relative movement, the magnetic unit may incorporate a magnetizable material, for instance a ferromagnetic or paramagnetic material.
[0019] To avoid having to separately provide each magnetic unit with a magnetizable material, the magnetic units may be interconnected by a magnetizable or magnetically conductive material.
[0020] For a secure installation of the magnetic unit, the unit may be placed for instance in a radial bore in the container wall. The radial bore should be at least deep enough in the radial direction for the magnetic unit to be fully insertable without protruding into the interior of the container.
[0021] To avoid having to drill a corresponding number of radial bores or similar recesses in the container wall while at the same time being able to simultaneously manipulate a larger number of magnetic units, it is possible to mount multiple magnetic units in a magnetic-detector insert which may be mounted for instance in a circumferential recess on the inside of the container. This recess can again be deep enough to prevent the magnetic-detector insert with the magnetic units from protruding into the interior of the container.
[0022] Suitably designed magnetic units allow for the deployment in objects with a variety of cross sections. Of course, for oil exploration and similar applications it will be advantageous, and at the same time the data capture for the detection of the object within the container will be simplified, if the container and/or object are essentially tubular in design. In applications related to oil and gas exploration, it is an essentially tubular object that is guided within an equally more or less tubular container. The object can be so guided that it is either in contact with or moves at a distance from the inside wall of the container.
[0023] In another possible, simple and space-saving design, a magnetic unit may be provided with a ramified and/or continuous helical, electrically conductive ribbon. Such a ribbon essentially corresponds to a coil and generates a comparable magnetic field.
[0024] For the convenient manipulation of ribbon-shaped magnetic units of this type, the ribbon may be mounted on a preferably annular insert. The insert, of course, is shaped to correspond to the cross section of the container, permitting easy installation on an inside surface of the container.
[0025] The insert can allow for further simplification in that the necessary electrical power-supply and/or signal-collecting leads are attached to the ribbon-shaped magnetic units mounted in the insert.
[0026] In analogous fashion it is possible in the case of the aforementioned magnetic-detector insert employing electrical coils to provide the electric coils with winding stems as magnetic units. The coils are wound on these winding stems which, like the entire magnetic-detector insert, may consist of a magnetizable material.
[0027] The evaluation especially of the signals received by the magnetic-field-sensing magnetic units is possible not only for determining the position of the object. A suitably equipped evaluation device may include a memory module and/or a display unit or may be connectable to the latter or for instance to a computer. Stored in the memory module may be the necessary mathematical evaluation algorithms and/or address tags permitting the analysis of the measured signals. The display unit may be used, for example, for a graphic illustration of the object or for detecting the object.
[0028] The evaluation device may also be so configured that in addition to merely detecting the presence of the object it also permits the determination of the position, shape, size or direction of movement of the object.
[0029] The analysis of the signals emanating from the magnetic units and the very positioning of the magnetic units can be simplified for instance by aligning the magnetic axes of the magnetic units with a longitudinal axis of symmetry of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The following describes desirable design examples of this invention in more detail with the aid of the figures in the attached drawings in which:
[0031] FIG. 1 is a perspective side view of a first design example of a detection system according to this invention, employing a tubular container;
[0032] FIG. 2 is a top view of a horizontal section through FIG. 1 ;
[0033] FIG. 3 is a perspective side view of a second design example of a detection system according to this invention;
[0034] FIG. 4 shows a partial vertical section through FIG. 3 ;
[0035] FIG. 5 is a perspective side view of a third design example of a detection system according to this invention;
[0036] FIG. 6 is an enlarged illustration of detail “A” in FIG. 5 ;
[0037] FIG. 7 is an enlarged illustration of detail “B” in FIG. 5 ;
[0038] FIG. 8 is a conceptual illustration of a horizontal cross section through a detection system according to this invention;
[0039] FIG. 9 is an illustration as in FIG. 8 with an object in central position;
[0040] FIG. 10 is an illustration as in FIG. 8 with an object in an off-center position;
[0041] FIG. 11 is an illustration as in FIG. 8 with an object in another off-center position;
[0042] FIG. 12 is an illustration as in FIG. 8 with an object in another central position;
[0043] FIG. 13 is a conceptual illustration explaining the magnetic flux; and
[0044] FIG. 14 shows in detail an area-array element per FIG. 13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] FIG. 1 depicts a first design example of a detection system 1 according to this invention, with a tubular container 2 and a similarly tubular object 3 . The container extends for instance from an ocean-surface platform, not shown, to a frame section anchored on the sea floor. Inside the container 2 the object 3 is guided in the longitudinal direction 33 i.e. in the direction of relative movement 14 . The object may for instance be a section of a drill rod, a tool or similar implement employed in submarine oil exploration.
[0046] In an orientational plane 16 which extends perpendicular to the direction of relative movement 14 , the container 2 accommodates a number of magnetic units 4 to 9 . These are housed in corresponding radial bores of the container 2 and support at least one electric coil 17 each. The central axes of the coils 17 are positioned in the orientational plane 16 and point toward the center of the longitudinal bore 36 . All magnetic units 4 to 9 are mounted in an equidistant relation to one another on the inside 15 along the internal circumference of the container 2 . The coils 17 are positioned within the radial bore 19 so that the magnetic units 5 to 9 will not protrude past the inner surface 15 into the longitudinal bore 36 .
[0047] Each coil 17 connects to the appropriate electrical leads 35 which extend outward away from the container 2 from where they are bundled in omnibus cables, not shown, and run for instance to a topside point.
[0048] At least magnetic unit 4 is a magnetic-field-generating magnetic unit. Its magnetic field is modified by the object 3 which at least in part consists of a magnetizable or magnetically conductive material 18 , and the magnetic field, modified by the movement and changed position of the object 3 relative to the longitudinal bore 36 , can be captured by the magnetic-field-sensing magnetic units 5 to 9 . By way of their electrical leads 35 , the magnetic units 5 to 9 thus generate a corresponding induced voltage as a function of the magnetic flux permeating them and changing with time.
[0049] Instead of arranging the magnetic-field-generating magnetic unit 4 and the corresponding magnetic-field-sensing magnetic units 5 to 9 in one single plane 16 per FIG. 1 , it is also possible to position the magnetic-field-sensing magnetic units for instance partly or entirely in different orientational planes which are spaced at a distance from and offset upward and/or downward relative to the orientational plane 16 per FIG. 1 .
[0050] FIG. 2 shows a horizontal section through FIG. 1 in the area of the orientational plane 16 and more specifically in the area where magnetic unit 7 is located. The radial bore 19 in a wall 37 of the container 2 opens toward the inside surface 15 while at its opposite end a wire duct 38 allows the electrical leads 35 to run from the coil 17 to the outside and away from the longitudinal bore 36 . The wire duct 38 can be closed off with a cap 39 through which the leads 35 are passed via a water-tight seal.
[0051] The magnetic-field-generating magnetic unit 4 per FIG. 1 is configured in analogous fashion. It should be mentioned at this point that all magnetic units per FIG. 1 are capable of serving as magnetic-field-generating or magnetic-field-sensing magnetic units. For example, magnetic units 6 , 7 and 8 may be used as the magnetic-field-sensing units and the magnetic units 4 , 5 and 9 as the magnetic-field-generating units. Obviously, any arbitrary assignment of these magnetic units is possible both before and during a given detection process.
[0052] FIG. 3 is a perspective view, corresponding to FIG. 1 , of a second design example of the detection system 1 according to this invention. In this figure and in the figures that follow as well as in FIGS. 1 and 2 , identical components bear identical reference numbers which will be mentioned only occasionally.
[0053] FIG. 3 differs from FIG. 1 by the consolidation of the magnetic units 4 to 10 in one magnetic detection insert 20 consisting of a magnetizable or magnetically conductive material 18 . The magnetic detection insert 20 is suitably mounted in a circumferential recess 21 on the inside 15 of the wall 37 of the container 2 . The magnetic detection insert 20 has an essentially U-shaped cross section. The open end of the U-profile faces inward in the direction of the longitudinal bore 36 . Located at given points in the annular gap 40 between the legs of the U-profile is a winding stem 28 consisting of a magnetizable material and radially extending parallel with the U-legs toward the inside in the direction of the longitudinal bore 36 . Wound onto each such winding stem 28 is a coil 17 of the respective magnetic unit 4 to 10 . These magnetic units, i.e. coils, are arranged in one orientational plane 16 analogous to FIG. 1 . It should be pointed out again that similar magnetic detection inserts can be mounted in more than one orientational plane.
[0054] FIG. 4 shows a partial vertical section through the design example per FIG. 3 . It clearly illustrates that the coil 17 is wound on the winding stem 28 and that the associated electrical leads 35 of the coil 17 run through a hole in the wall 37 to the outside in a radial direction relative to the container 2 . As has been explained in connection with FIG. 1 , the various magnetic units 4 to 10 may be optionally set to operate as magnetic-field-generating or magnetic-field-sensing units.
[0055] FIG. 5 is a perspective view, analogous to FIGS. 1 and 3 , of a third design example of the detection system according to this invention.
[0056] In this design example, the magnetic units 4 to 11 are in the form of ribbons 22 applied on an insert 23 by a thin-film or similar technology process. The ribbons extend in a ramified and/or helical configuration. Each ribbon is provided at one end with an electrical connector 41 and at the other end with a corresponding electrical connector 42 for supplying power or collecting sensing signals. On the outside of the insert 23 opposite the longitudinal bore 36 the contacts 41 , 42 are connected, for instance as shown in FIG. 6 , to electrical power supply lines 24 , 25 or electrical signal-processing lines 26 , 27 . These electrical lines 24 , 25 and 26 , 27 , for instance as shown in FIG. 7 , can be switched to serve either as power-supply or signal-processing lines, thus affording the option of using the magnetic units.
[0057] The insert 23 consists of a thin ring of a magnetizable material which allows easy mounting on the inside wall 15 of the container 2 in essentially any desired location. Similar inserts 23 can be mounted in different orientational planes as described in connection with FIGS. 1 and 3 .
[0058] At one point the insert 23 , by way of its leads 24 to 27 , is connected to an evaluation device 12 which in the case of submarine oil exploration is typically located in a suitable place on a surface platform. For other applications of the detection system according to this invention, such as land-based oil exploration, the evaluation device 12 will be set up in a conveniently accessible location.
[0059] In the design example per FIG. 5 , the evaluation device 12 incorporates for instance a memory module 29 for saving the incoming sensing signals or for storing appropriate programs for the analysis of these sensing signals. The sensing signals, processed as necessary, can be viewed on a display monitor 30 connected to the evaluation device 12 . The evaluation device 12 may be computerized or connected to a remote computer 31 which may also allow the evaluation device to be programmed for instance to switch the magnetic units into the magnetic-field-generating or, respectively, magnetic-field-sensing mode.
[0060] At this juncture it should be mentioned that the magnetic-field-generating magnetic units may also be in the form of permanent magnets, for one example. The magnetic-field-sensing magnetic units on their part may be in the form of magnetic sensors such as Hall elements.
[0061] The evaluation device 12 also offers the possibility to change the polarity or field intensity of the magnetic field generated. Alternating magnetic fields can also be produced.
[0062] FIGS. 8 to 12 are conceptual illustrations of the detection system 1 according to this invention, showing different magnetic units 4 to 11 without an object 3 ( FIG. 8 ) and, respectively, with different objects in different positions within the container 2 .
[0063] FIG. 8 shows the magnetic field generated by the magnetic unit 4 , unaffected, as in Figure 1 , by any object 3 . The corresponding magnetic-field flux lines 43 extend perpendicular to the longitudinal bore 36 and flow to the respective magnetic-field-sensing magnetic units 5 to 11 . The distance of the magnetic-field-sensing magnetic units 5 to 11 from the magnetic-field-generating magnetic unit 4 determines the extent to which the flux lines permeate the magnetic units. The magnetic flux itself varies accordingly.
[0064] The magnetic units 4 to 11 are arranged in a way that they, and in particular their respective magnetic axes 32 as shown for instance in FIG. 9 , are oriented toward a central point 34 in the longitudinal bore 36 , i.e. toward an axis of symmetry 34 which extends in the longitudinal direction 33 per FIG. 1 .
[0065] When an object 3 moves relative to the container 2 , the result will be a change in the path of the magnetic flux lines, as shown in FIGS. 9 to 11 . In FIG. 9 the object 3 is positioned at dead center 34 , causing a correspondingly symmetrical flux-line distribution pattern. In FIG. 10 , the object is situated off-center and close to the magnetic-field-generating magnetic unit 4 .
[0066] In FIG. 11 , the object 3 is again in an off-center position, in this case close to the magnetic-field-sensing magnetic unit 9 .
[0067] From the respective changes in the magnetic fields and the magnetic flux, detectable by the magnetic-field or magnetic-flux-sensing units 5 to 11 , conclusions can be drawn as to the presence of the object 3 in the vicinity of the magnetic unit as well as the distance between the object 3 and the individual magnetic units, the orientation and dimensions of the object 3 and its direction of movement. By means of appropriate imaging processes in the evaluation device 12 , for instance as shown in FIG. 5 , it is possible to view on the display monitor 30 the object 3 , its position, orientation, size and movement.
[0068] FIG. 12 shows an object 3 larger in overall dimensions and wall thickness, with corresponding changes in the magnetic field and magnetic flux pattern. FIG. 12 thus shows what other conclusions are possible in terms of the dimensions of the object 3 .
[0069] FIG. 13 is a simplified representation of a magnetic-field-generating magnetic unit 4 , the magnetic field and flux line 43 generated by it, and the respective magnetic flux 13 through different area-array elements 44 . Traditionally, the magnetic flux is determined by the following equation:
[0000]
φ
=
∫
Δ
Bx
A
[0000] where
Φ is the magnetic flux, B is the magnetic induction and dA is an infinitesimal vectorial area-array element. According to the invention, the magnetic units 4 to 11 are so arranged that the respective magnetic flux displays its maximum value perpendicular to the relative movement between the object and the container, meaning that the scalar product derived from magnetic induction and the vectorial area-array element takes on its maximum value for the respective area-array elements per FIG. 13 .
[0070] FIG. 14 is a conceptual illustration showing that for each area-array element 44 the magnetic flux derives from the scalar product of magnetic induction B und ΔA as the vectorial area-array element. The applicable equation is a follows:
[0000] Φ=|β|x|ΔA|x cos α
[0000] where
α is the corresponding angle 46 between the vectors B and ΔA.
[0071] The following will briefly explain the operating mode of the detection system according to this invention with reference to the attached drawings.
[0072] By way of the magnetic flux and/or the magnetic attenuation, the detection system according to this invention measures any given object of any given shape, orientation, position and geometry within a magnetic field generated inside a container 2 . One or several magnetic units serve to generate the magnetic field and the corresponding magnetic flux. One or several additional magnetic units capture the magnetic flux that has been modified by the object and its movement or location and on the basis of the sensing signals received it is possible to determine the distance between the object and these magnetic units as well as the position, size and direction of movement of the object. The magnetic-flux-based measurement can take place in static and/or dynamic fashion through alternating fields, variable field intensity and variable polarity.
[0073] The magnetic-field-generating magnetic units may be in the-form for instance of a permanent magnet or electrically powered and controlled coil. The magnetic-field-sensing magnetic units can measure the magnetic flux produced in static fashion employing Hall elements and/or in dynamic fashion by way of electromagnetic induction. The configuration and the number of the magnetic-field-generating and magnetic-field-sensing magnetic units are variable, and especially when coils are used as the magnetic units a switchover between the magnetic-field-generating and the magnetic-field-sensing mode of the magnetic units is easily accomplished.
[0074] The sensing signals are evaluated using mathematical operations and/or address tags and it is possible to display them in graphic form on a display monitor per FIG. 5 , showing the shape and position of the object under analysis.
[0075] The magnetic units can be arranged in a circular or other configuration in one or several planes and they are typically interconnected via a magnetically conductive or magnetizable material. The multiplicity of the different magnetic units and their utilization for generating or sensing and measuring magnetic fields produce magnetic flux patterns between all associated magnetic units which patterns, and any changes thereof, are used for the imaging and positional determination of the object to be measured. The varying magnetic flux is analyzed by appropriate metrics for a determination of the size, shape and position of drill pipes including their tool joints and any associated tools. It is also possible to detect the direction when the pipes or tools constituting the objects within the tubular container are moved. The magnetic units can further recognize drill pipes which are in contact with one of the inside walls of the container, causing the dreaded friction-induced wash-out of the equipment. | The invention relates to a measuring device for detecting a body moving in relation to an, in particular, tubular container. Said device comprises at least one magnet unit which generates a magnetic field, measures this magnetic field and which is assigned to the container and/or to the magnetic body. The device also comprises at least one evaluation device connected to the magnet units and provided for receiving measurement signals of the magnet units. The aim of the invention is to improve a measuring device of this type in order to be able to easily determine, in addition to the position of the body in relation to the container in a longitudinal direction, the position of the body in relation to the container in the transverse direction with a relatively high level of accuracy. To this end, the magnet units comprise a maximum magnetic flux that is essentially perpendicular to the direction of the relative motion of the body and container. |
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FIELD OF THE INVENTION
[0001] The present invention relates to locks and more particularly to a magnetic lock having a particular application in electronic device.
BACKGROUND OF THE INVENTION
[0002] A variety of electronic and information products are developed due to the fast progress in electronics and computer technology. Correspondingly, more and more users become more critical with respect to the functions and the quality of the products. The increasing consumer demand with respect to manufacturers of portable computer, particularly notebook computer, is very significant.
[0003] The trend of developing notebook computers is slimness, compactness, and lightweight in consideration of weight and size. Moreover, an all-in-one notebook computer is constantly being sought. Nowadays, all-in-one notebook computers are dominant type of portable computers. It is understood that the notebook computer market is very competitive. Fortunately, a wide variety of notebook computers are available for consumers to choose. It also understood that most consumers want to buy an all-in-one, ergonomic notebook computer in a cost effective price. It is concluded that if a notebook computer manufacturer wants to win over other competitive manufacturers how to provide user with ergonomic notebook computers in a reasonable price should be a deciding factor.
[0004] A notebook computer, as self-explanatory, means the computer can be easily opened or closed just like opening or closing a notebook. As shown in FIG. 1 , a prior parallelepiped notebook computer comprises a display 10 and a case 11 . At least one hinge 12 , provided at one side of the case 11 , is coupled to the display 10 . As such, in a nonoperating position the display 10 is covered the case 11 . For using the notebook computer, a user can pivot the display 10 about the hinge 12 upward to position the display 10 at an optimum angle about the case 11 for viewing. A keyboard 13 and a touch panel 14 are provided on top of the case 11 proximate the display 10 . Also, two spaced slots 15 are formed at a top edge of the case 11 distal from the display 10 . A slide lock 16 is provided on one side of the display 10 distal from the hinge 12 . The lock 16 is adapted to prevent the notebook computer from opening. For locking the notebook computer, slide the lock 16 to cause two hooks 161 at both sides of the lock 16 to move laterally. The lateral movements of the hooks 161 will cause the hooks 161 to insert into the slots 15 for fastening the display 10 and the case 11 together (i.e., locked) in response to closing the display 10 onto the case 11 .
[0005] However, a precise manufacturing of a connecting mechanism of the slide lock 16 and the hooks 161 is required since newly developed notebook computers are more lightweight and more compact. As a result, a user may have difficulty in feeling whether the hooks 161 are disengaged from the slots 15 in opening the display 10 since the lateral movement of the lock 16 is relatively small. It is typical that a user uses one hand to push the lock 16 and the other hand to open the display 10 . However, the user has to exert a great force to open the display 10 due to the own weight of the display 10 . Hence, it is not easy to open the display 10 . It is often that a user may use a great force to open the display 10 not being aware that the hooks 161 are not disengaged from the slots 15 . As a result, the lock 16 , the hooks 161 , and other associated members are susceptible of damage. Further, a great inconvenience and trouble may be brought to users.
[0006] Moreover, the protruding hooks 161 are not aesthetic in addition to the above drawback of being susceptible of damage. It is concluded that the prior lock is not a perfect design.
[0007] Thus, it is desirable among vast users and manufacturers to provide a notebook computer having a novel lock capable of easily, conveniently opening the display 10 from the case 11 or closing the display 10 onto the case 11 .
SUMMARY OF THE INVENTION
[0008] A primary object of the present invention is to provide a magnetic lock mountable on an electronic device capable of opening or closing. The magnetic lock comprises an upper magnetic plate formed on an upper housing of the electronic device and a lower magnetic plate formed on a lower housing of the electronic device. The electronic device is automatically locked because magnetic members of the upper magnetic plate attract magnetic members of the lower magnetic plate having a polarity different from that of the magnetic members of the upper magnetic plate when the upper housing is covered the lower housing. Alternatively, a user can move the upper magnetic plate about the lower magnetic plate a predetermined distance to repel the magnetic members of the upper magnetic plate from the magnetic members of the lower magnetic plate having the same polarity as that of the magnetic members of the upper magnetic plate to unlock the electronic device. By utilizing the present invention, the above drawbacks of the prior art can be overcome. These drawbacks are that the protruding hooks are not aesthetic, it is not easy to open the display for unlocking the notebook computer, and it is often that a user may use a great force to open the display not being aware that the hooks are not disengaged from the slots, resulting in a great possibility of easily damaging the slide lock, the hooks, and other associated. The magnetic lock of the present invention also has the following advantages. It can be realized in a simple construction, simple manufacturing, and low cost. Further, the magnetic lock of the present invention is compact, simple and easy in operation, and ergonomic.
[0009] The above and other objects, features and advantages of the present invention will become apparent from the following detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a notebook computer incorporating conventional slide lock and associated hooks;
[0011] FIG. 2 is a diagram schematically illustrating a magnetic lock according to a first preferred embodiment of the invention;
[0012] FIG. 3 is a perspective view of a notebook computer incorporating the magnetic lock;
[0013] FIG. 4 is a diagram schematically illustrating attracting force between an upper magnetic plate and a lower magnetic plate of the magnetic lock;
[0014] FIG. 5 is a diagram schematically illustrating repelling force between an upper magnetic plate and a lower magnetic plate of the magnetic lock; and
[0015] FIG. 6 is a perspective view of a notebook computer incorporating a magnetic lock according to a second preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring to FIG. 2 , there is shown a magnetic lock 2 in accordance with a first preferred embodiment of the invention. The magnetic lock is adapted to mount on an electronic device (e.g., notebook computer, palm computer, or the like) capable of opening or closing. The magnetic lock 2 comprises an elongate, rectangular upper magnetic plate 20 and an elongate, rectangular lower magnetic plate 30 . The upper magnetic plate 20 comprises a plurality of alternate magnetic members 21 of positive polarity (+) and magnetic members 21 of negative polarity (−) from one end to the other end. Each of the magnetic members 21 of positive polarity (+) and the magnetic members 21 of negative polarity (−) is formed of a magnetic pad 21 in this embodiment. As shown in FIG. 2 , similar to the upper magnetic plate 20 , the lower magnetic plate 30 comprises a plurality of alternate magnetic members 31 of positive polarity (+) and magnetic members 31 of negative polarity (−) from one end to the other end. Each of the magnetic members 31 of positive polarity (+) and the magnetic members 31 of negative polarity (−) is formed of a magnetic pad 31 in the embodiment. It is appreciated by those skilled in the art that the magnetic pads 21 and 31 may be replaced by members formed of similar materials in other embodiments without departing from the scope and spirit of the invention.
[0017] As stated above, the magnetic lock 2 is adapted to mount on an electronic device capable of opening or closing. Thus, following description will be made with respect to the magnetic lock 2 mounted on a notebook computer 40 . Referring to FIG. 3 , the notebook computer 40 is substantially the same as a typical one. The parallelepiped notebook computer 40 comprises a display 41 and a case 42 . At least one hinge 43 , provided at one side of the case 42 , is coupled to the display 41 . As such, the display 41 is able to pivot about the hinge 43 to open or close the notebook computer 40 . A keyboard 44 and a touch panel 45 are provided on top of the case 42 . A slide lock 46 is provided on one side of the display 41 distal from the hinge 43 . The upper magnetic plate 20 is able to engage with the lower magnetic plate 30 when the display 41 is covered the case 42 by pivoting (see FIG. 2 ). The upper magnetic plate 20 is adjacent the slide lock 46 on the display 41 (see FIG. 3 ). As shown in FIG. 4 , the other end of the upper magnetic plate 20 is coupled to one end of an elastic element (e.g., spring) 47 which has the other end anchored at an interior wall 411 of the display 41 .
[0018] By configuring the magnetic lock 2 as above, referring to FIGS. 3 and 4 again, the display 41 is covered the case 42 by pivoting. It is clearly seen that the magnetic pads 21 will attract the magnetic pads 31 if they are different in polarity (i.e., the magnetic pads 21 of positive polarity (+) attract the magnetic pads 31 of negative polarity (−) and the magnetic pads 21 of negative polarity (−) attract the magnetic pads 31 of positive polarity (+) respectively) due to magnetism. As a result, the notebook computer 40 is locked because the display 41 and the case 42 are fastened together.
[0019] Referring to FIGS. 3 and 5 , to the contrary, in a case of opening the notebook computer 40 by pushing the lock 46 toward the elastic element 47 for compression, the upper magnetic plate 20 moves laterally a distance. The magnetic pads 21 will also move. As such, the magnetic pads 21 of one polarity are aligned with the magnetic pads 31 of the same polarity (i.e., the magnetic pads 21 of positive polarity (+) are aligned with the magnetic pads 31 of positive polarity (+) and the magnetic pads 21 of negative polarity (−) are aligned with the magnetic pads 31 of negative polarity (−) respectively) if the moving distance of the upper magnetic plate 20 is sufficient. In this position, the upper magnetic plate 20 will repel the lower magnetic plate 30 (i.e., the magnetic pads 21 of positive polarity (+) repel the magnetic pads 31 of positive polarity (+) and the magnetic pads 21 of negative polarity (−) repel the magnetic pads 31 of negative polarity (−) respectively) due to magnetism. As a result, the repelling force between the display 41 and the case 42 will form a gap therebetween. As such, a user can quickly pivot the display 41 upward by inserting finger(s) into the gap. Moreover, the upper magnetic plate 20 will be pushed back to its original position immediately thereafter by the expansion of the elastic element 47 coupled to the other end of the upper magnetic plate 20 once the pushing force exerted on the lock 46 is released. This is done due to the elasticity of the elastic element 47 . Thus, the upper magnetic plate 20 and the lower magnetic plate 30 will attract again for locking the notebook computer 40 if they are engaged again when the display 41 is covered the case 42 (see FIG. 4 ).
[0020] The magnetic lock 2 of the invention is made possible by utilizing magnetism. That is, two magnetic members having different polarities will attract each other and to the contrary, two members having the same polarity will repel each other. As such, a device can be locked or unlocked by incorporating the above magnetic members. Further, the magnetic lock 2 can be implemented is one of a variety of forms. Referring to FIG. 6 , the upper magnetic plate 20 is implemented as a disc comprising a top ridge 22 across its center so as to form a magnetic pad 21 of positive polarity (+) at one half and a magnetic pad 21 of negative polarity (−) at the other half. The upper magnetic plate 20 further comprises a tab 23 extended downward from its bottom. Also, the upper magnetic plate 20 is rotatable about the tab 23 . The lower magnetic plate 30 is disposed corresponding to the upper magnetic plate 20 and is implemented as a circular one. The lower magnetic plate 30 comprises a hole 32 through its center, the hole 32 being conformed to receive the tab 23 , a magnetic pad 31 of negative polarity (−) at one half, and a magnetic pad 31 of positive polarity (+) at the other half. In a case of closing a device, the tab 23 will insert into the hole 32 as an upper case 60 of the device is engaged with a lower case 61 of the device by pivoting. At this position, the upper magnetic plate 20 formed on the upper case 60 and the lower magnetic plate 30 formed on the lower case 61 are coupled together in which the magnetic pad 21 of positive polarity (+) attracts the magnetic pad 31 of negative polarity (−) and the magnetic pad 21 of negative polarity (−) attracts the magnetic pad 31 of positive polarity (+) respectively due to magnetism. As a result, the device is locked because the upper case 60 and the lower case 61 are fastened together.
[0021] To the contrary, for opening the device it is possible of rotating the upper magnetic plate 20 180 degrees about the tab 23 which, as stated above, is fastened in the hole 32 . Once the magnetic pad 21 of one polarity is aligned with the magnetic pad 31 of the same polarity by the above rotation (i.e., the magnetic pad 21 of positive polarity (+) is aligned with the magnetic pad 31 of positive polarity (+) and the magnetic pad 21 of negative polarity (−) is aligned with the magnetic pad 31 of negative polarity (−) respectively) the upper case 60 will repel the lower case 61 (i.e., the magnetic pad 21 of positive polarity (+) repels the magnetic pad 31 of positive polarity (+) and the magnetic pad 21 of negative polarity (−) repels the magnetic pad 31 of negative polarity (−) respectively) due to magnetism. As a result, the repelling force between the upper case 60 and the lower case 61 will form a gap therebetween. As such, a user can quickly pivot the upper case 60 upward for opening the device by inserting finger(s) into the gap.
[0022] It will be evident from the foregoing that the magnetic lock 2 of the invention has the following advantages: It can be realized in a simple construction, simple manufacturing, and low cost. Further, the magnetic lock 2 of the invention is compact, simple and easy in operation, and ergonomic.
[0023] While the invention has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims. | The present invention is to provide a magnetic lock mountable on an electronic device, which comprises an upper and a lower magnetic plates respectively formed on an upper and a lower housings of the electronic device, enabling the electronic device to be automatically locked due to the attraction between a plurality of magnetic members disposed on the corresponding positions of the upper and lower magnetic plates having different polarities when the upper housing is covered the lower housing. Alternatively, when the upper magnetic plate is moved a predetermined distance, the corresponding magnetic members on the upper and lower magnetic plates are in turn having the same polarity to repel with each other, enabling the upper and lower housings of the electronic device to be automatically unlocked. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to Chinese Application No. 201610817103.6, filed on Sep. 12, 2016, entitled “A kick Information Identification Apparatus and Method Assisted for Wellbore Pressure Control during Horizontal Drilling”, which is specifically and entirely incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to the oil and gas well engineering field, in particular to a measuring unit, a kick information identification apparatus and method.
BACKGROUND OF THE INVENTION
Recently, the reservoir characteristics and well structures in oil and gas well drilling become more and more complex, and oil and gas kick accidents happen frequently, resulting in increase of non-operation time and drilling cost in well drilling. After kick happens in a well, the formation fluids (oil, gas, and water) may invade into the wellbore, be mixed with the drilling fluid and migrate along the wellbore. If the kick fluid is a gas, subjecting to the influence on the environment change on pressure and temperature, it may have severe phase transition, rise and expansion in the migration process, bringing a serious challenge to wellbore pressure control. Therefore, it is very important to identify and diagnose kick information timely, to ensure safe and efficient well drilling.
The invasion of formation fluids may result in change of flow behaviors and physical parameters of the fluid in the wellbore. Based on that fact, existing kick detection techniques have been developed, and these kick detection techniques can be categorized into: diagnostic methods based on flow measurement, including drilling fluid pit increment method, outlet flow difference method, and downhole micro-flow measurement method, etc.; diagnostic method based on pressure and temperature measurement, including Annulus Pressure While Drilling (APWD), Logging While Drilling (LWD), and Rapid Annulus Temperature (RAT), etc.; diagnostic methods based on measurement of gas void fraction in fluid, including acoustic measurement method, resistivity measurement method, and natural gamma monitoring method (LWD), etc.
To avoid gas over-expansion and control the wellbore pressure timely, diagnostic methods based on downhole measurement techniques were the main development direction of kick detection in the early stage. However, the applicability and time efficiency of those methods are quite limited in the kick detection in horizontal wells. Firstly, since gas doesn't expand when it migrates in a horizontal section, the flow and pressure variations are not apparent, and it is difficult to measure directly to realize early identification. Secondly, since a risk of formation fluid invasion exists at all positions in a horizontal section, it is unable to judge the kick information above the bottom hole based on the measurement data obtained at the bottom hole. Finally, since the pressure variations are not apparent, it is difficult to judge the kick information, etc timely. However, the identification of kick fluid type, kick rate, and kick occurrence position has important meaning in understanding about the formation characteristics, judging the causes for kick, and conducting follow-up wellbore pressure control.
To overcome the drawbacks in the prior art, the present invention provides a measuring unit, a kick information identification apparatus and method, which are applicable to kick information identification in horizontal wells.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a measuring unit, a kick information identification apparatus, and a kick information identification method, which can be used to identify kick information in horizontal wells by utilizing a throttling device and pressure sensors and/or temperature sensors.
To attain the object described above, in an embodiment of the present invention, a measuring unit for kick information identification is provided, comprising: a throttling device, mounted on a drill stem; sensors, arranged at the two sides of the throttling device, and configured to sense the pressure and/or temperature at the two sides of the throttling device; and a signal transmitter, configured to transmit the pressure and/or temperature values.
Optionally, the throttling device is a multi-stage throttling device.
Optionally, the signal transmitter is a wireless communication module; and the measuring unit further comprises a power supply unit configured to supply power to the measuring unit.
Accordingly, in an embodiment of the present invention, a kick information identification apparatus is provided, comprising: the measuring units described above; and a processor, configured to determine kick information according to the pressure and/or temperature at the two sides of the throttling device, the kick information comprises one or more of the following items: kick moment, kick rate, kick occurrence position, and kick type.
Optionally, when the pressure drop across the throttling device at the current moment is greater than the pressure drop at the previous moment by a value greater than a preset pressure drop, the processor determines the current moment as the kick moment.
Optionally, the processor calculates the drilling fluid flow corresponding to the pressure drop across the throttling device, and takes the difference between the drilling fluid flow and the current drilling fluid injection displacement as the kick rate.
Optionally, the processor determines the kick occurrence position according to the following equation:
L 1 = Q 1 ( t 1 - t 0 ) A
where, L 1 represents the distance of the kick occurrence position from the measuring unit, Q 1 is the fluid flow rate through the throttling device corresponding to the pressure drop in the throttling device, t 0 is the kick moment, t 1 is the moment when the temperature sensor in the measuring unit detects that the temperature rising rate is greater than the preset temperature rising rate, and A is the sectional area of the annulus.
Optionally, the processor calculates a pressure-drop coefficient with the following equation, and determines the kick type according to the pressure-drop coefficient:
x = Δ p 2 - Δ p 0 Δ p 1 - Δ p 0
where, x is the pressure-drop coefficient; Δp 0 is the pressure drop in the throttling device before kick; Δp 1 is the pressure drop at the moment before the kick fluid reaches to the throttling device after kick, Δp 1 −Δp 0 is the increment of the corresponding pressure drop; Δp 2 is the pressure drop at the moment after the kick fluid reaches to the throttling device after kick, and Δp 2 −Δp 0 is the increment of the corresponding pressure drop.
Optionally, the processor determines the kick fluid to be a gas, if the temperature difference across the throttling device is a negative value.
Accordingly, in an embodiment of the present invention, a kick information identification method is provided, comprising: sensing the pressure and/or temperature at the two sides of a throttling device on a drill stem; and determining kick information according to the pressure and/or temperature at the two sides of the throttling device, wherein the kick information comprises one or more of the following items: kick moment, kick rate, kick occurrence position, and kick type.
The present invention employs a throttling device and measures the pressure drop and/or temperature difference across the throttling device, and can identify kick information successfully according to the pressure drop and/or temperature difference. Even in the case of horizontal wells where the flow and pressure variations are not apparent, the present invention can still attain a good kick information identification effect. In addition, besides monitoring kick, the throttling device can also be used to increase pressure loss by means of throttling and pressure drop by means of friction resistance to avoid vehement kick development, and can assist wellbore pressure control on the basis of the kick information.
Other features and advantages of the present invention will be further detailed in the embodiments hereunder.
DESCRIPTION OF THE DRAWINGS
The accompanying drawings are provided here to facilitate further understanding on the present invention, and constitute a part of this document. They are used in conjunction with the following embodiments to explain the present invention, but shall not be comprehended as constituting any limitation to the present invention. Among the drawings:
FIG. 1 is a schematic diagram of the mounting positions of the measuring units for kick information identification according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of the measuring unit for kick information identification according to the embodiment of the present invention;
FIGS. 3A and 3B are longitudinal and transverse axial sectional views of the throttling device in the measuring unit for kick information identification according to the embodiment of the present invention, respectively;
FIG. 4 is a sectional view of a multi-stage throttling device;
FIG. 5 is a schematic relation curve diagram between pressure drop across the throttling device before different types of kick fluids reach to and after the throttling device (i.e., pressure difference before and after throttling) and kick fluid volume fraction after kick happens; and
FIG. 6 is a flow chart of the kick information identification process according to the embodiment of the present invention.
Description of the Symbols
1
First measuring unit
2
Second measuring unit
3
Drill bit
4
Drill stem
5
Oil-gas reservoir
6
Casing
7
Cement annulus
8
Lower ram-type
blowout preventer
9
Hydraulic throttle
10
Cutter ram-type
valve
blowout preventer
11
Upper ram-type
12
Annular blowout
blowout preventer
preventer
13
Throttling device
14, 17
Pressure sensor
15, 16
Temperature sensor
19
Power supply unit
20
Signal transmitter
21
Rock debris
flow-back hole
22
Wellbore wall
DETAILED DESCRIPTION OF THE EMBODIMENTS
Hereunder some embodiments of the present invention will be detailed with reference to the accompanying drawings. It should be appreciated that the embodiments described here are only provided to describe and explain the present invention, but shall not be deemed as constituting any limitation to the present invention.
FIG. 1 is a schematic diagram of the mounting positions of the measuring units for kick information identification according to an embodiment of the present invention. As shown in FIG. 1 , during horizontal well drilling operation, two measuring units are mounted on a drill stem 4 . The measuring unit 1 may be mounted at about 20 m behind a drill bit 3 on the drill stem 4 . Certainly, the number of measuring units mounted on the drill stem is not limited to 2 measuring units; a different number of measuring units is also permitted.
FIG. 2 is a schematic structural diagram of the measuring unit for kick information identification according to the embodiment of the present invention. As shown in FIG. 2 , the measuring unit comprises: a throttling device 13 , mounted on the drill stem 4 ; sensors, arranged at the two sides of the throttling device 13 , and configured to sense the pressure and/or temperature at the two sides of the throttling device ( FIG. 2 shows pressure sensors 14 and 17 and temperature sensors 15 and 16 mounted at the two sides of the throttling device respectively); and a signal transmitter, configured to transmit the pressure and/or temperature values, wherein, the signal transmitter may be a wireless communication module, in order to avoid wiring of signal wire on the drill stem 4 for transmitting the pressure and/or temperature values. In addition, the measuring unit may further comprises a power supply unit 18 configured to supply power to the electrical components in the measuring units and avoid wiring of a power cord on the drill stem 4 .
FIGS. 3A and 3B are longitudinal and transverse axial sectional views of the throttling device in the measuring unit for kick information identification according to the embodiment of the present invention, respectively. As shown in FIGS. 3A and 3B , the throttling device 13 is mounted on the drill stem 4 , and the throttling device 13 are foimed with three rock debris flow-back holes 21 in an annulus formed between the drill stem 4 and the wellbore wall 22 , to ensure normal flow-back of rock debris. In addition, through the radii of different protrusion parts of the throttling device 13 (e.g., radii r 1 -r 3 shown in FIG. 3B ), the throttling device 13 can change the area of passage in the annulus, so as to produce pressure drop by means of friction resistance and throttling. Preferably, the throttling device 13 comprises a plurality of throttling parts, and is a multi-stage throttling device, so as to produce enough pressure drop, as shown in FIG. 4 .
In the case of gas-liquid dual-phase flow, theoretically the pressure drop across the throttling device is equal to the sum of the pressure drop incurred by friction resistance and the pressure drop incurred by throttling:
Δ p=Δp f +Δp J (1)
where, the pressure drop incurred by friction resistance and the pressure drop incurred by throttling are:
Δ p f = ∫ 0 L f u m 2 2 d v m ⅆ x ( 2 ) Δ p J =M ( p 1 −p 2 ) (3)
u
m
2
2
-
u
m
1
2
2
=
nx
g
v
g
1
p
1
n
-
1
[
1
-
(
p
2
p
1
)
n
-
1
n
]
+
(
1
-
x
g
)
v
L
(
p
1
-
p
2
)
(
4
)
n = x g kC vg 1 + ( 1 - x g ) C L x g C vg 1 + ( 1 - x g ) C L , k = C pg 1 C vg 1 ( 5 )
where, L is the length of the multi-stage throttling device; d is the equivalent diameter of the annulus; f is a friction coefficient; M is the number of stages of the multi-stage throttling device; x g is the mass fraction of the gas phase; p is the pressure; v is the specific volume; C pg is specific heat capacity of the gas at a constant pressure; C vg is the specific heat capacity of the gas at a constant volume; u is the flow velocity. The suffix g represents gas phase, the suffix L represents liquid phase, the suffix m represents a mixture of kick fluid (oil, gas, water) and mud; the suffix 1 represents the position before throttling, and the suffix 2 represents the position after throttling, as shown in FIG. 3B .
In the initial stage of kick, before the kick fluid reaches to the throttling device, only the drilling fluid flow exits at the throttling device. The pressure drop across the throttling device is:
Δ p = ∑ i f Q 2 l i 2 v L d i A i 2 + M Q 2 2 v L ( 1 A 2 2 - 1 A 1 2 ) ( 6 ) A 1 =π( r 4 2 −r 1 2 ) (7)
A 2 =3 A cut +π( r 3 +r 4 ) x marg (8)
where, Q is the flow of the fluid flowing through the throttling device; A 1 is the cross-sectional area of the annulus before throttling; A 2 is the cross-sectional area of the annulus after throttling; A cut is the sectional area of the rock debris flow-back hole; x marg is the fitting margin between the throttling device and the wellbore wall, x marg =r 4 −r 3 ; l i is the length of the section i of the throttling device; r 1 -r 4 are the radii of the sections of the throttling device, as shown in FIG. 3B .
Particularly, for a 5-⅞-in wellbore, for example, the number of stages of the throttling device is 20, the length of the throttling device is 6.096 m, and the geometric parameters are as follows:
TABLE 1
Geometric Parameters of the Throttling Device
Radius
Value
Length
Value
r 1
30.8 mm
l
35
mm
r 2
55.6 mm
l 1
50.8
mm
r 3
69.6 mm
l 2
152.4
mm
r 4
74.6 mm
l 3
101.6
mm
Suppose the parameters of the drilling fluid and the kick fluid are those shown in Table 2, the calculated pressure drop across the multi-stage throttling device is shown in FIG. 5 .
TABLE 2
Calculated Simulation Parameters
Variable
Value
Variable
Value
Displacement of
15 L/s
Density of the
1200 kg/m 3
the drilling fluid
drilling fluid
Specific heat
1872
Density of the gas
117.86 kg/m 3
capacity of drilling
J/(kg • K)
fluid
Specific heat
3148
Specific heat
1950
capacity of the gas
J(kg • K)
capacity of the gas
J/(kg • K)
at a constant
at a constant
pressure
volume
Density of
1000 kg/m 3
Density of
800 kg/m 3
formation water
formation oil
Pressure at the
20 MPa
Temperature at the
80° C.
inlet
inlet
Type of the gas
CH 4
Friction coefficient
0.01
FIG. 5 is a schematic relation curve diagram between pressure drop across the throttling device before different types of kick fluids reach to and pass through the throttling device and kick fluid volume fraction after kick happens. The curve labeled as “pure mud stream” represents the variation of the pressure drop measured across the throttling device vs. the volume fraction of the fluid invading into the annulus before the kick fluid reaches to the throttling device, after kick happens; the curve labeled as “mud-formation water stream” represents the variation of the pressure drop measured across the throttling device vs. the volume fraction of the fluid invading into the annulus after the kick fluid reaches to the throttling device after kick happens, in the case that the kick fluid is a “formation water stream”; the curve labeled as “mud-oil stream” represents the variation of the pressure drop measured across the throttling device vs. the volume fraction of the fluid invading into the annulus after the kick fluid reaches to the throttling device after kick happens, in the case that the kick fluid is an “oil stream”; the curve labeled as “mud-gas stream” represents the variation of the pressure drop measured across the throttling device vs. the volume fraction of the fluid invading into the annulus after the kick fluid reaches to the throttling device after kick happens, in the case that the kick fluid is a “gas stream”.
It can be seen from FIG. 5 : as the volume fraction of the fluid invading into the annulus increases, the pressure drop measured across the throttling device increases remarkably. At the initial time, for the “pure mud stream” curve, under the condition of normal drilling fluid displacement, the measured pressure drop is 0.271 MPa; when the volume fraction of the kick fluid reaches 40% or a higher value, the pressure drop increases rapidly to 0.754 MPa. Thus, the occurrence of kick can be diagnosed and the kick rate can be determined quickly according to that characteristic.
In addition, it can be seen from FIG. 5 : the pressure drop across the multi-stage throttling device is very sensitive to the kick type. In the case that the volume fraction of the kick fluid reaches 40% as described above, the pressure drop is 0.704 MPa, 0.653 MPa, and 0.481 MPa respectively when three different types of kick fluids (“formation water stream”, “oil stream” and “gas stream”) flow through the throttling device respectively. Calculated with the following equation (9), the pressure-drop coefficients corresponding to oil, gas, and water invasion types are 89.65%, 79.09%, and 43.48% respectively. Thus, the kick rate and kick type can be identified.
x = Δ p 2 - Δ p 0 Δ p 1 - Δ p 0 ( 9 )
where, x is the pressure-drop coefficient; Δp 0 is the pressure drop before kick; Δp 1 is the pressure drop at the moment before the kick fluid reaches to the multi-stage throttling device after kick, Δp 1 −Δp 0 is the increment of the corresponding pressure drop; Δp 2 is the pressure drop at the moment after the kick fluid reaches to the multi-stage throttling device after kick, and Δp 2 −Δp 0 is the increment of the corresponding pressure drop.
The present invention further provides a kick information identification apparatus, comprising: one or more measuring units described above, configured to acquire pressure and/or temperature at the two sides of a throttling device and transmit the data via a signal transmitter; and a processor, arranged on the ground surface, for example, and configured to receive the pressure and/or temperature data at the two sides of the throttling device transmitted from the measuring units, and determine kick information according to the pressure and/or temperature at the two sides of the throttling device on the basis of the characteristic described above, wherein, the kick information includes one or more of the following items: kick moment, kick rate, kick occurrence position, and kick type, and thereby provide a kick warning accordingly.
For a multi-stage throttling device, theoretically the pressure drop under the condition of single phase fluid flow can be calculated with the equation (6). In view that the theoretically calculated value may not be accurate enough, empirical coefficients are fitted according to the test data, and an empirical relation formula of pressure drop vs. displacement of liquid phase flow at each measuring unit is determined:
Δ p = a 1 Q a 2 v L + a 3 N Q 2 2 v L ( 1 A 2 2 - 1 A 1 2 ) ( 10 )
where, a 1 , a 2 , a 3 are empirical coefficients, which are mainly related to the parameters of the throttling device; Q is the fluid flow through the throttling device, m 3 /s; A 1 , A 2 are sectional areas of the annulus before and after throttling, m 3 .
Before kick information identification, the drilling fluid may be injected in different drilling fluid injection displacements, and the pressure drops Δp of the measuring unit under different drilling fluid injection displacements are recorded. The empirical coefficients in the equation (10) can be determined by putting the recorded different groups of displacement —pressure drop values into the equation (10), so that the empirical coefficients can be utilized subsequently to calculate the kick rate with the equation (10).
Hereunder the specific methods for determining the kick moment, kick rate, kick occurrence position, and kick type will be described.
1) Judging Kick Occurrence Moment
The propagation velocity of a pressure wave in mud is as high as about 1,500 m/s. Hence, the propagation time of the pressure wave may be neglected, and the initial kick time recorded by the pressure sensor may be supposed as the true initial kick time.
Thus, the pressure drop Δp 1 across the throttling device in the measuring unit can be recorded in real time. If the Δp 1 increases remarkably compared with its value at the previous moment (e.g., the difference between the pressure drop values at the two moments exceeds a preset pressure drop value), it can be judged preliminarily that kick has happened; in that case, the kick occurrence moment is recorded and denoted by t 0 .
2) Calculating Kick Rate
According to the pressure drop Δp 1 across the throttling device in the measuring unit, the equation (10) is utilized to calculate the corresponding fluid flow rate Q 1 through the throttling device, and the kick rate ΔQ 1 can be determined according to the fluid flow rate and the drilling fluid injection displacement.
Δ Q 1 =Q 1 −Q 0 , (11)
where, Q 0 is the drilling fluid injection displacement.
3) Judging Kick Occurrence Position
After kick happens, the hot formation fluid invades into the wellbore and cause fluid temperature rising in the wellbore. Suppose that the heat conduction velocity is neglected, usually the temperature propagation velocity is approximately equal to the migration velocity of the kick fluid.
Therefore, after the hot formation fluid migrates to the measuring unit, the temperature recorded by the temperature sensor will rise apparently (e.g., the temperature rising rate is higher than a preset temperature rising rate); in addition, if the kick fluid is a gas, the pressure difference between the two ends of the throttling device will decrease obviously. The moment t 1 when the temperature begins to rise and/or the pressure decreases obviously is recorded, and the kick may happen at the following position L 1 from the measuring unit:
L 1 = Q 1 ( t 1 - t 0 ) A ( 12 )
where, A is the sectional area of the annulus.
4) Judging Kick Type
When the formation fluid migrates to the measuring unit and flows through the multi-stage throttling device, if the formation fluid is oil or water, the difference between the pressure drop Δp 1 across the multi-stage throttling device at the current moment and that at the previous moment is not great (it can be seen from FIG. 5 : the pressure-drop coefficient is slightly greater than 75%); if the formation fluid is a gas, the pressure drop Δp 1 across the multi-stage throttling device at the current moment is obviously lower than that at the previous moment (it can be seen from FIG. 5 : the pressure-drop coefficient is slightly less than 50%). Therefore, besides monitoring kick, the designed multi-stage throttling device can also increase the pressure loss by means of throttling and pressure drop by means of friction resistance, and thereby avoid rapid kick growth.
The method described above judges the type of the kick fluid by comparing the pressure drop across the multi-stage throttling device before and after the kick fluid reaches to the multi-stage throttling device. Alternatively, the type of the kick fluid can be judged according to the temperature change between the temperature before and after throttling.
The temperature change between the temperature before and after throttling may be calculated with the following equation (12):
Δ T=μ J Δp (12)
where, μ J is the throttling coefficient. In the case that the throttled fluid is a gas, the throttling coefficient μ J is a positive value, since gas usually has high compressibility, and the temperature drop after throttling is obvious; in the case that the throttled fluid is a liquid, the throttling coefficient μ J is a negative value and close to 0, such that the temperature of the liquid after throttling basically has not change or slightly rise.
In summary, after the occurrence of kick is ascertained (i.e., the pressure drop across the throttling device increases remarkably), if the pressure drop and/or temperature difference across the throttling device in the measuring unit doesn't change greatly, it indicates that the kick fluid is oil or water; in contrast, if the temperature difference is negative and the pressure drop is obvious, it indicates that the kick fluid is a gas.
FIG. 6 is a flow chart of the kick infatuation identification process according to the embodiment of the present invention, illustrating a scenario that two measuring units are arranged on the drill stem as shown in FIG. 1 .
Firstly, the measurement data of the temperature sensors and pressure sensors at the two sides of the measuring units 1 and 2 is recorded. If it is found that the pressure drop across the throttling device in the measuring unit 1 or 2 increases remarkably at a moment t 0 , it indicates that kick has happened, and that moment t 0 can be determined as the kick occurrence moment. Then, the values of fluid flow rates Q 1 , Q 2 through the corresponding throttling devices are calculated according to the values of pressure drop ΔP 1 ,ΔP 2 across the throttling devices in the measuring units 1 and 2 , wherein, ΔP 1 corresponds to the pressure drop across the throttling device in the measuring unit 1 , ΔP 2 corresponds to the pressure drop across the throttling device in the measuring unit 2 , Q 1 corresponds to the fluid flow rate through the throttling device in the measuring unit 1 , and Q 2 corresponds to the fluid flow rate through the throttling device in the measuring unit 2 . Next, the fluid flow rate values Q 1 , Q 2 and the drilling fluid injection displacement Q 0 are compared.
If Q 1 =Q 0 and Q 2 >Q 0 , it indicates that the kick happens between the measuring unit 2 and the measuring unit 1 ; in that case, the moment t 2 when the temperature T 2 rises at the measuring unit 2 is detected, and the kick occurrence position is determined as the position Q 2 ×(t 2 −t 0 )/A below the measuring unit 2 through calculation. The term “below” mentioned here and in the following text refers to downstream in the drill stem extension direction.
If Q 1 >Q 0 , Q 2 >Q 0 and Q 1 =Q 2 , it indicates that the kick happens between the measuring unit 1 and the bore-hole bottom (i.e., at the position of the drill bit); in that case, the moment t 1 when the temperature T 1 rises at the measuring unit 1 is detected, and the kick occurrence position is determined as the position Q 1 ×(t 1 −t 0 )/A below the measuring unit 1 through calculation.
If Q 1 >Q 0 , Q 2 >Q 0 and Q 2 >Q 1 , it indicates that the kick happens between the measuring unit 2 and the measuring unit 1 and between the measuring unit 1 and the bore-hole bottom, and the kick occurrence positions may be at a single kick point between the measuring unit 2 and the measuring unit 1 and at a single kick point between the measuring unit 1 and the bore-hole bottom, or the kick may happen in a continuous kick region that covers a position between the measuring unit 2 and the measuring unit 1 and a position between the measuring unit 1 and the bore-hole bottom. In that case, the moment t 2 when the temperature T 2 rises at the measuring unit 2 can be detected, and the kick occurrence position can be determined as a position Q 2 ×(t 2 −t 0 )/A below the measuring unit 2 through calculation. In view that the case described above is complex, herein only the method for determining a kick occurrence position near the measuring unit 2 will be described.
Next, the type of the kick fluid can be judged according to whether the temperature difference ΔT 1 between the two sides of the throttling device in the measuring unit 1 or the temperature difference ΔT 2 between the two sides of the throttling device in the measuring unit 2 is smaller than 0 and whether ΔP 1 or ΔP 2 decreases remarkably. If the temperature difference ΔT 1 between the two sides of the throttling device in the measuring unit 1 or the temperature difference ΔT 2 between the two sides of the throttling device in the measuring unit 2 is smaller than 0 or ΔP 1 or ΔP 2 decreases remarkably, the kick fluid can be judged as a gas; otherwise the kick fluid can be judged as a liquid, such as oil or water.
After the kick information is obtained, well shutdown operation is conducted (specifically, the well shutdown operation includes: open the hydraulic throttle valve 9 ; then, close the annular blowout preventer 12 ; next, close the upper ram type blowout preventer 11 and lower ram type blowout preventer 8 , but don't close the cutter ram-type blowout preventer 10 ); next, well killing operation is conducted; particularly, by adjusting the well killing rate, the throttling device can assist wellbore pressure control.
While some preferred embodiments of the present invention are described above with reference to the accompanying drawings, the present invention is not limited to the details in those embodiments. Those skilled in the art can make modifications and variations to the technical scheme of the present invention, without departing from the spirit of the present invention. However, all these modifications and variations shall be deemed as falling into the protected scope of the present invention.
In addition, it should be appreciated that the technical features described in the above embodiments can be combined in any appropriate manner, provided that there is no conflict among the technical features in the combination. To avoid unnecessary iteration, such possible combinations are not described here in the present invention.
Those skilled in the art can appreciate that all or a part of the steps constituting the method in the above-mentioned embodiment can be implemented by instructing relevant hardware with a program, which is stored in a storage medium and includes several instructions to instruct a single-chip microcomputer, a chipset, or a processor to execute all or a part of the steps of the methods in the embodiments of the present application. The storage medium comprises: U-disk, removable hard disk, Read-Only Memory (ROM), Random Access Memory (RAM), diskette, or CD-ROM, or a similar medium that can store program codes.
Moreover, different embodiments of the present invention can be combined freely as required, as long as the combinations don't deviate from the ideal and spirit of the present invention. However, such combinations shall also be deemed as falling into the scope disclosed in the present invention. | The present invention provides a measuring unit, a kick information identification apparatus and method, and relates to the oil and gas well engineering field. The measuring unit comprises: a throttling device, mounted on a drill stem; sensors, arranged at the two sides of the throttling device, and configured to sense the pressure and/or temperature at the two sides of the throttling device; and a signal transmitter, configured to transmit the pressure and/or temperature values. The present invention employs a throttling device and measures the pressure drop and/or temperature difference across the throttling device, and can identify kick information successfully according to the pressure drop and/or temperature difference. Even in the case of horizontal wells where the flow and pressure variations are not apparent, the present invention can still attain a good kick information identification effect. |
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FIELD OF THE INVENTION
The present invention relates to louver assemblies for use in the construction of buildings.
DESCRIPTION OF THE PRIOR ART
Louver assemblies are commonly placed in walls of gable areas of buildings to provide for passive ventilation of the building interiors. Virtually identical louver assemblies may be used in areas other than gables to achieve the same effect.
U.S. Pat. No. 3,120,036 to Minds describes a louver assembly comprising a jamb that has securing flanges 18 and 19 for securing the jamb to a vent opening frame structure. U.S. Pat. No. 3,943,679 to Dissinger describes a louver assembly that includes mating frame sections 22 and 24. U.S. Pat. No. 3,968,738 to Matzke describes a louver assembly that comprises two flanges 13 for fitting over a stud or other portion of a wall which supports a louver. Each of the above patents is concerned with louver assemblies that are mounted in a wall of a building.
U.S. Pat. No. 4,875,317 to Logan et al provides a vacuum-formed window or vent insert, wherein a perimeter can be curved and formed with an undercut to receive adjacent edges of aluminum or plastic siding. U.S. Pat. No. 5,596,852 to Schiedegger provides a plastic building product that is designed to be adjustable so that it can accommodate siding of different thicknesses. Both of these patents describe louver assemblies that are mounted on walls of buildings.
The prior art does not describe a flat-mount louver assembly that can be easily made in a wide variety of configurations from a small number of simple components and still provide high quality features.
It is an object of this invention to provide a louver assembly that can be easily constructed in a variety of shapes from a small number of relatively-uncomplicated components.
It is also an object of the present invention to provide efficient louver slats that have a continuous perimeter on all four sides which allows for reversibility.
It is another object of the present invention to provide louver jambs that encase slats in order to contribute stability to a flat-mount louver assembly.
It is yet another object of the present invention to provide for a louver mounting band that can be cut into segments to encase a slat/jamb subassembly and that exhibits a variety of functional as well as aesthetic benefits in use.
These and other objects and advantages of the present invention will be made apparent from the following description when taken in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION
According to principles of this invention, a louver assembly is constructed of slats, jamb segments, and mounting-band segments. Slats, jambs, and mounting bands are manufactured in lengths of 8 or 16 feet, and these are cut into the segments for making a louver assembly. The jambs and mounting bands might, for instance, be cut to 2 foot segments, their ends being trimmed to an appropriate angle. Two jamb segments are brought together in a V-shape. The slats might be cut in a series of lengths, ranging from 3 inches to 16 feet, and their ends would be trimmed to an angle determined by the side of the V. The series of trimmed slats are arranged in the V-shaped jambs, with the shortest closest to the apex of the V, forming a louver jamb subassembly. This louver jamb subassembly is encased within the trimmed mounting-band segments, forming the louver assembly.
The present invention provides a flat-mount louver assembly comprising a plurality of slats having two ends and mounted in a louver jamb subassembly. This louver jamb subassembly comprises first and second C-shaped channels (jamb segments) joined together at a mitered joint with their open faces facing one another. The first channel holds one end of each of the slats and the second channel holds the other end of each of the slats. The louver jamb subassembly is mounted in jamb slots of louver mounting-band segments. The louver mounting band comprises first and second segments, each having a planar mounting base, a planar connecting member perpendicular to that base with a connecting-member edge spaced from the base, and a flange extending substantially perpendicular to one side of the connecting member at the connecting-member edge. The flange and connecting member, together with a portion of the base, define the jamb slot.
The slats used to make the louver assembly have raised edges to resist the flow of water. Also, the base of the louver mounting band, which forms the louver jamb receiving area, is wider than the flange so as to inhibit flow of water into a building fitted with the louver assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described and explained in more detail below using the embodiments shown in the drawings. The described and drawn features, in other embodiments of the invention, can be used individually or in preferred combinations. The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings in which reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating principles of the invention in a clear manner.
FIG. 1 is a front view of a gable louver assembly of this invention;
FIG. 2 is an exploded front view of the gable louver assembly of FIG. 1;
FIG. 3 is a cross-sectional view of a slat of the gable louver assembly of FIG. 1;
FIG. 4 is a cross-sectional view of a jamb of the present invention;
FIG. 5 is a cross-sectional view of portions of a jamb having slats inserted therein in accordance with the present invention;
FIG. 6 is a perspective view of a louver jamb subassembly of the present invention with louvers mounted therein;
FIG. 7 is a perspective view of a mounting-band of the present invention;
FIG. 8 is a sectional view taken on line IIX--IIX of the mounting band of FIG. 7;
FIG. 9 is an exploded perspective cut away view of a mitered mounting band joint in accordance with the present invention;
FIG. 10 is a cross-section taken near the mitered mounting-band joint of FIG. 9;
FIG. 11a is a front view of an alternate triangular configuration of a gable louver assembly of the invention;
FIG. 11b is a front view of an octagonal configuration of a gable louver assembly of the invention;
FIG. 11c is a front view of a hexagonal configuration of a gable louver assembly of the invention;
FIG. 11d is a front view of a rectangular configuration of a gable louver assembly of the invention;
FIG. 11e is a front view of a quadrilateral configuration of a gable louver assembly of the invention; and
FIG. 11f is a front view of a diamond-shaped configuration of a gable louver assembly of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a front view of a gable louver assembly 9 in accordance with the present invention. The gable louver assembly of FIG. 1 has a plurality of slats 10 that are held in a jamb (not visible in FIG. 1) to form a jamb subassembly which is, in turn, held in a jamb slot (not visible in FIG. 1) of mounting-band segment 15'. A miter-cut mounting band 15 has as its visible portion mounting-band tops 18 of the mounting-band segments 15' joined together at mitered joints 17.
FIG. 2 shows in an exploded front view of the gable louver assembly 9 that the slats 10 are arranged in a pair of miter-cut jamb segments 20' (to form a louver jamb subassembly 40 shown in FIG. 6). The louver jamb subassembly 40 is held (by a jamb slot 25 shown in FIG. 7) within miter-cut mounting-band segments 15' joined together at mitered joints 17. The mitered joints 17 of the miter-cut mounting-band segments 15' are internally reinforced by miter stabilizer connectors 35 (held within miter stabilizer slots 38 shown in FIG. 7).
Slats
A slat 10 of a gable louver assembly (FIGS. 1 and 2) of the present invention is preferably configured with a 30° sloped side edge and a raised edge to divert rain from blowing into a building through a louver assembly of this invention. FIG. 3 shows a cross-section of a slat 10, having a raised edge 11 and a sloped side edge 13, where α is a 30° angle. As illustrated in FIG. 3, slats in accordance with the present invention are preferably configured to be reversible. However, a slat with only one raised edge (not shown) would perform equally well when its raised edge side is positioned to face outward from the building onto which it is installed.
Also as illustrated in FIG. 3, slats in accordance with the present invention are preferably made of a thin wall 19 of resinous material such as polyvinyl chloride, leaving an open inside space 31. This reduces weight and material cost. However, the hollow slats could be made of metal such as aluminum. Alternatively, the slats could be made of solid wood. An exterior polyvinyl chloride surface 33 can be textured to provide a wood grain effect. Slat 10 also has a flattened nose edge 12. These are preferred features that can contribute to a wood-like appearance in the slat.
In a preferred embodiment, a polyvinyl chloride slat wall thickness is 0.063 inches, a distance A from a nose edge to a raised edge is 0.875 inches, a height (or depth) of the raised edge is 0.063 inches, a distance B from the raised edge to a start of a sloped edge is 1.363 inches, and a distance C from the start of the sloped edge to a plane defined by the nose edge is 0.875, for an overall slat width of 3.000 inches, while a thickness of one nose edge is 0.249 inches and a thickness D from an end of a slope at that nose edge to a plane, defined by a flat surface which extends from the other nose edge of the slat to the raised edge, is 0.251, for an overall slat thickness of 0.725 inches. Those skilled in the art will recognize that slats with other dimensions can be made that will take full advantage of principles of the present invention.
Jambs
A jamb 20 (and jamb segments 20') of the louver jamb subassembly 40 of the present invention is made as a C-shaped member that is designed to encase the slats in order to hold them. FIG. 4 shows a cross-section of the jamb having a wall 29 of a resinous material such as polyvinyl chloride. Other materials could also be used, so long as they have an appropriate balance of rigidity and flexibility to provide a suitable anchor for the slats. The jamb 20 comprises a back 21 and two arms 22 and 22', extending outwardly at right angles β and β' from the back 21.
In a most preferred embodiment, a polyvinyl chloride jamb wall thickness is 0.063 inches, an outside width of the back is 1.438 inches, an outside width of each arm is 0.7 inches, and an inside width of the back is 1.312 inches. Those skilled in the art will recognize that dimensions of the jamb are related to dimensions of the slats and that jambs with other dimensions can be made that will take full advantage of principles of the present invention.
Louver Jamb Subassemblies
FIG. 5 is a cross-sectional view of a jamb segment 20 (only the arms 22 and 22' being visible) having slats placed therein. In FIG. 5, jamb arms 22 and 22' hold between them the slats 10. Each slat is arranged so that each of its edges 13 contacts an opposite jamb arm. Each slat 10 is arranged at an angle ∂30° with respect to arms 22 and 22' at points at which the slat contacts the arms. The angle ∂ can range from about 15° to about 45°, and is preferably about 30°. The slats are arranged so that their raised edges 11 are higher than their sloped side edges 13.
FIG. 6 is a perspective view of a louver jamb subassembly 40. The louver jamb subassembly comprises slats 10 and miter cut jamb segments 20' attached together. In FIG. 6, two miter-cut jamb segments 20' have been joined together, open face to open face, with a plastic mending plate at a mitered joint 44, to form a V-shape. Several slats 10 of varying lengths have been inserted into the miter-cut jamb segments 20' to form the louver jamb subassembly 40.
Mounting Bands
The louver jamb subassembly 40 of the invention is preferably mounted in a mounting band 15 (FIGS. 7 and 8). The mounting band defines a jamb slot 25 for receiving the louver jamb subassembly 40. The jamb slot 25 is defined by a backing 51 (which is to be attached to a building), a jamb wrap connector 52, and a decorative flange 53 (which is visible when the louver assembly is mounted on a building). The backing 51, being wider than the decorative flange 53, acts to divert water away from an interior of the building, for a bottom-mounted mounting-band segment 15' incorporated into a gable louver assembly.
Another slot, siding slot 60, also defined by the mounting band 15 but on the opposite side of the jamb wrapper connector 52, is for receiving vinyl, aluminum, or wood siding. The siding slot 60 is defined by a backing 63 (which is a continuation of the backing 51), the jamb wrap connector 52, and a bottom 65 of a member forming the miter stabilizer slot 38. The miter stabilizer slot 38 is yet another slot defined by the mounting band 15. The mounting-band top 18 helps to form the miter stabilizer slot 38 and is preferably provided with a molded profile for aesthetics.
The backings 51 and 63 combine to form a mounting base 75.
The jamb wrap connector 52 is preferably pierced by one or more weep holes 59. Likewise, a member 59' forming the miter stabilizer slot 38 is preferably pierced by one or more weep holes 58. Advantageously, a weep hole of the jamb wrap connector 52 will be lined up with the miter stabilizer slot 38 to permit water to drip out of a bottom mounting-band segment of an installed gable louver assembly. The member 59' forming the miter stabilizer slot 38 is also preferably provided with a drain opening 56 along its entire length to allow water to escape. The backing 63 is preferably provided with a plurality of nail holes 57 to facilitate installation of the gable louver assembly on an outer wall of a building.
The mounting band 15 is preferably made from rigid polyvinyl chloride, although it could be made from other materials conventionally used to manufacture molding and related products.
In a most preferred embodiment, a wall thickness of all mounting-band elements, except for the mounting-band top 18, is 0.125 inches. The mounting-band top 18 will be of variable thickness as determined by its aesthetic molded profile. The backing 51 is 1.375 inches wide, the decorative flange 53 is 0.875 inches wide, and a distance from a bottom of the backing 51 to a top of the decorative flange 53 is 1.875 inches. In this most preferred embodiment, the backing 63 is 2.000 inches wide, a distance from the backing 63 to the miter stabilizer slot bottom member 65 is 1.000 inches, and the mounting-band top 18 is 0.875 inches wide. An outer wall of the member 59' forming the miter stabilizer slot 38 is 1.125 inches in length. The mounting base 75 is 3.250 inches in width. The width of the jamb slot 25 is 1.625 inches, which is larger than the outside width of the jambs.
In use, a mounting band according to the present invention will be cut into segments in which the ends will be mitered, or angled. This is illustrated in FIG. 9, in which two segments of mounting band are shown, each having been cut to a complementary angle in a conventional manner, forming miter-cut mounting-band segments 15'. FIG. 9 also illustrates a miter stabilizer connector 35 in accordance with the present invention. The miter stabilizer connector 35 is designed to be inserted into the miter stabilizer slots 38 of both miter-cut mounting-band segments 15'. Accordingly, the miter stabilizer connector 35 will have an angle of opening that is double the miter angle of each mounting-band segment 15'. For instance, if each miter-cut mounting-band segment 15' has been cut back on an angle of 30°, miter stabilizer connector 35 will open 60°. The manner in which the miter stabilizer connector 35 acts to stabilize the miter joint when mounting-band segments in accordance with this invention are joined by a miter joint may be understood more fully by reference to FIG. 10. FIG. 10 shows a mounting band 15 having inserted within its miter stabilizer slot 38 a miter stabilizer connector 35. The miter stabilizer connector will be dimensioned to fit snugly within the miter stabilizer slot.
Putting It Together
As indicated above, slat, jamb, and mounting band components are generally manufactured in lengths, for instance of 8 or 16 feet, and are cut into segments for use in making gable louver units. The first step in using the components is to consider a shape of an unfinished vent hole. The gable louver system of the present invention can be adapted to virtually any shape hole.
One will cut a jamb 20 into jamb segments 20' of appropriate lengths, and then miter cut both ends of each jamb segment at an angle determined by a shape of the gable louver to be constructed. Two complementary jamb segments 20' are joined together as shown in FIG. 6, while being held in a V-shape by a jig. They are welded together, with a plastic mending plate for instance by sonic welding at the mitered joint 44. Slat segments of graduated lengths are cut. While the jamb segments 20' are held in the jig, the shortest slat segment is fitted therein near the joint. Longer slat segments are placed in the jamb V until the V-shaped jamb is filled with slats, forming the louver jamb subassembly 40 of FIG. 6. The slats are held in place in the louver jamb subassembly by sonic welds 77 (FIG. 5) at edges of the slats with the jamb arms 22, 22'. The louver jamb subassembly may optionally be reinforced, such as by further attaching each slat to the jamb with aluminum pop rivets 79. Alternatively, the slats could be glued, nailed, stapled or otherwise fixed in place. In one embodiment, the slats are placed in the jamb segments and sonic welded at one edge to form sonic welds 77. This holds the slats in place so that the pop rivets 79 can be applied at the opposite edge. The pop rivets ensure that the louver jamb subassembly has adequate strength.
One will cut a mounting band length into segments corresponding to the sides of the gable louver assembly to be constructed, with both ends of each mounting-band segment being at an angle determined by the desired gable louver assembly shape. Next at least two complementary mounting-band segments are joined together in a V-shape, with a miter stabilizer inserted into and linking their two complementary miter stabilizer slots. The miter joint of the mounting band subassembly is reinforced by sonic welding and/or a plastic mending plate 81 (FIG. 9) across the joint, for instance welded on the backing 51 inside the jamb slot 25. The jamb slot 25 is wide enough to receive the jamb subassembly 40 and the plastic mending plate 81.
Finally, the louver jamb subassembly 40 is inserted into the thusly assembled at least two mounting-band segments and an outer perimeter thereof is closed by at least one additional complementary mounting-band segment, forming a gable louver assembly. The gable louver assembly is then reinforced by attaching the louver jamb subassembly to the mounting band with aluminium pop rivets through jamb wrap connector 52. This provides a completed gable louver assembly which can now be easily installed over an unfinished vent hole by nailing its mounting base 75 to an exterior of a wall forming the vent hole. The gable louver assembly then receives siding in the siding slot 60.
Benefits
A gable louver assembly in accordance with the present invention is structurally sound and attractive in appearance. It is designed to abate water penetration problems and to permit easy escape of water that may get into the mounting band (especially the bottom segment thereof). Water penetration abatement features include the backing 51 being wider than the decorative flange 53, the miter stabilizer slot drain opening 56, the weep holes 58, and the weep holes 59, all of which help water escape when a mounting-band segment is used to form a horizontal base of a louver assembly. Yet another water abatement feature is the inclusion of the raised edges 11 on the slats 10, which tend to block water blown upwardly along the slats by wind.
The slat, jamb, and mounting band components described herein permit relatively easy construction of a wide variety of differently shaped gable louver assemblies from just three components.
It is also beneficial that the louver assembly of this invention has an integral louver jamb subassembly that is constructed separately from the band segments 15', because in this manner the band segments can have features most beneficial for mounting the assembly on a wall and for water abatement. Also, the features of the jamb subassembly can be mainly focused on securely holding the slats.
Variations
The present invention has been illustrated with reference to a gable louver assembly having an isosceles triangular configuration. However, those skilled in the art will recognize, first, that the louver assemblies need not necessarily be used in gable areas, although they are ideal for that application, and, second, that many other variations in the overall shape of louver assemblies may be made in accordance with principles of the present invention, including other types of triangles, rectangles, octagons, and any other shapes dictated by aesthetics or function and containing mitered joints. FIGS. 11a, 11b, 11c, 11d, 11e, and 11f illustrate, without limiting, various configurations of louver assemblies that can be made with the present system.
Likewise, with respect to shape of the slats and mounting bands, while various preferred embodiments are herein described, it will be understood that modifications, alternatives, and equivalents are to be included within the scope of the invention. For instance, slats 10 may have other cross-sectional shapes, and/or may omit raised edges 11. Walls 19 and/or 29 and/or mounting band 15 may be made of other materials such as polyethylene, polypropylene, polystyrene, and acrylonitrile butadiene styrene, or even, for some applications, of wood or aluminum.
Finally, other features may be added to the louver assemblies of the invention. For instance, a screen of fiberglass or aluminum may be affixed to the back (inside) of the louver assemblies to inhibit penetration by insects. In fact, in one embodiment such a screen is mounted on the louver jamb subassembly 40 before it is positioned in the mounting-band segments.
Thus, inasmuch as the present invention is subject to many modifications, variations, and changes in detail, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A flat-mount louver assembly (9) includes a plurality of slats (10) mounted in a louver jamb subassembly (40). The subassembly includes C-shaped jamb segments (20') joined together at a mitered joint (44) with their open faces facing one another and holding the slats between them. The louver jamb subassembly is mounted in a jamb slot (25) of a louver mounting band (15). The louver mounting band has a planar mounting base (75), a planar jamb wrap connector (52) perpendicular to the base and having a connecting-member edge spaced apart from the base, and a flange (53) substantially perpendicular to one side of the connecting member edge. The flange and jamb wrap connector, with a portion of the base, make up the jamb slot. The slats are preferably configured with raised edges to resist the flow of water. |
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TECHNICAL FIELD
The present invention relates to a guide assembly or apparatus for sliding doors or pivotable sliding doors of vehicles as well as to a sliding door or pivotable sliding door, and relates in general to a guide assembly or apparatus and a guide and drive principle for such vehicle doors.
RELATED ART
FIG. 1 shows a guide assembly for a sliding door with a conventional three-point guide according to the prior art. The guide assembly 1 comprises an upper guide rail 3 , a lower guide rail 4 and a middle guide rail 100 , which is disposed behind the upper and lower guide rail, respectively, as viewed in longitudinal direction of the vehicle. Lever-type connecting members (not shown) are fixedly mounted on the door 2 . The connecting members engage with the upper and lower guide rail 3 , 4 . A roll carriage comprising a pair of rollers engages with the middle guide rail 100 . The connecting members or the pair of rollers engage with the respective guide rail 3 , 4 or 100 in the areas highlighted by solid dots.
As shown in FIG. 1 , the weight of the door 2 is supported exclusively by the lower guide rail 4 and the middle guide rail 100 , as indicated by the two arrows Ff. For preventing tilting of the door 2 in longitudinal direction, two supporting portions, which are indicated by the arrows Ff and where the weight Fg of the door 2 is supported, are provided in a manner displaced relative to each other substantially by the width of the door 2 in longitudinal direction of the vehicle so that a comparatively long lever is provided.
According to the prior art the middle guide rail 100 is provided on the outer wall of the vehicle behind the door opening to be closed by the door, as viewed in longitudinal direction of the vehicle. A middle guide rail 100 , which represents an essential element of the outer vehicle body, is clearly visible. This results in serious limitations in the design of vehicle bodies.
Furthermore, according to the prior art it is difficult to integrate a drive unit for opening and closing the door by means of an electric motor in a door module to be received by the door. Furthermore, according to the prior art it is difficult to separate the drive elements for opening and closing the door from guide means for guiding the door. All this results in serious limitations in the design and configuration of vehicles with sliding doors or pivotable sliding doors.
U.S. Pat. No. 5,967,595 discloses a guide assembly for sliding doors, comprising an upper guide rail, a lower guide rail and a middle guide rail, which is fixed at the inner side of the door. For counteracting a tilting of the door in the opened position of the door, supporting points of the door are displaced relative to each other also in the opened position.
U.S. Pat. No. 6,038,818 discloses a drive mechanism for driving a sliding door of a motor vehicle. Guide rails are mounted on the vehicle body at the upper and lower edge, respectively, of the door opening. A respective roller or wheel, which is fixedly connected with the sliding door, is guided in a respective guide rail. The drive mechanism comprises a drive unit disposed at a rear end of the sliding door. The drive unit is coupled with a cable. The cable runs, beginning at the drive unit, towards the front end of the sliding door, is guided towards a guide sleeve mounted on the vehicle body and is guided from there back towards the drive unit by means of deflecting pulleys or rollers. The only function of the cable is to drive the door. Securing the cable is relatively complicated.
DE 196 32 427 A1 discloses a guide apparatus for pivotable sliding doors of busses. A flexible traction means is attached at the inner side of the door and deflected by means of an upper and lower deflecting means fixedly mounted on the door. The deflecting means engage with the at least one traction means for deflecting the traction means. A drive unit for opening and closing the door, which comprises an electric motor, is coupled with the traction means. The only function of the traction means is to drive the door.
The weight of the door is supported at the upper and lower guide rails. For preventing tilting of the door, the door is additionally supported at a relatively stable vertical rotary column.
This guide apparatus for busses is relative complicated and cannot be implemented easily for small motor vehicles, in particular automobiles and vans.
SUMMARY
It is an object of the present application to provide a guide assembly or apparatus for sliding doors or pivotable sliding doors of vehicles, in particular motor vehicles, which enables new design principles in the design of motor vehicles and enables new drive and guide principles. Furthermore, a corresponding sliding door or pivotable sliding door is to be provided.
According to the present invention there is provided a guide assembly or apparatus for sliding doors or pivotable sliding doors of vehicles, comprising at least one door that is supported in a slidable and/or pivotable manner at the vehicle by means of connecting members disposed vertically above each other, said guide assembly or apparatus comprising an upper guide means and a lower guide means, a respective connecting element cooperating with said guide means at least while said door is displaced, at least one flexible traction means and at least one upper deflecting means and at least one lower deflecting means respectively mountable on said door, said deflecting means engaging with said at least one traction means for deflecting said traction means. According to the present invention a respective traction means of the guide assembly or apparatus can be mounted on or supported at the vehicle wall by means of upper and lower traction means holding portions respectively mountable on said vehicle wall.
Whereas the weight of the door is supported essentially only by the lower and/or upper guide rail, according to the present invention the moment of tilt, which results from the weight of the door, can be absorbed by the flexible traction means and transferred to the traction means holding portions that are mounted on the vehicle wall. It is an advantage of the present invention that an additional third guide rail, which is usually provided on the outer wall of the vehicle according to the prior art, is not necessary anymore for supporting the door. This enables new possibilities in the design of vehicles having sliding doors or pivotable sliding doors. E.g. the rear portion of a car body can be designed in a completely different manner, because according to the invention it is not necessary anymore to integrate an additional third guide rail into the outer wall of the car body.
According to the invention, it is a function of the traction means, on the one hand, to transfer forces that result from the moment of tilt of the door to the traction means holding portions mounted on the car body and, on the other hand, to support the door for counteracting the moment of tilt resulting from the weight of the door. The deflecting means, which engage with the at least one traction means, are provided essentially for supporting the door at the traction means. Preferably, the deflecting means are disposed at the front edge portion of the door, preferably in proximity to the upper and lower front corner respectively of the door, so that the door can be supported efficiently against tilting even in its opened position.
For supporting the door even more efficiently, it may be preferred that the traction means cannot be stretched or elongated substantially along a longitudinal axis thereof. Any stretching or elongation of the traction means may be absorbed by tensioning means or compensation means.
According to the present invention, it is a function of the traction means holding portions to fix the flexible traction means so that end portions or reversal portions of the traction means near the traction means holding portions can be maintained essentially unchanged in any position of the door. Thus, the traction means embodies a guide, which is anchored relative to the car body in a fixed manner but is, nevertheless, flexible and along which the door can be moved while being secured against tilting of the door.
According to an embodiment, a respective traction means can be bent or flexured around at least one transverse axis of the vehicle. According to another embodiment, the traction means can be bent or flexured around all directions in space. For this purpose the traction means may be a cable, in particular a rope, a chain, a link chain, a bead chain, a belt, or may be formed in a similar manner. It may be preferred that the deflecting means engage with the at least one traction means in a friction-tight manner. However, irregularities or protrusions of the traction means, e.g. links or joints of the chain, protrusions of the belt or the like, can be utilized for a positive fitting (form-fitting) engagement of the deflecting means with the at least one traction means.
In general the traction means can be formed as an endless traction means, in which case it may be preferred that the running direction of the traction means is essentially reversed at the associated traction means holding portions. Such an endless traction means can be statically fixed at the traction means holding portions.
As an alternative such an endless traction means could also be supported in a movable manner. E.g. a deflecting means for deflecting a cable, in particular a rope, serving as a traction means, fixed at a traction means holding portion, might enable guiding the cable or rope in an endless and revolving manner. With such an embodiment the respective deflecting means can be connected with the traction means at the deflecting regions. Driving the traction means enables opening or closing of the door. Accordingly, such an alternative embodiment substantially relies on the principle of a kind of kinematics reversal of the principle described above, according to which respective end portions of the traction means are mounted or fixed on the vehicle body.
According to a preferred embodiment, the traction means comprises, however, two ends, which are mounted or fixed on the vehicle body wall at the traction means holding portions. For mounting or fixing the traction means, any frictional fixing technique, positive-fit fixing technique or welding or bonding can be utilized. Conveniently, a cable, in particular a rope, which serves as a traction means, is mounted on the vehicle wall by means of holding lugs or eyes, by means of connections for fixing the cable or rope, welding dots or the like.
According to another embodiment, the traction means holding portions, which are displaced relative to each other in a vertical direction, are displaced relative to each other in the horizontal direction, i.e. in the longitudinal direction of the vehicle, by at least a maximum displacement distance of the door. Accordingly, the door can be supported efficiently on the traction means in any position between the fully opened position and the fully closed position.
In general, according to the present invention it can be sufficient to provide only two deflecting means for deflecting the at least one traction means, i.e. an upper and a lower deflecting means. More preferably, however, the upper and lower deflecting means each comprises at least two deflecting means or a pair of deflecting members, which are displaced relative to each other along the transverse axis of the vehicle. Preferably, the respective traction means is deflected by the upper and lower deflecting means, which is respectively disposed closest to the vehicle wall, in opposite directions. E.g., if the traction means is deflected clockwise in the upper region of the door, if viewed from above on the deflecting means, then the traction means in the lower region of the door is deflected counterclockwise, if viewed from above on the deflecting means. Thus, moments of tilt, which result from the weight of the door, can be absorbed and transferred by the at least one traction means even more symmetrical.
According to another embodiment, the pair of deflecting elements mentioned above can be mounted on a connecting element associated therewith in such a manner that a traction means is guided essentially along the connecting element. For this purpose, it may be preferred that the deflecting means are fixed or mounted on the respective connecting element at dot-like mounting portions.
Preferably the deflecting means engage with a respective traction means in such a manner that the respective traction means is guided in a substantially z-shaped manner at least in an opened or closed position of the door, where the largest moments of tilt act on the door. A substantially z-shaped run of the traction means is of advantage, because the upper and lower deflecting means can then deflect the traction means by a relatively large angle and because the door can then be supported even more efficiently due to a maximum resistance, e.g. caused by the friction or stretching forces or by the deformation resistance acting when the run of the traction means is deformed.
In the region of a respective deflecting means the traction means is preferably deflected by an angle in the range between approximately 80° and approximately 100°. More preferably the traction means is deflected in a respective deflection area by an angle different from 90°, e.g. by 95° or 85°, so that the upper deflecting means is disposed behind the lower deflecting means, if viewed in the longitudinal direction of the vehicle.
According to a further embodiment, the guide assembly or apparatus comprises two traction means that run at least partially in opposite directions and that are tensioned or biased against each other. E.g. the two traction means can run in the car body at an upper and lower edge, respectively, of the door opening in substantially opposite directions, but can be deflected by two identical deflecting means, e.g. deflecting pulleys, in opposite directions. As the traction means runs are tensioned or biased against each other, the door can be supported even more efficiently. Furthermore, the moment of tilt can be absorbed by the traction means even more efficiently.
In order to avoid that a respective traction means sloughs off from the deflecting means or is lost as the respective traction means slides along the deflecting means while the door is displaced, the deflecting means preferably comprise a seat formed in correspondance with a profile of the associated traction means for receiving the associated traction means therein. E.g. in the case of a cable, in particular a rope, which serves as a traction means, a guide groove for guiding the cable could be provided on the outer circumference of a deflecting pulley.
According to another embodiment, the connecting members each comprise at least one joint for joining the door to the vehicle wall or to a guide means disposed therein in an articulated manner. Thus, the guide means can also comprise portions that are curved or bent inwardly towards the vehicle or outwardly away from the vehicle in order to guide the door additionally towards the vehicle or away from the vehicle during displacement of the door along the longitudinal axis of the vehicle.
According to another embodiment the connecting members are formed as levers that support an articulated engaging member for engaging with the upper and lower guide means, respectively, at an end of the lever turned away from the door. The engaging member is preferably formed in correspondence to a profile of the guide means so that the door can be guided by the guide means substantially without play. If the guide means is formed e.g. as a guide rail having a longitudinal receptacle, the engaging elements can be formed as a pair of rollers, which are movably supported in the longitudinal receptacle, or as a sliding member, which is received in the longitudinal receptacle in a slidable manner. Due to the articulated support of the engaging member at the connecting member the engaging member can be moved further easily even while engageing with the portions curved or bent inwardly towards the vehicle or outwardly away from the vehicle.
Preferably guide rails are disposed at the upper and/or lower edge of the door, each comprising a curved portion at a rear end thereof. An engaging member supported by a pivot lever, which is fixedly mounted on the vehicle wall and is supported pivotably, can engage with such a guide rail for additionally guiding the door during displacement and/or swinging. It is to be appreciated that this feature is turning away from the conventional guide principle, according to which a pivot lever having a roller carriage is always mounted fixedly on the door.
Preferably the above guide assembly or apparatus is assembled in advance in such a manner that a complete vehicle door or a door module, which is to be received by a vehicle door, is provided with a complete guide assembly or apparatus and/or with a traction means system so that it is only necessary to connect the elements of the guide assembly or apparatus and/or of the traction means system with the vehicle body in a suitable manner.
According to another embodiment the traction means or traction means system is coupled with a drive unit for displacement and/or swinging or swivelling the door relative to the vehicle wall. Preferably, the drive unit is directly mounted on the door or on the pre-assembled door module to be received by the door. Thus, the door or the door module can be assembled in advance completely, can be supplied together with its own drive unit and can be mounted on the vehicle. Thus, this feature enables novel drive principles for displacing and/or swinging or swivelling vehicle doors by means of an electric motor.
Preferably, a driven member of the drive unit engages with the traction means or traction means system in a form-fitting manner or friction-tight manner. Even more preferably, the drive unit comprises a cable or rope drum, around which a respective traction means is wound. When the cable or rope drum is rotated, it unrolls the respective traction means or winds the traction means up.
According to a further aspect of the present invention, there is also provided a sliding door or a pivotable sliding door for vehicles, in particular motor vehicles, comprising a guide assembly or apparatus as described above.
According to a further aspect, the present invention relates to a guide assembly for sliding doors or pivotable sliding doors of vehicles comprising at least one door that is supported at the vehicle slidably and/or pivotably by means of connecting members disposed above each other in a vertical direction, said guide assembly comprising an upper guide means and a lower guide means cooperating with a respective connecting member at least while said door is displaced, at least one flexible traction means and at least an upper deflecting means and a lower deflecting means respectively mounteable on the door, said deflecting means engaging with said at least one traction means for deflecting said traction means. According to the present invention, a respective traction means is mounted on or supported at the vehicle wall by means of upper and lower traction means holding portions mounted at the vehicle wall.
BRIEF DESCRIPTION OF DRAWINGS
In the following the invention will be described in an exemplary manner and with reference to the accompanying drawings, from which further features, advantages and objects can be concluded and wherein:
FIG. 1 is a schematic view of a guide apparatus with a sliding door according to the prior art;
FIG. 2 is a schematic view of a guide apparatus with a sliding door according to the present invention;
FIGS. 3 a and 3 b are schematic views of the sliding door according to FIG. 2 in a closed position and an opened position, respectively;
FIG. 4 is a schematic view of a modification of the sliding door according to FIG. 2 ;
FIG. 5 is a schematic view of a further modification of the sliding door according to FIG. 2 ;
FIG. 6 is a schematic perspective view of the sliding door according to FIG. 5 ;
FIG. 7 is a schematic perspective view of the run of the traction cables or ropes according to FIG. 6 ;
FIG. 8 is a schematic side view of the sliding door according to FIG. 5 in a half-opened position;
FIG. 9 is a perspective partial cross section of the sliding door according to FIG. 8 ;
FIG. 10 is a perspective partial cross section of the sliding door according to FIG. 9 in a closed position; and
FIG. 11 is a perspective partial cross section of the sliding door according to FIG. 9 in an opened position.
DETAILED DESCRIPTION
Throughout the drawings identical reference numerals relate to elements or groups of elements that are identical or function in a substantially equivalent manner.
FIG. 2 is a schematic view of a guide apparatus or assembly (hereinafter: guide apparatus) according to the present invention having a sliding door. The guide apparatus 1 comprises an upper guide means 3 and a lower guide means 4 for guiding the door 2 . The guide means 3 , 4 , which are formed e.g. as guide rails (compare FIG. 6 ), guide the movement or displacement of the door 2 such that a play in a direction transverse to the longitudinal axis of the vehicle, i.e. in FIG. 2 perpendicular to the drawing plane, can be neglected in practice. By moving or displacing the door 2 along the longitudinal axis of the vehicle or by displacing and swinging or swivelling the door 2 in the direction of a transverse axis of the vehicle, the door opening can be opened or closed.
The guide apparatus 1 further comprises a cable or rope 9 , which serves as a traction means. In the illustrated embodiment both ends of the cable or rope 9 are mounted on the vehicle wall at the upper mounting portion 5 and the lower mounting portion 6 . For this purpose suitable holding members or anchoring members are disposed at the vehicle wall, optionally with an associated tensioning means for tensioning the cable or rope 9 . As shown in FIG. 2 the cable 9 is guided in a substantially z-shaped manner. For guiding the cable 9 an upper deflecting pulley 7 , which serves as an upper deflecting means, and a lower deflecting pulley 8 , which serves as a lower deflecting means, are attached at the door 2 in the upper and lower region, respectively, of the door 2 . The deflecting pulleys 7 , 8 guide the cable or rope 9 and deflect forces, which act on the cable or rope 9 , to another direction in space, as described below. For reliably guiding the cable 9 , a guide groove that matches to the profile of the cable 9 is respectively provided in the deflecting pulleys 7 , 8 .
As shown in FIG. 2 , the deflecting pulleys 7 , 8 are displaced relative to each other in a vertical direction and are also displaced in the illustrated embodiment in a horizontal direction although this is not absolutely necessary. According to FIG. 2 , a projection of the upper deflecting pulley 7 onto the lower guide rail 4 overlaps with the lower guide rail 4 . Referring to FIG. 2 , the deflecting pulleys 7 , 8 are mounted at the left edge of the door 2 . Thus, the cable 9 leaves the upper edge 11 of the door 2 and extends substantially parallel to the window 10 and spaced apart to the window 10 downwardly towards the lower deflecting pulley 8 . The position of the mounting portions 5 , 6 and of the deflecting pulleys 7 , 8 is chosen such that the cable or rope 9 runs along an upper and lower edge, respectively, of the door 2 substantially parallel to the upper and lower guide rail 3 , 4 , respectively, in any position of the door 2 .
Of course, the positions of the directing pulleys 7 , 8 can also be varied. Furthermore, additional deflecting pulleys can be provided for suitable guiding the cable or rope 9 . It is to be noted that the cable or rope 9 is suitably guided around the window 10 and members, e.g. a window regulator, received in the door 2 .
As shown in FIG. 2 , the weight Fg of the door 2 is absorbed exclusively by the upper and/or lower guide rails 3 , 4 . For this purpose respective connecting members that are mounted on the door 2 and/or to the vehicle wall engage with guide rails or similar guide means mounted on the vehicle wall and/or the door 2 .
As shown in FIG. 2 , a moment of tilt Mg, which results from the weight Fg of the door 2 , acts on the lower deflecting pulley 8 and attempts to tilt the door 2 around an axis intersecting the drawing plane perpendicularly. A corresponding moment of tilt also acts on the upper deflecting pulley 7 . As the deflecting pulleys 7 , 8 are supported by the tensioned cable or rope 9 , a load moment or counteracting moment counteracts the moment of tilt resulting from the weight of door. Thus, the moment of tilt is absorbed by the cable or rope guide.
FIGS. 3 a and 3 b are schematic views of the sliding door according to FIG. 2 in a closed position and an opened position, respectively. As shown in FIGS. 3 a and 3 b , the door 2 is opened by displacement to the right or to the rear end of the vehicle (not shown). During displacement the connecting members not shown (compare FIG. 6 ), which are fixedly connected with the door 2 , cooperate with the upper and lower guide rail 3 , 4 for supporting the weight of the door 2 . When the door 2 is displaced, the cable or rope 9 is guided by the upper and lower deflecting pulleys 7 , 8 mounted on the door 2 . The z-shaped configuration of the cable is maintained in any position of the door 2 . According to FIGS. 3 a and 3 b , the upper and lower deflecting pulleys 7 , 8 are displaced to each other by a distance x in a horizontal direction. The substantially parallel run of the cable or rope 9 at the upper and lower edge of the door 2 towards the upper and lower guide rail 3 , 4 , respectively, is clearly visible. Preferably, the cable or rope 9 extends above and below the upper and lower guide rail 3 , 4 , respectively, e.g. within an interior cover of the vehicle, so that the cable or rope is not visible in the opened position shown in FIG. 3 b.
FIG. 4 is a schematic view of a modification of the guide apparatus or assembly according to FIG. 2 . Referring to FIG. 4 , the guide apparatus or assembly 1 comprises two cables or ropes 9 a , 9 b that partially run in opposite directions. Starting at the front upper mounting portion 5 a the first cable 9 a is wound around the upper deflecting pulley 7 clockwise, then extends in a substantially parallel manner towards the left edge of the door 2 , is wound around the lower deflecting pulley 8 counterclockwise and runs towards the lower guide rail 4 in a substantially parallel manner towards the rear lower mounting portion 6 b . Starting at the rear upper mounting portion 5 b , the second cable 9 b runs in a substantially parallel manner towards the upper guide rail 3 in the region of the upper edge 11 of the door 2 , is wound around the upper deflecting pulley 7 counterclockwise, extends in a substantially parallel manner towards the left edge of the door 2 downwardly in the vertical direction, is wound around the lower deflecting pulley 8 clockwise and extends from there in a substantially parallel manner to the lower guide rail 4 towards the front lower mounting portion 6 a . Thus, the cables 9 a , 9 b are wound around the upper and lower deflecting pulleys 7 , 8 , respectively, in opposite directions so that identical deflecting pulleys can be utilized for deflecting the cables 9 a , 9 b when the door 2 is displaced. Of course, in the upper and lower region of the door 2 also respective separate deflecting pulleys may be provided for deflecting the first and second cable 9 a , 9 b . In the configuration shown in FIG. 4 , the first cable 9 a and the second cable 9 b are guided in a substantially z-shaped manner and laterally reversed or mirror-inverted. The support of the door 2 at the two cables 9 a , 9 b , which are biased against each other, results in an even more efficient absorption of the moment of tilt resulting from the weight of the door 2 .
FIG. 5 is a schematic view of a further modification of the guide apparatus or assembly and of the sliding door according to FIG. 2 . As shown in FIG. 5 , a drive unit 12 is mounted on the door 2 at the left edge of the door 2 . The drive unit 2 is coupled with a cable or rope 9 . The drive unit 12 comprises a cable or rope drum 13 and a drive motor 14 and acts on the cable or rope 9 , which serves as a traction means, for causing a displacement of the door 2 relative to the vehicle wall. In the illustrated embodiment the drive unit 12 is a drive for a cable or Bowden window regulator so that the cable or rope 9 is wound around the cable drum 13 at least once or so that an end of the cable or rope 9 , e.g. a cable nipple, is received in a receptacle of the cable drum 13 . A rotary movement of the electric drive motor 14 is transmitted into a rotary movement of the cable drum around a rotary axis, which intersects the drawing plane perpendicularly. During rotary movement of the cable drum 13 , the cable 9 or the cable 9 ′ is unwound or wound up, which results in a propulsion of the door 2 .
As will become apparent to a person skilled in the art, a drive unit 12 can also engage with a chain, link chain, or bead chain or with traction means of the belt-type or toothed belt-type for causing a propulsion of the door 2 .
FIG. 6 is a schematic perspective view of the guide apparatus or assembly and of the sliding door according to FIG. 5 . As shown in FIG. 6 , two levers 24 , 25 , which act as connecting members, are fixedly mounted on the door 2 at the front upper and lower edge of the door 2 . The upper and lower levers 24 , 25 , respectively, extend in a substantially horizontal direction and transverse to the longitudinal axis of the vehicle. At their front ends, the upper and lower levers 24 , 25 , respectively, support an upper and lower pair of rollers or wheels 22 , 23 , respectively, in an articulated manner that engage with the upper and lower guide rail 3 , 4 , respectively, and are guided therein. The upper and lower pair of rollers or wheels 22 , 23 is pivotably supported around the vertical axis at the associated levers 24 and 25 .
As shown in FIG. 6 , the upper guide rail 3 comprises, at its front end, a portion 20 , which is curved inwardly towards the vehicle. The lower guide rail 4 comprises, at its front end, a portion 21 , which is curved inwardly towards the vehicle. While the door 2 is guided substantially parallel to the exterior wall of the vehicle at the rear end of the guide rails 3 , 4 , the door 2 is additionally moved towards the vehicle at the front end of the guide rails 3 , 4 for closing the door opening, as is known from the prior art.
Referring to FIG. 6 , the two cables 9 a , 9 b act as cable guides that are guided within the door 2 , e.g. by being covered by an interior cover of the door, at the left edge of the door 2 in a vertical direction. The two cables 9 a , 9 b are then guided in a substantially horizontal direction towards the vehicle along the upper and lower lever 24 , 25 , respectively, and are then guided in opposite directions and in a substantially horizontal direction towards the mounting portions 5 , 6 in the configuration according to FIG. 4 . According to FIG. 6 , the upper and lower guide rails 3 , 4 guide not only the pair of rollers or wheels 22 , 23 but also the cables or ropes 9 a , 9 b received therein.
As shown in FIG. 6 , the upper lever 24 bears at its front end a deflecting pulley 15 , which is rotary movable around a substantially vertical rotary axis and around which the two cables or ropes 9 a , 9 b are wound in the same directions, as described more in detail with reference to FIG. 4 . In the region of the left upper corner of the door 2 an additional deflecting pulley 16 is provided, which is rotary movable around a substantially longitudinal axis of the door 2 and around which the two cables or ropes 9 a , 9 b are wound around in the same directions. Two deflecting pulleys 18 , 19 are also provided at the lower lever 25 in a corresponding manner. An additional deflecting pulley 17 is used for guiding and deflecting the second cable or rope 9 b so that two cables 9 a , 9 b are wound around the cable drum 13 in opposite directions.
As shown in FIG. 6 , a third guide rail, which is otherwise disposed between the upper guide rail 3 and the lower guide rail 4 on the exterior wall of the vehicle, as described with reference to FIG. 1 , is not provided in the guide apparatus or assembly 1 .
FIG. 7 is a schematic perspective view of the run 27 of the cables according to FIG. 6 .
FIG. 8 is a schematic side view of the configuration of the door according to FIG. 4 in a motor vehicle. Between the front car body portion 28 comprising a front window 29 and the rear car body portion 30 comprising a rear window there is provided a sliding door 2 , which is slidable in the direction of the longitudinal axis of the vehicle, for optionally closing or at least partially opening the door opening 32 .
FIG. 9 is a perspective partial cross section of the configuration of the guide rails according to the present invention. In this superimposed drawing both the run of the upper guide rail 3 having the front curved portion 20 and the run of the lower guide rail 4 having the front curved portion 21 are illustrated. As indicated by the arrows, the upper and lower guide rails 3 , 4 are displaced relative to each other by a horizontal displacement x. The upper and lower guide rails 3 , 4 are mounted on the vehicle wall 28 , 29 near the opening or opening 32 .
According to FIG. 9 the door 2 is in a half-opened position. Guide rails 34 comprising a rear curved portion 35 , which is curved outwardly away from the vehicle, are disposed at the upper and lower edge region of the door 2 .
The upper and lower levers 24 , 25 are fixedly attached to the door 2 , each lever 24 , 25 bearing at its front end a pair of rollers or wheels shown in FIG. 6 , which engages with the upper and lower guide rail 3 , 4 , respectively, to be received therein in a displaceable manner. In the half-opened position according to FIG. 9 the pairs of rollers or wheels engage with the transition portion of the upper and lower guide rails 3 , 4 , respectively, towards the front curved portions 20 , 21 , respectively.
A respective pivot lever 33 is mounted on the vehicle wall 30 in the region of the rear upper and/or lower corner of the door opening. According to FIG. 9 the pivot lever 33 can be pivoted or swivelled around the rotary axis 39 extending in a substantially vertical direction. At its front end the pivot lever 33 bears a pair 36 of rollers or wheels, which acts as an engaging element, which engages with the guide rail 34 of the sliding door 2 and is received therein slidably. In the half-opened position of the door according to FIG. 9 the pair 36 of rollers or wheels engages with the front portion of the guide rail 34 extending in a substantially linear manner. In this position the distance between the sliding door 2 and the vehicle walls 28 , 30 is given by the length of the levers 24 , 25 and by the transverse dimensions of the pivot lever 33 so that the sliding door 2 extends substantially parallel to the guide rails 3 , 4 and to the vehicle walls 28 , 30 .
FIG. 10 is a perspective partial cross section of the sliding door 2 according to FIG. 9 in the fully closed position. For transferring the sliding door 2 into the closed position according to FIG. 10 from the half-opened position according to FIG. 9 , the sliding door 2 is displaced in the direction of the longitudinal axis of the vehicle so that the pairs 22 , 23 of rollers engage with the curved portions 20 , 21 of the upper and lower guide rails 3 , 4 and so that the pair 36 of rollers engages with the rear curved portion 35 of the guide rail 34 until the pairs 22 , 23 and 36 of rollers have reached the respective ends of the guide rails. Due to the engagement of the pairs 22 , 23 , 36 of rollers with the curved portions 20 , 21 and 35 , respectively, of the guide rails 3 , 4 , 34 a swivelling or swinging movement of the door 2 is caused so that the door 2 is swung or swivelled around the rotary axis 39 inwardly towards the vehicle for closing the door opening 32 .
FIG. 11 shows the sliding door 2 according to FIG. 9 in the fully opened position, wherein all pairs 22 , 23 , 36 of rollers engage with those portions of the guide rails 3 , 4 , 34 that extend linearly along the longitudinal axis of the vehicle.
As will become apparent to a person skilled in the art from the above description, according to the present invention a guide and drive principle for sliding doors or pivotable sliding doors is implemented that works without the conventional three-point guide according to FIG. 1 . Thus, according to the present invention the spoiling third guide rail 100 shown in FIG. 1 , which is disposed on the exterior wall of the vehicle, is not necessary anymore, which enables new possibilities in the design of motor vehicles. The guide and drive principle according to the present invention is particularly preferred in applications with sliding doors or pivotable sliding doors for automobiles, vans or similar small vehicles.
In general, however, it cannot be excluded that in addition to the above-mentioned guide rails 3 , 4 and 34 one or more additional guide rails are provided, e.g. an additional guide rail in the area of the interior side of the door, engaging with an engaging element, e.g. a guide pin, which is disposed on the exterior wall of the vehicle, e.g. near the edge region of the door opening, serving as a guide or the like.
According to the present invention, also a drive unit with an electric motor for opening the sliding door can be integrated into the door itself or into a door module to be mounted on the door. Thus, according to the present invention powered doors or powered door modules having a drive unit with an electric motor integrated therein can be assembled completely in advance and can be supplied, which feature helps to reduce the efforts during assembly planning. The door or the door module to be received can be provided at a substantially unchanged run of the traction cables with a drive unit so that according to the present invention sliding doors or pivotable sliding doors can be implemented either to be actuated manually or electrically, as desired.
As will become apparent to a person skilled in the art when studying the above description, various modifications and changes can be performed without departing from the spirit of invention or the extent of protection of the accompanying claims. Therefore such modifications and changes are to be covered by the present invention.
The present application claims priority of German patent application no. 103 39 347.1 filed Aug. 25, 2003, the whole contents of which is hereby incorporated by reference. | Guide assembly for sliding doors or pivotable sliding doors for vehicles having at least one door displaceably supported at the vehicle by means of connecting members disposed vertically above each other. The guide assembly includes: upper guide means and lower guide means, each cooperating with a respective connecting member at least during displacement of the door; at least one flexible traction means; and at least an upper and a lower deflecting means to be mounted on the door, each engaging with the at least one traction means for deflecting said traction means. The traction means can be mounted on vehicle wall by upper and lower traction means holding portions, wherein each traction means holding portion can be mounted on said vehicle wall. The invention further relates to sliding door or pivotable sliding door comprising the guide assembly and an electric motor for driving the door. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an improved apparatus for gravel packing a screen and the adjoining perforated production zone of a subterranean well.
2. History of the Prior Art
Apparatus for effecting the gravel packing of a screen and the adjoining perforated production zone of a subterranean well is well known in the prior art. For example, see the 1982-1983 Catalog issued by BAKER SAND CONTROL, a Division of BAKER OIL TOOLS COMPANY of Houston, Tex. In this catalog there are disclosed typical gravel packing apparatuses and, on pages 8 and 9 of the catalog, there is described a conventional sequence for effecting the gravel packing and related operations such as squeezing and reverse flow.
In the apparatus disclosed in the aforementioned catalog, a liner assemblage is connected in depending relationship to a settable packer. The packer in turn is run into the well by a conventional setting mechanism which is connected to the bottom end of a tubular production string or work string. The tubular liner assemblage includes one or more screen which, when the apparatus is properly positioned in the well, are located adjacent the perforated production zone. The packer is then set in that position.
A gravel packing apparatus, including a conventional crossover tool, is supported in depending relationship to the packer setting mechanism and includes a wash pipe which extends downwardly through the liner assemblage and terminates at a position below or adjacent the screen. The gravel packing operation then proceeds in conventional fashion with a slurry containing the gravel being pumped down the tubular string and passed through the central bore of the set packer in the crossover tool. Below the packer seal, the gravel carrying slurry is directed outwardly through cooperating radial ports provided in the crossover tool and the adjacent portion of the liner, and flows downwardly through the annulus defined between the liner and the interior of the well casing to pile up above a sump packer or similar casing annulus sealing element or well bottom until the layer of deposited gravel covers the screen and the adjoining casing perforations. If desired, a squeezing operation can then be performed to apply pressure to the deposited gravel to force it outwardly into the perforations in the adjoining production formation. A return path for the liquid component of the gravel carrying slurry is provided by the screen and the open bottom end of the wash pipe, and this liquid component, together with any particulate matter which was small enough to pass through the screen, is flowed upwardly to the well surface through the outer passages conventionally provided in the crossover tool.
There comes a time, however, when the gravel packing and related operations are completed and the gravel packing apparatus, including the wash pipe, must be removed from the well. During this removal operation, particulate matter contained in the fluid remaining in the lower portions of the wash pipe and the crossover element of the gravel packing apparatus are free to flow downwardly into the well perforations. Also any fluids and particulates in the casing annulus above the set packer can flow into the bore of the liner assemblage and penetrate the production formation.
A principal object of this invention is to provide a reliable, automatically operating valving apparatus for effecting a complete seal of the bore area of the liner assemblage above of the screen element upon the withdrawal of the wash pipe, thus protecting the screen and the adjoining production formation from penetration by undesirable fluids and particulate matter.
SUMMARY OF THE INVENTION
This invention contemplates the provision in an otherwise conventional gravel packing apparatus of an annular valve seat located in the interior of the liner assemblage at a position above the gravel packing screen. A flapper valve is pivotally mounted to the liner assemblage for pivotal movement about a horizontal axis. During run-in and the gravel packing operation, the flapper valve is normally prevented from assuming a horizontal sealing position with respect to the annular valve seat by virtue of being trapped in a vertical position between the outer surface of the wash pipe and the adjoining inner bore of the liner assemblage. However, upon vertical movement of the wash pipe incident to the removal of the gravel packing apparatus from the well, the restraint imposed upon the flapper valve is removed and such valve pivots downwardly about its horizontal axis into engagement with the annular valve seat under the bias of a torsion spring.
The mere engagement of the flapper valve with the valve seat does not, however, solve all of the problems. It is a matter of some difficulty to effect the accurate pivotal mounting of the flapper valve so that the periphery of the valve will effect a sealing engagement around the entire periphery of the annular valve seat. To overcome this problem, the seating surface of the annular valve seat is formed as a spherical segment surface and the peripheral seating surface of the flapper valve is correspondingly formed as an annular spherical segment surface. These spherical segment surfaces are of substantially the same radius so that when the flapper valve is released to engage the valve seat, a full sealing engagement of the cooperating spherical segment surfaces will be achieved even though the pivot axis of the flapper valve may be displaced from a position in exact horizontal and vertical alignment with the annular valve seat.
Further advantages of the invention will be readily apparent to those skilled in the art from the following detailed description, taken in conjunction with the annexed sheets of drawings, on which is shown a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B collectively represent a schematic vertical sectional view of a gravel packing and well completion apparatus embodying this invention, with the components of the apparatus shown in their run-in positions.
FIGS. 2A and 2B are views respectively similar to FIGS. 1A and 1B but represent the positions of the components of the apparatus during the actual gravel packing operation.
FIGS. 3A and 3B are views respectively similar to FIGS. 2A and 2B but illustrate the position of the components of the gravel packing apparatus after completion of the gravel pack and during removal of the gravel packing apparatus from the well.
FIG. 4 is an enlarged scale, partial sectional view of a portion of FIG. 3B illustrating the construction of the flapper valve.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1A and 1B, there is shown a combined well completion and gravel packing apparatus 10 shown in inserted relationship within the well casing 1, having a plurality of perforations 1a disposed in vertically spaced relationship adjacent a production formation. Prior to insertion of the apparatus 10, a sump packer 11 may be installed by wireline at a position below the perforations 1a.
The well completion apparatus includes a settable packer 12 which is carried into the well by a conventional hydraulic packer setting mechanism 14 which in turn is run into the well on the bottom end of a tubular work string 5.
Packer 12 is threadably and sealably secured to the top end of a liner assemblage 20 which includes, in descending order, a ported liner element 21, a seal bore sub 22, a lower extension sub 23, a shear-out safety mechanism 24, a space-out blank pipe 25, a valve seat sub 26, a tell-tale screen 27, a second space-out blank pipe 25a, a gravel pack screen 28, and a snap latch seal assembly 29 for effecting a sealing engagement with the sump packer 11. Except for the valve seat sub 26, all of the aforedescribed elements of the liner assemblage 20 are conventional and are illustrated in the aforementioned pages 8 and 9 of the BAKER SAND CONTROL CATALOG. Accordingly, further detailed description of the conventional elements is unnecessary.
Additionally, a conventional gravel packing tool assemblage 30 is supported in depending relationship from the packer setting tool 14 and projects downwardly into the bore of the liner assemblage 20. The gravel packing tool assemblage comprises a conventional crossover tool 31 having the usual ported passages 31a and 31b respectively at its lower and upper ends to provide communication with the casing annulus respectively below and above the set packer 12, as illustrated in FIG. 2A. Lastly, a wash pipe 32 is secured to the bottom end of the crossover tool 31 and projects downwardly through the bore of the liner assemblage 20 terminating at a position adjacent the bottom end of the gravel packing screen 28. Again, all of this portion of the gravel packing apparatus is conventional and is described and illustrated on pages 8 and 9 of the aforementioned catalog.
The entire apparatus 10 is lowered into the well by tubular work string 5 with the elements thereof disposed in the positions illustrated in FIGS. 1A and 1B. The snap latch seal assembly 29 is engaged with the sump packer which positions the gravel pack screen 28 immediately adjacent the casing perforations 1a.
A ball 35 (FIG. 2A) is then dropped through the tubular work string 5 to seat upon an annular seating surface 31d provided on a disposable valve sleeve 31c mounted within the central bore of the crossover tool 31 by and secured by shear pins 31e. Fluid pressure is then built up within the tubular work string 5 sufficient to effect the operation of the hydraulic setting tool 14 to effect the expansion of the slips 12a and the elastomeric seal element 12b of the settable packer 12 into engagement with the bore of the casing 1, as illustrated in FIG. 2A. Following the setting of the packer 12, the setting tool 14 is released from the packer by right hand rotation of the tubular work string, thus effecting separation of the setting tool from the left hand threads 12c conventionally provided in the packer 12. The gravel packing apparatus 30 is then elevated until an indicating ring 30a contacts the bottom end of the seal bore sub 22, at which position the various external seals provided on the crossover tool 31 are properly positioned with respect to ports in the liner assemblages 20 to effect the gravel packing operation in conventional fashion. The disposable valve sleeve 31c is forced downwardly by increasing the fluid pressure in work string 5 sufficient to shear pins 31e.
As illustrated in FIGS. 2A and 2B, a slurry containing gravel is then pumped downwardly through the work string 5 and flows outwardly through the lower port 31a provided in the crossover tool 31 and thence through the ported sleeve 21 into the annulus defined between the liner assemblage 20 and the bore of the casing 1. The gravel contained in the slurry is thus permitted to build up in the casing annulus above the sump packer 11 so that the gravel pack screen 28 is covered by the deposited gravel. The liquid component of the gravel slurry is returned upwardly to the well surface by passing through the gravel pack screen 28 and entering the open bottom end of the wash pipe 32. The liquid component passes upwardly through the outer axial passages 31f provided in the crossover tool 31 and exits into the casing annulus through the upper radial crossover port 31b at a point above the annulus seal provided by seal element 12b of the set packer 12. The gravel packing operation is continued until the accumulated gravel covers the tell-tale screen 27, which results in a pressure indication to the operator at the surface that sufficient gravel has been deposited to insure that the gravel pack screen 28 and the casing perforations 1a have been covered with deosited gravel.
At this point, a squeezing operation can be performed in the manner indicated on page 8 of the aforementioned BAKER SAND CONTROL catalog.
When the gravel packing operation has been completed, the customary procedure is to remove the tubular work string 5 from the well and thus carry the gravel packing apparatus 30 out of its cooperating relationship with the liner assemblage 20. Thus obviously permits fluids and particulates contained in the gravel pack apparatus 30, as well as in the casing annulus above the packer 12, to flow downwardly into the bore of the liner assemblage 20 and thus pass through the gravel packing screen 28 and enter the production formation through the casing perforations 1a.
In accordance with this invention, such deleterious flow of undesired fluids and contaminates is prevented through the incorporation in the liner assemblage of a valve seat sub 26. As best shown in FIG. 4, valve seat sub 26 defines at its upper end an annular valve seat 26a having a spherical segment shaped cross-sectional configuration. Additionally, valve seat sub 26 is provided with a recess 26c which is traversed by a horizontal pivot pin 26b for effecting the horizontal pivotal mounting of a flapper valve arm 41. A flapper valve body 40 is secured to the outer end of the mounting arm 41 by a bolt 42. A seal washer 43 underlies the head of bolt 42. The outer perimeter 40a of the flapper valve body 40 is formed as a spherical segment shaped surface having a radius closely approximating but less than that of the spherical segment shaped valve seat 26a. The upper portion of the perimeter of the flapper valve body 40 is provided with an annular recess 40b to accomodate an O-ring 44 which also sealingly engages the spherical segment shaped sealing surface 26 a.
In accordance with this invention, during the run-in, gravel packing and related operations, the flapper valve body 40 is trapped in a substantially vertical position as indicated by the dotted lines in FIG. 4 between the outer wall of the wash pipe 32 and the inner bore of the blank pipe 25. Thus, the flapper valve does not in any manner interfere with the run-in or gravel pack operations. However, when the gravel pack is completed and the gravel packing apparatus 30, including the wash pipe 32, is moved upwardly for withdrawal from the well by the tubular string 5, as indicated in FIGS. 3A and 3B, the flapper valve body 40 is freed to move downwardly into sealing engagement with the spherical segment shaped sealing surface 26a. A torsion spring 45 mounted between the valve support arm 41 and the valve seat sub 26 assists in urging the flapper valve body 40 into its sealed engagement with the valve seat 26a.
It is thereby assured that no significant quantities of undesired contaminates or well fluids will be permitted to enter the bore of the liner assemblage 20 during the removal of the gravel packing apparatus 30 from the well. Moreover, a perfect seal is assured for flapper valve 40 by virtue of the utilization of cooperating spherical segment surfaces as the sealing members. It is therefore unnecessary that the horizontal pivot axis of the support arm 41 be precisely aligned with the axis of the annular valve seat 26a, inasmuch as the spherical configuration of the cooperating sealing surfaces will compensate for a substantial misalignment of such pivot axis from the correct position.
If desired, the flapper valve body 40 may be formed from a glass or other frangible ceramic material so that it may be readily broken and the fragments thereof dropped down into the well rat hole whenever it is desired to open the passage through the bore of the liner assemblage 20 for production purposes.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention. | An apparatus for gravel packing a screen positioned adjacent the casing perforations of a subterranean well incorporates an annular sealing surface immediately above the gravel pack screen. A flapper valve is mounted for movement about a horizontal pivot axis into engagement with the annular valve seat. The flapper valve and the cooperating valve seat are both provided with spherical segment sealing surfaces so as to prevent leakage through the valve due to any misalignment of the pivot axis of the flapper valve with respect to the annular valve seat. With this apparatus, the withdrawal of the gravel packing apparatus at the completion of the gravel packing operations prevents the entry of undesired fluids and contaminates into the producing formation. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to a composite structure, in which a layer is fastened to a metal sheet the back of which is inaccessible. Such structure is used particularly for the installation of insulating coverings or claddings of facades in the building sector.
An insulating covering, for example, insulating coverings includes an insulating layer consisting of panels and a sealing lining, the assembly as a whole being fastened to a roof carrier element formed of ribbed metal sheets fastened to a framework. At the present time, use is made of self-drilling and -tapping countersunkhead screws of small diameter (diameter 3 mm to diameter 6 mm), of a length greater than the thickness of the insulating panels (10 to 30 mm more) and fastened by means of threads in the upper areas of the ribbed metal sheets. A metal distribution washer having a pierced and countersunk central cup and of small thickness and large diameter (approximately 70 mm) is interposed between each screw head and the upper face of the insulating panel. The sealing lining is subsequently adhesively bonded or welded to the upper face of the insulating panels and to the distribution washers which are theoretically in the upper plane of the insulating panels.
One version involves employing the fastenings, comprising a washer and screw, after the installation of a first sealing membrane. A second membrane subsequently covers the first membrane and the visible washers and screw heads. Another version involves employing the fastenings, comprising washers of elongate shape and the screws, along the edge of a width of a sealing lining. An adjacent width subsequently covers the first width and all the visible washers and screw heads.
The use of such screws is far from satisfactory. The screws are installed by means of an electric screwdriver of rapid rotational speed and high torque. It often happens, especially if the insulating panels are dense and scarcely compressible and if the metal sheet is thin, that the screw, once it has come into abutment on its washer, continues to rotate without being capable of penetrating. Consequently, the diameter of the hole in the metal sheet becomes equal to the outside diameter of the threads of the screw, and the fastening is no longer effective.
For the same reasons of high screwing speed and/or torque, the screw can be screwed too deeply into the ribbed metal sheet, the screw head being driven, together with the distribution washer which may even bend, into the insulating panel. In such case, the sealing lining is not applied onto a continuous and flat support, thus impairing its proper functioning. This phenomenon becomes more serious if the insulation used is highly compressible, for example panels of mineral wool. Moreover, an aesthetic defect appears on the underside of the roof. That is the screw deforms the area of ribbed metal sheet upwards, with the result that such sheet no longer is plane.
Furthermore, even if the screw is correctly installed, when the roof is completed the screw can be forced in by one or more thread flights in the region of the ribbed metal sheet under the effect of a load, for example when a person walks on the distribution washer and the screw head. In such case, the external threads of the screw enlarge the hole in the metal sheet, and the fastening is no longer effective.
To overcome these disadvantages and to guarantee a high reliability of the fastening, whatever the compressibility of the insulating panels, composite structures of the type comprising a layer fastened to a metal sheet by at least one fastening device have been proposed, Such device includes, on the one hand, a threaded assembly member consisting of a rod having at one end thereof a head for driving the rod in rotation, a threaded part at an opposite end and, between the threaded part and the head, a smooth part adjacent to the threaded part, and, on the other hand, a distribution element on which bears the head for driving such member in rotation. The length of the assembly member as far as the threaded part corresponds to the thickness of the layer and of the distribution element, if appropriate after a predetermined compression of the layer, plus the length of a deformation flange of the metal sheet.
U.S. Pat. No. 4,453,361 describes a structure of this type, in which the diameter of the smooth part of the assembly member is reduced substantially to the threadroot diameter of the threaded part.
This design has serious disadvantages:
the assembly member can oscillate freely in the hole in the metal sheet, and therefore it is impossible to fasten in this way either a vertical cladding or a flexible insulating layer surmounted by a sealing membrane which would quickly form folds;
moist air can infiltrate between the hole in the metal sheet and the smooth part and cause corrosion of the metal sheet. When rust has developed, the tearing resistance of the sheet falls sharply;
the assembly member is not safeguarded against inopportune unscrewing under the effect of vibrations.
SUMMARY OF THE INVENTION
The object of the invention is to eliminate these disadvantages by ensuring a firm positioning of the axis of the assembly member and protection against corrosion and against unscrewing.
To achieve and subject, the invention provides a composite structure of the abovementioned type, but wherein the diameter of the smooth part of the assembly member is markedly larger than the threadroot diameter of its threaded part. Thus, a flange is internally upset and substantially mates with the smooth part.
According to other characteristics:
the diameter of the smooth part is approximately equal to half the sum of the said thread-root diameter and of the outside diameter of the thread;
the assembly member terminates beyond the threaded part in a self-drilling tip or alternatively in a drill bit;
the smooth part extends as far as the head of the assembly member;
the structure forms a building covering, the layer being an insulating layer, if appropriately surmounted by a sealing membrane, the head of each assembly member bearing on a washer forming the distribution element, and if appropriate the fastening device being covered by the sealing membrane;
the structure forms a facade lining;
the layer comprises a cladding and an intermediate insulating jacket of predetermined compression, the metal sheet forming a supporting skeleton for the cladding;
the layer comprises rigid panels, the metal sheet forming a supporting skeleton, especially in the form of longitudinal members, for such panels.
BRIEF DESCRIPTION OF THE DRAWINGS
Some exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a section showing the fastening of an insulating layer to a supporting metal sheet for the covering of a building, according to the invention;
FIG. 2 is a section showing a detail of such fastening on a larger scale;
FIG. 3 is perspective cut away view showing the fastening of a building facade cladding to a supporting skeleton, according to the invention;
FIG. 4 is a view taken in section along the line IV--IV of FIG. 3; and
FIG. 5 is a section illustrating another use of the invention in a manner similar to that of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the fastening of an insulating panel 1 of thickness e, surmounted by a sealing membrane 1A, to a ribbed metal sheet 2 previously fastened to the framework 3 of a building. This fastening is carried out on corrugation crests of the metal sheet 2 by means of devices 4, each consisting of an assembly member 5, which will be designated hereinafter by the term "screw" for the sake of convenience, and of a distribution washer 6. The screws 5 and the metal sheet 2 have corrosion-proof coatings.
The screw 5 comprises a countersunk head 7 at its upper end, a threaded lower end part 8 located under the metal sheet 2 and, between the head 7 and part 8, a smooth cylindrical body 9. The threaded part 8 is extended downwards by a self-drilling cutting tip 10. The screw 5 is produced in a conventional way simply by the non-cutting deformation of a rod having the diameter of the body 9, so that the latter (FIG. 2) has a diameter a which is intermediate between the thread-root diameter b and the outside diameter c of the part 8 and which can, in particular, be approximately equal to (b+c)/2. Moreover, the height 1 of the head 7 and of the body 9 is in the neighbourhood of the thickness e to be fastened, as will be explained in more detail below.
The washer 6 is circular or of elongate shape and has a countersunk central hole 11, the periphery of which is matched to the screw head 7.
The use of the device 4 by means of an electric screwdriver includes a sequence of the following operations assumed to be conducted along one edge of two widths of the sealing lining 1A:
installation of the distribution washer 6 on the upper face of the edge of one width 14A of the membrane 1A;
installation of the screw 5 in the hole 11 of the washer and through the width 14A and the insulating layer 1;
drilling of the metal sheet 2 by the rotation of the tip 10. The metal sheet 2 is thus deformed locally downwards;
screwing of the threaded part 8 into the metal sheet 2 until a thread head 12, including the junction of the body 9 of the screw and of the threaded part 8, has projected downwards beyond the drilled hole which at such time has the same diameter b as the thread root of the threaded part 8;
the screw then rotates rapidly on itself, driven by the screwdriver. Since the diameter a of the body 9 of the screw is markedly larger than the diameter b and therefore larger than the diameter of the drilled hole, the latter is widened by radial upsetting and forms a flange 15, the inner surface of which is approximately smooth and closely mates over its entire height h with the smooth part 9. The height h is in all cases markedly larger than the thickness of the metal sheet 2, and the diameter d of the flange is equal to a.
Thereafter, the screw does not continue to penetrate. The thread head 12 remains substantially in the plane of the lower face of the metal sheet 2, and the flange 15 forms a bearing which firmly positions the axis X--X of the screw 5, while allowing the screw to rotate about such axis and slide axially thereof.
When all the devices 4 are in place, the edge of a second width 14B of the sealing membrane 1A is finally adhesively bonded or welded to the edge of the first width and to the washers 6.
Under the effect of a load applied vertically to the screw, the screw 5, as well as the washer 6 can penetrate into the insulating panel 1 without any subsequent loss of tearing resistance. Moreover, as a result of the vertical guidance ensured by the flange 15, the sealing membrane does not risk being folded. Furthermore, the close contact between the flange 15 and the body 9 protects the assembly against corrosion, even though, due to the screwing of the screw 5, the flange 15 does not have a corrosion-proof coating.
It will also be noted that the screws 5, once in place, are unscrewable, since the upsetting of the flange 15 has virtually eliminated the threads cut into the metal sheet by the threaded part 8.
The exact length 1 of the head 7 and of the body 9 is calculated so that, when the thread head 12 butts against the metal sheet 2, the upper surface of the screw head 7 is in the plane of the upper face of the washer 6. The length 1 must therefore take into account the length h of the flange 15.
FIGS. 3 and 4 show the use of the invention for the fastening by means of devices 4 of a metal cladding 16 having vertical corrugations to horizontal ribs 17 of a metal skeleton 18, with a flexible insulating jacket 19, for example consisting of mineral wool, being interposed, for the purpose of lining a building facade. The use of screws according to the invention makes it possible to compress the jacket 19 only to a predetermined extent at the location of the fastenings, as can be seen clearly in FIG. 4, the thread head 12 coming into abutment behind the ribs 17. The planeness of the outer face of the cladding can thus be improved. It will be appreciated that the heads of screws 5 bear directly on the cladding 16. The flanges 15 keep the screws 5 in the horizontal position.
FIG. 5 illustrates the use of a screw 105 similar to that of FIG. 1, but with a flat head 107, for fastening a structure 101 of low compressibility, for example a vertical sandwich structure comprising a plaster or wooden panel 120 and two skins 121, 122, to a thick supporting metal sheet 102, such as a longitudinal member. In this case, the screw 105 preferably terminates in a drill bit 110. If necessary, a flexible sealing washer (not shown) can be pressed between the head 107 and the outer skin 121 which itself serves as a clampingforce distribution element, in the same way as the cladding 16 in the example of FIGS. 3 and 4.
It was found, surprisingly, that the tearing resistance of the fastening device according to the invention is virtually the same as that of conventional screws, the thread of which remains in engagement with the supporting metal sheet. | An assembly member includes a rod having at one end thereof a head for driving the rod in rotation, a threaded part at an opposite end and, between the threaded part and the head, a smooth part the diameter of which is markedly larger than a threadroot diameter of the threaded part. Such member is used for the fastening of insulating layers of facade coverings or claddings. |
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This is a continuation-in-part of our pending U.S. patent application Ser. No. 06/743,573 filed June 11, 1985 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the servicing of wells by use of coil tubing and more particularly to removal of scale and other downhole deposits from the inside diameter of well tubulars.
2. Description of the Prior Art
It has been common practice for many years to run a continuous reeled pipe (known extensively in the industry as "coil tubing") into a well to perform operations utilizing the circulation of treating fluids such as water, oil, acid, corrosion inhibitors, cleanout fluids, hot oil, and the like fluids. Coil tubing being continuous, rather than jointed, is run into and out of a well with continuous movement of the tubing through use of a coil tubing injector.
Coil tubing is frequently used to circulate cleanout fluids through a well for the purpose of eliminating sand bridges, scale, or other downhole deposit obstructions. Often such obstructions are very difficult and occasionally impossible to remove because of the inability to rotate the coil tubing to drill out such obstructions. Turbo-type drills have been used but have been found to develop insufficient torque for many jobs.
Thus, it is desirable to perform drilling operations in wells through use of coil tubing which can be run into and removed from a well quickly in addition to performing the usual operations which require only the circulation of fluids.
U.S. Pat. No. 3,285,485 which issued to Damon T. Slator on Nov. 15, 1966 discloses a device for handling tubing and the like. This device is capable of injecting reeled tubing into a well through suitable seal means, such as a blowout preventer or stripper, and is currently commonly known as a coil tubing injector.
U.S. Pat. No. 3,313,346 issued Apr. 11, 1967 to Robert V. Cross and discloses methods and apparatus for working in a well using coil tubing.
U.S. Pat. No. 3,559,905 which issued to Alexander Palynchuk on Feb. 2, 1971 discloses an improved coil tubing injector.
High pressure fluid jet systems have been used for many years to clean the inside diameter of well tubulars. Examples of such systems are disclosed in the following U.S. Pat. Nos.:
______________________________________3,720,264 3,850,241 4,442,8993,811,499 4,088,1913,829,134 4,349,073______________________________________
Outside the oil and gas industry, tubing cleaners have been used for many years to remove scale and other deposits from the inside diameter of tubes used in heat exchangers, steam boilers, condensers, etc. Such deposits may consist of silicates, sulphates, sulphides, carbonates, calcium, and organic growth. Tubing cleaners and associated equipment are disclosed in Elliot tubing cleaners bulletin Y-100 1580F-second edition. This bulletin is incorporated by reference for all purposes within this application. Elliot Company is a division of Carrier Corporation, a subsidiary of United Technologies Corporation.
The preceding patents are incorporated by reference for all purposes within this application.
SUMMARY OF THE INVENTION
The present invention is directed towards improved methods and apparatus for cleaning well tubulars using coil tubing.
One object of the invention is to provide a high speed, fluid-powered cutter head to remove scale and other deposits from the inside diameter of a well tubular.
Another object of the present invention is to provide guide means to prevent the cutter head from becoming fouled with other downhole well tools.
A further object of the present invention is to provide sleeve means to centralize the universal joint connecting the fluid motor with the cutter heads and avoid fouling with downhole tools.
A still further object of the present invention is to provide a combination cutter and guide means with improved ability to remove all types of downhole deposits.
Additional objects and advantages of the present invention will be readily apparent to those skilled in the art after studying the written description in conjunction with the drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing partially in elevation and partially in section with portions broken away showing a coil tubing unit and tubing cleaner removing deposits from the inside diameter of a well tubular.
FIG. 2 is an enlarged drawing partially in section and partially in elevation showing guide means to prevent the tubing cleaner from becoming fouled with other downhole well tools.
FIG. 3 is schematic drawing partially in elevation and partially in section showing alternative guide means to prevent the tubing cleaner from becoming fouled with other downhole well tools.
FIG. 4 is a schematic drawing partially in elevation and partially in section with portions broken away showing a tubing cleaner having a fluid motor, hose, and cutter/guide means.
FIG. 5 is an enlarged schematic drawing partially in elevation and partially in section with portions broken away showing a guide means with an alternative fluid flow path.
FIG. 6 is drawing in section taken along line 6--6 of FIG. 5.
FIG. 7 is a schematic drawing in elevation showing a tubing cleaner with guide means attached thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 well 20 extends from wellhead 21 to an underground hydrocarbon or fluid producing formation (not shown). Well 20 is defined in part by casing string or well flow conductor 22. This embodiment will be described with respect to casing 22. However, the present invention can be used with other types of well tubulars or flow conductors including liners and production tubing strings. Also, the present invention is not limited to use in oil and gas wells.
During the production of formation fluids, various types of deposits may accumulate on the inside diameter of the well tubulars. Examples of soft deposits are clay, paraffin, and sand. Examples of hard deposits are silicates, sulphates, sulphides, carbonates and calcium. The present invention is particularly useful for removal of hard deposits found in some geothermal and oil wells but may be satisfactorily used to remove other types of deposits.
Using conventional well servicing techniques, injector 25 can be mounted on wellhead 21. Continuous or coil tubing 26 from reel 27 is inserted by injector 25 into bore 23 of casing 22. Tubing cleaner assembly 39 is attached to the lower end of coil tubing 26. Manifold 28 includes the necessary pumps, valves, and fluid reservoirs to discharge power fluid into bore 23 via coil tubing 26. Valves 29 and 30 can be used to control the return of spent power fluid to the well surface.
Fluid motor 40 is attached to the extreme end of coil tubing 26 disposed in casing 22. Fluid motor 40 is mechanically connected to cutter heads 42 by universal joint 41. Motor 40, universal joint 41, and cutter heads 42 are commercially available from Elliot Company. Deposits 36 can be removed from the inside diameter of casing 22 by inserting coil tubing 26 with tubing cleaner assembly 39 including motor 40 and cutter head 42 attached thereto to the desired downhole location. Power fluid from manifold 28 is supplied to motor 40 via coil tubing 26 to rotate cutter heads 42 at a relatively high rate of speed. High speed is particularly useful in removing hard deposits. Power fluid discharged from motor 40 is returned to the well surface via valves 29 or 30.
Many well completions have deviated well tubulars and/or downhole well tools which might restrict longitudinal movement of cutter head 42 throughout the length of the well bore. An example of such a tool is a side pocket gas lift mandrel (not shown). This downhole tool typically has a main bore extending longitudinally therethrough compatible with the bore of the well tubular. A second, smaller bore is offset from the main bore to provide a receptacle for gas lift valves. Cutter heads 42 might become fouled in this offset bore. An example of a side pocket mandrel is shown in U.S. Pat. No. 4,333,527 incorporated by reference for all purposes within this application.
FIGS. 2 and 3 show guide means 50 which can be attached to cutter heads 42 by flexible shaft 51 and universal joint 52. Preferably, flexible shaft 51 extends downwards from cutter heads 42 with guide means 50 positioned therebelow. Guide means 50 is selected to be compatible with the main bore of the well tubular which cutter heads 42 will clean but larger than any offset bore or potential restriction that cutter head 42 might encounter downhole. Thus, guide means 50 will prevent the fouling of cutter head 42 in such restrictions.
Depending upon the type of deposit to be cleaned and other downhole conditions, universal joint 52 may be subject itself to fouling in other downhole tools. In FIG. 2, rubber sleeve 53 is disposed around universal joint 52 to centralize joint 52 and the tools attached thereto while being lowered through well flow conductor 22. When motor 40 is operating, sleeve 53 allows limited flexing of joint 52. In FIG. 3, spring 54 is disposed around the exterior of universal joint 52 for this same purpose. The use of either rubber sleeve 53 or spring 54 will be contingent on the anticipated downhole environment.
Guide means 50 will rotate due to the mechanical connection with cutter head 42 by flexible drive shaft 51. Teeth or serrations 55 may be formed on the exterior of guide means 50 to initially remove a portion of deposits 36 prior to engagement by cutter head 42.
ALTERNATIVE EMBODIMENT
An alternative tubing cleaner assembly 139 is shown in FIG. 4 attached to the lower end of coil tubing 26. Tubing cleaner assembly 139 includes fluid motor 140, hose 70 and combination cutter/guide means 150. Fluid motor 140 preferably includes two fluid-powered turbines 141 and 142 to take maximum advantage of the energy available in the power fluid supplied by coil tubing 26. Power fluid flows from coil tubing 26 through multiple ports 143 and contacts first turbine 141. Power fluid continues through fixed stator 144 and then contacts second turbine 142. A plurality of openings 145 are provided in hollow drive shaft 146 to allow spent power fluid to exit from second turbine 142. Various bearings 191, 192, and 193 are provided in motor 140 to allow rotation of drive shaft 146 and attached turbines 141 and 142. Some components in motor 140 are commercially available from various sources including the Elliot Company.
Flexible hose 70 is attached to hollow drive shaft 146 by threaded connection 71. Hose 70 and combination cutter/guide means 150 rotate in unison with drive shaft 146. Cutter/guide means 150 is similar to previously described guide means 50. The principal differences are flow path 151 and exit ports 152 and 153 which allow spent power fluid to flow from hose 70 through cutter/guide means 150. Serrations 155 are provided on the exterior of cutter/guide means 150 to remove deposits from the interior of well flow conductor 22. The efficiency of serrations 155 is greatly increased by having spent power fluid from exit ports 152 flow upwardly therepast. The power fluid flow path of tubing cleaner assembly 139 optimizes both the rotational effect of serrations 155 and the lifting of loosened deposits by spent power fluid to the well surface. For well cleaning operations involving soft deposits, exit ports 152 can be designed to produce a jetting effect as spent power fluid leaves guide means 150. This jetting effect will remove soft deposits before they can foul serrations 155.
Hose 70 may be selected from many commercially available products including flexible steel hoses as well as elastomeric hoses. Hose 70 must be selected to withstand wear on its exterior associated with rotating inside well flow conductor 22.
An alternative cutter/guide means 250 is shown in FIG. 5. Cutter/guide means 250 is attached to and rotated by hose 70 in the same manner as previously described cutter/guide means 150. Cutter/guide means 250 includes mandrel means 252, end cap 253, housing means 270, and serrations 255. Mandrel means 252 has flow path 251 extending partially therethrough with threads 259 formed in flow path 251 to allow attachment of cutter/guide means 250 to hose 70. Flow path 251 extends only partially through the length of cutter/guide means 250 as compared to flow path 151. A plurality of ports 280 extend radially from flow path 251 above serrations 255.
Housing means 270 is disposed around the exterior of mandrel means 252 and covers ports 280. Annular chamber 271 is formed between the exterior of mandrel means 252 and the interior of housing means 270 to receive spent power fluid from ports 280. As best shown in FIG. 6, a portion of the exterior of housing means 270 has been removed by machining longitudinal groove 273 partially therethrough. A plurality of openings 272 extend from groove 273 to tangentially intersect chamber 271. Groove 273 has surfaces 273a and 273b perpendicular to each other. Openings 272 are machined normal to surface 273b. The result is that spent power fluid can flow from hose 70 through flow path 251 and ports 280 into annular chamber 271. Openings 272 allow spent power fluid to exit from chamber 271 at a tangent relative to the outer surface of mandrel means 252. Exhausting spent power fluid in this manner will cause increase oscillation of cutter/guide means 250 within well flow conductor 22. Openings 272 can also be designed to produce a jet spray as power fluid exits housing means 270. A jet spray may be desirable to remove soft deposits.
Serrations 255 are shown disposed on the exterior of mandrel means 252 below housing means 270. The relative longitudinal position of serrations 255 and housing means 270 could be modified as taught by cutter/guide means 150. End cap 253 is used to hold serrations 255 and housing means 270 on the exterior of mandrel means 252.
The previous description is illustrative of only some embodiments of the present invention. Those skilled in the art will readily see other variations and modifications without departing from the scope of the invention as defined in the claims. | A system for cleaning wells with coil tubing, a fluid motor and cutter heads. The invention allows equipment used to clean boiler tubes or heat exchangers to effectively remove downhole deposits from the inside diameter of well tubulars. |
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TECHNICAL FIELD
This patent disclosure relates generally to hydrostatically driven machines and, more particularly, to hydrostatically driven machines having hydraulically operated implements associated therewith.
BACKGROUND
Hydrostatically driven machines having hydraulically actuated implements are known. Such machines typically use an internal combustion engine or another type of prime mover to provide power to one or more hydraulic pumps or transmission systems. Such machines typically operate under varied conditions requiring either power to propel the vehicle, power to operate the implements, or a combination thereof. For example, a loader operating to load loose material onto a truck may perform quickly repeating loading operations that require relatively low loading of the implement and propel systems. Alternatively, an excavator digging into virgin earth may encounter various obstacles, such as rocks and other debris, which demand momentary increased loading of the implement system until the obstacle breaks loose. It is often challenging for a machine to effectively address varying operating conditions while consistently maintaining high productivity, cycle time, and fuel economy.
Various features have been incorporated into electronic controllers associated with such machines to ensure proper operation. For example, an excavator machine attempting to lift a large or otherwise unmovable object encounters a spike in the load required by the implement. Because the implement is hydraulically driven, the increased load translates to an increased hydraulic fluid pressure at the hydraulic pump operating the implement. Hydraulic pumps are typically connected to the engine of the machine, such that an increased pressure at the pump under these conditions tends to stall the pump, and with it, the engine. To avoid such conditions, most modern machines have electronic controllers that limit the speed the engine may obtain during operation. This limit is implemented as a set-point that is either pre-programmed into the controller or as a series of discrete values that are selected by the machine operator based on the type of operation the machine is performing. This limit is known as an underspeed setpoint. Thus, when encountering a potential stall condition, the electronic controller operates to maintain engine speed at the selected setpoint.
Prior attempts to provide the operator with control over an appropriate engine or transmission underspeed set point, depending on the operating mode of the machine, have been provided. Past solutions generally include selector switches or knobs placed in the operator cab to allow an operator to select a desired setpoint operating mode for the machine. However, these predetermined and manually selectable modes of operation are not efficient in optimizing operation of the machine when the machine is operating under a mode that is not closely related to one of the modes the operator can select. Moreover, an operator may neglect to change the mode of the machine when performing mixed tasks. These limitations often result in under-optimized machine performance, increased fuel consumption and increased noise output by the machine, as well as higher cycle times when performing various tasks. From a broader perspective, under-optimized machine performance on a regular basis may lead to shorter service intervals and increased downtime for repairs and service.
SUMMARY
The disclosure describes, in one aspect, a machine that includes an engine connected to an implement pump operating an actuator and to a propel pump operating a motor. An electronic controller is disposed to receive at least one parameter selected from the group of a pressure of fluid at the at least one motor, a pressure of fluid at the at least one implement actuator, a rate of rotation of the engine, a rate of rotation of the at least one motor, and a torque output of the engine. The electronic controller determines an operating mode of the machine from the at least one parameter. The electronic controller then adjusts an underspeed setting for the engine based on the operating mode.
In another aspect, this disclosure provides a method for operating a machine having a tractive system and an implement system each operating with hydraulic power. The method includes operating an engine at an engine speed that is greater than an underspeed setpoint thus generating power. The power is divided into tractive power and implement power while being used or consumed by the respective systems. Tractive information relative to power consumed by the tractive system of the machine and implement information relative to power consumed by the implement system of the machine are collected and processed by the controller. A usage profile for the machine that is based on tractive information and implement information processed is determined and used as a basis for a determination of the operating mode of the machine. The underspeed set cut-in rate is adapted based on the operating mode determined.
In yet another aspect, a control algorithm for improving productivity and power utilization of a machine is disclosed. The control algorithm is executed within an electronic controller associated with a machine and disposed to receive information from the propel and implement hydraulic circuits. The control algorithm uses information associated with data obtained from at least one sensor disposed to measure a pressure of hydraulic fluid in at least one of a propel hydraulic circuit and an implement hydraulic circuit of the machine. Information already collected is continuously updated and processed to obtain an inferred usage profile for the machine. The algorithm determines a mode of operation of the machine based on the inferred usage profile. Finally, the algorithm adaptively sets a desired underspeed cut-in rate for the machine based on the determined mode of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a tracked loader in accordance with the disclosure.
FIG. 2 is a block diagram of the engine and associated hydraulic circuits of the machine shown in FIG. 1 , in accordance with the disclosure.
FIG. 3 is a functional diagram of an electronic controller in accordance with the disclosure.
FIG. 4 is a qualitative graph of a histogram in accordance with the disclosure.
FIG. 5 is a flowchart for a method in accordance with the disclosure.
DETAILED DESCRIPTION
This disclosure relates to hydrostatically or electrically driven machines. In the embodiment described below, a tracked loader is disclosed. It should be appreciated, however, that other types of machines can benefit from the embodiments disclosed herein. In the present embodiment, an electronic controller associated with the machine is operably connected to various machine components and systems. The controller operates in a logical fashion to transmit and receive information relative to the operation of the vehicle. Various sensors located throughout the vehicle provide information to the electronic controller concerning an operating state of the vehicle. For example, various pressure sensors may be arranged to provide information about various pressures in a drive circuit or in an implement circuit of the vehicle during its operation. Various other sensors, such as one or more speed sensors associated with either the engine or a transmission, may provide data indicative of the rotational speed of these components to the electronic controller.
The electronic controller may be further capable of communicating either directly or indirectly with the engine of the vehicle, such that an underspeed set point may be supplied to the engine during service. These functions of the vehicle may advantageously be carried out automatically and independent of any selections that may be required by the operator. In this fashion, the vehicle may operate with improved overall machine productivity and power utilization, thus decreasing fuel consumption and cost of ownership for the operator.
An outline view of a machine 100 is shown in FIG. 1 . The term “machine” is used generically to describe any machine having a hydrostatically operated propel circuit for moving the machine across the terrain, and having a hydraulically operated implement circuit operating an implement for performing various machine tasks. The machine 100 is a tracked loader used for the sake of illustration only.
In the illustrated embodiment, the machine 100 includes an engine 102 connected to a frame or chassis 104 . The engine 102 is arranged to operate one or more hydrostatic pumps (not shown) that are configured to operate one or more propel motors 106 . In an alternate embodiment, the engine 102 may be connected an electrical power generator (not shown) that is arranged to operate one or more electric motors (not shown). In the embodiment illustrated, each propel motor 106 drives a gear 108 , which is meshed with a track 110 . When the gear 108 rotates, the track 110 is urged to rotate and propel the vehicle. In this type of tracked vehicle, the track 110 rotates around a series of pulleys 112 and a free rotating drum 114 , which align the moving track 110 with the chassis 104 . As can be appreciated, the machine 100 may be propelled either forward or in a reverse direction depending on the rotation of the gear 108 .
An operator cab 116 containing various controls for the machine 100 is connected to the chassis 104 . The operator cab 116 includes a seat for the operator and a series of control levels, pedals or other devices that control the various functions of the machine 100 . Lift arms 118 (only one seen in this view) are connected to the frame of the machine 100 at a hinge 120 . The lift arms 118 can pivot about the hinge 120 so that a bucket 122 , or any other implement, may be raised or lowered by the machine 100 . The pivotal motion of the lift arms 118 is controlled by lift cylinders 124 . In this embodiment, the bucket 122 may be tilted by tilt cylinders 126 via a linkage system. The lift cylinders 124 , the tilt cylinders 126 , the gear 108 , and other actuators and/or motors on the machine 100 may be operated by hydraulic systems or systems selectively providing pressurized fluid to these actuators during operation.
A simplified block diagram of the engine and various other hydraulic systems of the machine 100 is shown in FIG. 2 . The machine 100 includes an engine 202 that is directly connected to an implement pump 204 such that rotation of the engine causes a rotation of the implement pump 204 . Alternatively, the engine 202 may be connected to a generator (not shown). The pump 204 yields a supply of pressurized hydraulic fluid that is supplied to an implement control 205 , which may include one or more valves or other devices that individually control the flow of fluid to and from the various actuators of the machine 100 . In this embodiment, for the sake of simplicity, two implement actuators 206 are shown connected to the implement control 205 . These two implement actuators 206 may be, for example, the lift cylinders 124 and tilt cylinders 126 that are illustrated in FIG. 1 .
The engine 202 is also connected to a torque splitter 208 . The torque splitter 208 may be a fixed or a variable gear transmission that accepts a torque input via rotating shaft from the engine 202 . The torque splitter 208 distributes this torque to a right hand transmission 210 and a left hand transmission 212 . The right hand transmission 210 and left hand transmission 212 operate independently of each other, such that the tracked vehicle shown in FIG. 1 is moveable in various directions. The right hand transmission 210 is connected to a hydrostatic motor 214 . Similarly, the left hand transmission 212 is connected to an additional hydrostatic motor 216 . In accordance with the description provided above in relation to FIG. 1 , the motor 214 connected to the right hand transmission 210 may be the motor 106 as shown in FIG. 1 , which operates the drive gear 108 causing the track 110 to move relative to the vehicle. In an alternate embodiment, electric motors may be connected to the transmissions 210 and 212 .
An electronic controller 218 is arranged to communicate with various components on the machine 100 . In this embodiment, shown simplified for the sake of clarity, the electronic controller 218 can supply and receive information to and from sensors and actuators (not shown) associated with the engine 202 via an engine communication bus 220 . The engine communication bus 220 may be an analog and/or digital communication bus, which can include one or more channels that effectively communicate data and command signals between the electronic controller 218 and the sensors and actuators (not shown) associated with the engine 202 . In a similar fashion, the electronic controller 218 may be connected to the right hand transmission 210 and the left hand transmission 212 via, respectively, a right hand communication line 222 and a left hand communication line 224 . The right hand communication line 222 may connect the electronic controller 218 to a right hand drive sensor 223 that is integrated with the right hand transmission 210 . The right hand drive sensor 223 is arranged to sense and provide data indicative of the rotational speed and/or the pressure of hydraulic fluid operating the motor 214 ( FIG. 2 ) to the electronic controller 218 . Similarly, the left hand communication line 224 may connect the electronic controller 218 to a left hand drive sensor 225 that is integrated with the left hand transmission 212 . The left hand drive sensor 225 is arranged to sense and supply data indicative of the rotational speed and/or the pressure of hydraulic fluid operating the motor 216 ( FIG. 2 ) to the electronic controller 218 .
In a similar fashion, the electronic controller 218 may be connected to one or more sensors 227 that are associated with the implement pump 204 , which connection is established via an implement communication line 226 . The data supplied to the electronic controller 218 from the sensors 227 may be indicative of the rotational speed of the implement pump 204 and/or the pressure of fluid passing through the implement pump 204 during operation. This information may be used by the electronic controller 218 to automatically distinguish the operating mode of the vehicle as well as command other operating parameters that can improve the efficiency and operation of the machine 100 .
A functional diagram, which qualitatively shows at least some of the functions performed by the electronic controller 218 , is shown in FIG. 3 . The electronic controller 218 is arranged to receive, generally, four types of input information from four different sources relative to the operation of the vehicle. Specifically, the electronic controller 218 may first receive information relative to the operating state of the engine via a first input node 302 . Information indicative of the operating state of the propel system of the machine, which includes the motors 214 and 216 and/or other driving devices that propel the vehicle, may be input to the electronic controller 218 via a second input node 304 . Information indicative of the operating state of an implement drive circuit may be input to the electronic controller 218 via a third input node 306 . Finally, the electronic controller 218 may be arranged to receive input at a fourth input node 308 that is indicative of operator commands. Other input information may also be provided to the electronic controller 218 .
Data indicative of the operating state of the engine, such as engine speed or torque output, which enter the electronic controller 218 via the first input node 302 , may be accessed by an engine map look-up function 310 . The engine map look-up function 310 may include information relative to optimized engine operating points that are determined based on the engine's operating speed and operating load. The output from the engine map look-up function 310 may be an appropriate engine parameter 312 , for example, an instantaneous engine speed or torque output, which is relayed to the mode determinator function 314 .
The mode determinator function 314 may, in addition to the engine parameter 312 , receive information provided to the electronic controller 218 via the third input node 306 and the fourth input node 308 . This information may be used to determine a calculated available power in the machine 100 , or a ratio thereof, that is consumed by either the propel circuit or the implement circuit. The calculated available power for the systems of the machine 100 can be determined by calculations that are based on the engine parameter 312 , which is also input to the mode determinator function 314 . With such information, the mode determinator function 314 may perform various calculations and/or data manipulations to determine an actual operating mode of the machine.
Before proceeding with the description, a few examples may be used to illustrate three of the various operating modes of the machine 100 . The first example is when the machine 100 is engaged in an operation requiring high cycle times at relatively low implement loads, such as during a truckloading operation. In this instance, the engine may operate at a relatively low power output but at a high speed to provide an adequate supply of fluid to the implement circuit. The power consumed by the driving or propel and implement circuits loads may be relatively low. The second example is when the machine is operating in a mode requiring greater forces to be applied by the implement, for instance, when the machine is digging into a hard substrate, a mode also known as pioneering. In this mode, the engine of the machine may operate at a relatively high power output, the majority of which may be used by the implement circuit. Finally, a third example may be illustrated when the machine 100 is dragging an implement across the substrate, for example, a ripper or tiller attachment. In this mode, the engine may operate at a relatively high power output, but in this instance, the majority of the power produced by the engine is consumed by the propel or driving circuits.
The actual operating mode of the machine determined in the mode determinator function 314 may be a mode selected from two or more predetermined operating modes. Alternatively, the mode determinator function 314 may calculate a continuously adapting mode that tracks the actual operation of the machine. In either instance, the mode determinator function 314 provides a value indicative of the machine's operating mode to an underspeed determinator logic function 316 .
The underspeed determinator logic function 316 may receive the value indicative of the machine's operating mode from the mode determinator function 314 and, in combination with the operator input entering at the fourth input node 308 , determine an optimum underspeed setpoint for the engine. The underspeed setpoint is appropriate for the actual operating conditions of the machine in the illustrated embodiment. For example, the underspeed setpoint may be set high in a truckloading mode to ensure operation at a high engine speed, and may be set low when in a pioneering or ripping mode, to guard the machine against stalling during unexpected load increases. Thus, “optimum” as used herein should not be construed as the best operating mode but, rather, as an operating mode that is appropriate for the task the machine is performing at any given time.
This underspeed set point, generally shown as 318 , may be supplied to a secondary engine controller (not shown) that directly controls the operation of the engine. As can be appreciated, changed conditions in either the propel or implement circuits of the machine can adaptively cause a change in the underspeed set point 318 , thus allowing the machine to operate in an optimal setting under most operating conditions.
The mode determinator function 314 may use continuously updated data to determine the actual mode of operation of the machine. One method by which this can be accomplished is for the mode determinator function 314 to continuously process obtained data relating to the operation of the machine. One example of such data processing is shown in the histogram of FIG. 4 .
Turning now to FIG. 4 , a histogram graph is presented. In the graph, a horizontal axis separates the various classes of information used to plot the graph. Here, the horizontal axis 402 represents the percentage of time during a pre-determined period of operation of the machine for which data has been collected. For example, the pre-determined period may be set to 10, 20, 30 or more minutes representing periods over which the electronic controller determines incrementally the appropriate operating mode of the machine. Plotted against time, on the vertical axis 404 , is the percent load experienced by the machine, where 100 percent corresponds to the maximum load output of the machine and 0 percent represents no loading of the machine. This load parameter can be correlated to either a power and/or torque output of the engine, a pressure of fluid measured at the propel and/or implement systems over time, or any other appropriate parameter. Two sample curves have been plotted on the histogram of FIG. 4 as illustrations of one method for selecting an appropriate mode of operation for the machine. Each of these two curves is described below.
A first curve 406 is shown in dashed lines, and a second curve 408 is shown in dot-dot-dash line. As can be seen from the graph, the first curve 406 represents a mode of operation where the machine operates less than 40% of a fixed time period operating at a relatively high load, for example, a load of about 80%. The machine operates in conditions with low loads or conditions where the load is less than about 40% in this mode. In contrast, the mode of operation represented by the second curve 408 indicates that the machine operates more than 60% of a fixed time period at a high load condition, with lower load conditions occurring less than 50% of the time. For purpose of illustration, one can appreciate that operation of the machine in a condition indicated by the first curve 406 might occur when operating in a truckloading or any other similar mode. The second curve 408 may represent an operating mode of the vehicle that often requires higher loads, for example, when the machine is used for pioneering, ripping, or any other similar mode.
Through the processing discussed above, the electronic controller 218 may build one or more graphs, such as the graph presented in FIG. 4 , that plot parameters that are the same or similar to the parameters discussed in conjunction with FIG. 4 . In this way, the electronic controller 218 determines an appropriate operating mode of the machine. In the example presented in FIG. 4 , the distinction between the two different operating modes represented by the first curve 406 and the second curve 408 can be analytically determined based on each of the two curves. Hence, an underspeed setpoint corresponding to a first mode, MODE 1 , may be applied when a curve similar to the first curve 406 has been detected. An underspeed setpoint corresponding to a second mode, MODE 2 , may be applied when a curve similar to the second curve 408 has been obtained, and so forth. It can be appreciated any number of modes may be pre-programmed into the controller of the machine, such that an appropriate mode that best fits the curve of data detected may be used to achieve an adaptive underspeed control for the machine.
Industrial Applicability
The present disclosure is applicable to vehicles or machines having hydrostatically operated propel and/or implement driving arrangements. Although a tracked loader is illustrated in FIG. 1 , the term “machine” may refer to any machine that performs some type of operation associated with an industry such as mining, construction, farming, transportation, or any other industry known in the art. For example, the machine 100 ( FIG. 1 ) is an earth moving machine, but may alternatively be a wheel loader, excavator, dump truck, backhoe, motor-grader, material handler or the like. Similarly, although a bucket 122 ( FIG. 1 ) is illustrated as the attached implement, an alternative implement may be included. Any implements may be utilized and employed for a variety of tasks, including, for example, loading, compacting, lifting, brushing, and include, for example, buckets, compactors, forked lifting devices, brushes, grapples, cutters, shears, blades, breakers or hammers, augers, and others. Regardless of the type of machine used or the type of implement employed, the methods described herein are advantageously capable of improving the performance of any machine by optimizing the split of power distribution between propel and/or implement arrangements of the machine that are used to move the machine across the terrain and/or perform various tasks.
A machine controlled software algorithm for improving overall machine productivity and power utilization by monitoring machine operation to determine the machine operating mode is presented in the flowchart of FIG. 5 . The algorithm collects and/or updates information relative to power consumed by either propel or implement systems of the machine at 502 . The information collected is aggregated at 504 . Aggregation of information or data may be accomplished continuously for pre-determined times during operation of the machine. In one embodiment, the aggregation of data may be represented by a relatively short duration histogram of various engine and/or machine parameters, for example, transmission and engine speeds, hydraulic pressures in the drive or implement circuits, and so forth.
The aggregate information may be used to infer a usage profile at 506 . The usage profile inferred may be based on continuous and/or temporary trends in operation of the machine that are distinguished by the electronic controller. This inferred usage profile might be used to determine an operating mode of the machine at 508 . Examples of different operating modes include machines operating in pioneering, ripping, truckloading, and so forth. Having determined the operating mode, the algorithm may use this information to adjust the underspeed set cut-in rates to provide the appropriate power split between tractive power and implement power for the machine. For example, when the algorithm determines that the machine is operating in a truckloading mode, the under speed set point may be set to a higher value such that priority is provided to the implement system. By setting the set point at a relatively higher value, the engine of the machine operates at a higher speed providing a steady flow of hydraulic fluid to the implement actuators, which ensures that more hydraulic fluid is available for operation of the implement system. In this manner, the machine can operate with lower cycle times and at higher engine revolutions. On the other hand, if the algorithm determines that the machine is operating in a ripping mode, the set point may be set lower. The lower set point will allow the engine to operate over a broader range thus providing the opportunity to operate the machine continuously while providing enough power to accommodate peaks in load that the machine might encounter when, for example, an obstacle is met while in operation.
Based on the foregoing, it can be appreciated that a machine operating with the afore presented algorithm can advantageously optimize its operation automatically and without input from the user. The automation of this operation insures that the machine will operate more efficiently and in a more optimized manner over a broader range in duration of operation. Thus, fuel consumption may be reduced and cycle times may be improved during service of the machine and any application.
It will be appreciated that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated.
Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context. | A machine ( 100 ) includes an engine ( 102 ) connected to an implement pump ( 204 ) operating an actuator and to a propel pump operating a motor ( 106 ). An electronic controller ( 218 ) is disposed to receive at least one parameter selected from the group of: a pressure of fluid at the at least one motor ( 106 ), a pressure of fluid at the at least one implement actuator, a rate of rotation of the engine ( 102 ), a rate of rotation of the at least one motor ( 106 ), and a torque output of the engine ( 102 ). The electronic controller ( 218 ) monitors the at least one parameter for a predetermined period, and determines an operating mode of the machine ( 100 ). The electronic controller ( 218 ) then adjusts an underspeed setting for the engine ( 102 ) based on the operating mode. |
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an antitheft method for a vehicle having an immobilizer which prohibits the engine from starting when a key with an ID code, which does not match an ID code previously registered in a controller mounted on the vehicle is used and to a method and device for providing an antitheft operation in the event a person attempts to defeat the theft by replacement of the controller.
[0002] Typical antitheft devices for vehicle as shown the U.S. Pat. Nos. 6,525,433 and 6,683,391 and co-pending U.S. application Ser. No. 10/707689, filed Jan. 5, 2004, of the assignee hereof and comprises a key cylinder and a controller on a vehicle body, that control an ignition immobilizer. The operation is such that when a key having a built-in transponder is inserted into the key cylinder, the controller performs an ID check through a circuit that communicates with the transponder via an antenna located in the vicinity of the key cylinder to read an ID code of the key. The immobilizer only permits the engine to start if the ID code matches the one previously registered in the controller.
[0003] In accordance with the disclosure thereof backup power is constantly supplied to the immobilizer generally through the vehicle battery even when the vehicle is not running. Thus even when the main switch is off the immobilizer is kept in an alert mode for theft through illegal means.
[0004] When a vehicle is equipped with such an antitheft device, the engine cannot be started without a key with an ID code which matches the ID code previously registered in the controller. Thus, the vehicle cannot be illegally driven by someone other than the owner of the vehicle and is prevented from being stolen.
[0005] However, such an antitheft device are commercially available and the coupler for coupling the device and the on-board battery is a standardized product. Therefore a prospective thief can steal the vehicle by removing the entire antitheft device could be removed and replacing it with another device that matches a key possessed by the prospective thief.
[0006] One conventional preventive measure against such theft of a vehicle is to make it difficult to steal the vehicle by complicating the structure in which an antitheft device is attached to the vehicle, for example, by increasing the number or types of attaching devices or encasing the device, so that it cannot be removed quickly. However these remedies add to the cost of both assembly and servicing and also can be defeated by skilled thieves.
[0007] Therefore it is a principal object of this invention to provide an easily attached, serviced and removed system and method of antitheft protection that nevertheless makes it difficult to remove the device within a short period of time.
[0008] It is a further an object of the invention is to provide antitheft method and device for a vehicle which does not complicate the structure of the attachment but nevertheless prevents theft.
SUMMARY OF THE INVENTION
[0009] A first feature of the invention is adapted to be embodied in an antitheft method for a vehicle equipped with an immobilizer having a controller which transmits an ignition prohibition canceling signal to an ignition control unit of an engine when an ID code of a transponder built in a key matches an ID code previously registered in the controller on the vehicle. The method comprises the steps of maintaining the ignition control unit in an ignition prohibition mode for a predetermined period of time after the immobilizer has been disconnected from a power source and is subsequently connected to a backup power source.
[0010] Another feature of the invention is adapted to be embodied in an antitheft device for a vehicle having an engine comprising an immobilizer having a controller that checks an ID code of a transponder built in a key against an ID code previously registered in the controller. A timer circuit counts the connection time that has elapsed after the immobilizer has been disconnected from a power source and is connected to a backup power source for prohibiting starting of said engine when the connection time is shorter than a predetermined period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic view illustrating the components of an embodiment of the invention.
[0012] FIG. 2 is a block diagram illustrating the embodiment
[0013] FIG. 3 is a circuit diagram of the antitheft device.
[0014] FIG. 4 is a flowchart illustrating the operation of the device and its method.
DETAILED DESCRIPTION
[0015] Referring now to the drawings and initially to FIGS. 1 and 2 these illustrate the configuration of an antitheft device of the present invention. The antitheft device of the present invention is comprised of a vehicle mounted immobilizer 11 connected to an on-board battery 12 with a voltage of 12V, for example, an ignition control unit (ECU) 13 , a key cylinder assembly, indicated generally at 14 , and a cooperating key 15 . The immobilizer 11 has an antenna 16 , generally incorporated in the body of the key cylinder 14 , and a controller, indicated generally at 17 . The antenna 16 and the controller 17 may be integrated with each other.
[0016] A main switch 18 is built in a key cylinder 14 . When the appropriate key 15 is inserted into the key cylinder 14 and operated, the main switch 18 is turned on or off. In addition to its keying, if employed, the key 15 has a built-in transponder 19 in which a unique ID code is recorded.
[0017] The controller 17 is formed on a printed circuit board and has an ID reading circuit 21 , a CPU 22 , a power source circuit 23 , a timer circuit 24 and a memory 25 . The controller 17 is connected to the antenna 16 and the ignition control unit, and has a function of communicating with the transponder 19 built in the key 15 and the ignition control unit 13 of an engine 12 . The ignition control unit may be incorporated in the controller 17 . The battery 12 is connected to the immobilizer 11 via a coupler 26 ( FIG. 3 ) as described later, and supplies backup power with a low voltage (5V, for example) to keep the controller 17 operational regardless of the on or off condition of the main switch 18 .
[0018] When the key 15 is operated and the main switch 18 is turned on, the battery 12 is connected to load components such as lights and an ignition circuit (not shown), and an ID code signal is transmitted from the key 15 to the controller 17 via the antenna 16 of the key cylinder 14 .
[0019] The timer circuit 24 counts the connection time, that is, the amount of time which has elapsed after the last initial connection of the immobilizer 11 to the battery 12 (the amount of time from the point at which the backup power starts to be supplied from the battery 12 by connecting the coupler 26 ). Since backup power is kept supplied to the immobilizer 11 even when the main switch is off, the timer circuit 24 can count the connection time after the immobilizer 11 has been attached.
[0020] The immobilizer 11 is programmed not to read the transponder 19 even if the key 15 is turned to the on position until a predetermined period of time elapses. Each of the immobilizer 11 and the ignition control unit 13 is connected to the on-board battery 12 via a respective coupler 26 as shown in FIG. 3 , and the counting of the connection time is automatically started when the immobilizer 11 is connected to the coupler 26 . Although shown separately in FIG. 3 , the couplers 26 may be contained in a common body. Thus, the connection time cannot be changed illegally from the outside.
[0021] The ignition control unit 13 may be also counted the connection time and controlled not to be activated until a predetermined period of connection time elapses as in the case with the immobilizer 11 .
[0022] The ID code recorded in the transponder 19 of the key 15 is recorded in the memory 25 , and the CPU 22 determines whether the ID code, read by the ID reading circuit 21 when the key 15 is inserted into the key cylinder 14 , matches the ID code recorded in the memory 25 . When the ID codes match with each other, an ignition prohibition canceling signal is transmitted from the CPU 22 to the ignition control unit 13 to activate the ignition control unit 13 , allowing a starter motor 27 and ignition coil 28 of the of an associated engine 29 to start.
[0023] When the ID codes do not match with each other, the ignition control unit 13 is maintained in an ignition prohibition mode and the engine 29 cannot be started. At this time, an alarm or indication lamp indicates the improper operation.
[0024] The implementation procedure of the present invention will be described with reference to FIG. 4 . When the key 15 is inserted into the key cylinder 14 at the step S 1 ) and turned to the on position, the main switch 18 is turned on and the controller 17 detects this at the step S 2 . The controller 17 then determines at the step S 3 whether a predetermined period of time has elapsed after the connection of the immobilizer 11 to the on-board battery 12 via the coupler 26 . If the connection time is determined to be insufficient, jumps to the step S 8 and no further operations are performed and the engine 29 cannot be started.
[0025] If, however, the predetermined period of time has elapsed, the program moves to the step S 4 where an ID code check is performed. Radio waves are transmitted from the battery 12 to the key 15 via the antenna 16 to supply electric power to the transponder 19 to perform the ID code check. When a predetermined amount of electric power is charged in the transponder 19 , the unique ID code of the transponder 19 is transmitted to the controller 17 via the antenna 16 . The controller 17 reads the ID code with the ID reading circuit 21 and transmits it to the CPU 22 , where the read ID code is compared with the ID code registered in the memory 25 to determine whether they match with each other, that is, whether the key is the correct key for the controller 17 at the step S 5 .
[0026] If the key 14 is determined to be the correct key, a canceling signal for canceling the start prohibition mode of the engine 29 and permitting the engine 29 to start is transmitted to the ignition control unit at the step S 6 . Then at the step S 7 the ignition control unit starts the engine 29 .
[0027] On the other hand the code is different from the previously registered ID code, the key is determined to be an incorrect key and the engine 29 is maintained in the start prohibition mode by jumping to the step S 8 . Then, the operation is completed.
[0028] Alternatively, the step S 3 may be programmed to be performed after the step S 5 . That is, the determination of the connection time of the backup power source may be conducted after the ID check.
[0029] As described above, the vehicle cannot be illegally driven by someone other than the owner of the vehicle having the correct key 15 . Even if the immobilizer 11 mounted on the vehicle is illegally removed and replaced with a new one, the vehicle cannot be driven within a short period of time due to the necessity of the time set at step S 3 is reached. Thus, it is very difficult to steal the vehicle during temporary parking.
[0030] When the key 15 is turned to the off position to turn off the main switch and then removed from the key cylinder 14 after the vehicle has been stopped, the engine 29 is stopped but backup power is kept supplied to the controller 17 .
[0031] Thus from the foregoing description it should be readily apparent that the described constructions and methods a very effective and difficult to defeat vehicle antitheft protection is provided without interfering with the simplicity of instillation and servicing as well as reducing the cost thereof. Of course those skilled in the art will readily understand that the described embodiments are only exemplary of forms that the invention may take and that various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims. | Simple but very effective vehicle antitheft methods and apparatus that avoid theft by replacement of the antitheft device by determining the time it has been before the device is powered up and prohibiting starting if it is not long enough. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 11/550,113, filed Oct. 17, 2006, which is a continuation-in-part of U.S. patent application Ser. No. 11/339,147, filed Jan. 24, 2006, which is a continuation-in-part of U.S. patent application Ser. No. 11/231,996, filed Sep. 21, 2005, the contents of which are herein incorporated by reference in their entirety.
FIELD OF INVENTION
[0002] This invention relates to a trowel assembly for distributing spreadable material onto virtually any work surface at various depths and/or different groove patterns by adjusting two overlapping plates of the assembly relative to each other by use of a slide lock.
BACKGROUND OF THE INVENTION
[0003] Hand trowels are commonly used in the building and do-it-yourself industry to distribute spreadable material (e.g., adhesives, plaster, grout, fillers or the like) along a work surface (wooden or cement subfloors, walls, etc.) A typical trowel is of a single, rectangular plate-like configuration having at least one notched edge in the form of a square or saw-tooth configuration. Often these trowels include only one notched side edge sized and selected for their particular thickness of spread. Recently, however, trowels have been manufactured to include two different sides with different sized notching. Notches having a larger distance between them create a thicker layer of material, and those having a smaller distance between the notches spread thinner layers of material.
[0004] For example, a person using a conventional trowel for applying tile, brick, block or the like, uses it to scoop out the necessary amount of adhesive material onto the work surface. The user then holds the trowel such that the notched side edge of the trowel makes adequate contact with the adhesive and pulls the notched edge along the adhesive to create the grooves (or ridges) in the adhesive. The notch's size and shape determines the depth of the resulting ridges and should be appropriate to the type and size of the tile being installed. Generally, for tiles of less than 10 in., one would use notches with dimensions of ¼×¼ in.; for tiles between 10 and 14 in., use ⅜ in.×¼ in. trowel; and for tiles larger than 14 in. use a ½×½ in. trowel. Previously, should a tiler need to adjust the depth or shape of the resulting grooves in the adhesive, the user would need to employ a second trowel having the desired notch characteristics (e.g., depth or shape). The user is unable to adjust the trowel notch configuration to vary the resulting depth of the grooves in the spreadable material.
[0005] When trying to apply the spreadable material into internal corner joints defined by two planar surfaces meeting at a fixed angle, the user has been limited to pre-manufactured right-handed or left-handed trowels having two adjacent notched edges. Because of the difficulty of positioning two adjacent notched edges in corresponding internal corners, the worker will often have to employ two separate trowels, (i.e., a left-handed trowel and right-handed trowel) each of which are notched at oppositely, adjacent edges to access the corresponding internal corners of the structure.
[0006] It has been proposed to provide trowel assemblies comprising two removable and interchangeable plate-like members, one plate having at least one threaded post and the other plate having at least one corresponding slot for slidably receiving the post, wherein the two plates are held stationary relative to each other at the desired position using a wing-nut that engages the threaded post. However, unlike the instant invention which utilizes quick release cam clamps that engage threaded or non-threaded posts, the wing-nut type attachments of the prior art are time consuming to attach, and the threads often become fouled with the material being applied. Thereby, making the wing-nut difficult to rotate about the threads. In addition, during the cleaning process the plate-like members of the assembly must be completely disassembled which can lead to the trowel assembly components (e.g., wing nuts, plates) becoming lost or misplaced.
[0007] The instant invention allows the user to modify the notch configuration such that the depth of material being applied can be varied over a wide range until the desired depth is attained. The user is able to employ either the notches formed on the first or second plate-like members alone or in overlapping combination to obtain different groove configurations. The present trowel assembly also allows the user to readily expose the appropriate notched edges of adjacent sides of the trowel assembly to provide a right- or left-handed configuration using a single trowel. In addition, the plates and the quick release cam clamp of the assembly remain connected yet separable so as to allow for easy cleaning therebetween without the possibility of one of the plate-like members becoming lost or misplaced.
DESCRIPTION OF THE PRIOR ART
[0008] Currently there are a few patents directed toward trowel assemblies that are capable of adjusting the depth of the spreadable material as well as the shapes of the resulting grooves created in the spreadable material by the edge of the trowel. For example, U.S. Pat. No. 5,231,729 to Rose discloses a tilers trowel having at least one edge which is notched, wherein an adjustment means is provided for limiting the depth of material which can be applied by adjusting the size of the notching by sliding two plate-like members relative to one another. Adjustment occurs by way of loosely held posts which pass through holes in the lower plate and move along slots in the upper plate, covering the plates to move relative to one another. However, unlike the instant invention which utilizes an integrate and attached quick release cam clamps designed to engage threaded or non-threaded posts, the wing-nut/post type attachment of the aforementioned patent is time consuming to attach and remove, and often becomes occluded with the material being applied making them difficult to rotate about the threads. Moreover, the movement of the two plates is limited to predetermined directions defined by the slots, thereby limiting the user to strictly right- or left-handed operation of the trowel assembly. The multi-directional slot configuration and enlarged cutouts in the plate-like members of the present invention allow the user to move the plates between left- and right-handed operations as desired. This is especially advantageous when the user needs to access internal corner joints defined by two planar surfaces.
[0009] GB 2,259,938 to Phillips, is drawn to a trowel assembly comprising a base having edges with notches therein and an un-notched obturator which resides atop the base and movable relative thereto to vary the effective size of the notches. The base has upstanding studs which mate with guiding slots formed in the obturator. However, like the aforementioned patent, the obturator is attached to base by a wing-nut type attachment. Additionally, the invention to Phillips differs from a particularly preferred embodiment of the present invention whereby the handle is slidably attached to the upstanding fastening means of the second plate-like member. Thus, the trowel assembly can be cleaned without having to be completely dissembled so that the component parts are not lost or misplaced.
[0010] U.S. Pat. No. 2,167,996 to Pritz discloses a trowel onto a top face is attached a pair of comb-like plate members comprising spaced apart fingers or teeth. The fingers or teeth are spaced apart in accordance with the spacing between the openings in the fold at the longitudinal edges of the blade so as to register with and pass or extend through the openings. By loosening the nuts the members can be shifted inwardly or outwardly beyond the edges of the blade. This length and angular position in which the user holds the trowel determines the depth of the ridges of material formed.
[0011] U.S. Pat. No. 3,916,472 to Carder discloses a trowel for spreading adhesives for floor and/or wall coverings. It comprises a handle having a base section, and an integral handgrip. A rhomboidally shaped spreading blade is releasably and reversibly attached to the bottom of the base section, and has serrated edges for spreading adhesive in striated form on a surface. A plurality of spaced slots in the blade is insertable over the heads of a plurality of screws that project from the bottom of the base section. Two of the screws latch the blade in place in either of two different operating positions, when the blade is shifted laterally relative to the handle. A third one of the screws is threadable into a bore in the base section releasably to secure the blade against movement on the handle when the blade is latched in either operating position.
[0012] U.S. Pat. No. 6,178,586 to Jafarmadar discloses a hand-held trowel that includes first and second adjoining edges that have a plurality of notches disposed therein that is used to provide grooves in cementious material, the trowel used for spreading cementious material and the trowel including a third edge extending away from the trowel body having sufficient rigidity and strength for prying up a ceramic tile for use as a margin trowel. The trowel also includes a handle for grasping by hand that is rigidly attached to the trowel body which may include a level indicating device to tell with an air bubble and liquid whether or not the fourth edge of the trowel, which is straight when placed on the surface of a tile, is level relative to the gravitational field of the earth.
[0013] While the foregoing described prior art trowels may have advanced the art in a variety of ways, there nevertheless remains a need for an adjustable, left- and right-handed trowel capable of applying a spreadable material at a predetermined thickness in a predetermined pattern while remaining capable of being readily separated for thorough cleaning by the user after application of the spreadable material without fear of losing one of its component parts.
[0014] All patents and publications are herein incorporated by reference in their entirety to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
SUMMARY OF THE INVENTION
[0015] Consequently, in response to the aforementioned problems found in the prior art, it is an objective of the instant invention to provide an adjustable, equipoise (i.e., left-handed or right-handed) trowel assembly capable of distributing a spreadable material onto a work surface at various depths and/or with different groove patterns. According to one embodiment, the trowel assembly may be readily separated, yet not completely dissembled, for easy cleaning.
[0016] The adjustable trowel assembly of the instant invention includes an upper, first plate-like member having an upper surface with at least one multi-directional slot or enlarged cut-out portion therein, a bottom surface, and a pair of spaced apart side edges, wherein at least two of the adjacent side edges include a plurality of notches. According to a preferred embodiment, the cut-out portion has a substantially rectangular or square shape.
[0017] The assembly includes a lower, second plate-like member of approximately the same dimension as the first plate-like member. The second plate-like member having an upper surface with at least one fastening means (post, stud, pin, etc.) integrally connected thereto and projecting upward therefrom at a location which corresponds to the multi-directional slot or enlarged cutout portion in the first plate-like member. The second plate-like member further includes a bottom surface, and a pair of spaced apart side edges wherein at least two of the adjacent side edges include a plurality of notches.
[0018] The trowel assembly includes a handle. According to one embodiment, the handle is integrally connected to the upper surface of the first plate-like member. More preferably, the handle is slidably attached to the fastening means of the second plate-like member, so that the plates may be separated after use for easy cleaning yet remain connected so that no part of the assembly is lost. The handle may also include at least one level indicating means integrally connected thereto such that the user may place any of the side edges or bottom surface of the second plate-like member of the assembled trowel assembly against a work surface to determine whether the surface is, in fact, level and/or plumb with respect to the earth. This is especially advantageous when using the trowel assembly of the instant invention to install tile onto a work surface, such that, once the tile are in place the trowel itself can be placed against the installed tile to ensure it is level and/or plumb without having to employ a separate level.
[0019] The trowel assembly includes a plurality of simple, quick release cam clamps which correspond with the plurality of fastening means integrally attached to the second plate-like member, such that the first plate-like member may be adjusted relative to the second plate-like member along parallel planes to provide the desired amount of overlap between corresponding notched side edges of the first and second plate-like members. This provides the user with a means to easily and quickly disassemble the trowel, which may prove advantageous when working with fast-setting (or curing) spreadable material, so that the two plate-like members do not become permanently adhered together.
[0020] It is another objective of the present invention to teach at least one multi-directional slot formed in the first plate-like member for providing a trowel assembly for left- or right-handed use; this is particularly advantageous for positioning adjacent notched edges of the trowel in various corresponding corner joints, wherein two planar surfaces meet at a particular angle.
[0021] It is a further objective of the instant invention to provide a trowel assembly wherein the first and second plate-like members each comprise notches of a disparate size along their respective edges whereby the user can chose the appropriate notch size available on one of the two plates, or create a unique notch size by overlapping the two plates.
[0022] It is yet another objective of the current invention to provide a trowel assembly wherein the first and second plate-like members each comprise different shaped notches available on either of the two plates or create a unique notch shape by overlapping the two plates.
[0023] Another objective of the instant invention is to provide a trowel assembly that is capable of being utilized to apply plasters, cementations materials, grouts or the like.
[0024] Another objective of the present invention is to disclose an aesthetically appealing trowel assembly that more closely resembles commercially available single plate trowels.
[0025] It is still a further objective of the invention to provide a trowel assembly wherein the handle includes the use of a slide lock for engaging the two plates in a juxtaposition.
[0026] Yet another objective of the instant invention is to provide a trowel assembly wherein the bottom surface of the second plate-like member is a smooth surface in order that this surface may be used to smooth out the spreadable material, which can be particularly advantageous when using the instant assembly for plastering.
[0027] An additional objective of the present invention is to provide a trowel assembly that is economical to manufacture in that it has few components or complicated moving parts.
[0028] Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0029] FIG. 1 is an upper perspective, exploded view of a trowel assembly according to one embodiment of the invention;
[0030] FIG. 2 a is a side view of the trowel assembly of FIG. 1 , wherein the cam clamp is in an “open” position, such that the first and second plate-like members are not affixed relative to each other;
[0031] FIG. 2 a is the same side view of the trowel assembly shown in FIG. 2 a , wherein the cam clamp is in a “closed” position, such that the first and second plate-like members are affixed relative to each other;
[0032] FIG. 3 is an upper perspective view of the trowel assembly of FIG. 1 , illustrating an exploded view of the cam clamp used to affix the two plate-like members of the trowel assembly;
[0033] FIG. 4 is top view of the assembled trowel of FIG. 1 , wherein the first plate is attached to the second plate by the cam clamp positioned at the furthermost end of the diagonal slot such that the adjacent side edges of first plate-like member extend over the second plate-like member;
[0034] FIG. 5 is another top view of the assembled trowel of FIG. 1 , wherein the first plate-like member is attached to the second plate-like member by the cam clamp such that the adjacent side edges of each plate overlap;
[0035] FIG. 6 is top view of the assembled trowel of FIG. 1 , wherein the first plate is attached to the second plate by the cam clamp positioned at the furthermost end of the diagonal slot such the adjacent side edges of second plate-like member extend over the first plate-like member;
[0036] FIG. 7 is an upper perspective, exploded view of a trowel assembly according to a second embodiment of the present invention;
[0037] FIG. 8 is a top view of the second embodiment of the present invention illustrated in FIG. 7 , wherein the cam clamps are located at the one end of the substantially horizontal cutout member of the multi-directional slot;
[0038] FIG. 9 is a top view of the second embodiment of the present invention, the cam clamps are affixed at the side directly opposite the horizontal cutout member illustrated in FIG. 8 for left- or right-handed use;
[0039] FIG. 10 illustrates a top view of the second embodiment, wherein the cam clamps are located at one end of the cutout portion 30 c , wherein the entirety of notches on two adjacent edges on the first plate-like member are exposed for distributing an adhesive bed for right-handed applications;
[0040] FIG. 11 illustrates a top view of the second embodiment, wherein the cam clamps are located at the one end of the cutout portion 30 b , wherein the entirety of notches on two adjacent edges on the second plate-like member are exposed for distributing an adhesive bed for left-handed applications;
[0041] FIG. 12 is a top view of the first plate-like member in accordance with a third embodiment showing the two enlarged substantially rectangular cut-out portions 30 d;
[0042] FIG. 13 a is a top view of the second plate-like member in accordance with the third embodiment showing the two fastening means which correspond and are received in the cutout portions 30 d shown in FIG. 12 ;
[0043] FIG. 13 b is a side view of the second plate-like member shown in FIG. 13 a;
[0044] FIG. 14 a is a side view of the trowel handle shown disconnected from the plate-like members;
[0045] FIG. 14 b is a front side view of the handle depicted in FIG. 14 a;
[0046] FIG. 15 is a side view of the trowel assembly of the third embodiment, wherein the cam clamp is in an open position, such that the first and second plate-like members are not affixed relative to each other;
[0047] FIG. 16 is the same side view of the trowel assembly shown in FIG. 15 , wherein the cam clamp is in a closed position, such that the first and second plate-like members are affixed relative to each other;
[0048] FIG. 17 is top view of the assembled trowel of the third embodiment, wherein the first plate is attached to the second plate by the cam clamps;
[0049] FIG. 18 is an upper perspective view of an alternate embodiment of the trowel assembly having two level indicating means in the handle;
[0050] FIG. 19 is a perspective view of an alternate embodiment of the trowel assembly having a slide lock;
[0051] FIG. 20 is a cross-sectional view of the trowel having a slide lock;
[0052] FIG. 21 is a enlarged cross-sectional view of the slide lock in an un-locked position; and
[0053] FIG. 22 is a top view of the slide lock.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] Detailed embodiments of the instant invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0055] Referring now to FIGS. 1-6 , wherein like elements are numbered consistently throughout, FIG. 1 shows an exploded, upper perspective view of one embodiment of the instant trowel assembly, generally referenced as 10 . The trowel assembly shown herein is capable of applying an even distribution of spreadable material onto virtually any work surface (e.g., wall, floor, etc).
[0056] The trowel assembly comprises an upper, first plate-like member 12 comprising an upper surface 34 and a bottom surface 36 with a handle 14 integrally connected to the upper surface 34 by any means of attaching known in the art, for example, welding, adhesives, rivets, etc. As shown herein, the first plate-like member 12 includes two adjacent edges 18 , 20 having substantially rectangular notches 22 formed therein, useful for installing larger tiles. The first plate-like member also includes oppositely adjacent edges 19 , 21 , shown here without any notches.
[0057] The assembly 10 further includes a second, lower plate-like member 16 . The second plate-like member 16 includes an upper surface 38 and a bottom surface 40 . As with the first plate-like member, the two adjacent edges 24 , 26 of second plate-like member 16 , shown here provided with smaller serrated notches 28 suitable to spread the material in a striated form often used when installing smaller tiles, however, other shapes (v-shaped, scalloped, etc.,) could be used without departing from the scope of the instant invention. Again, the second plate-like member includes oppositely adjacent edges 23 , 25 , shown here without any notches formed therein.
[0058] Referring again to FIG. 1 , the first plate-like member 12 is provided with at least one diagonal elongated slot 30 formed therein, shown here as two parallel slots. The second plate-like member 16 has a corresponding number and size of fasteners 32 , such as posts, pins, bolts, studs, or the like, known to those skilled in the art. The fasteners 32 are integrally attached to the upper surface 38 of the second plate-like member by any means of attaching known to the skilled artisan, e.g., welding, rivets, adhesives, or the like, in order that the bottom surface 40 of the plate-like member has a smooth surface, useful for creating an even and smooth surface on the spreadable material if preferred.
[0059] Upon assembly, the user places the first plate-like member 12 above the second plate-like member 16 such that the slots 30 in the first plate-like member are aligned with the threaded fasteners 32 on the second plate-like member. The user places the fasteners through the slots 30 in the first plate-like member. Next, the user places the two cam clamps 42 over each of the fasteners 32 , as shown in FIG. 2 a , shown in the “open” position. When shaft of the fastener is translated along the slot to the desired position within the slot, the user pivots the lever portion 50 of the cam clamp along its horizontal axis to the “closed” position, as shown in FIG. 2 b.
[0060] One such cam clamp 42 (like those sold by Rockler®, Minnesota) is shown in detail at FIG. 3 . This cam clamp includes a cross dowel 44 sized for receipt within the cam portion of the clamp. The dowel 44 includes a threaded aperture 52 , along the vertical axis of the dowel, adapted to engage the threaded surface of the fastener 32 , which is integrally attached to the upper surface 38 of the second plate-like member 16 . Attachment of the cam clamp is created by the force of the gradual curved surface or throw 48 against the upper surface 34 of the first plate-like member 12 onto the fastener 32 , upon pivoting the lever portion 50 toward the closed position, thereby affixing the first and second plates relative to each other.
[0061] In an alternative embodiment, a washer (not shown) can be placed juxtaposed to the throw 48 and the 34 upper surface of the first plate-like member to protect the upper surface 34 from becoming worn upon repeated actuation of the lever. The cam clamp of the instant invention is an improvement over conventional types of means of attachment, including wing nuts, which are time consuming to assemble and often become occluded with the material being applied making them difficult to rotate about the screw.
[0062] As illustrated in FIGS. 4-6 , the depth of notches 22 , 28 revealed by the plate-like members 12 and 16 , respectively, can be adjusted by sliding the plates relative to one another as the shaft of the attached fasteners 32 are able to travel along the slots 30 , which are formed at about 45 degrees relative to the edge 19 . Once the desired depth (or shape) of notch is reached, each of the levers of the cam clamps 42 are pivoted to the closed position lock the plates relative to each other.
[0063] FIG. 4 shows an extreme position of the cam clamps 42 located at the one end of the slots 30 . In this configuration, the plates are set to show the entirety of notches 22 on the adjacent edges 18 , 20 which is suitable for applying a thick adhesive bed.
[0064] FIG. 5 shows one of the numerous intermediate positions wherein the cam clamps 42 are affixed in an approximately the middle of the slots 30 so that notches 22 , 28 on the first and second plate 18 , 20 overlap, to provide a shallower depth of spreadable material and/or change the shape of the resulting grooves.
[0065] FIG. 6 shows another extreme position opposite that observed in FIG. 4 , wherein the cam clamps 42 are located at the one end of the slots 30 . The plates are set to show the entirety of notches 28 on adjacent edges 18 , 20 suitable for distributing a thin adhesive bed.
[0066] Referring now to an alternate embodiment illustrated in FIGS. 7-11 , FIG. 7 shows an exploded upper perspective view of a second embodiment of the instant trowel assembly. As with the previous embodiment, this trowel assembly is capable of applying an even distribution of spreadable material onto a work surface. Moreover, this embodiment allows the worker to readily adjust the trowel between left- and right-handed configurations to access corresponding internal corners of the structure.
[0067] In the present embodiment of the trowel assembly, the first plate-like member 12 includes at least two ( FIGS. 1-6 ) or three ( FIGS. 7-11 ) adjacent edges 18 , 20 , 21 , each having substantially rectangular notches 22 formed thereon. Moreover, the first plate-like member includes at least one multi-directional slot 30 ′ formed therein. Although FIG. 7 is depicted as having two multi-directional slots, it is within the purview of the instant invention to provide a single multi-directional slot.
[0068] The multi-directional slot 30 ′ comprises a plurality of interconnected cutout portions ( 30 a , 30 b , 30 c ). As shown herein, the first cutout portion 30 a is substantially parallel to the edge 19 of the first plate-like member. The second cutout portion 30 b is formed at a predetermined angle α with respect to the axis 35 of the first cutout 30 a , for example, shown here as approximately 45 degrees. The third cutout portion 30 c is formed at another predetermined acute angle β relative to the axis 35 of the first cutout 30 a (shown here as substantially equal to angle α).
[0069] As with the first embodiment, the second embodiment of the trowel assembly 10 includes a second plate-like member 16 having an upper surface 38 , a bottom surface 40 and two or three adjacent edges 24 , 25 , 26 with smaller serrated notches 28 formed thereon useful for installing smaller tiles. Again, the edge 23 of the second plate-like member is shown here without any notches formed therein, however, it is contemplated that this edge may also include notches without departing from the scope of the invention.
[0070] The second plate-like member 16 also includes at least one threaded fastener 32 (posts, studs, pins, bolts, etc.), constructed and arranged for receipt within the multi-directional slot 30 ′ of the first plate-like member. The threaded fasteners are integrally connected to the upper surface 38 of the second plate-like member by any means of attaching known to the skilled artisan.
[0071] As with the first embodiment, the depth of notches 22 , 28 revealed by the plate-like members 12 , 16 , respectively, can be adjusted by sliding the plates relative to one another as the shaft of the attached fasteners 32 are able to travel along the interconnected cutout portions ( 30 a , 30 b , 30 c ) of the multi-directional slot 30 ′. Once the notched side appropriate for left- or right-hand application is exposed, each of the levers of the cam clamps 42 is pivoted to the closed position to lock the plates relative to each other, as illustrated in FIGS. 8-11 .
[0072] FIG. 8 illustrates a top view of the second embodiment, wherein the cam clamps 42 are located at one end of the substantially horizontal cutout member 30 a . In this configuration, the plates expose the entirety of notches 22 on edge 20 for applying a thick adhesive bed. Notches 28 on opposite edge 16 are also exposed for applying a thin adhesive bed. In addition, notches 22 , 28 on edge 18 are overlapped for creating the desired patterns in the adhesive.
[0073] FIG. 9 illustrates a top view of the second embodiment, wherein the cam clamps 42 are affixed at the opposite side of the horizontal cutout member 30 a exposing notches 22 , 28 opposite that of the assembly shown in FIG. 8 for left- or right-handed use.
[0074] FIG. 10 illustrates a top view of the second embodiment, wherein the cam clamps 42 are located at one end of cutout portion 30 c . In this configuration, the plates show the entirety of notches 22 on adjacent edges 18 , 20 , which is particularly suitable for distributing a thick adhesive bed during right-handed use.
[0075] FIG. 11 illustrates another top view of the second embodiment, wherein the cam clamps 42 are disposed within slots 30 b . The plates are set to show the entirety of notches 22 on adjacent edges 16 , 18 suitable for distributing a thick bed of adhesive during left-handed use.
[0076] Referring now to a third embodiment of the present invention, illustrated in FIG. 12-17 , FIGS. 12 shows the first plate-like member provided with at least one enlarged and substantially rectangular cut-out 30 d (two cutouts shown). Unlike the slot configurations described above, which limit the adjustment of the two plate-like members along predetermined slots, these enlarged cutouts allow for a nearly infinite adjustment and notch overlap between the first and second plates. Although the cutouts are depicted here as substantially rectangular, any other shape could be used without departing from the scope of the invention, e.g., circular, oval, rhomboidal or square configuration.
[0077] As with the previous embodiments, the trowel assembly is capable of applying an even distribution of spreadable material onto a work surface. The second plate-like member 16 has number of fastening means 32 a (e.g., posts, studs, pins, bolts or the like) extending upward therefrom. The number and location of the fastening means correspond to the enlarged cutouts. The fastening means may be threaded like those depicted in FIGS. 1-11 , or non-threaded like those illustrated in FIG. 13 b . The fasteners 32 a are integrally attached to the upper surface of the second plate by any means of attaching known to the skilled artisan. Each of the fastening means in this embodiment includes a slot 70 formed therethrough, along their longitudinal axis. The slot is constructed and arranged to slidingly receive a pin, post, or the like therein, as discussed further below.
[0078] In this particular embodiment, the trowel assembly also includes a modified handle 14 a (see FIGS. 14 a and 14 b ). Unlike the aforementioned embodiments described above, this handle is not integrally connected to the first plate-like member; rather, the handle is slidingly attached to the fastening means 32 a (see FIGS. 15 and 16 ). The handle includes a first aperture 80 and a second aperture 82 , both extend therethrough (see FIG. 14 b ). In addition, the handle includes a slot 78 that divaricates each of the legs 84 of the handle. The slot is constructed and arranged to pivotally receive a cam clamp 42 a therein. As shown in FIG. 14 a , the slot is formed with at a particular angle 92 relative to the handle base 90 . The slot angle should allow the cam clamp 42 a able to fully pivot when attached to the handle. The cam clamp includes an aperture 74 ( FIG. 17 ) within the cam portion of clamp, the aperture is constructed and arranged to receive a pivotal attachment means 76 , e.g., a bolt, pin, screw, or the like therethrough, to pivotally attach the clamp to the handle.
[0079] Upon assembly, the cam clamp is placed inside the slot 78 formed inside the handle. The pivotal attachment means 76 is then guided through both the handle aperture 82 and cam clamp aperture 74 , thereby pivotally attaching the cam clamp to the handle. In a similar manner, the fastening means 32 a is slidingly attached to the handle 14 a as well. That is, the fastener attachment means 72 (pin, screw, bolt, etc) is guided through both the aperture 80 in the handle and the slot 70 formed in the fastener 32 a . The fastener attachment means 72 should be sized so that it easily slides within slot 70 of the fastener.
[0080] According to a preferred embodiment, pivotal attachment means and fastener attachment means both include a tool opening 86 , 88 respectively, which remains accessible after assembly the trowel so that it may be completely dissembled periodically for more thorough cleaning if needed. Alternatively, the pivotal attachment means and fastener attachment means may be permanently installed by the manufacturer so the user cannot dissemble it. The fastener attachment 72 prevents the first and second plates of the assembly from becoming completely separated when the cam clamp is opened (see FIG. 15 ), thereby reducing the possibility of the trowel components getting lost during normal use. In like manner, the pivotal attachment means keeps the cam clamp attached to the handle so that it does not get lost during cleaning.
[0081] Upon assembly, the first plate-like member 12 is positioned above the second plate-like member 16 such that the fasteners 32 a on the second plate-like member extend through the cutouts 30 d (see FIGS. 15 and 16 ). With the cam clamps in the “open” position shown in FIG. 15 , the plates are easily maneuvered along parallel planes within the enlarged cutouts 30 d until the desired amount of notch overlap is achieved (see for example, FIG. 17 ). Then, the user presses the two plates together so that the fastener attachment means 72 slides to the lower portion of the fastener slot 70 and pivots the lever portion 50 of the cam clamp about the axis defined by the cam attachment means 76 until the gradual curved surface of cam throw frictionally engages the fastener in a “closed” position as shown in FIG. 16 . Thus, the handle base 90 pressed flush against the top surface of the first plate-like member 12 , and the first plate-like member is tightly sandwiched between the handle and the second plate-like member 16 . After use, the cam clamps are rotated into the “open” position shown in FIG. 15 , and the fastener attachment means 72 slides to the upper portion of the fastener slot 70 . The plates are then easily separated by lifting the first plate-like member so that any spreadable material that may have gotten in between the two plate-like members is readily cleaned.
[0082] The third embodiment depicted in FIGS. 12-17 , is particularly advantageous as the handle substantially encloses the cam clamp and the fastening means, thereby protecting the user from the moving parts of the cam clamp. Moreover, the substantially hidden cam clamps are aesthetically more appealing in that they closely resemble currently commercially available trowels comprising a single plate.
[0083] Although in all of the aforementioned embodiments the plate-like members 12 , 16 are depicted as rectangular, the shape of the plate-like members is not limited thereto. Other possible shapes include, albeit not limited to, rhomboidal, square or the like. Additionally, either or both of the plate-like members can be constructed from any durable material including, albeit not limited to, an elastomeric material, polymeric material, wood, metal, or combination thereof. Similarly, the handle 14 of any of the aforementioned embodiments can be constructed from any durable material known to those skilled in the art, including wood, metal, elastomeric, polymeric materials or combinations thereof. The handle can also include ergonomic gripping indentions formed therein to provide comfortable handling, as is well known in the art.
[0084] Referring now to FIG. 18 , any of the aforementioned embodiments of the trowel assembly may include a first level indicating means 54 integrally attached to the upper surface along the longitudinal axis of the handle, or attached to the upper surface 34 of the first plate-like member (not shown). The level indicating means includes a gas bubble 56 suspended in a fluid encapsulated within a housing, as is well known in the art. The housing has indicia 58 on each side calibrated to indicate when one of the sides of the trowel assembly, preferably a side without notches, is placed flush against a horizontal work surface and the bubble becomes centered between the indicia, then the trowel is level (i.e., substantially horizontal with respect to the earth).
[0085] In addition, the trowel assembly can also include a second level indicator 60 substantially identical to the first but located along a different plane (i.e., perpendicular) than the first level indicator 54 . The second level indicator 60 will indicate whether the trowel assembly is plumb (i.e., substantially perpendicular with respect to the earth). The user places the bottom surface 40 of the second plate-like member against a vertical work surface to determine whether the bubble 62 falls between the two indicia 64 .
[0086] Although in the aforementioned examples the first plate-like member possesses larger notched edges and the second plate-like member has serrated edges, it will be understood to those of ordinary skill that the second plate-like member could comprise larger notched edges and the first plate-like member could include serrated (or other shaped) edges. Moreover, it is contemplated herein that the adjacent edges 18 , 20 , 21 of the first plate could include different sized and/or shaped notches, respectively. Similarly, the adjacent edges 24 , 25 , 26 of second plate 16 could also include different sized and/or shaped notches than that those of the first plate.
[0087] In yet another embodiment, not shown, at least one cam clamp could include integrally connected spreader arms formed perpendicular to the vertical axis of the clamp, which upon actuation of the arm reciprocally engage two corresponding fasteners integrally attached to the upper surface of the second plate-like member to fasten the first and second plates relative to each other.
[0088] Referring now to FIGS. 19-22 , set forth is yet another embodiment wherein the locking mechanism is a slide lock 88 . The slide lock 88 is used to secure the upper plate 90 having large spaced apart notches 92 in a fixed position to the lower plate 94 having small angular shaped notches 96 . As detailed in the earlier embodiments, notches can be overlapped for creating the desired patterns in application.
[0089] The handle includes a slot 102 for receipt of the slide lock 88 . The slide lock engages a fastening means such as a bolt like shape having a stem portion 106 coupled to a lower plate 94 which is sized to pass through a slot 108 of the slide lock and a head portion 110 sized to engage an upper surface 112 of the slide lock. The slot 108 is continuous having first end 114 sized to allow the head portion 110 to pass there through and a second end 116 sized to engage a lower surface 118 of said head portion.
[0090] As illustrated, the stem portion 106 may be threaded allowing use of commonly made bolts for lower cost production but further allowing adjustment of the lower surface of the head portion 110 to the upper surface of the slide lock 112 to secure the upper and lower plates in a fixed juxtaposition. A tang 120 on the end of the slide lock permits ease of insertion for purposes of locking the plates as well as removal from the insertion position to allow for plate relocation and/or cleaning. The slot 102 in the handle providing an alignment guide for the slide lock to maintain directional insertion and prohibit movement when the plates are in a fixed position. An opening 122 is provided over the head of the fastener allowing visual inspection, ease of cleaning, and access for adjustment.
[0091] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
[0092] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments described herein are representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims.
[0093] It should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention, which are obvious to those skilled in the art, are intended to be within the scope of the following claims. | An adjustable trowel assembly capable of distributing spreadable material along the work surface at various depths and/or different groove patterns formed in the material by simply adjusting the two overlapping sliding plates of the assembly relative to each other. The trowel employs a slide lock that allows securement of the handle to the plates when in a closed position and release of the plates for positioning and/or cleaning while in an unlocked position. |
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CROSS-REFERENCE TO PRIOR APPLICATION
[0001] Priority is claimed from U.S. provisional patent application Ser. No. 60/867,433, filed Nov. 28, 2006, the disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to shelter systems for use in emergency situations, providing temporary shelter for persons who are trapped in a hostile environment.
[0003] More specifically, the invention relates to systems and devices for providing breathable air for shelters used to protect humans from unsafe atmospheres, such as those which are deficient in oxygen, or which contain unsafe levels of carbon monoxide, methane, or other toxic chemicals, including toxic industrial chemicals or chemical, biological, or radiological warfare agents.
[0004] Typical events which could cause the local atmosphere to become unsafe for human respiration include mine or tunnel emergencies, fires, terrorist activity, acts of war, chemical spills or other industrial accidents, and accidents at nuclear power plants. These events could take place in a mine, a tunnel, or a building. They could also occur outside, where such events could produce an atmospheric plume which is unsafe for breathing.
[0005] Political and criminal events in the early twenty-first century have highlighted, to an unprecedented level, the threat of a terrorist attack by “weapons of mass destruction”, such as chemical, biological, or radiological agents, or toxic industrial chemicals. Mine emergencies, in which the atmosphere inside the mine becomes unsafe for human respiration, have taken the lives of numerous miners throughout the history of underground mining. Fires in high-rise buildings, both commercial and residential, have caused the atmosphere above the level of the fire to become unsafe for human respiration. The result has been loss of life due to asphyxiation from toxic chemicals or inhalation of smoke.
[0006] For the above reasons, systems for protection of persons from the above-described events have become highly desirable.
[0007] An example of an emergency shelter for use in a hostile environment is shown in international patent publication No. WO 2005/086613, the disclosure of which is incorporated by reference herein. The above-cited document describes a collapsible shelter which can be quickly configured to provide a breathable atmosphere in which persons trapped in an emergency situation can survive.
[0008] The present invention provides a further improvement over the emergency shelters of the prior art.
SUMMARY OF THE INVENTION
[0009] The present invention includes a storage container, intended to be kept indefinitely at or near a site of a potential emergency, such as in a mine or tunnel or other installation. The storage container includes all of the materials necessary for quickly erecting a shelter for protecting personnel from a hostile environment, such as would be experienced in a mine explosion, a fire, a terrorist attack, or in other emergency situations. The shelter and container are completely sealed against intrusion of harmful gases, and preferably contain enough breathable air to keep the shelter under positive pressure during a designated rescue period, such as up to 96 hours.
[0010] The storage container used in the present invention includes a flexible, inflatable shelter, intended to be inflated by a compressed gas stored or produced within the container. The container also houses a source of gas which can be directed into the inflated shelter to provide a breathable atmosphere.
[0011] The storage container also includes an air lock door, preferably located on a side of the container which is distinct from the side from which the flexible and inflatable shelter emerges. Personnel using the shelter pass through the air lock door, the air lock door being closed off from the outside before the personnel proceed into the inflated shelter. In this way, toxic gas from the outside is prevented from entering the shelter while the personnel are entering.
[0012] The storage container preferably also includes sufficient supplies to sustain life for personnel within the shelter, for a period of at least several days. The container may include other supplies, such as communications equipment, for contacting rescuers located, for example, at the surface of a mine, or otherwise outside the shelter.
[0013] The air lock door may comprise a flexible door which can be made to extend outward from the storage container, and through which personnel can enter the container on their way into the inflated shelter. Alternatively, the air lock door may be rigid, and may be formed of one or more non-flexible doors which also prevent inflow of harmful gases into the shelter.
[0014] In another, and more preferred embodiment, most of the air lock is located within the flexible material defining the shelter. This arrangement conserves space in the storage container, enabling more supplies to be stored in such container. The air lock is folded into the flexible material for storage, and is deployed together with the shelter. When deployed, the air lock is fully, or at least partially, contained within the shelter.
[0015] The storage container preferably rests on a skid. Although the container may be permanently stored at one location, it may occasionally be desirable to move the container to another location. The skid makes it easier to do so.
[0016] The invention therefore has the primary object of providing a shelter for protecting personnel from a hostile environment in an emergency situation.
[0017] The invention has the further object of providing an emergency shelter for use in mines, tunnels, industrial plants, or other locations at which hazardous atmospheres may be created in emergency situations.
[0018] The invention has the further object of providing an emergency shelter for protection of personnel following a terrorist attack.
[0019] The invention has the further object of providing a compact, self-contained unit which can be used for rapid erection of a shelter in the event of an emergency.
[0020] The invention has the further object of providing an apparatus and method for protecting personnel from hostile environments, for extended periods of time, in emergency situations.
[0021] The reader skilled in the art will recognize other objects and advantages of the present invention, from a reading of the following brief description of the drawings, the detailed description of the invention, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 provides a front elevational view showing the storage container of the present invention, the container being held on a skid, the figure showing the doors of the container in a closed position.
[0023] FIG. 2 provides a front elevational view of the storage container of FIG. 1 , with its doors in the open position.
[0024] FIG. 3 provides a perspective view of the storage container of FIG. 1 .
[0025] FIG. 4 provides a top view of one embodiment of the storage container used in the present invention, in which the doors are closed, this embodiment including a flexible air lock sleeve.
[0026] FIG. 5 provides a top view of the storage container of the present invention, wherein the shelter has been deployed, and in which the flexible air lock sleeve has also been extended.
[0027] FIG. 6 provides a top view of another embodiment of the storage container of the present invention, in which the air lock comprises a rigid door, the door being shown in the closed position.
[0028] FIG. 7 provides a top view of the embodiment of FIG. 6 , wherein the air lock is in the open position.
[0029] FIGS. 8 a - 8 c provide front elevational views showing the shelter of the present invention as it is being deployed from the storage container.
[0030] FIG. 9 provides a partially schematic top view illustrating the deployment of the shelter according to the present invention.
[0031] FIG. 10 provides a partially schematic top view, illustrating the shelter of the present invention wherein a flexible air lock has been opened, and wherein persons have occupied the space defined by the shelter.
[0032] FIG. 11 provides a view similar to that of FIG. 10 , but in which the air lock is rigid.
[0033] FIG. 12 provides a view similar to that of FIG. 9 , showing an alternative embodiment in which the air lock is at least partly located within the deployed shelter.
[0034] FIG. 13 provides a view similar to that of FIG. 10 , also showing the alternative in which the air lock is at least partly located within the deployed shelter.
DETAILED DESCRIPTION OF THE INVENTION
[0035] FIG. 1 provides a front elevational view of one embodiment of the storage container used in the present invention. Storage container 1 sits on skid 3 . Instead of a skid, one could use some other device such as a wheeled platform or trailer. The storage container is preferably made of a rigid and durable material, such as steel. The skid may similarly be made of metal. The storage container holds all of the components necessary to erect a shelter, as well as materials necessary to sustain life within the shelter for an extended period. In the view of FIG. 1 , all of the doors of the storage container are closed. Specifically, the figure shows valve access door 5 , service access door 7 , entrance ramp door 9 , and service access panels 11 .
[0036] FIG. 2 shows the same structure as illustrated in FIG. 1 , but in which the doors are in the open position. The opened valve access door 5 reveals push valves used to deploy the shelter, and gauges used to monitor the air bottle pressure. FIG. 2 also shows the position of the optional flexible air lock, not shown in FIG. 2 , but which can be formed around door 13 . The functions of the components revealed by FIG. 2 will be described later.
[0037] FIG. 3 provides a perspective view showing the storage container, with its top removed for visibility of its interior. The container is still resting on the skid, with the entrance ramp door 9 in the open position.
[0038] FIG. 4 provides a top view of the storage container with its doors closed, and illustrating the typical contents of the storage container. This figure shows the flexible air lock sleeve 21 , shown in the stored condition. The flexible air lock sleeve is made of a foldable material so that the entire sleeve can be stored within the storage container as shown. Tanks 23 contain breathing air. A supplemental storage container 25 is provided behind the stored flexible air lock. Tanks 27 represent an oxygen supply, which could take the form of compressed air bottles or a chemical system for generating oxygen, or both.
[0039] Flexible shelter 29 is stored in a shelter storage area within the storage container. Deployment door 31 prevents the flexible shelter from deploying until needed.
[0040] The shelter 29 comprises an inflatable structure, made of a material which is flexible and which is substantially impermeable to gas and vapor. The shelter, which will be described in more detail later, preferably comprises columns and/or beams which assume their desired shape when fully inflated. In other words, the emergency shelter can be characterized as a balloon which, when inflated, assumes the shape of the desired shelter structure.
[0041] The storage container preferably contains supplies necessary for a group of persons to remain in the shelter for an extended period of time, such as two or more days, or longer. Typical supplies preferably include potable water, food, a chemical toilet, chemicals for generating oxygen, chemicals and/or devices for scrubbing carbon dioxide from the atmosphere in the shelter, equipment for removal of heat, a first aid kit, batteries, a battery charger, and monitoring devices for oxygen and carbon monoxide. Additional equipment and supplies could be stored in the container appropriate for the specific use for which the shelter is intended. For example, if the shelter is to be used in an underground mine, a methane monitor and/or communications equipment for contacting personnel at the surface could be provided.
[0042] In the stored configuration, as represented in FIG. 4 , the shelter and all of the supplies and equipment are stored inside the storage container. When needed, the shelter can be deployed directly from the storage container. When deployed, the shelter stands adjacent to the storage container. During the deployment process, the storage container does not move, but the shelter is erected in a space adjacent to the container.
[0043] The shelter remains attached to the storage container in a substantially airtight manner. The storage container thus becomes part of the envelope of the shelter when the shelter has been deployed. All equipment and supplies can be accessed from inside the shelter without allowing any contaminated atmosphere to enter the shelter. The latter is accomplished by accessing the equipment and supplies through an opening linking the shelter and the storage container. In this way, once the storage container is positioned for storage, it does not need to be moved to operate the shelter. All equipment and supplies in the container are immediately available to the inhabitants of the shelter without being moved. The equipment and supplies in the container can thus be accessed as needed, throughout the entire time the shelter is operated.
[0044] FIG. 5 provides a top view, in partial schematic form, of the storage container of the present invention, showing a partial view of the shelter in its deployed condition, and showing the flexible air lock sleeve extended. Shelter 41 , which is formed from structural elements defined by the material stored in the shelter storage area shown in FIG. 4 , is shown in its fully extended position. Air lock sleeve 43 , which provides access to the container, from the side opposite to that of the shelter, is also shown in the open and extended position.
[0045] FIG. 6 provides a top view, similar to those of FIGS. 4 and 5 , showing the container with its doors closed. The embodiment of FIG. 6 has a rigid air lock, formed by a door or panel instead of a flexible structure. The container is otherwise similar to those described above.
[0046] FIG. 7 provides a top view, similar to that of FIG. 6 , showing the container with the shelter deployed. The embodiment of FIG. 7 uses a rigid air lock, which is shown in the extended position.
[0047] FIGS. 8 a - 8 c provide a progression of diagrams illustrating the deployment of the shelter. Deployment of the shelter is initiated by operating a valve, such as one of the valves located behind access door 5 of FIG. 2 , the valve being arranged to allow gas to flow from a source into the inflatable shelter.
[0048] FIG. 8 a shows shelter structure 51 emerging from container 53 , as the shelter is beginning to be inflated. FIG. 8 a shows only one panel of the container, corresponding to side panel 8 of FIG. 3 . The shelter emerges as a consequence of inflation. That is, compressed air is allowed to fill the shelter structure, causing the structure to assume its final desired shape. Thus, for example, the shelter includes column 55 and base 57 , both formed from the inflation of the shelter structure, shown in FIG. 8 b . FIG. 8 c shows the shelter structure after it has been fully inflated. There are now a plurality of columns 55 , extending from base 57 .
[0049] FIGS. 9-11 provide diagrams further illustrating the deployment and use of the shelter of the present invention. As shown in FIG. 9 , storage container 65 , which stores the shelter and the necessary life-supporting equipment, is positioned between walls 61 and 63 . The walls may be the walls of a chamber in a mine, or they may be the walls of a tunnel, or other structure. The storage container may be positioned virtually anywhere, as long as there is space adjacent to the container, within which to erect the shelter.
[0050] Deployment of the shelter is accomplished by operating a first valve, which opens deployment door 67 (which is the same as deployment door 31 of FIG. 4 ) which allows the shelter 69 to emerge from the container, and then operating a second valve, which causes compressed air to fill the flexible shelter material 69 to build the shelter.
[0051] In the preferred embodiment, there are two operations requiring compressed air. First, compressed air is used to fill the flexible material defining the shelter, so as to construct the shelter. Secondly, air is directed into the space within the shelter, to provide a breathable atmosphere. Thus, air is used both for purposes of inflation of the structural members of the shelter, and then for the purpose of filling the shelter enclosure with a breathable atmosphere. Separate valves can be used to perform these two operations.
[0052] In one preferred embodiment, the present invention is designed to provide space for about 18-20 persons. The shelter can be formed in various heights. In one embodiment, the height of the inflated shelter could be about 54 inches. The total time for full deployment can be about 1-3 minutes. During this time, the persons who will be using the shelter can open the entry door, represented by reference numeral 71 in FIG. 9 , and expand the flexible air lock (shown in FIGS. 9 and 10 ), or open the rigid door air lock (as shown in FIG. 11 ), in preparation for their entry into the shelter.
[0053] In another embodiment, the scale of the shelter can be enlarged, and the shelter can be designed to accommodate up to 35 persons, for periods as long as 96 hours. Other such variations can be made, within the scope of this disclosure.
[0054] FIG. 10 provides more detail about the process for entry into the shelter. This figure shows the flexible air lock sleeve 81 in its open condition. The flexible air lock contains a zipper or equivalent fastener (not shown). After the person or persons using the shelter enter through the flexible air lock, and have moved towards the shelter door (towards the left in FIG. 10 ), the zipper is closed. Then, the door leading from the container to the shelter can be opened, and the persons can enter the shelter. The door to the shelter is then preferably closed. FIG. 10 illustrates various persons located within the shelter.
[0055] FIG. 11 illustrates the same process shown in FIG. 10 , for the case in which the air lock is rigid. In this case, the air lock comprises a double door system. The persons entering the shelter open the outer door, then move into the air lock area and close the outer door. The persons move towards the shelter door (towards the left in FIG. 11 ). The door to the shelter is opened, and the persons enter. The shelter door is then preferably closed.
[0056] The rigid air lock, discussed above, comprises two rigid doors with a flexible curtain located between the two doors. The air lock reduces the likelihood that toxic air will enter the shelter when persons enter the device. The flexible air lock has the additional advantage that it permits up to three more persons to be located within the air lock, due to the fact that the flexible air lock can be extended in length. The flexible air lock is especially suitable for accommodating a person on a stretcher.
[0057] An alternative, and more preferred, embodiment is shown in FIGS. 12 and 13 . FIGS. 12 and 13 provides views which correspond, respectively, to those of FIGS. 9 and 10 . In this preferred alternative, the air lock is located at least partly within the shelter portion of the structure, instead of being located entirely within the storage container. This embodiment conserves valuable space within the storage container, making it possible to store more supplies in the container.
[0058] In FIG. 12 , the air lock 91 is represented by a shaded portion. As in the other embodiment, the air lock itself comprises a flexible, inflatable material. The air lock has a forward end which can be opened with a zipper, or its equivalent, providing access to the inside of the shelter. Before deployment of the shelter, the air lock is contained within the folded flexible material which will define the shelter, and is itself folded. The air lock is arranged such that it deploys at the same time as the shelter as a whole. As shown in FIG. 12 , which shows the shelter after it has been deployed, the air lock extends into the shelter. A separate air lock door 93 provides access to the air lock from the outside.
[0059] In this alternative embodiment, at least part of the air lock is within the deployed shelter. The entrance from the outside, into the air lock, is through door 93 , which may be made of steel. The entrance from the air lock into the inside of the shelter is through a zippered opening.
[0060] A low-pressure one-way relief valve or check valve 95 vents air from the living space, within the deployed shelter, to the air lock. A second check valve 97 vents air from the air lock to the outside. This arrangement is useful for the following three reasons.
[0061] First, the air flow into the air lock area prevents the creation of a vacuum in the air lock during deployment, and thus allows the air lock area to inflate during initial deployment.
[0062] Secondly, whatever contaminated air may enter the shelter during the initial entry of victims will be purged through the air lock area to the outside.
[0063] Thirdly, continuing the slow air flow from the compressed air cylinders will maintain a slight positive pressure. Therefore, if there were any harmful gases in the vicinity of the shelter, such gases could not enter the shelter due to the positive pressure therein. This positive pressure is controlled and regulated by setting a predetermined air flow resistance level over the pressure relief valve.
[0064] The present invention has the major advantage that it is compact in size when not in use, all components being densely packed within the container. The shelter occupies substantial space only when deployed. Indeed, when the shelter is deployed, the volume of the shelter may become comparable to, or greater than, the volume of the storage container from which it emerges.
[0065] In FIGS. 12 and 13 , the air lock is partly disposed within the shelter and partly located within the storage container. Other configurations could be used instead. For example, the air lock could be positioned entirely within the shelter. The air lock could also be located at various positions within the shelter. Such alternatives should be apparent to the reader skilled in the art.
[0066] FIGS. 12 and 13 also show the main door 98 which provides access to the storage container, as well as the valve access door 96 , which provides access to the control valves used to inflate the shelter.
[0067] The invention may be modified in various other ways, as will be apparent to those skilled in the art. The specific contents of the storage container can be varied, as can the structure of the air lock doors. The configuration of the shelter itself can also be modified, within the scope of the invention. Also, the positions of the valves and the valve access door can be modified, and can be different from those shown in the figures. These and other modifications should be deemed within the spirit and scope of the following claims. | A flexible, inflatable shelter is held within a storage container. The shelter can be erected rapidly, by directing compressed gas held or produced within the container, into the flexible material which will define the finished shelter. Personnel using the shelter then enter through an air lock door located in the storage container. An air lock may be alternatively provided such that is located at least partly within the deployed shelter, and so that it does not occupy substantial space in the container. The container includes supplies necessary to sustain life for an extended period. The shelter can be used to protect personnel from harmful environments caused by accidents or explosions in mines, tunnels, industrial plants, and the like. The container is compact, but allows rapid deployment of the flexible material to produce a shelter which is of approximately the same volume, or greater, than that of the storage container. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a means whereby an operator controls a machine, for example, the control of an earth working back-hoe digger. The operator is typically located upon the machine and operates it through pushing or pulling numerous levers arranged before him. Each lever usually activates only one motion of the many required to perform useful work. The operator must be trained as to the functions of each lever and must concentrate upon the sequence and degree of actuation required to obtain the desired motions. Improper sequencing or over-actuation can cause accidents such as load dropping or striking objects. Efficiency and speed of operation are very dependent upon operator skill at manipulating this multiplicity of levers with split-second timing.
2. Prior Art
This control problem has been recognized in previous inventions. Askins (U.S. Pat. No. (3,642,159) utilizes one manually operated valve, linkages, and a pneumatic circuit to sequence movements on a shovel loader. Wallace (U.S. Pat. No. 3,614,273) controls the boom arms and bucket on a front-end loader through one control handle, linkages, and three valves, providing sequential operation. Fuzzell (U.S. Pat. No. 3,524,562) controls the bucket of a loader by means which electrically release a detent which is holding the control valve at a given setting. Horsch (U.S. Pat. No. 3,534,881) utilizes linkages connected to the control valve to maintain bucket position during raising and lowering. These inventions all relate to a relatively simple machine utilized to perform repetitive operations. The operator cannot interrupt the sequence at will and quickly, and he must be seated upon the equipment. Ito and Aihara (U.S. Pat. No. 3,695,377) remotely control a tractor through electrical signals sent through a control cable to operate relays and electropneumatic actuators connected to the various tractor controls.
3. Utility
The operator of farming, mining, or earth-moving machinery often finds himself in a noisy, dusty (or wet), vibrating, and generally unpleasant environment. He may not be in the best location to observe the results of his actions. He may also be in physical danger such as cave-ins when working in tunnels, at the base of cliffs, or in excavations; his machine could tumble down steep slopes or have the ground give way beneath him when working around excavations; he may be in toxic or inflammable environments; or he might accidentally sever high pressure pipes or contact high voltage lines. This invention allows the operator to move his operating controls to a location away from the equipment and operate the equipment by actuating a size-scaled version of the movably connected portions of the equipment with the actual equipment mimicking his motions. A feedback feature restricts the operator's motions when the equipment is incapable of following within certain limits. In many cases it is not desirable to remove the operator from the machine. The use of a vehicle mounted control station provides the improved control inherent with this system, thereby enhancing the efficiency of the operation.
SUMMARY OF THE INVENTION
This invention describes a three-cylinder control system for powered machinery in which a master cylinder attached to a particular linkage at the control station is connected hydraulically with a slave cylinder attached to the corresponding working element on the machinery and also to a control cylinder that is attached to the machinery lever that actuates that particular working element on the machinery. With the machinery power turned off, the master cylinder timing valves are opened and the control station handle is manipulated until the control station linkages have the same geometrical configuration as the machinery, at which point the master cylinder timing valves are closed. A movement of the control station handle moves one or more of the master cylinder pistons, forcing fluid into the control cylinders since the slave pistons have not moved. The control cylinder pistons move the original equipment levers, powering the machinery, thereby moving the slave cylinders, forcing their fluid into the control cylinders, and returning the control pistons to their centered positions. This returns the original equipment control levers to the neutral position and stops the motion of the machinery so that it corresponds to the new position of the linkages on the control station. By moving the control station handle in the desired fashion, the machinery is directed to follow without the operator having to think about the control of each motion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the three-cylinder system of this invention and also shows an alternate to the control cylinder.
FIG. 2 is a partial cross-sectional view of the accumulator shown in FIG. 1.
FIG. 3 is a schematic of a throttle control system which employs the hydraulic control system shown in FIG. 1.
FIG. 4 is a partial, cross-sectional view of the enlargement of the slave cylinder shown in FIG. 3.
FIG. 5 is a perspective view of a remote station controlling a wheel-backhoe using multiple control systems of the type shown in FIG. 1.
FIG. 6 is a side view of the control station mounted on a vehicle using the control system of the type shown in FIG. 1.
FIG. 7 is a perspective view of the enlargement of the control station shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A control station, either mounted on the machine or at a remote location, for the working elements of the machinery, is constructed to a scale convenient for the operator. The station may incorporate a counterweighting system and motion locks. To each rotating or sliding linkage on both station and machine are mounted double-acting hydraulic cylinders or rotary actuators. Those on the station are called master cylinders and those on the equipment are called slave cylinders. A third set of double-acting cylinders, called control cylinders, are used to push or pull the original machinery control levers. Tubing is used to connect the various cylinders together. Timing and locking valves can be provided to permit positioning the pistons of the various cylinders with respect to each other. Accumulators can pressurize the system and enable the system to withstand temperature variations. The hydraulic system is filled with any low viscosity fluid as the force and displacement working medium.
As shown in FIG. 1, master cylinder A with push rod 12 displaces fluid volumes 1 and 2 such that fluid is forced from volume 1 into volume 3 of control cylinder C by means of tubes 15, 24, and 19. Fluid from volume 1 also attempts to enter volume 5 of slave cylinder B via tubes 15, 24, and 16; however, volume 5 is fixed because slave cylinder piston rod 13 cannot move since it is attached to the machinery which has not yet moved. The increase in fluid in volume 3 forces fluid from volume 4 through tubes 20, 25, and 18 into volume 2; therefore, control cylinder piston rod 21 is slaved to follow master cylinder piston rod 12. The movement of control cylinder piston rod 21 actuates valve lever 8 which in turn through the normal hydraulic or electric system of the machine moves a linkage on the machine. By moving lever 8, a corresponding motion is generated in the linkage of the machinery. The movement of the linkage creates a movement of slave cylinder piston rod 13 causing the fluid in volume 6 to be displaced through tubes 17 and 20 into volume 4 of the control cylinder C. Increased fluid in volume 4 causes fluid to flow from volume 3 through tubes 19 and 16 into volume 5. Volumes 3 and 4 are equalized in cylinder C moving lever 8 to a central position which stops the motion of the linkage. Continued motion of master cylinder piston rod 12 keeps control cylinder C in an unequalized position which continues the motion of the linkage until such time as the slave cylinder piston rod 13 is in a corresponding position with master cylinder piston rod 12. Should the linkage be unable to move because of striking an object or reaching its mechanical limit, master cylinder piston rod 12 will be prevented from further motion. This provides position feedback to the operator. A timing valve 10 may be provided to allow flow between volume 1 and volume 2 so as to permit the control station linkages to be placed in a configuration similar or relative to the working elements of the machinery, thereby enabling the control station to have the same geometric configuration as the machinery, or a configuration that is more comfortable to the operator rather than a true geometric configuration of the machinery. An additional timing valve 9 may be provided to allow free flow of fluid between volumes 5 and 6 and volumes 3 and 4, thus permitting the normal operation of the equipment through manual actuation of lever 8. Closing valves 23 hydraulically lock the master cylinder piston rod 12 to hold the position of the linkage. Quick disconnect couplings 42 may be provided on the machine to facilitate convenient removal of the remote portions of the circuit. The control cylinder C is intended to be used as a retrofit to existing equipment. For original equipment installation on hydraulic machines, it is more practical to incorporate a pilot operated valve 11 in the basic construction of the machine's hydraulic system. This valve 11 would still have a lever actuator 14 to permit conventional manual operation.
A fluid pressurization system may be provided by accumulator 7. The accumulator is shown in partial cross-sectional detail in FIG. 2. The accumulator 7 provides means to maintain pressurization in the system, and an expansion volume to accommodate system temperature fluctuations. Other desirable features of this accumulator are that it provides the following functions:
a. rigid location to attach the hydraulic lines from a remote control station,
b. includes a pump means to increase the system pressure,
c. a visual means of indicating fluid level in the system,
d. incorporates overpressure relief to reduce the possibility of equipment damage due to operator attempting to overload control station,
e. incorporates timing valve 9 at a convenient location on the machine, allowing the machine to be operated manually when the control station is disconnected,
f. incorporates air venting means,
g. and fluid pressure gage.
Accumulator 7 is provided fluid from a reservoir by gravity feed through tube 31 into volume 26. Raising plunger 27 by hand draws fluid from volume 26 past check valve 28. Manual depression of plunger 27 forces the fluid past foot valve 29 into volume 30. Volume 30 is connected to the system through lines 15, 24, 18, and 25. Continued pumping of plunger 27 fills volume 30 raising piston 32 against spring 33. The spring 33 provides a force on the fluid in volume 30. The vertical position of piston 32 is indicated by the extent of the height of pump housing 34 above the top of the accumulator 7. Air trapped in volume 30 is expelled through pressure relief valve 35 into volume 26 where it raises through tube 31 into the fluid storage reservoir (not shown). The system pressure is indicated by gage 36 after all air is bled from all parts of the system. Volume 30 communicates with tubes 18 and 25 through fitting 37. Tubes 15 and 24 communicate with each other through fittng 43, but do not communicate with volume 30 since timing valve 9 is closed. Pulling plunger 39 of timing valve 9 and holding it open with wire clip 40 allows the free communication of fluid between tubes 24 and 25 (also tubes 15 and 18) through volume 30. On the occasion of overpressure of tubes 17, 25, and 18, fluid will flow into volume 30 and may vent through valve 35 and/or force down plunger 39 against spring 38 allowing fluid to pass into tubes 15 and 24. Overpressurization of tubes, 15, 16, and 24 is relieved through valve 41 through volume 30 into tubes 18 and 25 and/or out through valve 35.
One particular embodiment of this invention useful as a control system for an engine is shown in FIGS. 3 and 4. FIG. 3 is a schematic of the throttle control, while FIG. 4 is an enlargement of the slave cylinder B of FIG. 3. When remotely advancing a throttle, a question always exists as to the actual engine speed since that is a function of engine load as well as throttle setting. Use of the basic three-cylinder control system of FIG. 1 relieves this problem. In this case, the control cylinder piston rod 21 is connected to the throttle 45 and the position of slave cylinder piston rod 13 is determined by the length of an engine-driven flyball inkage 46. Advancing the remote throttle 47 displaces fluid from volume 2 through tubes 18, 25, and 20 into volume 4 of the control cylinder C. This displaces the piston rod 21 and the throttle linkage 49 connected to it. The engine 50 will spend up and the engine-driven shaft 51 will rotate faster, causing the weighted linkages 46 to separate by centrifugal force. The centrifugal force is balanced by the force of a spring located at 52 and/or 53. The separation of the linkages 46 in response to the larger centrifugal force reduces the distance between the engine-driven shaft 51 and the swivel bearing 55, thereby moving the piston rod 13 of the slave cylinder B, displacing fluid from volume 5 through tubes 16 and 19 into volume 3 of the control cylinder C, retarding the throttle 45. As the engine 50 slows in response to the new throttle setting, the flyball linkages 46 are pulled together by the springs 52 and/or 53, displacing fluid from volume 6 through tubes 17 and 20 into volume 4, thereby advancing the throttle 45. The tubes and volumes are sized to provide a damping to this oscillatory behavior and the engine settles to a consant speed determined by the fluid distribution set by the remote throttle 47. An increase in load will slow the engine, thereby displacing the fluid from volume 6 into volume 4 as before, advancing the throttle 45. A reduction of load has the opposite effect. Should the engine stop due to stalling or running out of fuel, the piston rod 13 of slave cylinder B would move to its extreme, forcing much of the fluid from volume 6 through tubes 17 and 20. Volume 4 of the control cylinder C is not large enough to accept this much fluid so it will flow into volume 2 of the master cylinder A, forcing piston rod 47 to move within its friction position holder 56, indicating to the operator that the engine speed has decreased below a controllable level. Valves 57 permit the bleeding of air from slave cylinder B and are present but not shown on all the cylinders and other locations wherever air could be trapped.
An example of a remote control station using the system of this invention is shown in FIG. 5. Multiple master, control, and slave cylinders provide this control although only one control and two slave cylinders are shown on the machinery for sake of simplicity. FIG. 5 is a perspective view of a remote control station 60 controlling a wheel-backhoe 65 with bucket attachment 62. The control station 60 is connected to machine 65 by means of a bundle of hydraulic tubes 63 which connect to the machine by means of rack 64 in which are mounted multiple accumulators (not shown). All master cylinders A are located on control station 60, and some of these master cylinders are shown as rotary actuators instead of as cylinders. Slave cylinders B are located on machine 65, and control cylinders C are located on machine 65 mechanically connected to levers 66. One sample operation is as follows: Associated with actuation of working element 67 is slave cylinder 68, master cylinder 69, and control cylinder 70, and accumulator 71 mounted on rack 64. While sitting at control station 60 the operator pulls handle 72 toward him which causes pivotal motion which displaces fluid from master rotary actuator 69 incorporated in the linkages. The fluid is displaced through tubes enclosed in the structural member 73 to manifold block 74, hence through tube bundle 63 to accumulator 71, to control cylinder 70, and slave cylinder 68. The displaced fluid moves a piston in control cylinder 70, actuating lever 66 which powers a piston in cylinder 75 causing motion about working element 67, resulting in motion of a piston in slave cylinder 68, displacing fluid which causes revers motion of the piston in control cylinder 70 which returns lever 66 to a neutral position stopping the piston in cylinder 75. Continued pulling of handle 72 will continue the displacement of the piston in control cylinder 70 and actuation of control lever 66 and power cylinder 75, resulting in continued motion of working element 67. Each linkage on the machine is controlled by a master A, control C, and slave B cylinder in a similar hookup. Control station 60, as depicted in FIG. 5, shows control means of all functions of the backhoe. Every working element on the machine that is hydraulically controlled is shown on control station 60. In addition, the throttle 47 is hydraulically controlled using the three-cylinder system of this invention (see FIGS. 3 and 4). The other control features, namely, braking 77, steering 76, gear shifting 78, and starting 79 are two-cylinder operations (not part of this invention) and are shown only to depict a complete remote control station. For operator comfort, possible counterbalancing means 80 are shown schematically, relieving the dead weight of the master system linkages.
FIG. 6 depicts the control station 81 and FIG. 7 is an enlargement of same mounted on vehicle 82. The operator sitting in the vehicle seat 83 has handle 84 in his hand. The valves which cause bucket curl and lift both are controlled by systems of the type shown in FIG. 1. Lifting handle 84 results in raising bucket 85. Rotating handle 84 results in curl of bucket 85. Swinging handle 84 in the horizontal plane results in turning vehicle 82 since column 86 is connected directly to the vehicle power steering 87. Forward and reverse control of the vehicle 82 is accomplished by pushing or pulling handle 84 which tilts column 86 actuating transmission lever 88. Vehicle's speed and braking are part of the conventional vehicle control system. Having this control system mounted on the vehicle provides the following advantages: (a) less fatigue on the operator, (b) faster operation of the vehicle, (c) less training needed for operator, and (d) better control of operation of the bucket, vehicle, and therefore, enhanced job performance.
While the invention has been described in detail with respect to a specific embodiment, it will be apparent that many variations are possible. Certain of the functions of devices described herein, including the accumulator, timing, and locking valves, may be accomplished by other mechanisms without departing from the scope of the invention. Other modifications are possible and accordingly it is not intended to limit the invention except as defined by the following claims. | A three-cylinder hydraulic system providing position feedback for controlling powered machinery is described wherein an operator moves a control handle and the various working elements of the machinery respond to follow the path of the control handle, the freedom of movement of which is limited by the ability of the machinery to respond. The system consists of a control station comprised of an assemblage of linkages resembling the machinery to be controlled. Associated with each movable element on both the control station and machine, and with each lever or switch on the machine, are double-acting hydraulic cylinders or rotary actuators. The three cylinders thereby associated with each particular working element and its actuation are connected hydraulically so that the control station cylinder hydraulically manipulates the cylinder that moves the lever or switch that actuates that working element on the machine. The cylinder on that working element on the machine in turn hydraulically manipulates both the control station cylinder and the cylinder that moves the lever or switch. The control station may be located either upon the machinery or at a position remote from the machinery. |
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BACKGROUND OF THE INVENTION
The present invention relates to a modular containment wall system, and more specifically, to an interlocking modular building block which permits the formation of 90° corners and other variations in otherwise straight modular block containment walls.
BRIEF DESCRIPTION OF THE RELATED ART
Currently, there are several techniques and devices known in the patented prior art for modular construction of retaining walls.
The U.S. Pat. No. 5,537,796 issued to Kliethermes, for example, discloses a retaining wall block and system. The construction block has first and second pins in a top surface to be received in corresponding first and second slots in the bottom surface of an adjacent block to form an interlocking connection. While pin and slot connections may be of sufficient strength to hold material such as soil, such interconnections do not provide the necessary strength and tight fitting seal to retain a fluid, such as water.
U.S. Pat. No. 4,920,712 issued to Dean discloses a concrete block retaining wall and method of construction therefor. Walls constructed according to the method of this patent include special clips used to secure the individual blocks together. While the blocks provide for the construction of curved walls, they do not provide for the construction of vertically interlocking corners.
U.S. Pat. No. 4,936,712 issued to Glickman discloses a retaining wall system utilizing specially formed upwardly convex shaped blocks containing a plurality of longitudinal ridges. The shape and ridges enable the blocks to be stacked in offset overlying courses rather than directly vertically atop one another. U.S. Pat. No. 5,030,035 issued to Babcock discloses an earth retaining system formed of a plurality of relatively complex preformed blocks. While these building blocks operate satisfactorily for their intended purpose, they are unsuitable for use as corner structures.
The present invention was developed in order to overcome these and other drawbacks of the prior devices for modular block construction of retaining walls.
SUMMARY OF THE INVENTION
Accordingly, a primary object of the present invention is to provide an improved containment wall construction block which interlocks with other similar construction blocks to form a containment wall or the like. The block has a generally rectangular body with complimentary interlocking step and overhanging portions at opposite ends thereof for connecting the ends of laterally adjacent blocks. The block further includes a plurality of ridges and channels integrally formed on the top and bottom surfaces to form secure joints between blocks when they are stacked vertically atop one another.
Another object of the invention is to provide an improved containment wall construction block wherein the interlocking step and overhanging portions contain complimentary inclined surfaces to further secure the blocks together.
It is another object of the present invention to provide an improved containment wall construction block wherein the interlocking step and overhanging portions contain a connector bore for receiving a connector member for further securing laterally mated blocks.
Another object of the invention is to provide a modular block that can be used in conjunction with straight blocks to laterally offset an otherwise straight wall to assist in contouring the wall to the specific design needs of a user.
Still another object of the present invention is to provide an improved wall system which includes the capability of forming right angled corners using a specialized modular block.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent from a study of the following specification when viewed in light of the accompanying drawings, in which:
FIGS. 1-3 are top, side, and end plan views, respectively, of a straight block according to the invention;
FIG. 4 is a perspective view of a containment wall constructed of the straight blocks;
FIGS. 5 and 6 are side plan views of the connector and fastener, respectively, for connecting adjoining blocks of FIG. 1;
FIG. 7 is a side plan view showing the connection between the connector and fastener of FIGS. 5 and 6;
FIGS. 8-10 are top, side, and end plan views, respectively, of a 90° block according to the invention;
FIG. 11 is a top plan view of an off-setting block according to the invention;
FIG. 12 is an end plan view of the overhanging end of the block of FIG. 11; and
FIG. 13 is an end plan view of the step end of the block of FIG. 11;
DETAILED DESCRIPTION
Referring to FIGS. 1-3, there is shown a straight modular block 2 having a generally rectangular configuration and a longitudinal axis 4. The block has top 6 and bottom 8 surfaces and overhanging 10 and step 12 portions at opposite ends thereof. Extending parallel to the longitudinal axis 4 and running the length of the block 2 are a series of ridges 16. The ridges 16 are formed in the top surface 6 of the blocks 2 and have a triangular cross-section. Preferably, an equal number of ridges 16 are positioned on both sides and equidistant from the longitudinal axis 4 to produce a block which will stack evenly and maintain a level position while under load, as will be developed below.
The block bottom surface 8 contains a plurality of channels, each having a triangular cross-section and extending the length of the block 2. The channels 18 are molded within the bottom surface and are of equal number and in corresponding locations in order to receive the ridges 16 of the upper surface 6 of a separate block 2 when stacked on top of one another. The ridges 16 and channels 18 provide additional structural strength to each modular block 2. They also ensure a proper fitting and alignment between the stacked blocks along with increased resistance to any lateral displacement once the blocks are stacked, thereby increasing the overall rigidity of a containment wall structure.
The block step end 12 is defined by cutting away a portion of the top surface across the width of the rectangular block 2. An interlocking surface 22 of the step end receives an overhanging end 10 of an adjacent block. The interlocking surface 22 includes a portion 24 which is inwardly declined at an angle α with respect to the bottom surface and has ridges 26 of triangular cross-section extending parallel to longitudinal axis 4 and integrally molded thereon. The interlocking surface 22 also contains a connector bearing surface 28 positioned symmetrically between the top 6 and bottom 8 surfaces along longitudinal axis 4. The connector bearing surface 28 contains a connector bore 29 therein which extends through the block 2 towards the bottom surface 8.
The block overhanging end 10 is defined by cutting away a portion of the bottom surface 8 and has an interlocking surface 30 at the bottom thereof. The interlocking surface 30 includes a portion 34 which is inwardly declined at angle α with respect to the top surface 6 and has channels 36 of triangular cross-section therein. Interlocking surface 30 also contains a connector bearing surface 38 positioned symmetrically between the top 6 and bottom 8 surfaces and along longitudinal axis 4. Connector bearing surface 38 contains a connector bore 40 therein which extends through the block 2 towards the top surface 6. Therefore, straight block 2 has a step end 12 and an overhanging end 10 with interlocking surfaces 22, 30, respectively, which are rotated 180° from each other along the same longitudinal axis 4.
Referring now to FIG. 4, a block 2 is connected with similar blocks by positioning the overhanging end 10 of the block over the step end 12 of another block, thereby causing the interlocking surfaces of both ends to mate, creating a secure joint between blocks having flush top 6 and bottom 8 surfaces. The flush surfaces permit further rows of blocks 2 to be successively stacked on top of one another to construct a containment wall 48.
For additional structural integrity of the containment wall, the blocks 2 contain vertical alignment bores 42 positioned along longitudinal axis 4. It is important to note that when successive layers of interlocked blocks 4 are stacked on top of one another, alignment bores 42 of the block segments of each layer of the containment wall are aligned so that a reinforcing shaft 43 may be passed vertically down through all layers of the wall and secured into the earth beneath the wall. In this manner, the alignment bores 42 not only increase the strength of the joints of the block segments to each other, they also ensure that the constructed containment wall maintains proper vertical alignment despite external loads acting on the wall.
Alignment of the alignment bores 42 results in an overlap between rows of the blocks which ensures that joints 50 between laterally adjacent blocks are staggered vertically within the wall 48. The effect of this alignment is that the blocks are stacked directly above or below a joint 50 having half of the block on either side of the joint. Staggering the blocks in such a manner eliminates weak points in the wall 48 which are more likely to give way under heavy loads.
To increase the strength of the joint between blocks, a connector 302 and a fastener 304, as shown in FIGS. 5-7, is employed. The connector is constructed of a resilient material and has an elongated cylindrical body 306 with annular flanges 308 adjacent each end. The body 306 terminates in outwardly tapering conical portions 310 each having an annular grove 312 inscribed therein along an outer surface. Each end of the connector 302 is designed to be received within a fastener 304 which is mounted within the connector bore 29, 40 of the step and overhanging ends respectively. The fastener has a hollow cylindrical body of slightly larger diameter than the connector 302 on which a flanged portion 316 is located on one end and an outwardly threaded portion 318 is arranged on the other. Internally, the fastener 304 contains a raised annular rib 320. As shown in FIG. 7, when a conical end 310 of the connector is inserted into the fastener 304, the rib 320 is received by groove 312 which holds the connector 302 in locking engagement within the fastener 304 which in turn holds together the connector bores 29, 40, and therefore the respective ends of adjacent blocks.
The block 2 is generally hollow and includes a resealable cap 44 for filling the segment with material, such as water, to increase the overall weight and strength of the block. The block may later be emptied for ease of handling and storage.
For additional structural integrity, vertical channels 46 may be molded within the side surfaces of the blocks 2. As shown in FIG. 2, channels 46 extend from top 6 to bottom 8 surfaces.
Referring now to FIGS. 8-10, there is shown a 90° modular block 102 having top 106 and bottom 108 surfaces. The 90° block 102 further includes step 110 and overhanging 112 ends located adjacent opposite ends of longitudinal axis 104. Within the top surface 106 and extending parallel to and along either side of longitudinal axis 104 there are ridges of triangular cross-section. Adjacent the overhanging end 112, additional ridges in the top surface extend perpendicular to longitudinal axis 104. The bottom surface contains a corresponding pattern of channels 118 for receiving the ridges of a segment 102 on which it is stacked upon.
The step end 110 is cut away from top surface 106 which extends across the width of the 90° block 102. The step end 110 is of identical design to the step end 12 of straight block 2, shown in FIGS. 1-3.
On the overhanging end 112 of the 90° block 102, the bottom surface 108 is cut away equal in length to the width of the 90° segment block 102 and is positioned parallel to longitudinal axis 104. An interlocking surface 122 identical to interlocking surface 30 is provided so that it can receive in locking engagement the step end 12 of a like modular block.
Refering back to FIG. 4, it can be seen that in operation the 90° block 102 is used in conjunction with straight blocks 2 for the construction of corners in the containment wall 48. By placing a straight segment block's step end 12 into a 90° block's overhanging end recess 120, the segments will mate to form a 90° joint having flush top and bottom surfaces so that successive layers of similarly configured blocks may be stacked on top to form a corner of desired height.
Referring now to FIGS. 11-13, there is shown an angled modular block 202 having step 210 and overhanging 212 ends at opposite ends thereof. Located between the ends, there is a straight portion 208 and an angled portion 204 which laterally offsets the overhanging end 212 from longitudinal axis 214. As shown in this embodiment, the offsetting portion 204 shifts the step end 212 over at a specified angle φ necessary for the specialized needs of the design of a contoured wall.
In operation, an angled block 202 may be utilized with straight blocks 2 by mating respective step and overhanging ends of the blocks together to form locking joints. The angled blocks 202 are specially advantageous when only slight contouring of the containment wall is necessary. In other circumstances, a 90° block could be employed.
While in accordance with the provisions of the Patent Statute, the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those of ordinary skill in the art that various changes and modifications may be made without deviating from the inventive concepts set forth above. | A system for the construction of containment walls or the like using a plurality of modular blocks each having interconnectable ends for laterally mating with like blocks to form secure joints. The blocks include a plurality of corresponding ridges and channels in the block's top and bottom surfaces, respectively, for successively stacking rows of the blocks securely and properly atop of one another. The modular block system also includes specialized blocks which are capable of being stacked to form right-corners or to laterally offset an otherwise straight wall to permit contouring to suit the needs of the user. |
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FIELD OF THE INVENTION
This invention relates to a method of eliminating the play between the different parts of a mechanically connected wear parts system for earth-working machines and a wear parts system designed in accordance therewith.
BACKGROUND OF THE INVENTION
The term wear part is nowadays widely used within the trade as a general designation of all types of more or less easily replaceable wear protectors and teeth used on soil working implements and tools such as buckets, shredders, cutters, etc. on excavators etc. As a rule, a wear parts system consists of adapters attached to the tool concerned with a greater or lesser degree or permancency and one or a plurality of removable front parts, mechanically attached to each and every one of these adapters, the said front parts being the wear parts proper in the form of teeth, cutting edges etc. The ease with which a wear part of this kind is interchangeable varies with the amount of wear to which it can be expected to be exposed. The teeth protruding in front of the tools are particularly exposed to very heavy wear. These, or their outermost tips, to the extent that these are demountable, are therefore nowadays secured in their adapters by means of an easily removable locking element. Changing a damaged tooth is therefore usually done in a matter of a minute or so. The previously mentioned adapters are often welded to or at the front edge of the tool but they can also be mounted with bolts, wedges or by some other means.
Several different wear parts systems are now available on the market but none of them is completely perfect. The main fault with the majority of these systems is that success has not being achieved in mastering the play that which is mechanically secured in the adapter. As a rule, moreover, this play increases in magnitude with the passage of time and cannot be eliminated by a simple replacement of the wear part, since the contact surfaces of the adapter are gradually worn down because the wear part proper mountd therein moves in the adapters as work is being carried out. Hitherto, it has been economically unfeasible to manufacture wear part system components with such fine tolerances that no initial play occurs since this would have required machining the contact surfaces to narrow tolerances. Wear parts are mass-produced goods which, in order to be sold at competitive prices, must be able to be cast or forged directly to their final dimensions without any subsequent chip-forming machining, with the exception of normal burring operations.
Although wear parts subject to play give rise to strikingly increased wear in the vast majority of earth-working tool types, the wear caused by play is nevertheless decidedly the most in the case of rotary dredging cutters or suction dredging cutters. These are used for bottom work, mainly in coral and limestone or otheer softr species of rock. The actual tool consists of a rotary front portion formed by a plurality of toothed spirally twisted vanes disposed at a certain distance from each other which together form a very large drill bit. This drill bit is subsequently rotated with the teeth of the vanes in direct engagement with the bottom rock which is to be worked, at the same time as water is continuously sucked in between the rotating vanes and removed from the point of work. By this means, continuous disposal of broken rock and other bottom sediment is accomplished. The wear parts for such earth-working tools are exposed to extremely heavy wear in their points of attachment on account of the vibrations in the tool and because the tool constantly works in a slurry of sand, clay and/or other abrasive particles. The object of the present invention is to offer a solution to this problem, primarily intended for such dredging cutters but also applicable to every other place where there is a need for wear parts which are seated entirely without play, cannot be loosened by vibrations and are nevertheless very easy to replace.
SUMMARY OF THE INVENTION
According to the invention, the joint between the tooth and the adapter is designed as a self-impeding press fit which is blocked against vibrating apart by means of a spring-tensioned resilient blocking means which constantly presses the parts against each other. A further characteristic of the device according to the invention is that the contact surfaces betwen wear part and adapter are designed in such a manner that these not only give rise to a press fit byt are also pressed against each other by the normal machining forces acting on the wear part. In order to afford a press fit also between cast or forged, otherwise unmachined surfaces and surfaces which have only been given the least possible machining after casting or forging, one of the two interconnection parts, the mal portion, has been made solid and non-resilient, while the other interconnection part, the female portion, has been elaborated with such a wall thickness that the material properties of the actual material used, in most cases steel, imparts to this a certain elasticity so that the contact surfaces of the female portion, as closely as possible, mate with the contact surfaces of the male portion whent he portions are forced together with a certain force, e.g. when the parts are stuck together by one or several blows with a sledge hammer or similar tool. As intimated by the designation male portion, this consists of a protruding nose orthe equivalent, whereas the female portion consists of a recess or cavity. If a press fit between the members is to be obtainable at all, it is necessary for the male and female portions to be elaborated with suitable clearancee angles and adpated to each other. A forward tapering towards the tip of the male portions giving a tip angle of 5°-15°, preferably around 10°, is then necessary. At the same time,it has been found appropriate to elaborate the male and female portions with at least three contact surfaces angled relative to each other as a three-point contact or perhaps rather three-line contact all the way around. The cross-sections of the respective members may then have the form of a parallel trapezoid with contact between them along the base and the two inclined side edges and clearance in the corners and along the shorter upper edge. To prevent the press fit which is obtained when the portions are stuck together from vibrating apart, special resilient locking means are fitted between locking surfaces disposed opposite to each other in the respective member. At the same time, as the locking means are brought down into their locking positions, they are pretensioned so that once in place they continuously press the members together with a certain specific spring force. A suitable location of the applying the locking means has been found to be across each and every one of the sides forming the two inclined edges of the parallel trapezoidal cross section. Half the space for the locking means is then located in each part in such a manner that the parting line between the space located in each part runs diagonally through the rectangular cross section of the total space.
One type of locking means which has proved to be highly functional since it is simple to manufacture and can be given a powerful pretension is a resilient wire rebent in one plane which has been bent so as to have two or more shanks running longitudinally at a distance from each other, the outer edges of the rebent in the unloaded state being located further from each other that the distance between the oppositely located locking surfaces in the interconnected female and male portions. When the locking means has more than two longitudinal shanks, are located spirally inside each other. The distance between these shanks along the long sides of the locking means is then appropriately chosen in such a manner that the more the outer shanks are pressed towards each other, the more the shanks disposed inside each other are brought into contact with and interact with one another. The outer contour of the locking means can be made in the form of an extended ellipse or with one largely straight longitudinal shank and one arc-shaped longitudinal shank. The locking means can be bent from spring wire of round or rectangular cross section. The last inner shank can be terminated with a rebending which in principle implies a total stop for the compression of the locking means. As the locking means is pressed down into place, it is pretensioned at the same time and thus provides reliable locking of the press fit, which it continually acts upon in the direction of interconnection. When the locking means have been removed, for instance by being forced out of the locking position with the aid of an arbor,the press fit can be broken by striking the parts apart with a sledge hammer.
The invention is defined in the accompanying claims and will now be described in greater detail and with reference to the accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a vertical view of a wear parts system according to the invention,
FIG. 2 shows a section along the line II--II in FIG. 1,
FIGS. 3 and 4 show a side projection and vertical view, respectively, of the adapter included in the wear parts system,
FIG. 5 shows the tooth tip included in the wear parts system according to the invention seen along section II--II in FIG. 1, while
FIGS. 6 and 7 show on a double scale the left-hand portion and right-hand portion respectively of sections VI--VI and VII--VII in FIG. 2 and, finally,
FIG. 8 shows section VIII--VIII in FIG. 7, and
FIGS. 9 and 10 show a further type of resilient locking means in side projection and cross section (double scale).
DETAILED DESCRIPTION OF THE INVENTION
The wear parts system illustrated in the figures consists of an adapter 1, the rear outer portion of which has been dispensed with since it is of less interest in the present context. The adapter 1 is intended to be welded to the tool in question along the edges 2 and 3. The adapter 1 is also provided with a male portion 4, protruding forwards in the working direction, in this case to the left in the illustration. This male portion 4 supports a tooth tip or actual wear part 5. The wear part 5 displays a recess or female portion which in the fitted condition is passed over the male portion and secured to this means of a self-impeding press fit accomplished by driving the wear part onto the male member portion by means of one or several blows with a sledgehammer against the tip. The press fit is broken in a corresponding manner by striking it loose, directing the blows towards the edge 7 surrounding the female portion 6. The upper edge 8 of the adapter 1 can then be used as a guide for the sledgehammer.
The male portion 4 is solid whereas the material surrounding the female portion 6 is no thicker than that of the material in the wear part impart a little elasticity which contributes towards good contact against the male portion. Both the male and the female portion taper off forwards with a nose angle of around 10°.
As evident from FIGS. 6 and 7, in particular, both the male portion 4 and the female portion 6 have also a largely parallel trapezoidal cross-section where the base and the inclined edge sides afford the press fit between the portions, whereas there is a clearance along the shorter top side and at the lower corners which have been thoroughly bevelled off. In the figures, these components have been given the following reference numerals: the male portion base edge 9, its two inclined side edges 10 and 11 respectively and its top edge 12. The female portion base edge 13, its two inclined side edges 14 and 15 respectively and its top edge 16. The clearance at the top is designated by reference numeral 17 and at the corners by reference numerals 18 and 19 respectively.
To prevent the press fit from vibrating loose it is possible to apply two resilient locking means 20 and 21 in two locking seats provided for this purpose which run across the inclined side edges of the male and female portions respectively.
Such a locking means can have one of the forms illustrated in FIG. 2 and in FIGS. 9 and 10 or any other form which falls within the definition given in the claims. In purely longitudinal shanks of bent spring wire of optional cross-section. The locking means according to FIG. 2 consists of a spring wire bent in one plane, the middle largely straight portion of first shank 22 of which has been rebent in one end a good 180° into a second shank 23 which is bent inwards towards the first shank 22. In its other end, the shank 22 is bent not fully 180° to an arc-shaped third shank 24 which towards its outer end rests against the rebending towards the second shank 23. The locking means are forced, when the wear part has been fitted, through locking apertures 26, 27 in the upper side of the wear part 5 down to their respective locking seats on either side of the male portion. In their locking seats they are clamped between locking surfaces in the male and female portion respectively. In the underside of the wear part 5 are apertures 28, 29 through which the locking means can be struck out when the wear part is to be removed.
The locking means according to FIGS. 9 and 10 consist of a first longitudinal slightly arc-shaped shank 34 which in its free inner end, has been rebent to a stop cam 35 which limits the total compression of the locking means and which, in its other end, via a smaller radius of curvature, has been rebent to a second longitudinal shank 36 arc-shaped in the opposite direction which, via a new rebending with a small radius, passes into a shank 37 lying beyond shank 34 which via a further spiral-shaped rebend with a small radius is transformed into the shank 38 located beyond shank 36 which in its free outer end rests against the shank 36. When the outer shanks 37 and 38 of the locking means are pressed against each other, e.g. when the locking means is moved down to the respective locking seat through any of the locking apertures 26 or 27, the shanks 37 and 38 will be pressed against the shanks 34 and 36 which will then also be incorporated in the function. A locking means of this type can give a fairly long path of resilience at the same time as it will be very strong. As previously pointed out, all the rebendings have been done in the same plane so that the locking means is flat.
FIGS. 2, 7 and 8 illustrate a locking means made of a spring wire of round cross section whereas FIGS. 9 and 10 illustrate a locking means made of a resilient wire of largely rectangular cross-section with rounded lateral edges. Both types of locking means fit into the same locking seats.
The aforesaid locking seats are formed by opposing locking surfaces 30, 31 in the male and female portion respectively and recesses in the respective portion corresponding to half the space for the respective locking element. The space required for locking means is of rectangular cross-section (see FIG. 8) and the recesses 32, 33 have been designed so that the parting line between them runs diagonally through this cross-section.
As evident from FIG. 1 the locking surface 31 has been given a central recess 34 which is adapted to the arc-shaped part 24 or alternatively 37 or 38 of the locking means.
The distance between the locking surfaces 30 and 31 is less than the normal distance between the shanks 22 and 24 or alternatively 37 and 38 of the locking means 20, 21. This implies that the locking elements are pretensioned when they are forced down between the locking surfaces. Here, it is a matter of relatively stout spring steel in the locking means which, in the locking seat, act upon the members with spring forces of 200 kp or more. | The present invention relates to a method of attaching a wear part to an earth-working tool and a thereto adapted wear part. Characteristic of the invention is that the parts are joined together by means of a press fit which in turn is blocked by means of pretensioned resilient locking means which when fitted in place continually act upon the parts in the direction of interconnection. The invention provides a play-free and reliable interconnection for the tool and wear part, which is also very easy to remove. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority and is based on Provisional Application 60/088,586 filed on Jun. 9, 1998.
BACKGROUND OF THE INVENTION
This invention relates to quick connect assemblies including quick connector fittings which quickly and releasably connect to a well casing for providing an interface for attaching well related equipment such as blowout preventors to the casing.
Fittings, such as drilling flanges, are currently used to provide an interface to well casings for mounting various equipment such as blowout preventors. A conventional fitting, such as a drilling flange, is threaded onto the casing until a shoulder within the drilling flange makes contact with the casing mouth. An elastomeric O-ring seals the drilling flange/casing interface. Once such a drilling flange is mounted on a casing, it is difficult to remove. Consequently, in many instances, the drilling flange remains permanently on the casing. As a result, on the field where multiple drilling operations may be going on at once, a separate drilling flange is required for each casing. This can be expensive.
Another problem with these flanges is that their orientation with respect to the casing cannot be accurately predetermined. The orientation depends on how tight the flange is threaded on the casing. This shortcoming poses a problem in situations where the equipment to be attached requires a specific orientation relative to the casing.
As such, a quick connect assembly is needed which provides for the easy installation and removal of a quick connector fitting so as to allow the fitting to be used on multiple casings in the field and which allows the fitting to be oriented to any desired position relative to the casing.
SUMMARY OF THE INVENTION
The present invention is directed to quick connect assemblies allowing for the quick and releasable connection of a quick connector fitting to a well casing for providing an interface for the attachment of well related drilling equipment such as blowout preventors. In a first embodiment, a male receiver is coupled to the casing. The receiver has an annular lip formed on its outer surface near its upper open end or mouth. The annular lip has a lower surface which slopes upward in a radially outward direction. A quick connector fitting has a first cylindrical section which tapers to a smaller second cylindrical section. A flange extends radially from an upper end of the smaller cylindrical section. The flange provides the interface for attaching well related equipment. The larger cylindrical section of the fitting is slid over the mouth of the male receivers. Threaded openings are formed radially through the larger section of the fitting and are arranged circumferentially around the fitting. Lock screws are threaded through the openings to engage the lower sloping surface of the annular lip male receiver. As the lock screws are tightened, the lip sloping surface guides them downward thereby causing the fitting to seat and lock on the male receiver mouth. To remove the fitting, the lock screws are loosened.
In another embodiment, a quick connector fitting is used having an annular lip formed on its inner surface. A flange extends from an upper end of the fitting to provide the interface for attachment of the various well related equipment. The fitting lower end is slid over the casing head such that a lower surface of the annular lip is seated on the mouth of the casing. An annular groove is formed circumferentially around the outer surface of the fitting near the fitting lower end. The annular groove has a lower surface that slopes downward in a radially outward direction. A retainer slip, preferably a four piece retainer slip, having an upper and a lower annular lip is used to secure the fitting to the casing. The upper lip engages the groove, while the lower lip engages the outer surface of the casing. Teeth are formed on the face of the lower retainer slip lip that engages the casing. A clamp surrounds the retainer slip. As the clamp is tightened, it provides radial forces on the retainer slip causing the teeth formed on the lower lip to engage the casing outer surface and thus fix the position of the retainer slip relative to the casing. As the clamp is further tightened, the retainer slip upper lip engages the lower sloping surface of the groove formed on the outer surface of the fitting and causes the fitting to move downward against the casing. As a result, the annular lip formed on the inner surface of the fitting sits tightly against the casing mouth.
In yet a further embodiment, an annular bushing is threaded on the outer threads formed on the casing. Preferably the bushing is threaded downward about ¼ inch±⅛ inch from the casing mouth. An annular groove is formed on the outer surface of the bushing. The groove has an upper surface which slopes upward in a radially outward direction. A fitting is then fitted over the casing and the bushing. The fitting has an inner shoulder which sits on the mouth of the casing. On its opposite end, the fitting forms a flange for providing an interface for the well related equipment. Fasteners are threaded radially through the fitting to engage the upper surface annular groove. The sloping upper surface guides the fasteners downward thereby causing the fitting to tightly seat on the mouth of the casing and to lock on the bushing and thereby on the casing. Lock nuts may be threaded on the fasteners from the ends opposite the ends engaging the groove on the bushing. These lock nuts are threaded until they engage the outer surface of the fitting providing a radially outward force on the fasteners preventing them from loosening from the fitting.
In another embodiment an annular casing head is coupled to the casing. The casing head can be threaded directly to the casing or may be coupled to the casing using a coupling. An annular groove is formed on the outer surface of the casing head. The annular groove has an annular upper surface and an annular base.
A quick connector fitting is mated to the casing head. The quick connector fitting has a flange that extends from an upper end of the fitting for providing an interface for connecting well related equipment.
An annular drilling flange nut is threaded on the lower outer surface of the quick connector fitting. Load key bolts are fitted through radial openings formed on the flange nut. A retainer is used to retain each bolt on the flange nut. A preferably arc-shaped load key located inside the flange nut is threadedly engaged by each load key bolt. As a load key bolt is turned it causes its corresponding load key to translate radially and into the groove formed on the outer surface of the casing head. The flange nut is then further torqued causing the load keys to contact and apply a force against the upper surface of the annular groove on the casing head. As result, a downward force is applied by the flange nut on the quick connector fitting causing the quick connector to further sit on the mouth of the casing head forming a tight connection.
With any of the above described embodiments, a wear bushing may be fitted such that it provides a protecting lining to the inner surface of the casing head and a portion of the quick connector inner surface extending above the casing head. Moreover, with all of these embodiments, the quick connector fittings are preferably fastened to a groove. As a result, the fittings can be oriented to any position over the casing mouth prior to being quickly and releasably connected to the casing.
DESCRIPTION OF THE DRAWINGS
FIG. 1A is an exploded cross-sectional view of a quick connector assembly including a male receiver coupled to a well casing and a quick connector fitting.
FIG. 1B is a cross-sectional view of the assembled quick connector assembly shown in FIG. 1 A.
FIG. 2A is a partial cross-sectional view of an alternate embodiment quick connector.
FIG. 2B is a partial cross-sectional view of the quick connector shown in FIG. 2A prior to the tightening of a slip retainer clamp.
FIG. 2C is a partial cross-sectional view of the quick connector shown in FIG. 2A with the quick connector body welded to the casing.
FIG. 3 is a cross-sectional view of an alternate embodiment quick connector assembly incorporating a bushing.
FIG. 4A is an exploded cross-sectional view of an alternate embodiment quick connector assembly prior to the mounting of the quick connector fitting on to the casing head.
FIG. 4B is an enlarged cross-sectional view of the coupling member of the assembly shown in FIG. 4A coupling the casing head to the casing.
FIG. 4C is an enlarged cross-sectional view of the drilling flange nut of the assembly shown in FIG. 4 A.
FIG. 4D is another cross-sectional view of the drilling flange nut shown in FIG. 4 C.
FIG. 4E is a cross-sectional view of the assembled quick connector assembly shown in FIG. 4 A.
FIG. 4F is an enlarged cross-sectional view of the drilling flange nut of the assembly shown in FIG. 4 E.
FIG. 5A is an exploded cross-sectional view of another embodiment quick connector assembly.
FIG. 5B is a partial enlarged cross-sectional view of the casing head of the assembly shown in FIG. 5A threaded to a casing.
FIG. 5C is a cross-sectional view of another embodiment quick connector fitting assembly.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to quick connect assemblies which include a quick connector fitting (also referred to herein as a “quick connector”) that can be mounted quickly on a well casing providing an interface for the mounting of well related equipment such as blow out preventors (“BOP”). The quick connector fittings may be used and re-used on many different casings.
In a first embodiment, the quick connect assembly comprises a quick connector fitting 10 and a male receiver 12 . The quick connector fitting 10 releasably connects to the male receiver 12 which is coupled to a well casing 14 (FIGS. 1 A and 1 B). The casings typically have a diameter of 13-⅜ inches. The male receiver is typically connected to the casing using a coupling 16 . The coupling is an internally threaded cylindrical member. One end of the coupling is threaded to the external casing threads. The male receiver is then torqued to inner threads on the coupling other end.
The male receiver is typically a tubular member. The male receiver has a first end or mouth 18 for connecting with the quick connector fitting and a second end 20 for threading on the coupling. Two parallel annular lip protrusions are formed on the outer surface of the male receiver near it first end (FIGS. 1 A and 1 B). The first or upper lip 22 is formed around the mouth of the male receiver. The upper lip has an upper surface 19 that slopes downward in a radially outward direction. The upper lip also has a lower surface 23 that slopes upward in a radially outward direction. The second or lower lip 24 is formed below and spaced apart from the upper lip. An annular groove 26 is formed between the two lips.
The coupling 16 is threaded to the casing 14 . The male receiver is then torqued to the coupling. The male receiver may be torqued to the coupling using conventional tools such as tongs (not shown). Once the male receiver is torqued in place, the quick connector is fitted over the male receiver. The quick connector has a first larger cylindrical section 50 which tapers via a tapered section 52 to a second smaller cylindrical section 54 (FIG. 1 A). A flange 56 is formed around the mouth of the second section to allow for the connection of a BOP or other well related equipment. The BOP or other well related equipment may be connected to the flange prior to installation of the quick connector to the male receiver.
The larger cylindrical section of the quick connector is placed over the male receiver such that its tapered section contacts and mates with the sloping upper surface 19 of the upper lip 22 at the mouth of the male receiver. At least two internally threaded holes 58 are formed circumferentially on the larger cylindrical section of the quick connector. When in position over the male receiver, the holes 58 are aligned with an upper portion of the groove 26 formed between the lips on the male receiver (FIG. 1 B). Lock down screws 60 are then threaded through the holes and engage the lower sloping surface 23 of the upper lip. As the lock down screws are threaded farther, they ride on the sloping lower surface of the upper lip pulling the quick connector tighter against the mouth of the male receiver.
Preferably, two annular grooves 28 are formed on the inner surface of the first cylindrical section above the threaded holes 58 . A pressure or mechanically energized seal 30 is fitted in each groove. A single groove fitted with a single seal may suffice. When the quick connector is mounted on the male receiver, the seals 30 also contact the outer surface of the upper lip of the male receiver. As such, the seals form a seal against the upper lip as well as against the inner surface of the first cylindrical section of the quick connector fitting. Alternatively, the grooves 28 may be formed on the outer surface of the upper lip of the male receiver instead of the quick connector first section inner surface. The seals 30 are then seated on the grooves such that when the fitting is positioned over the male receiver, the seals will again seal against the inner surface of the first section of the quick connector and against the upper lip of the male receiver. Alternatively, the groove(s) and seal(s) may be positioned so that the seal(s) seal against the male receiver lower lip and the inner surface of the first cylindrical section of the quick connector. In a further embodiment, a seal or multiple seals may be used to form a seal against the inner surface of the quick connector and the male receiver upper lip while a second seal or second set of seals may be used to form a seal between the quick connector and the male receiver lower lip.
In an alternate embodiment, a quick connector fitting 62 is used that fits directly over the outer casing 14 (FIG. 2 A). This quick connector consists of a cylindrical body 64 . An inner annular lip 66 is formed on the inner surface of the cylindrical body. An outer annular flange 68 is formed on the upper end of the cylindrical body. The upper flange serves as the connection interface with the BOP or other well related equipment. An annular groove 72 is formed on the outer surface of the cylindrical body near the body lower end (FIG. 2 B). In cross-section, the groove has an upper surface 74 , a base 76 parallel to the longitudinal axis of the body and a lower surface 78 that slopes downward in a radially outward direction.
One, but preferably two, spaced apart annular grooves 80 are formed on the inner surface of the body below the inner annular lip (FIG. 2 A). These grooves are designed to accommodate pressure or mechanically energized seals (not shown). In an alternate embodiment, an injection fitting 82 and a pressure relief fitting 84 are fitted in the wall of the body such that they extend from the outer surface of the body to an inner groove. The injection fitting and the pressure relief fitting should be spaced preferably 180° apart. An injection and a pressure relief fitting may be incorporated for each of the inner grooves.
The quick connector is slid over the outer surface of the casing 14 until the lower face 70 of the inner lip 66 rests against the mouth 86 of the casing. In the embodiment where the inner annular grooves 80 are fitted with seals, the seals must be fitted in the grooves prior to the installation of the quick connector over the casing.
A retainer slip 88 is fitted over the quick connect. The retainer slip is preferably in four pieces, each forming a 90 degree arc. However, a two or more piece retainer slip may also be used. The retainer slip consists of a lower annular lip 90 extending radially inward. Teeth 92 are formed on the inner surface of the lower annular lip. The retainer slip also has an upper inwardly extending annular lip 94 that has a shape complementary to the shape of the groove 72 formed on the outer surface of the quick connector body. As such, the lower surface 96 of the retainer slip upper lip slopes downwardly in a radially outward direction such that it is complementary to the bottom sloped surface 78 of the annular external groove formed on the quick connector body.
A slip retainer clamp 98 is clamped around the retainer slip so as to hold all the retainer slip pieces in place. As is apparent to one skilled in the art, it may be preferable to place the retainer slip and clamp over the casing prior to the placement of the quick connector body over the casing. In this regard, when the body is fitted over the casing, the slip may be easily moved over the quick connector body and clamped into place.
Initially, the clamp is tightened just enough to hold the retainer slip pieces in place as shown in FIG. 2 B. When this occurs the tip portion 100 of the retainer slip upper lip is in contact with the lower sloped surface 78 of the groove formed on the body outer surface. As the clamp is further tightened, the teeth 92 formed on the inner surface of the lower lip of the retainer slip bite onto the outer surface of the casing 14 fixing the relative position between the casing and the retainer slip. As the clamp is further tightened, it causes the lower sloped surface 96 of the upper lip of the slip to attempt to travel up the lower sloped surface 78 of the external groove. As a result, the retainer slip, which is now fixed relative to the casing, causes the quick connector body to move downward and therefore the body inner lip lower surface 70 to tightly engage the mouth 86 of the casing.
If the body has injection and pressure relief fittings, a sealing material 81 may be injected into the annular grooves through the injection fittings 82 until it is relieved through the pressure relief fittings 84 to form a seal between the casing and the connector.
A production or inner casing 102 is always fitted within the casing 14 (i.e., the outer casing) forming an annulus 104 therebetween (FIG. 2 C). In many situations, after drilling is completed, a predetermined amount of cement is pumped down the production casing until it exits the lower end production casing and comes around filling and sealing the annulus.
For proper sealing, the Department of Oil and Gas (“DOG”) requires that the annulus is completely filled with cement. As such, enough cement must be pumped to fill the annulus. If more cement than required to fill the annulus is pumped, the cement will stay within the bottom of the production casing creating a blockage. As such, operators are inclined to be conservative in the amount of cement pumped into the production casing. As a result, sometimes the amount of cement pumped may be insufficient and does not fill the annulus completely. In these situations, the DOG permits the use of an automatic casing hanger 106 —or with a pack-off hanger (not shown) or with a mandrel casing hanger (not shown)—fitted within the quick connector as a supplement for sealing the annulus. Automatic casing hangers, pack-off hangers and mandrel casing hangers are well known in the art. When a hanger is used for sealing, the quick connector becomes a permanent fixture of the casing and thus, cannot be used with another casing. For economic purposes, however, it is recommended that the retainer clamp 98 and retainer slip 88 are removed so that they can be re-used. In their stead, the lower edge 108 of the quick connector body is welded to the outer casing.
In a further embodiment, an annular bushing 110 is threaded hand tight on the outer threads 111 formed on the outer surface of the casing head 112 (FIG. 3 ). The casing head is coupled to the open end of a casing (not shown), preferably by threading. The outer bushing is preferably threaded down a distance 116 of about ¼ inch±⅛ inch from the casing head mouth 120 . A circumferential groove 129 is formed on the outer surface of the bushing. The groove has an upper surface 146 that slopes upward in a radially outward direction. A quick connect fitting 124 is fitted over the bushing and the casing head.
The quick connector fitting has an upper and a lower section. The lower section defined by an annular lip wall 128 which defines a first opening with a diameter slightly larger than the bushing outer surface diameter. At least two internally threaded holes 126 are defined circumferential through the wall 128 . A second opening 132 is defined in the upper section of the fitting. The second opening concentric to and in communication with the first opening and has a diameter preferably equal to the inner diameter of the mouth of the casing head. A flange 134 is formed at the mouth 136 of the upper section for mating with a BOP or other well related equipment. An internal annular shoulder 138 is formed at the interface between the upper and lower sections of the flange member. An annular groove 140 is formed on the shoulder to accommodate a pressure or mechanically energized seal 141 .
The fitting is fitted over the bushing and rotated to a desired position. When the flange is fitted over the casing head, the seal sits on the mouth 127 of the casing head. When the fitting is seated on the casing head mouth, the threaded hole 126 centers will be located at a level aligned with an upper portion of the bushing circumferential groove. Lock down screws 142 having a threaded head 145 are then threaded through the threaded holes. The lock down screw heads have a tip portion 144 that is frusto-conical in shape having a frusto-conical surface 143 . As the lock down screws are threaded into the holes their tip portions first engage the sloping upper surface 146 of the bushing groove. As they are further threaded on the fitting they ride against the groove upper sloping surface pulling the quick connector fitting further downward and creating a tight seal between the fitting shoulder, the seal, and the mouth of the casing head. Consequently, the fitting is locked on the bushing and thereby on the casing head. Because the fitting locks against a groove (i.e., the bushing groove 146 ), the fitting can be rotated and locked at any desired position.
In a further embodiment, the lock down screws 142 have a section 150 of their shaft threaded. This threaded shaft section is spaced apart from the threaded head section of the screws which engage the threaded holes 126 . A lock nut 152 is threaded on the threaded section 150 formed on the shaft of each screw after the screws have locked the fitting on the bushing. The lock nut 152 has a central threaded bore section 154 which extends into a non-threaded bore section 156 . The non-threaded bore section has a diameter larger than the threaded bore section. As the nut is screwed on the threaded shaft, its unthreaded bore section contacts the fitting annular wall 128 outer surface. As it is further screwed, it exerts a radial outward force on the screw which is threaded on the fitting wall, thereby locking the screw in place. A retainer ring 158 may then be fitted on the screw behind the nut to prevent the nut from getting lost if it were to loosen. The screw with lock nut can be preassembled with the retainer ring in place.
In another embodiment an annular casing head 212 is coupled to the casing 214 using an annular coupling member 216 (FIG. 4 A). Typically the casing head has a first annular portion 218 which tapers into a second annular portion 220 via a truncated cone shaped annular third portion 222 . The first portion has an inner diameter greater than the inner diameter of the second portion. The second portion has threads 224 formed on its outer surface at its and furthest from the first portion. The inner surface of the third portion defines a shoulder 226 that slopes upward in a radially outward direction.
The coupling member 216 is a cylindrical member having inner threads. Preferably two sets of threads are formed beginning on the inner surface of the coupling member, one set at either end. The first set of threads 228 are matched to the outer threads 224 formed on the second portion of the casing head (FIG. 4 B). The second set of threads 230 are matched to the outer threads 232 on the casing. The coupling through its second set of threads is threaded on the outer threads of the casing. The casing head is then threaded onto the first set of the coupling threads.
An annular groove 234 is formed on the outer surface of the first portion of the casing head near the intersection of the first portion with the truncated cone shaped portion. The annular groove has an annular upper surface 236 and an annular base 238 .
A quick connector fitting 240 is then mated to the casing head. The quick connector fitting has a first section 242 which extends into a second section 244 forming an inner annular shoulder 246 at interface between the first and second section inner surfaces. In other words, the fitting first section has an inner diameter is larger than the inner diameter of the second section. The length of the first section as measured from the annular shoulder should be slightly less then the length 250 measured from the mouth of the casing head to the upper surface of the annular groove. A flange extends from the end of the second section opposite the first section providing an interface for connecting well related equipment.
Preferably two annular grooves 254 are formed on the inner surface of the first section, preferably on the upper thicker wall portion of the section. A flange seal 256 , which is typically an 0 -ring seal, is fitted into each groove. An annular wall 252 defines the fitting first section. The annular wall 252 is thinner at the open or lower end of the first section. However, the inner diameter of the first section in constant throughout the length of the section. Threads 260 are formed on the outer surface of the lower thinner portion 258 of the fitting first section.
An annular drilling flange nut 262 has an annular upper section 264 , an annular intermediate section 266 and an annular lower section 268 (FIGS. 4 A and 4 C). The inner surface diameter of the upper section is smaller than the inner surface diameter of the intermediate section and greater than the inner surface diameter of the lower section. The inner surface diameter of the lower section should preferably be at least slightly larger than the outer surface diameter of the casing head first section 218 . The three sections form an annular channel 272 . Threads 270 are formed on inner surface of the upper annular section matched to the threads 260 on the outer surface of the lower portion 258 of the fitting first section.
The outer surface of the drilling flange nut 242 preferably has an octagonal shape providing grip 274 areas for torquing on to the fitting using a wrench or a hammer (FIG. 4 D). Radial openings 276 are formed equidistantly through the nut outer surface penetrating the nut intermediate section and exiting on the annular channel 272 formed on the inner surface of the flange nut. The openings are formed to accommodate load key bolts 278 . Each load key bolt is rotatably connected to a retainer 280 . The retainer is perpendicular to the load key bolt. Each load key bolt can rotate relative to, but cannot longitudinal translate through, its corresponding retainer. The load key bolts are fitted through the radial opening 276 on the flange nut and the retainer 280 is bolted on the outer surface of the flange nut using retainer bolts 282 .
A tip portion 286 of each load key bolt shaft extending radially beyond its corresponding radial opening 276 is threaded. Each load key bolt is able to freely rotate relative to its corresponding opening 276 formed on the flange nut. An arc shaped load key 288 is threaded to each threaded shaft portion 286 . In a preferred embodiment, eight load keys are used, one for each load key bolt. Each load key is an eighth of a ring section. The load key bolt is threaded to a threaded opening 290 formed on the center section of the load key causing the load keys to translate radially outward and rest against the annular channel 272 formed on the flange nut.
The inner surface diameter of the quick connector first section 242 is slightly greater than the outer surface diameter of the casing head first portion 218 . The quick connector is slid over the casing head until the annular shoulder 246 sits on the mouth 292 of the casing head (FIG. 4 E). When at this position, the lowest end 243 of the fitting first section 242 extends almost to the upper surface 236 of the annular groove formed on the outer surface of the casing head. The fitting is rotated in relation to the casing head to a desired orientation.
The flange nut is then threaded to the outer threads 260 formed on the first section of the fitting. The flange nut may also be pre-threaded on the first section of the fitting prior to mounting the fitting over the casing head. When the flange nut is threaded on the fitting, the load keys are sandwiched between the lower portion 288 of the flange nut 262 and the lower end 243 of the fitting first section.
The flange nut is threaded sufficiently for aligning the load keys with the groove 234 formed on the outer surface of the casing head. Each load key bolt is then rotated causing its respective load key to unthread from the load key bolt and travel radially inward into the groove 234 formed on the casing head (FIG. 4 D). The load keys bolts are rotated until the load keys stop against the base 238 of the casing head groove without exerting a force on the groove. When in that position, preferably, all the load keys abut each other forming a continuous ring.
The flange nut is then further torqued on the lower portion of the fitting first section causing the load keys to contact and apply a force against the upper surface 236 of the annular groove 234 on the casing head (FIG. 4 F). As result, a downward force is applied by the flange nut on the quick connector first section causing the quick connector to further sit on the mouth 292 of the casing head forming a tight connection.
In an alternate embodiment, a casing head 312 is directly threaded on to the casing 314 (FIGS. 5 A and 5 C). With this embodiment, the casing head has a first portion 318 . A second portion 320 extends below from the first portion. Threads 394 are formed in the lower inner surface of the second portion. These threads are matched to threads 328 formed on the outer surface of the casing head allowing for the torquing of the casing head to the casing (FIG. 5 B). An annular lip 396 is formed on the inner surface of the second portion. The annular lip formes an upper shoulder 395 that slopes upward in a radially outward portion direction. In addition, the annular lip forms a lower annular shoulder 326 . The quick connector fitting 340 mates with the casing head as described above in relation to the previous embodiment. The quick connector fitting also has a first section 342 which extends into a second section 344 forming an inner annular shoulder 346 at the interface between the first and second section inner surfaces.
With any of the above described embodiments, a wear bushing 400 (FIGS. 4E and 5C) may be fitted such that it lines the inner surface of the casing head first portion 218 , 318 and a portion of the quick connector inner surface extending above the casing head first portion. When in position, typically, the bottom edge 401 of the wear bushing which is sloped mates with and rests against the sloping shoulder 226 , 326 formed on inner surface of the casing head. Preferably, a threaded hole 298 , 398 is formed radially through the second section 244 , 324 of the quick connector fitting near the fitting inner shoulder 246 , 346 . When the wear bushing is properly seated, the threaded hole provides access to an outer surface of the bushing. A lock screw 299 , 399 is threaded through the threaded hole for engaging and locking the wear bushing in place.
With any of the aforementioned embodiments, the BOP 8 (FIGS. 4A, 4 E, 5 A, 5 C) or other well related equipment is connected, typically by fasteners, to the fitting. In this regard, the BOP or other well related equipment can be easily connected to or disconnected from the well casing.
Although the present invention has been described and illustrated to respect to multiple embodiments thereof, it is to be understood that it is not to be so limited, since changes and modifications may be made therein which are within the full intended scope of this invention as hereinafter claimed. | A quick connector fitting assembly is provided which includes a fitting which releasably connects to a well casing for providing an interface for the attachment of various types of well related equipment. The quick connector fitting connects using fasteners to a lip or groove formed on the casing. The fasteners can easily connect or disconnect from the groove or lip facilitating the quick connection and disconnection of the fitting from the casing. |
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BACKGROUND OF THE INVENTION
Various means have been proposed to increase the security of closures, such as cabinet drawers and doors, against unauthorized opening movements, and/or to give clear visual indication of the occurrence of any such unauthorized movement.
In typical cabinets, such as may be defined by the desk pedestal or a separate filing cabinet employing closures in the form of sliding drawers and by storage cabinets employing closures in the form of swinging doors, it is conventional practice to provide the cabinet or its individual closures with built-in, key operated locks for security purposes. Drawbacks of typical cabinets involve the ease with which its key operated lock(s) may be tampered with in the absence of later observable signs of unauthorized entry and/or the difficulty with which persons, such as security personnel, may determine the locked/unlocked condition of the cabinet closures without manual inspection/manipulation. To overcome these drawbacks, it has long been the practice, when maximum security is required, to retrofit commercially available cabinets with security bars, which are sized to bridge across the cabinet closures and have their opposite ends secured to closure bounding portions of the cabinet frame by means of one or more padlocks, whose locked/unlocked condition is visually discernible without resort to manual inspection. For cases wherein less than all of the closures of any given cabinet are required to be afforded extra security, it has been normal practice to fit each closure to be afforded extra security, with a conventional hasp intended to be releasably secured to an associated frame mounted staple by means of a padlock; such hasps typically being similar in construction and mode of operation to hasps conventionally employed to secure diverse types of single swinging doors in closed condition relative to their associated door frames.
SUMMARY OF THE INVENTION
The present invention is directed to security devices and more particularly to an improved hasp construction for use in releasably securing a pair of adjacently disposed closures in a closed condition relative to a closure bounding, cabinet frame; the present hasp being equally adapted for use with closures in the form of sliding drawers or in the form of swinging doors.
The present hasp has for instance, utility in cabinets having extra security requirements for only two adjacent drawers of a three or more drawer cabinet installation, such as the bottom or top two drawers provided in a standard three drawer desk pedestal. The advantage stemming from the use of the present hasp construction, as opposed to hasps of prior practice, is that one hasp and one padlock serves to replace two conventional hasps and two padlocks previously required. Moreover, the time required for authorized personnel to properly secure the drawers in closed condition and unlock same is reduced essentially by one half.
More specifically, the present hasp includes a first plate secured to one of the closures and a second plate hingedly mounted on the first plate for movement between an operative position in which it overlies the second closure and cooperates with a frame mounted staple to releasably secure both of the closures in their closed conditions and inoperative position in which it is removed from cooperative association with the staple and arranged to overlie the first closure to permit selective opening movements of the closures relative to one another and the frame.
DRAWINGS
The nature and mode of operation of the present invention will now be more fully described in the following detailed description taken with the accompanying drawings wherein:
FIG. 1 is a fragmentary front elevational view of a desk pedestal cabinet having a pair of adjacent sliding drawers releasably secured in closed condition by the security device of the present invention;
FIG. 2 is a sectional view taken generally along the line 2--2 in FIG. 1;
FIG. 3 is a view similar to FIG. 2, but showing the hasp in inoperative condition; and
FIG. 4 is a fragmentary front elevational view of a cabinet having a pair of adjacent swinging doors releasably secured in closed condition by the security device of the present invention.
DETAILED DESCRIPTION
Reference is first made to FIG. 1, wherein a cabinet is generally designated as 10 and shown for example as being defined by a desk pedestal having a plurality of closures in the form of drawers 14 slidably supported by a drawer bounding cabinet frame 16 for independent movement between closed and open conditions. The construction and design of cabinet 10 may be conventional in all respects and thus forms no part of the present invention other than as same is employed in combination with the security device of the present invention, which is generally designated as 20 in FIGS. 1-3. However, to facilitate description of the present invention, including an understanding of the mode of operation thereof, cabinet 10 will be described in part as including at least two adjacently disposed drawers, including a first drawer 14a and a second drawer 14b forming for example, the upper two drawers of a desk pedestal, wherein such drawers include front surfaces 22a and 22b; end edges 24a and 24b; and parallel side edges 26a and 26b. End edges 24a and 24b are disposed in essential alignment and side edges 26a and 26b are disposed relatively adjacent one another when drawers 14a and 14b are disposed in their closed positions shown in FIGS. 1 and 2. Further, in the illustrated cabinet construction, frame 16 is shown in part as including a frame member 16a extending along drawer end edges 24a and 24b and transverse frame members 16b extending lengthwise of drawer side edges 26a and 26b.
Reference is now made to FIGS. 1-3, wherein security device 20 is shown as generally including a hasp 30 formed in accordance with a preferred form of the present invention and means, such as a staple 32, arranged to cooperate with hasp 22 for purposes of releasably securing drawers 14a and 14b in closed condition relative to frame 16. Hasp 22 includes a rigid, one piece first plate 34, which is suitably fixed to lie in engagement with front surface 22a of first drawer 14a, such as by means of bolt fasteners 36 extending through plate apertures, not shown; a rigid, one piece second plate 38 having an elongated slot 40; and hinge means 42 for joining one of the side edges 38a of second plate 38 to an adjacent side edge 34a of first plate 34 for swinging movement about a hinge axis 42a between an operative position shown in FIGS. 1 and 2, and an inoperative position shown in FIG. 3.
In a typical installation illustrated by way of example in FIG. 1, first plate 34 is fixed adjacent an upper right hand corner of front surface 22a with its side edge 34a and one of its end edges 34b arranged essentially parallel to drawer side edge 26a and end edge 24a, respectively. The exact positioning of first plate 34 relative to side edge 26a of first drawer 14a is not critical, so long as the transverse dimension of second plate 38, as measured between its side edges 38a is sufficient to permit the second plate, when in its operative position to bridge across drawer side edge 26b and lie in a position for abutting engagement with front surface 22b of second closure 14b, as shown in FIGS. 1 and 2, while at the same time permitting the second plate, when swung into its inoperative position, to be removed from such position, as shown in FIG. 3 in order to free second drawer 14b for unobstructed opening movements relative to both first drawer 14a and frame 16. Again, the exact positioning of first plate 34 relative to end edge 24a of first drawer 14a is not critical, so long as the lengthwise dimension of second plate 38, as measured lengthwise of hinge means 42 is sufficient to permit the second plate, when in its operative position, to bridge across drawer end edge 24b for cooperation with staple 32 for purposes of securing drawers 14a and 14b in their closed positions. Preferably, plates 34 and 38 are in the form of generally rectangular metal plates, wherein second plate 38 has a length exceeding that of plate 34, such that a portion thereof containing slot 40 is arranged for overlying engagement with frame member 16a, when first plate end edge 34b is disposed in alignment with first drawer end edge 24a.
The construction of staple 32 and the mode of attaching same to frame member 16a may be conventional and thus forms no part of the present invention. However, for purposes of illustration, staple 32 is shown as being of a typical U-shaped configuration and as having its leg portions 32a suitably fixed to upstand from a mounting plate 32b, which may in turn be suitably fixed to frame member 16a, such as by threaded fasteners or bolts 32c. When staple 32 utilizes a mounting plate, as opposed to having the ends of its leg portions connected directly to frame member 16a, it would be desirable to bend second plate 38 in the area designated as 38b in FIG. 1 to provide a main plate portion 38c and an offset, parallel extension or locking portion 38d adapted to be disposed in simultaneous engagement with drawer front surface 22b and the outer surface of mounting plate 32b, respectively.
The size of staple 32 is not critical, so long as same is sufficient to receive the shackle 44a of a conventional key or combination style padlock 44 for purposes of releasably retaining the staple seated within slot 40. In like manner, the size of slot 40 is not critical, so long as same is sufficient to removably receive staple 32, as second plate 38 is pivoted between its operative and inoperative positions shown in FIGS. 2 and 3, respectively. However, it is desirable that slot 40 and staple 32 be arranged such that same are lengthwise bisected by a plane, not shown, arranged normal to hinge axis 42a.
Hinge means 42 may be of any desired construction, so long as it serves to prevent unauthorized separation of plates 34 and 38. However, hinge means 42 is shown as comprising a plurality of interfitting hinge curls 42b formed integrally with side edges 34a and 38a of plates 34 and 38, respectively; and a hinge pin 44c, which freely extends through the curls, but is permanently secured therewithin by suitable means, such as by welding same to an endmost curl 42b'.
From the foregoing, it will be understood that, when second plate 38 is in its operative position with staple 32 received within slot 40 and shackle 44a in turn received within the staple, second plate 38 is retained in position for engagement with surface 22b of second drawer 14b, thereby preventing opening movements thereof; retention of the second plate in this manner additionally serving to prevent opening movements of first drawer 14a, due to the hinge connection between the second plate and first plate 34. When it is desired to open drawers 14a and/or 14b, padlock 44 would be unlocked and shackle 44 removed from within staple 32 to free second plate 38 for pivotal movement into an inoperative position, such as the position shown in FIG. 3, wherein the second plate will not obstruct opening movements of second drawer 14b and/or interfere with independent opening movements of first drawer 14a.
Reference is now made to FIG. 4, wherein security device 20 is shown as being identical in construction and mode of operation to that described with reference to FIGS. 1-3, but employed in association with a cabinet 10' of the type having a pair of adjacently disposed closures 14' in the form of doors 14a' and 14b', which are supported on a cabinet frame 16' by hinge means 48a and 48b for oppositely directed swinging movements from their illustrated closed positions about hinge axes arranged parallel to the axis of hinge means 42. For purposes of reference, portions of doors 14a' and 14b' and frame 16', which correspond to drawers 14a and 14b and frame 16 are designated by like primed numerals.
Although the security device of the present invention has been described with reference to its use with only two types of cabinets, it will be understood that its use is not so limited. Further, it will be understood that, while the preferred form of the invention employs a conventional staple positioned for receipt within a through slot defined by the second or hinged plate of the present hasp, the invention is not limited thereto. Rather, it is contemplated that any suitable means may be employed to releasably lock the second plate to a cabinet frame, so long as same is properly positioned on the frame for cooperation with such second plate when disposed in its operative position. | An improved hasp construction is disclosed for use in releasably securing a pair of adjacently disposed closures in a closed condition relative to a closure bounding frame; the hasp including a first plate secured to one of the closures and a second plate hingedly mounted on the first plate for movement between an operative position in which it overlies the second closure and cooperates with a frame mounted staple to releasably secure both of the closures in their closed condition and inoperative position in which it is removed from cooperative association with the staple and arranged to overlie the first closure to permit selective opening movements of the closures relative to one another and the frame. |
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FIELD OF THE INVENTION
[0001] This invention relates generally to the field of in situ hydrocarbon extraction and more particularly to in situ extraction of hydrocarbons by means of a condensing solvent process which mobilizes the hydrocarbons for extraction by, for example, gravity drainage.
BACKGROUND OF THE INVENTION
[0002] Tar sands or oil sands such as are found in Canada, contain vast reserves of hydrocarbon resources of the type referred to as heavy oil or bitumen. Such heavy oil or bitumen is a hydrocarbon that has a high specific gravity and viscosity. These properties make it difficult to extract the hydrocarbon from the tightly packed sand formations in which it is found because unlike lighter oil deposits, heavy oil and bitumen do not readily flow at in situ conditions.
[0003] In prior Canadian Patent No. 2,299,790, a condensing solvent based in situ hydrocarbon recovery process is disclosed. This patent teaches, among other things, using a condensing solvent and controlling the in situ pressure to achieve a condensation temperature for the solvent within the formation which is suitable for reducing a viscosity of the in situ hydrocarbon by warming and solvent effects so that the hydrocarbon will flow under the influence of gravity. The result of this process is a volume in the formation which is stripped of the mobilized hydrocarbons, and which is called a gravity drainage chamber. As more solvent is circulated more hydrocarbon is removed resulting in a chamber which grows upwardly and outwardly from the injection well.
[0004] Canadian Patent No. 2,351,148 teaches, among other things, using a solvent which has been purified sufficiently to allow the solvent to achieve bubble point conditions at the extraction interface of the gravity drainage chamber whereby non-condensable gases naturally arising from the warming bitumen or hydrocarbon will be carried away with the draining liquids also in liquid form. In this way, a continuous extraction process is achieved at the extraction interface, because the potential impediment of an insulating layer of non-condensable gases existing between the incoming condensing solvent and the extraction interface is removed as part of the process.
[0005] The geological characteristics of the tar sands or oil sands can vary from deposit to deposit. While some deposits are relatively thick deposits in the order of 40 to 50 or more metres thick, many deposits are relatively thin being less than 20 metres thick and in many cases even 10 metres or less thick. In addition, the characteristics of the overburden can vary considerably. In some cases, the overburden is comprised of the cap rock which can act as a containment layer, but in other cases the overburden may be a sand layer or gravel or other porous material that provides poor confinement.
[0006] Where good confinement is available it is preferred to let the chamber grow to all the way to the overburden layer to extract all of the available hydrocarbon, but, leaving the overburden exposed to condensing solvent in the chamber is undesirable. More specifically, the overburden will continue to attract condensing solvent and the latent heat of condensation of such condensing solvent will be passed to the overburden but to no useful extraction effect. There is simply no hydrocarbon located in the overburden which can be warmed and removed. Therefore, any heat transfer to the overburden layer is wasted, thereby reducing the efficiency of the condensing solvent process.
[0007] In some cases, the overburden layer may not be a good confinement layer. In cases where the overburden layer is sand or other porous material it may also be saturated with water. In such a case, if the chamber growth extends vertically to the overburden layer the water will be provided with a pathway into the chamber which could result in the chamber being water flooded. Once the chamber is water flooded, further extraction from the chamber through a condensing solvent process is unlikely. Thus, when poor confinement exists it is preferred to stop vertical chamber growth at a point below the overburden layer to preserve a layer of hydrocarbon to that provides the necessary confinement.
SUMMARY OF THE INVENTION
[0008] What is desired is a method of controlling the location in the gravity drainage chamber where the solvent condensation occurs to control the flow of heat and chamber growth in a condensing solvent process to more efficiently extract in situ heavy oil and bitumen from an oil sand deposit under an overburden layer. In other words, it is desirable, in some circumstances, to preserve the integrity of a layer of bitumen saturated sand at the top of the reservoir in order to provide a confining barrier for the extraction chamber. In other circumstances it is desirable to control the location of condensation in the extraction chamber in order to maximise the thermal efficiency of the condensing solvent process.
[0009] According to the present invention the growth of the extraction chamber in situ can be controlled through the accumulation of non-condensable gases within the extraction chamber that act as a thermal barrier between the condensing solvent on a warm side of said layer, and the overburden or unextracted bitumen on a cold side of said layer. The vapour density of the non-condensable barrier gas, relative to the vapour density of the solvent vapour, at in situ or extraction conditions can be selected to optimize chamber growth and improve extraction effectiveness. By accumulating non-condensable gases having a vapour density which is less than the vapour density of the condensing solvent at extraction conditions, the barrier layer can be preferentially located or floated to a top or attic of a gravity drainage chamber. In this manner, vertical heat flow and vertical chamber growth can be restricted when desired, without stopping continued chamber growth in other directions, such as horizontally along a bitumen layer. By limiting vertical heat flow and vertical growth while encouraging horizontal growth, the horizontal wells may be spaced within the layer to optimise capital costs.
[0010] According to a preferred aspect of the current invention, a relatively pure solvent can be used to commence initial extraction of hydrocarbons in situ to form an extraction chamber. According to the invention of Pat. No. 2,351,148 the purer the solvent the more non-condensables can be removed from the extraction chamber. Most preferably, the removal of heat transfer poisoning non-condensable gases, which arise for example, from the mobilization and extraction of the reduced viscosity hydrocarbons will occur at a rate that prevents non-condensable gas from accumulating within the extraction chamber, thereby permitting continued chamber growth to occur.
[0011] According to the present invention, the vertical heat flow and vertical growth of the chamber can be measured over time and at a time at or before the vertical growth reaches the top of the bitumen layer, i.e., reaches to the overburden layer, the solvent purity can be temporarily varied to permit non-condensable barrier gas to accumulate in the chamber. The non-condensable barrier gas can arise either naturally from the bitumen which is being warmed and extracted, or, can be specifically added to the solvent to be carried to the extraction surface by the solvent within the chamber and may be one or more than one species of non-condensable gases.
[0012] Therefore, according to one aspect of the present invention there is provided a method of forming an in situ gravity drainage chamber while extracting hydrocarbons from a hydrocarbon bearing formation, the method comprising:
[0013] a. Injecting a condensing solvent which is sufficiently pure, having regard to the in situ conditions, to extract non-condensable gases from said chamber in liquid form;
[0014] b. Monitoring a growth of said chamber in a vertical direction; and
[0015] c. Establishing a non-condensable barrier gas layer at a top of said chamber to reduce the vertical heat flow and vertical growth rate of said chamber at or before said chamber reaches an overburden layer.
[0016] According to a further aspect of the invention there is provided a method of forming an in situ gravity drainage chamber in a hydrocarbon bearing formation comprising injecting a condensing solvent into said formation and varying a solvent purity over time to cause enough of a barrier gas to be introduced into said chamber to halt vertical growth of said chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Reference will now be made to preferred embodiments of the present invention, by way of example only, and in which:
[0018] FIG. 1 shows a schematic of solvent purity of injected solvent over time according to one aspect of the present invention;
[0019] FIG. 2 shows an extraction chamber being extracted during an initial stage with substantially pure solvent according to the present invention;
[0020] FIG. 3 shows the chamber of FIG. 2 at a later stage of extraction where the vertical growth of the chamber has reached a desired upper limit and a barrier gas is being accumulated in the chamber at the extraction (condensation) interfaces;
[0021] FIG. 4 is a different cross section view of the chamber of FIG. 3
[0022] FIG. 5 is a subsequent cross-section view similar to FIG. 4 ; showing that after a period of time, the barrier gas floats up towards the top of the chamber and begins to accumulate there;
[0023] FIG. 6 is the chamber of FIGS. 3 and 4 after a further period of time under substantially pure condensing solvent injection showing the continued horizontal extraction or growth of the chamber but very limited vertical growth according to the present invention;
[0024] FIG. 7 shows a buoyancy curve of methane in propane at various pressures and saturation temperatures;
[0025] FIG. 8 shows a buoyancy curve of methane and hydrogen or a 1:1 ratio in propane at various pressures and saturation temperatures; and
[0026] FIG. 9 shows the mol fraction of propane solvent in the saturated vapour as a function of chamber pressure and local temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] In FIG. 1 , a time line schematic is provided that generally illustrates the trends of purity of the injected condensing solvent over time according to a first aspect of the present invention. The horizontal or x-axis represents time, and the vertical or y-axis represents solvent purity. A horizontal denoted line 10 is also shown, which represents a desired purity of the solvent which is capable of extracting hydrocarbons and bitumen from the formation. This purity is referred to here in as extraction purity since at this purity hydrocarbon extraction occurs. Extraction purity means a solvent that is pure enough to continuously remove non-condensable gases from the chamber. The precise solvent purity required for extraction purity will vary from reservoir to reservoir depending upon in situ conditions such as pressure, temperature and amount of non-solvent gas naturally present and dissolved into the bitumen.
[0028] Also shown is an injected solvent purity line 12 , which represents the purity of the injected condensing solvent over time. For efficient non-condensable gas removal the extraction purity is able to achieve bubble point conditions for the condensing solvent at the extraction interface in the chamber. To achieve effective chamber growth rates, it is most desirable to remove any such expressed non-solvent gases, which are non-condensable at extraction conditions, from the chamber. At extraction purity for the solvent such other gases are able to dissolve into the solvent condensing onto the bitumen interface to permit these other gases to be carried away in a liquid form out of the chamber.
[0029] As fresh solvent is continually injected into the extraction chamber, it condenses onto and mobilizes the bitumen, scavenges other non-solvent gases present and results in a liquid mixture of solvent and hydrocarbons and other liquids draining down the chamber walls to collect in the bottom of the extraction chamber. From there the liquids are lifted or pumped to the surface for separation of solvent and hydrocarbons and then purification and preferably reuse of the solvent in the formation. Over time the extraction chamber will grow as more solvent is circulated and more hydrocarbon and bitumen is produced. Provided that the bubble point conditions are achieved at the interface, due to the solvent being at extraction purity, the chamber will grow outwardly both horizontally and vertically without undue accumulations of non-condensable gases occurring within the chamber. As the chamber grows, the vertical growth will eventually reach a point where it is at or near the overburden, or at a maximum desired vertical height.
[0030] According to the present invention, it is desirable to monitor the vertical growth of the chamber to be able to identify when the vertical growth is at or near the overburden layer or more specifically at an optimum height. This, according to the present invention, is the time to preferentially reduce and restrict further vertical growth. The preferred means used to measure vertical growth of the chamber of the present invention is discussed in more detail below.
[0031] FIG. 2 shows an injection well 20 with extraction purity condensing solvent being injected (arrows 22 ) during an initial time period 15 ( FIG. 1 ). The condensing solvent 22 exits the injection well 20 into an extraction chamber 24 where it is shown flowing by convection outwardly as arrows 23 . It condenses on the extraction interface and results in draining liquids 26 which drain down the sides of the chamber 24 under the influence of gravity. These liquids 26 enter the production well 28 , and are pumped to the surface by a pump 30 . The hydrocarbon bearing formation 32 includes an overburden layer 34 , a hydrocarbon pay zone 36 , and an underburden 38 . FIG. 2 depicts the chamber at a point in time towards the end of the time period 15 of FIG. 1 .
[0032] While FIG. 2 and the other figures depict horizontal well pairs it will be understood that the wells need not be truly horizontal and may be sloped or the like. Thus the term horizontal as used herein means somewhat or generally horizontal. Further other well configurations are contemplated by the present invention, such as a generally vertical single well arrangements or configurations of multiple generally horizontal wells.
[0033] As can now be understood, during this part of the process (time period 15 ) the solvent has extraction purity and gases other than the solvent gas, which are noncondensable at the condensing conditions for the solvent, are being removed from the chamber 24 at a rate which permits extraction to continue. In other words, these other gases are not allowed to accumulate in the chamber to any significant degree during this step in the process and thus are not present in FIG. 2 . Time period 15 ends when the extraction chamber has reached its desired maximum height.
[0034] Once the maximum chamber height is reached, the present invention provides that the solvent purity of the injected condensing solvent is changed. This is shown in FIG. 1 , at 14 . At this point, it is desirable to reduce the solvent purity and introduce more non-condensable barrier gas into the chamber, in other words the injection solvent purity is no longer at extraction purity. The change in injection solvent purity will have two in situ effects according to the present invention. The first effect is that more non-condensable barrier gas will be carried into the chamber by the solvent itself and then concentrated at the condensation surfaces as the solvent condenses. The second effect is that the condensed liquid solvent leaving the chamber is less able to extract the non-solvent gases arising naturally in the formation as liquids as the solvent is somewhat or fully saturated with barrier gases already. Depending upon how far below extraction purity the solvent is it can only scavenge barrier gases from the chamber at a reduced rate, if at all. As a result, non-solvent barrier gases now begin to accumulate within the chamber, at the condensation surfaces, over the time period 16 of FIG. 1 .
[0035] According to the present invention the preferred non-solvent barrier gas is a light gas having a vapour density which is most preferably significantly lower than the vapour density of the solvent at extraction or in situ conditions. The density difference should be sufficient, at the extraction chamber temperature and pressure to permit the barrier gas to accumulate at a preferred location in the chamber, such as at the roof of the chamber as described below.
[0036] FIG. 3 shows the in situ conditions in the extraction chamber corresponding to the end of the time period 16 on FIG. 1 . As shown in FIG. 3 , as the condensing solvent carries the non-condensable or barrier gas into the formation where it will be released at the extraction interface around the perimeter of the chamber when the solvent condenses. The barrier gas will, over time, build up as a relatively thick barrier layer 50 on all of the surfaces on which the condensing solvent is condensing.
[0037] FIG. 4 is a different cross-sectional view of FIG. 3 and like numbers are used for like elements. Again the barrier gas layer can be seen on all of the condensing surfaces. At a certain point enough noncondensable gas has been allowed to accumulate in the chamber to form the desired barrier layer.
[0038] Turning back to FIG. 1 , during the time period 16 , the purity of the condensing solvent has been decreased to introduce an appropriate amount of barrier gas into the extraction chamber. The appropriate amount will depend upon the size of the chamber and the rate of extraction and will vary from chamber to chamber. However, for the purposes of this specification, it will be understood that an appropriate amount means an amount that will permit the barrier gas to accumulate in the chamber and form a barrier layer.
[0039] FIG. 5 is later in time than FIGS. 3 and 4 and depicts a transition period represented by the time span 52 in FIG. 1 . The solvent purity of the injected solvent has been changed again and the solvent is now at extraction purity again. In FIG. 5 the accumulated non-solvent barrier gases are shown moving towards the top of the chamber since they are less dense than the condensing solvent vapour. Eventually the non-condensable gases will accumulate and be confined to a layer which is floating at the top of the chamber into a relatively thicker layer 60 .
[0040] FIG. 6 shows the effect of the continued steady state extraction, further along in time period 52 of FIG. 1 . As can be seen the barrier layer 60 is restricting further vertical growth and vertical heat loss, while the absence of a barrier layer on the vertical surfaces of the chamber is permitting further horizontal growth of the chamber at 62 .
[0041] It can now be appreciated that the present invention provides a solution to both undesirable effects of having a chamber grow uncontrolled into the overburden layer. Firstly, the non-condensable barrier gas layer will prevent heat loss through the top of the chamber. This will permit more heat to be contained within the chamber and directed usefully to heating the bitumen at the extraction interfaces for continued horizontal extraction. Secondly, the presence of the barrier gas or insulating layer will prevent the extraction interface from continuing to grow upwardly limiting vertical chamber growth. In this manner, the chamber can be prevented from being flooded, for example from an overlying water layer. At the same time, a continued extraction can occur in the horizontal directions by means of the solvent which is at extraction purity. According to an alternate embodiment of the present invention during the time period 16 (after point 14 ) the solvent injection could stop altogether, to be temporarily replaced with an injection of an amount, preferably a defined amount, of non-solvent barrier gas. Thus the schematic of FIG. 1 is also intended to comprehend that solvent injection may temporarily halt at point 14 in order to permit a volume of non-condensable gases to be injected over a short period of time. Injection of the non-condensable gases then ceases and thereafter continued solvent extraction through use of extraction purity solvent can recommence. Convection flow will carry the barrier gases outwardly and distribute the barrier gas around the perimeter of the chamber on the condensing surfaces.
[0042] Although many different gases are comprehended by the present invention as the barrier gas, when the solvent gas is propane, the preferred barrier gas is one or more of helium, hydrogen, methane or ethane. Methane is desirable because it is naturally occurring and typically in abundance at the extraction site and has a low vapour density relative to propane. It will therefore tend to rise to the top of the chamber and form a barrier layer. Helium and hydrogen are desirable in that each is also a light gas which can be easily obtained and introduced in the chamber as needed to provide buoyancy. Other barrier gases are also comprehended by the present invention provided they meet the vapour density criteria of being able to rise within and remain above the solvent gas. In this specification the term solvent gas is meant to comprehend many different solvents, such as propane, ethane, butane, and the like. The choice of the condensing solvent will depend upon the reservoir conditions. According to the present invention, the choice of barrier gas will be one that is less dense than the selected solvent gas at reservoir conditions.
[0043] FIG. 7 shows the vapour density of various concentrations of methane in propane at various temperatures. FIG. 8 shows the vapour density of various concentrations of methane/hydrogen at 1:1 ratio in propane over a range of temperatures FIG. 7 shows the density of pure propane vapour as a function of saturation temperature. FIG. 7 also has a series of curves showing the density of saturated propane vapour at fixed pressures, ranging from 0.75 MPaA to 2.5 MPaA. In these curves, at fixed pressures, the saturation conditions are achieved by dilution of the propane vapour with a non-condensable gas, methane.
[0044] FIG. 8 is similar to FIG. 7 , except than the non-condensable gas is a 50/50 mixture of methane and hydrogen instead of methane. The hydrogen vapour has a lower density that the methane so the 50/50 mix is more likely to rise than methane alone. Consequently the curves of FIG. 8 show lower density at a given temperature and pressure than the curves of FIG. 7 .
[0045] As can now be appreciated from FIGS. 7 and 8 the barrier gas which is at the same pressure as the chamber, but at a lower temperature due to the non-condensable gas, has a vapour density which is less than that of pure propane vapour at the same pressure. This is relevant because this density difference provides a buoyancy driving force tending to float the barrier gas upwards towards the top of the chamber. Furthermore, the higher the accumulation of non-condensable gas (i.e. the lower the saturation temperature) in the barrier gas, the greater the buoyancy driving force.
[0046] Another aspect of the present invention is the convection flow rate of solvent through the chamber. If the solvent flow rate is very slow, diffusion forces can cause the non-condensable barrier gases to diffuse throughout the chamber and away from the condensation or extraction surfaces. However, providing that there is a sufficient flow of fresh condensing solvent gas flowing towards the condensing surfaces the diffusion effects will be mitigated. Thus, an aspect of the present invention is to maintain a sufficient flow of injection solvent through the chamber towards the extraction surfaces to overcome any diffusion effects that might otherwise encourage the barrier gases to diffuse through the chamber, and thus limit their effectiveness as a barrier gas. The exact rate will vary depending upon the chamber characteristics, but a flow rate of solvent that is higher than the diffusion rate of the barrier gas is most preferred.
[0047] To facilitate the operation of the present invention, it is desirable to know where the extraction interface which defines the extraction chamber is located. The present invention comprehends monitoring the movement of the extraction interface over time to ensure that the vertical growth of the chamber can be controlled. Various means of monitoring the extraction rate and the chamber growth can be used however, a preferred method according to the present invention is to position an observation well or wells in the formation at a location which is at or near a middle of said chamber (i.e., where the peak of the chamber roof will be). An example of such an observation well is shown as 70 in FIG. 6 . The position of the observation well may be offset slightly from production and injection wells to reduce the risk of damage of one or the other during well drilling as shown in FIG. 6 or could be directly above, but not as deep as these wells. A logging tool 72 such as a reservoir saturation tool (RST) can be used to determine the nature of the material in the pores space (i.e., gas, water or hydrocarbon liquid). This tool can be used to periodically locate the roof of the vapour chamber. A temperature sensor 74 located within the observation well 70 can provide temperature measurements at specific locations or heights within the chamber.
[0048] FIG. 9 shows the mol fraction of propane solvent in the saturated vapour as a function of temperature for various chamber pressures. The data of FIG. 9 can be used to relate the reduced temperatures within the barrier gas to the local concentration of propane solvent in the vapour. In this way, a real time vertical temperature profile can be used to calculate non condensable gas concentrations within the barrier gas blanket to determine its thickness and composition. This information can be used to monitor the gas blanket and relate the characteristics of the gas blanket to the vertical growth rate of the gravity drainage chamber. While this is the preferred method, the invention is not limited thereto and other methods of monitoring the chamber growth are also comprehended.
[0049] Prior to the extraction process being started, the position of the overburden layer will be identified. Then, it is a matter of monitoring a rise in temperature up the vertical column of the observation well or wells to monitor chamber growth.
[0050] In situations where the overburden is not capable of acting to confine the chamber, it will be desirable to maintain a pressure within the chamber at or slightly above formation pressure. This is to prevent leakage of fluid from the overburden layer of water into the chamber.
[0051] This invention comprehends that multiple adjustments to the solvent purity, may be necessary from time to time, to manage the barrier gas layer thickness and prevent it from thinning too much as the chamber grows horizontally. The horizontal growth of the chamber and/or removal of the barrier gas from the chamber via dissolution in the draining liquids would tend to thin the gas layer. By further adjustments to the solvent purity, it is possible to maintain the barrier layer to continue to restrict the upwards growth rate of the chamber and also reduce heat losses to the overburden.
[0052] In some cases the barrier layer may tend to be persistent in the attic region of the vapour chamber. This is because solvent condensation in the cooler region of the gas blanket will produce gas saturated liquid solvent. As this liquid drains down towards the bottom of the chamber, it will encounter warmer temperatures and consequently the non-condensable gas will be preferentially stripped out of the liquid. This non-condensable gas will then be returned to the gas blanket by convection movement of the injected condensing solvent in the gas phase.
[0053] It will be understood that as the chamber grows in size the heat losses to the overburden will increase and this has the effect of increasing the solvent to oil ratio. If the ability to recover and recycle the solvent is restricted, say by processing plant capacity, then it may not be feasible to maintain the chamber pressure at the desired pressure. In this situation, the use of a barrier layer to reduce overburden heat loss and consequently reduce solvent demand is desirable to allow the chamber pressure to be maintained at the preferred value.
[0054] It will be appreciated by those skilled in the art that while reference has been made to a preferred embodiment of the present invention above, various modifications and alterations can be made without departing from the broad spirit of the appended claims. Some of these variations have been discussed above and others will be apparent to those skilled in the art. What is desired according to the present invention is the use of a condensing solvent process to form an in situ gravity drainage chamber, where the chamber has a source of condensing fluid injection, a production means to remove extracted hydrocarbons and a system to monitor chamber growth and a means to preferentially accumulate barrier gas with the chamber. The precise choice of solvent and barrier gas can vary, provided that the barrier gas layer can be established where desired. | This invention is a solvent based gravity drainage process whereby the vertical growth rate of the chamber is restricted by placing, monitoring and managing a buoyant gas blanket at the top of the vapour chamber. This invention reduces the heat loss to the overburden as well as providing a means to preserve a barrier layer of bitumen saturated reservoir sand at the top of the pay zone in reservoirs where there is limited or no confining layer present. |
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TECHNICAL FIELD
[0001] This invention relates generally to interconnected lock assemblies used to secure doors. More particularly, the present invention relates to an interconnected lock assembly which provides a feature to automatically lock a deadbolt when the door is opened from the inside and closed. This application claims the benefit of U.S. Provisional Application No. 60/176,999 filed Jan. 19, 2000, herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] An interconnected lock assembly is characterized by an inside handle, either knob or lever, which simultaneously retracts both a deadlatch and a deadbolt. Such a lock assembly is commonly found in public accommodations such as hotels and motels in which, for security purposes, the occupant wishes to set both a deadlatch and a deadbolt. The same type of lock assembly may also be found in a residential or other environments. It is particularly important that both locks be retracted by the turning of a single inside operating member as it has been found that in the event of a fire or other panic situation it is desirable that the occupant only need turn a single knob or lever to operate all of the lock mechanisms in a particular door.
[0003] Such interconnected lock assemblies have been on the market for a number of years. Some interconnected lock assemblies are adjustable to compensate for varying distances between the latch assemblies. The adjustable feature is particularly helpful if there is a slight misalignment of the latch assembly bores, or when retrofitting an existing door if the distance between bore centerlines is not the same as the distance between the latch assemblies of the interconnected lock. U.S. Pat. No. 6,128,933 discloses an adjustable interconnected lock which enables interconnection of an exterior assembly that has an adjustable spacing between the exterior dead bolt assembly and a lower lock assembly.
[0004] One problem with interconnected lock assemblies is that when leaving, the user can open the door by using just the interior handle, even if the door is locked, but must use a key to lock the door behind them. This can provide an inconvenience especially when the keys are not readily available, the user is carrying objects, the user does not have a key, or the user is in a hurry. Thus the convenience and ease of operation provided by the interconnect lock is lost.
[0005] The foregoing illustrates limitations known to exist in present interconnected lock assembly designs. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to provide an interconnected lock assembly in which can selectively engage a mechanism to automatically throw the deadbolt and lock the door when the door is closed. This and other objects of the present invention are provided by an interconnected lock assembly mounted in a door. The interconnected lock assembly comprises a first lock assembly including an inside handle and an outside handle and a second lock assembly interconnected to the first lock assembly. The second lock assembly comprises a deadbolt assembly operably connected to a deadbolt latch. The deadbolt latch comprises a deadbolt movable between an extended position and a retracted position. The interconnected lock assembly further comprises an automatic locking mechanism selectively engageable to automatically move the deadbolt to an extended position when the door is closed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is an exploded perspective view of the interconnected lock assembly with keyless exit of the present invention;
[0008] [0008]FIG. 2 is a perspective view of the assembled interconnected lock assembly with keyless exit in accordance with the present invention of FIG. 1;
[0009] [0009]FIG. 3 is a side elevational view of the assembled interconnected lock assembly with keyless exit, shown without the escutcheon assembly, in accordance with the present invention of FIG. 1;
[0010] [0010]FIG. 4A is an rearward perspective view of the escutcheon assembly, in accordance with the present invention of FIG. 1;
[0011] [0011]FIG. 4B is an frontal perspective view of the escutcheon assembly, in accordance with the present invention of FIG. 1;
[0012] [0012]FIG. 5 is an exploded perspective view of the backplate assembly in accordance with the present invention of FIG. 1;
[0013] [0013]FIG. 6A is a partial side elevational view of the backplate assembly with the carrier component removed, revealing the catch mechanism of the keyless exit feature and movement of the spring trigger rod to various positions;
[0014] [0014]FIG. 6B is a partial side elevational view of the backplate assembly with the carrier component removed, revealing the catch mechanism of the keyless exit feature in a disengaged position;
[0015] [0015]FIG. 7A is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in an extended position;
[0016] [0016]FIG. 7B is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in a partially extended position; and
[0017] [0017]FIG. 7C is an partially exploded perspective view of the deadbolt latch assembly and strike plate showing the deadbolt in a retracted position.
DETAILED DESCRIPTION
[0018] Referring now to the drawings, wherein similar reference characters designate corresponding parts throughout the several views, there is generally indicated at 10 an adjustable interconnected lock assembly with automatic locking, also referred to as keyless exit, of the present invention. Referring specifically to FIGS. 1 and 2, lock assembly 10 comprises a first or lower interconnected lock assembly 18 comprising outside housing assembly 12 , rose 14 , and outside knob/lever 16 , attached from the outside of a door (not shown) through a first or lower bore in the door, and through a back plate assembly 20 positioned on the inside of the door, to inside housing assembly 22 . Interconnect cam 24 , escutcheon assembly 28 , and inside knob/lever 26 are attached to inside housing assembly 22 on the inside of the door. Although not shown, a latch assembly could be operably connected between outside housing assembly 12 and inside housing assembly 22 . Interconnected lock assembly 10 also comprises a second or upper interconnected lock assembly 40 comprising a deadbolt housing assembly 42 and a deadbolt latch assembly 44 . Deadbolt housing assembly 42 is attached from the outside of the door through a second or upper bore and operably connected to deadbolt latch assembly 44 , and through back plate assembly 20 and secured thereto by deadbolt plate 46 and mounting screws 48 . Deadbolt housing assembly 42 is operably connected to a deadbolt pinion 50 which engages a deadbolt rack 52 connected to back plate assembly 20 as discussed in detail below. The lower interconnected lock 18 and upper interconnected lock 40 are standard configurations that are well-known in the art, and as such, the workings of these locks will not be described in detail, except as they relate to the present invention.
[0019] Referring now to FIG. 3, interconnected lock 10 shown with escutcheon assembly 28 removed. Back plate assembly 20 comprises a carrier component 54 vertically movable on, and slidably attached to a back plate 56 by a plurality of tangs 58 . Deadbolt rack 52 is oriented vertically and fixedly attached to carrier component 54 such that it engages pinion 50 . Interconnected lock 10 is adjustable in that upper lock assembly 40 can move up or down to properly fit the upper bore of the door. Deadbolt plate 46 is movable within a slot 62 in back plate 56 to allow the proper positioning of upper lock assembly 40 . Upper lock assembly 40 is then secured to deadbolt plate 46 by mounting screws 48 which secure upper lock assembly 40 in a fixed position. Deadbolt assembly 42 is operably connected to deadbolt pinion 50 by a driver bar 60 which is co-rotatingly attached to deadbolt pinion 50 . Carrier component 54 is shown in a raised, or unlock position. When carrier component 54 is in a lowered, or locked position, a mating cam surface 64 of carrier component 54 engages cam 24 . Cam 24 is attached to knob/lever 26 in a co-rotating manner such that rotation of knob/lever 26 rotates cam 24 which engages mating cam surface 64 , causing carrier component 54 to move vertically, upwardly to a raised, or unlock position. The rack 52 attached to carrier component 54 causes deadbolt pinion 50 to rotate as carrier component 54 moves either upward or downward. Driver bar 60 co-rotates with deadbolt pinion 50 . Rotation of driver bar 60 causes retraction and extension of a deadbolt 90 of deadbolt latch assembly 44 in a standard fashion. Accordingly, as carrier component 54 moves upward, deadbolt 90 of deadbolt latch assembly 44 is retracted, allowing the door to be opened. Deadbolt 90 is shown in an extended position and a retracted position in FIGS. 7A and 7C, respectively. Deadbolt 90 is distinguished from standard deadbolts in that deadbolt 90 includes a cam surface 96 at a distal end. While cam surface 96 is similar to cam surfaces used in standard spring latch assemblies, cam surface 96 only partially extends along the extended deadbolt 90 as best shown in FIG. 7C. Accordingly, the door cannot be closed when the deadbolt 90 is in an extended position. However, when the deadbolt 90 is partially extended in a manner that cam surface 96 is configured as shown in FIG. 7B, the door can be closed as cam surface 96 will engage strike plate 94 , forcing deadbolt 90 to retract. It should be noted that depression of deadbolt 90 results in deadbolt latch 44 rotating deadbolt pinion 50 in a standard manner, moving carrier component 54 to a raised position.
[0020] Referring now to FIGS. 4A and 4B, escutcheon assembly 28 comprises escutcheon 30 , thumbturn 32 , and thumbturn link component 34 . Thumbturn 32 is coupled to thumbturn link component 34 in a co-rotating manner through an aperture in escutcheon 30 . Thumbturn link component 34 comprises at least one pin 36 which engages an aperture 38 in rack 52 , linking thumbturn 32 to carrier component 54 . It is noted that rack 52 can be positioned on either side of carrier component 54 such that a pin 36 will engage an aperture 38 in rack 52 , allowing thumbturn 32 to be appropriately attached for right and left-hand opening doors. Movement of the carrier component 54 results in rotation of thumbturn 32 , and conversely, rotation of thumbturn 32 causes movement of carrier component 54 , and extension and retraction of said deadbolt 90 .
[0021] Referring now to FIG. 5, the back plate assembly 20 is shown in greater detail. To enable the keyless exit function of the present invention, interconnected lock 10 utilizes carrier component 54 which is biased in a downward, or locked position. Accordingly, a spring carriage 72 is attached to carrier component 54 . Spring carriage 72 houses a spring 74 such that one end of spring 74 is attached to the assembled spring carriage 72 /carrier component 54 and the other end of spring 74 is fixedly attached to back plate 56 . Spring 74 is of sufficient strength to cause carrier component 54 to move downward to locked position and cause extension of deadbolt 90 of deadbolt latch assembly 44 .
[0022] In order to prevent spring 74 from returning carrier component 54 to a locked position, back plate assembly includes a catch mechanism 80 comprising a catch component 82 , a catch release 84 , and a spring trigger rod 86 as shown in FIGS. 6A and 6B. Catch component 82 and catch release 84 are each pivotally attached to back plate 56 by a pin 88 . Catch release 84 is biased toward catch component 82 by catch release spring 83 . Spring trigger rod 86 is affixed to carrier component 54 and moves along a guide portion 92 in catch component 82 . Spring trigger rod 86 is also biased toward spring 74 .
[0023] The operation of interconnected lock 10 is best described in a dynamic manner starting with carrier component 54 position in a lowered, or locked position. Movement of carrier component 54 from a locked position to an unlocked position can be accomplished by either rotating inside knob/lever 26 , rotating thumbturn 32 , or by turning a key to rotate the rotating driver bar 60 of deadbolt assembly 42 , typically with a key. As carrier component 54 moves upward, spring trigger rod 86 moves upward along guide portion 92 of catch component 82 from its initial position A, shown in FIG. 6A. Movement of carrier component 54 and attached rack 52 causes rotation of pinion 50 and driver bar 60 , retracting deadbolt 90 of deadbolt latch assembly 44 . At the end of the carrier component 54 travel, the deadbolt latch assembly 44 is fully retracted. Spring trigger rod 86 , now at position C, and catch release 84 , biased by catch release spring 83 , force a tab feature 93 of catch 82 to move underneath spring carriage 72 in a manner locking carrier component 54 in an unlocked position. Spring 74 is now in an extended position, storing energy needed to extend the deadbolt 90 in the keyless exit feature. At this point, further opening enclosing of the door will not affect catch mechanism 80 as the guide path of the spring trigger rod 86 does not release the spring carriage 72 . Spring trigger rod 86 will move upward from position A to position C along guide path 92 of catch component 82 . When carrier component 54 moves downward, trigger spring rod 86 will move downward from position C, through position B, back to position A. Spring trigger rod 86 deviates from guide path 92 in the downward direction. Guide path 92 of catch component 82 is configured with a ramp portion between lowered portions generally corresponding to positions A and C. Between positions A and C, trigger spring rod 86 moves up a ramp portion to a drop-off 76 shown generally adjacent to position B. In the downward direction, spring trigger rod 86 is forced by the wall of drop-off 76 to move off of catch component 82 to a position below a portion of catch release 84 . In normal operation of the lock 10 , spring trigger rod 86 will continue downward from position B and return to position A. Accordingly, standard operation of the lock does not affect the catch mechanism.
[0024] In order to actuate the keyless exit feature of the present invention, when deadbolt 90 of deadbolt latch assembly 44 is retracted, to thumbturn 32 is rotated to an intermediate position. Rotation of thumbturn 32 causes thumbturn link component 34 to rotate. At least one pin 36 of thumbturn link component 34 engages rack 52 , such that rotation of thumbturn 32 causes carrier component 54 to move partially downward, partially extending deadbolt 90 of deadbolt latch assembly 44 as best shown in FIG. 7B. In addition, spring trigger rod 86 moves from position C to a position adjacent catch release 84 , shown as position B.
[0025] Referring now to FIG. 6B, operation of the keyless exit feature is shown. The deadbolt 90 is in a partially extended position such as that shown in FIG. 7B. When cam surface 96 of deadbolt 90 is driven back by a strike plate 94 of the doorjamb (not shown) such as when the door is closed, linear movement of deadbolt 90 within deadbolt latch assembly 44 is converted to rotation of deadbolt pinion 50 in a standard manner. Rotation of deadbolt pinion 50 causes carrier component 54 to move upward, moving spring trigger rod 86 to position D, forcing catch release 84 to rotate and free catch 82 . This action allows spring carriage 74 /carrier component 54 to move downward under the force of spring 72 . As carrier component 54 moves downward, the deadbolt 90 of deadbolt latch assembly 44 is fully extended via the interaction of the deadbolt pinion 50 and rack 52 .
[0026] When the keyless exit function is not in use, interconnected lock 10 will operate as a normal, or standard, interconnected lock.
[0027] Although the present invention has been described above in detail, the same is by way of illustration and example only and is not to be taken as a limitation on the present invention. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims. | An interconnected lock assembly mounted in a door which provides a feature to automatically lock a deadbolt when the door is opened from the inside and closed. The interconnected lock assembly comprises a first lock assembly including an inside handle and an outside handle and a second lock assembly interconnected to the first lock assembly. The second lock assembly comprises a deadbolt assembly operably connected to a deadbolt latch. The deadbolt latch comprises a deadbolt movable between an extended position and a retracted position. The interconnected lock assembly further comprises an automatic locking mechanism selectively engageable to automatically move the deadbolt to an extended position when the door is closed. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to trowels for use in spreading of a cement or adhesive on a substrate surface for the laying of tiles on the substrate surface, and more particularly relates to a notch trowel having a substantially rigid trowel blade portion with a peripheral blade edge having a notch pattern providing improved contact between the cement or adhesive and applied tiles, a wedge member or shank for prying up tiles to be removed, and an ergonomic reversible grip handle used to manually grasp the notch trowel.
2. General Background and State of the Art
Trowels are commonly used for spreading cement or adhesive for installation of tiles on a substrate surface such as a wall or floor. Such trowels typically have a generally flat blade portion for spreading and smoothing the cement or adhesive, and a handle connected to the blade portion. Such trowels are also commonly used to pry up tiles to be removed, which can bend and otherwise damage the trowel to such an extent that the trowel can become unusable for spreading cement.
One conventional trowel is known having a blade that includes two adjoining edges having multiple notches, for spreading cementitious material, and a third edge that includes a rectangular extension of the blade for use as a margin trowel for prying up tiles. The trowel also includes a tubular handle rigidly attached to the trowel body.
Conventional notch trowels have used patterns of notches having square, rounded, saber tooth, and triangular shapes, as well as rounded shapes with obliquely angled sides flaring outwardly and inwardly. One conventional adhesive trowel has a blade edge with large notches, and small notches interspaced between the large notches. It has been found that spreading of cement or adhesive with a trowel having square notches or round notches commonly forms air bubbles in the cement or adhesive, interfering with optimal contact of the cement or adhesive with applied tiles, requiring application of heavy pressures to improve the degree of contact to an acceptable amount. For example, without application of pressure to applied tiles, such notch trowels commonly provide a contact spread with the tiles of only about 50%, indicating that approximately half of the surface of the applied tiles faces a space left between ridges of the cement or adhesive. In order to achieve a greater contact spread of 80%, which is considered to be the industry standard, it is commonly necessary to apply heavy pressures to tile applied to a cement or adhesive spread on a substrate surface, which can cause the contact spread to be inconsistent. It would be desirable to provide a notch pattern that can achieve a greater contact spread of 80%, without the application of heavy pressures, and with improved consistency.
It is also often necessary to turn a trowel around to use the trowel backwards to use a smooth flat side of a trowel to fill in pores or spaces in spreading cement based adhesive. This can be accomplished by switching from using the dominant hand to the non-dominant hand in using the trowel, i.e. using the trowel with both the left and right hands for the different directions of use of the trowel, but this can be awkward for users who are not ambidextrous. For trowels with a conventional short cylindrical configuration with a relatively thin rod connecting the handle to the blade portion of a trowel, using the trowel forwards and backwards with the same hand can be awkward. Although trowels having a handle with a “D” shaped configuration allow the trowel to be more easily reversible for use with a dominant hand, this type of handle is commonly centered on the blade of the trowel, making use of the trowel equally awkward forwards and backwards, with either hand.
It would be desirable to provide a notch trowel with a wedge on one side of the trowel allowing a user to use the wedge side of the trowel as a margin trowel to pry up tiles. It would also be desirable to provide a notch trowel with a notch pattern with conically shaped trapezoidal and parabolic notches with non-parallel sides to produce improved suction of the notches over the cement or adhesive to be spread, and that provides an improved, more consistent contact spread of cement or adhesive. It would also be desirable to provide a notch trowel with an ergonomic reversible handle with a rounded shoulder and thinner neck portion, allowing users to more easily turn the trowel around to use the trowel backwards with a dominant hand. The present invention satisfies these and other needs.
INVENTION SUMMARY
Briefly, and in general terms, the invention provides for a notch trowel with a reversible grip handle and an integrated wedge, for applying cement or adhesive to a substrate surface for installation of tiles. The notch trowel includes an ergonomically contoured reversible handle that allows a user to use the notch trowel in a forward or backwards position with the same hand to spread the cement or adhesive over a substrate surface for installation of tile. The blade portion of the notch trowel includes a series of notches on a long side and a short side of the blade edge with a notch pattern of conically shaped trapezoidal and parabolic notches with non-parallel sides to produce improved suction of the notches over the cement or adhesive to be spread, and that provides an improved, more consistent contact spread pattern of cement or adhesive. The integrated wedge of the notch trowel is provided on one side of the trowel to allow a user to use the wedge side of the trowel to pry up tiles.
The present invention accordingly provides for a notch trowel for spreading cement or adhesive over a substrate surface for the installation and removal of tiles, the notch trowel including a substantially rigid trowel blade portion having a flat bottom surface and a peripheral blade edge with a smooth side and a series of notches formed in the peripheral blade edge along one or more other sides of the blade edge. In one presently preferred aspect, the notch trowel includes a wedge member mounted to the blade portion. The wedge member has an elongated flattened rectangular wedge main body portion and a beveled wedge portion tapering from the main body portion to a narrowed rear edge portion abutting the smooth side of the peripheral blade edge. The wedge member thus can be placed under an edge of a tile to be removed, and can be used to pry up the tile without bending or otherwise damaging the blade portion of the trowel. The notch trowel also includes a handle mounted to the blade portion for manually grasping and manipulating the notch trowel.
In a presently preferred aspect, the wedge member is formed of hollow cast aluminum. In another presently preferred aspect, the wedge member is mounted to blade portion by an adhesive. The handle includes a base support portion that may be mounted to the wedge member.
In another presently preferred aspect of the invention, the handle is an ergonomic reversible grip handle, including a cylindrical main body formed by a grip portion and a handle support member. The handle support member has an S-shaped curved configuration with an upper support portion connected to the grip portion, a middle neck portion having a curvature tapering from the upper support portion to a base support portion connected to the blade portion, wherein the handle support member curves from the base support portion to extend over the wedge member toward the smooth side abutting the narrowed rear edge portion of the wedge member. In another presently preferred aspect, the grip portion extends over half of the length of the blade portion. In another aspect, the ergonomic reversible grip handle includes a joint interfacing between the grip portion and handle support member. The grip portion currently preferably has a rounded butt end, which may be formed by a rounded end cap.
In a presently preferred aspect, the peripheral blade edge comprises a notched long side, an adjacent notched short side, a smooth long side opposing the notched long side, and a smooth short side opposing the notched short side. In another presently preferred aspect of the notch trowel of the invention, the plurality of notches include a plurality of first short trapezoidal notches, a plurality of second large parabolic notches interspersed among the short trapezoidal notches, and a plurality of third intermediate size trapezoidal notches interspersed among the plurality of first short trapezoidal notches and the plurality of second large parabolic notches. The plurality of second large parabolic notches preferably extend into the blade edge to a greater depth than the first short trapezoidal notches, and the plurality of third intermediate size trapezoidal notches preferably extend into the blade edge to a greater depth than the large parabolic notches. The notches advantageously have conically configured first and second side edges that are oblique to a corresponding side of the blade edge.
Other features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments in conjunction with the accompanying drawings, which illustrate, by way of example, the operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the combination wedge and notch trowel with reversible grip handle, according to the present invention, showing the handle gripped by a user in a forward position with a right hand.
FIG. 2 is a perspective view of the combination wedge and notch trowel with reversible grip handle of FIG. 1 , showing the handle gripped by a user in a reversed position with a left hand.
FIG. 3 is a perspective view of the combination wedge and notch trowel with reversible grip handle of FIG. 1 , showing the handle gripped by a user in an alternate grip in a forward position with the right hand.
FIG. 4 is a top plan view of the combination wedge and notch trowel with reversible grip handle of FIG. 1 , showing the complete notch pattern of the blade portion.
FIG. 5 is an exploded view of the combination wedge and notch trowel with reversible grip handle of FIG. 1 .
FIG. 6 is a side sectional view of the handle support member of the combination wedge and notch trowel with reversible grip handle of FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, which are provided for purposes of illustration and by way of example, the present invention provides for notch trowel 10 for spreading cement or adhesive over a substrate surface, such as a floor or a wall, for the installation of tile for example. As is illustrated in FIG. 1 , the notch trowel includes a substantially rigid trowel blade portion 12 with a peripheral blade edge 14 , a wedge member or shank 16 mounted to an upper surface of the blade portion, and an ergonomic reversible grip handle 18 used to manually grasp the notch trowel, shown gripped by a user in a forward position with a right hand in FIG. 1 . The blade portion is typically rectangular in shape, having a flat bottom surface 20 , an upper surface 21 , and a series of notches 22 having a desired shape or shapes in a desired pattern along at least one side of the blade edge. Other shapes of the blade portion may also be suitable, such as square, triangular, tear drop, or the like. In a presently preferred aspect, the peripheral edge of the blade portion has a notched long side 24 , an adjacent notched short side 26 , a smooth long side 28 opposing the notched long side, and a smooth short side 30 opposing the notched short side. The blade portion is typically made of a metal, such as stainless steel, for example.
In a presently preferred embodiment, the series of notches formed on the notched sides of the blade portion are formed in a notch pattern that has been found to be particularly suitable in forming a pattern of ridges and valleys in cement or adhesive spread over a substrate surface, such as a floor or wall, for example, that provides a desired contact spread of the cement or adhesive when a tile is applied over the cement or adhesive spread with the notch trowel. Referring to FIGS. 1-4 , the notch pattern preferably includes a plurality of first short trapezoidal notches 32 , a plurality of second large parabolic notches 34 , and a plurality of third intermediate size trapezoidal notches 36 . Referring to FIG. 4 , in a presently preferred aspect, the short trapezoidal notches have a wide opening or mouth portion 38 typically about 0.250 inches across, a narrower opposing closed end portion 40 typically about 0.083 to 0.166 inches long, and a first side edge 42 and second side edge 44 that are oblique to the corresponding side of the blade edge extending into the blade edge to a first short depth, which is typically about 0.225 to 0.375 inches.
The large parabolic notches are preferably interspersed among the short trapezoidal notches, and have a relatively large opening or mouth portion 46 typically about 0.375 inches across an opposing closed rounded end portion 48 , a first side edge 50 , and a second side edge 52 that are oblique to the corresponding side of the blade edge and that extend into the blade edge to a second depth greater than the depth of the short trapezoidal notches. The large parabolic notches typically extend to a depth of about 0.375 to 0.5 inches.
The intermediate size trapezoidal notches, which are interspersed among the other notches, and are smaller than the larger parabolic notches, typically have a opening or mouth portion 54 equal to the opening or mouth portion of the short trapezoidal notches, typically about 0.250 inches across, a narrower opposing closed end portion 56 , typically about 0.098 to 0.101 inches long, a first side edge 58 , and a second side edge 60 that are oblique to the corresponding side of the blade edge. The intermediate size trapezoidal notches preferably extend into the blade edge to a longer depth than the depth of the large parabolic notches. The intermediate size trapezoidal notches typically extend into the blade edge about 0.406 to 0.656 inches. The depth of the intermediate size trapezoidal notches is typically about 0.031 inches greater than the depth of the large parabolic notches
The notched sides of the notch trowel are used to apply and spread the cement based adhesive to provide a series of ridges and valleys with desired spacing between the ridges of cement based adhesive laid down on the substrate surface, for achieving a desired degree of contact of the cement based adhesive with the tiles placed over the cement based adhesive when the cement based adhesive spreads under pressure applied to the tiles.
Referring to FIGS. 1-3 , the notch trowel wedge member or shank has an elongated flattened rectangular wedge main body portion 62 , a beveled wedge portion 64 tapering from the main body portion to a narrowed rear edge portion 66 abutting and coterminous with the short smooth side of the blade portion, so that the wedge member can be placed under an edge of a tile to be removed, and can be used to pry up the tile without bending or otherwise damaging the blade portion of the trowel. The wedge member is typically formed of hollow cast aluminum, but the wedge member may optionally be formed of solid metal. The wedge member can be mounted to blade portion by rivet plus adhesive, or by an adhesive film alone, such as an adhesive film available from 3M, although alternatively the wedge member may be mounted to the blade portion by bolts, rivets, welding, or the like.
In a presently preferred aspect, the ergonomic reversible grip handle is formed in the shape of a generally curving elongated cylindrical rigid member having a generally cylindrical main body 70 formed by a curving half cylindrical handle grip portion 72 which mates with a correspondingly curved half cylindrical handle support member 74 , and a joint 76 interfacing between the grip portion and handle support member. The grip portion is typically formed of polyurethane, but can be formed from rubber, wood, metal or plastic, for example. The handle support member is typically formed of aluminum, but may be made of other suitable rigid materials, such as stainless steel, for example. In a presently preferred aspect, in order to allow the handle to be gripped more comfortably with either hand or in a forward or reversed position, the grip portion preferably extends over half of the length of the blade portion.
Referring to FIGS. 4-6 , the handle support member typically has an S-shaped curved configuration with an upper support portion 77 connected to the grip portion, a middle neck portion 81 having a curvature tapering from the upper support portion to a base support portion 78 mounted to the blade portion, wherein the handle support member curves from the base support portion to extend over the wedge member toward the smooth side abutting the narrowed rear edge portion of the wedge member. The base support portion is typically flattened to be mounted to the blade portion, and typically has a rounded triangular shape. The base support portion may be mounted to the wedge member by bolts 79 , welding, or adhesive, for example, adjacent to the short notched side of the blade portion. Alternatively, the base support portion may be mounted directly to the blade portion adjacent to the short notched side of the blade portion. The intermediate handle support member is preferably connected to the flattened base support portion at approximately a 90 degree angle, and curves from the flattened base support portion to extend toward the short smooth side over the wedge member.
The grip portion preferably includes a tapering neck portion 80 extending from the main body of the grip portion following a corresponding curvature of the handle support member and extending substantially perpendicular to the base support portion. The grip portion preferably widens from the handle support member, curving toward the rounded butt end 82 of the grip portion, typically formed by an end cap 84 which is mounted to the handle grip portion, such as by a bolt or otherwise threadedly securing the end cap to the handle support member to connect the handle support member and handle grip portion, which slides on to the handle support member. The shape of the ergonomic reversible grip handle allows the user to grip the handle with either hand, and reverse the direction of the handle in a user's hand.
It will be apparent from the foregoing that, while particular forms of the invention have been illustrated and described, various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims. | The combination wedge and notch trowel includes a reversible grip handle and an integrated wedge, for applying cement or adhesive to a substrate surface for installation of tiles. The ergonomically contoured reversible handle allows a user to use the notch trowel in a forward or backwards position with the same hand. The blade portion includes a notch pattern of conically shaped trapezoidal notches and large parabolic notches. The integrated wedge allows a user to use the wedge side of the trowel to pry up and remove tiles. |
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FIELD OF THE INVENTION
This invention relates generally to modular structural elements, and more particularly, relates to modular frame structures having flexible sheet panels attached thereto forming tent, roof or container elements or the like, capable of sustaining high wind, hydrostatic, or vacuum loading.
BACKGROUND OF THE INVENTION
Like conventional structural components, tent-like structures are capable of sheltering most objects against the elements. However, unlike conventional structural components, tent-like structures usually employ a fabric covering held in place by a series of support members. The flexible sheet panels used in such structures have a number of advantages over conventional rigid structural panels such as low overall weight and costs of construction, installation and maintenance. Such flexible coverings include woven or extruded skins of cotton, canvas, polyethylene, acrylic ester, vinyl, glass or similar materials.
A serious problem inherent in tent-like structures is their inability to withstand the substantial aerodynamic lift forces generated under high wind conditions. The substantial efforts at providing modular structural members which can be combined to create expansive cover structure is evidenced in the prior art. However, the Applicant is not aware of any effort which has successfully countered the aerodynamic lift phenomenon caused by high wind loading.
The instant invention is therefore directed to a tent-like structure employing securely fastened flexible sheet panels spanning rigid structural frame members in such a way that the modular structural element created thereby is capable of withstanding extreme downloading and uploading forces by use of symmetrically upwardly and downwardly directed airfoil sections. These characteristics also lend it to being combined into structures adaptable to use in space.
SUMMARY OF THE INVENTION
The instant invention is directed to modular structural elements which may be configured as tent-like structures capable of withstanding high winds by minimizing the aerodynamic forces imparted on the tent covering material by innovative structural and covering geometric organization. The invention is directed to three main embodiments: an eight-sided, six-sided, and four-sided main structure, the eight-sided and six-sided structures each disclosed in two subembodiments.
Each embodiment comprises a plurality of elongated structural supports which terminate at common apical coupling points depending on the desired configuration. A covering fabric is suspended between the covering points and drawn into a plurality of curved sections which assist in reducing aerodynamic loading on the entire assembly by acting as a series of negatively cambered air foils.
It is a principal object of the instant invention to provide modular structural elements which can be combined in a variety of patterns to create a structural composite panel capable of withstanding extreme windloading.
It is an additional object of the present invention to provide modular structural elements which may be configured in a variety of different patterns to maximize the available space when housing objects in tent-like container structures.
It is yet another object of the present invention to provide a modular tent assembly that maximizes the benefits of reduced aerodynamic uploading in high winds while minimizing the necessary amount of covering material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a single octagonal tent structure;
FIG. 2 is a sectional view of the embodiment in FIG. 1;
FIG. 3 is an isometric view of two octagonal tent structures joined together at common coupling points;
FIG. 4 is a plan view of two octagonal tent structure joined together at common coupling points;
FIG. 5 is a sectional view of the embodiment in FIG. 4;
FIG. 6 is a sectional view of the embodiment in FIG. 4;
FIG. 7 is a view of a representative apical coupling point;
FIG. 8 is a plan view of an alternative octagonal-shaped tent module;
FIG. 9 is a sectional view of the embodiment in FIG. 8;
FIG. 10 is a sectional view of the embodiment in FIG. 8;
FIG. 11 is a plan view of a single hexagonal tent structure;
FIG. 12 is a sectional view of the embodiment in FIG. 11;
FIG. 13 is a plan view of a plurality of hexagonal structures joined together at common coupling points;
FIG. 14 is a plan view of a four-sided tent structure;
FIG. 15 is a frontal elevational view of the embodiment in FIG. 14;
FIG. 16 is a side elevational view of the embodiment in FIG. 14; and
FIG. 17 is a top plan view of second embodiment of the six sided tent structure; and
FIG. 18 is a top plan view of the tent structure of FIG. 17 with a fabric covering.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the several views of the drawings, there are depicted three main embodiments of a geodetic tent structure utilizing an eight-sided, six-sided, and four-sided basic structure.
The eight-sided tent structure may be constructed in either of two basic embodiments, the first thereof adapted to comprise a plurality of individual modules generally characterized by the reference numeral 10, and the second thereof adapted to stand alone as a single module denoted by the reference numeral 10'.
Referring now to FIGS. 1 and 2, there are depicted plan and sectional views of a single octagonally shaped structure 10 which may be joined into several structures at common points as shown in FIG. 3. The basic structure comprises eight elongated support members 12 of equal length which extend from four apical couplings 14 disposed coplanar relative to a support surface or plane, to four apical couplings 16 which are oriented in a coplanar arrangement a distance H above the support surface. The support members may be constructed from material such as steel, aluminum, plastic or composites. Four pairs of elongated support members 18 of equal length each extend from a respective coupling 14 to adjacent apical couplings 20 which define a square disposed coplanar with coupling 16, and situated on phantom radials coincident with coupling 16. Couplings 16 are attached to one another by four elongated support members 17. A covering fabric 22 may be hung beneath, draped over, or sandwiched in layers around the structure, and attached to the upper structure apical couplings by frame, for example, suspension rings 24 and the lower couplings, drawn to define a plurality of curved sections which can best be seen in the sectional view depicted in FIG. 2. The inverted curvature of these sections in combination with the cavities 26 defined by this geometry reduce the tendency for the covering 22 to lift away from the frame due to aerodynamic lift induced by pressure differentials between the interior and exterior of the tent in strong winds. The covering may be fabricated from a flexible material such as woven or extruded skins of cotton, canvas, polyethylene, acrylic ester, vinyl, glass, or similar materials.
Referring now to FIGS. 3, 4, 5 and 6, two individual structures 10 are joined together at common apical couplings 14' on the support surface capable of joining six support members. Note that in the triangular section 24 defined by the union, support members 12 are replaced by support members 18 from the adjacent structure. In this manner, a large number of structures may be joined together at common apical couplings. Curved brace members 25 and 27 are disposed between diametrically opposed coupling points to impart overall structural rigidity and to minimize the likelihood of structural failure. Stands 26 may be attached to lower coupling points 14 to elevate the entire assembly a distance above the support surface to permit greater space utilization.
Referring now to FIG. 7, a representative coupling point for attaching several support members is depicted. This may be accomplished by providing a universal fitting 27 which accommodates the individual support members 29 in predetermined angular relationship dependent upon how many support members are joined at the particular joint, the fitting having a series of short tubes extending therefrom, each having an internal bore to accept the respective support member.
Referring now to FIGS. 8, 9 and 10, a second embodiment of the octagonal-shaped tent structure 10' is depicted, which is adapted to stand alone as an individual unit. Tent 10' comprises a base structure having eight elongated support members 28 joined at eight apical coupling points, four denoted by the reference numeral 30 which accommodate three support members, and four denoted by the reference numeral 30' which accommodate four support members. The base is arranged in the shape of an octagon and adapted to rest on a support surface. A square-shaped upper support structure is disposed in a plane parallel to the support surface, and elevated a distance H to provide suitable interior space. The upper support structure is comprised of four elongated support members 32 joined at four apical coupling points 34. Each coupling point 34 has a pair of elongated support members 36 extending downwardly to coupling points 30' and a single elongated support member 38 similarly extending downwardly in the middle of each support member 36 to coupling points 30. A covering fabric 40 may be hung beneath, draped over, or sandwiched in layers around the structure and attached thereto in like manner to the first embodiment by frame suspension rings 42 and the lower couplings, drawn to define a plurality of curved sections as best seen in the sectional view in FIGS. 9 and 10. If necessary for adequate structural rigidity in the case of a very large structure, a plurality of secondary frame members 44 may be added as shown in the plan view.
Referring to FIGS. 11 and 12, a single six-sided tent 46 is depicted, comprising a base adapted to rest on a support surface arranged in the shape of a six-pointed star when viewed from above in planform, the base consisting of twelve elongated support members 48 joined at six apical coupling points 50 and six inner base points 52. A hexagonal-shaped upper support structure is disposed in a plane parallel to the support surface and is elevated a distance H to provide suitable interior space. The upper support comprises six elongated support members 54 joined together at six apical coupling points 56. Extending downwardly to base couplings 50 from upper support structure couplings 56, are twelve elongated support members 58 which define the vertical structure as six points of a star when viewed from above. A covering fabric 60 may be hung beneath, draped over, or sandwiched in layers around the structure and attached to the respective couplings in like manner to the other embodiments by frame suspension rings 62 and the lower couplings, drawn to define a plurality of curved sections as best illustrated in the sectional view in FIG. 12.
Referring now to FIG. 13, a plurality of six-sided tents 46 are joined together into a larger assembly, at common coupling points 50'. To complete the structure, additional elongated support members 54' are added and joined at apical couplings 56' which define intermediate hexagonal-shaped upper support structures coplanar with the upper support structure of each tent 46 itself. Elongated support members 58' extend downwardly from couplings 56' to common couplings 50' where adjacent tents 46 are coupled. Covering fabric 60' is added to define inverted pyramidal-shaped areas which assist in geometrically canceling aerodynamic lift components on adjacent tent covering surfaces which may be induced by the wind.
Referring now to FIGS. 14, 15 and 16, a four-sided embodiment 60 of the tent is disclosed, comprising a quadrilateral base adapted to rest on a support surface when viewed from above in planform, defined by four elongated support members 62 including two apical coupling points 64 for joining two support members 62 together, and two apical coupling points 66 for joining members 62 and the following support members. Elongated support members 68 extend upwardly from opposing coupling points 66 in a plane perpendicular to the support surface and define the highest point on the structure, elevated a distance H and joined at apical coupling point 70. Situated on planes 45° from the plane perpendicular to the support surface, are elongated support members 72 which similarly extend upwardly from coupling points 66, and terminate at apical coupling point 74, each pair of support members 72 and associated coupling point 74 in mirror image relationship about the plane normal to the support surface through coupling point 66. A covering fabric 76 may be hung beneath, draped over, or sandwiched in layers around the structure and attached thereto in a manner similar to the other embodiments by frame suspension rings 78 and the lower couplings, drawing to define a plurality of curved sections as best illustrated in the side elevational view depicted in FIG. 16.
Referring now to to FIGS. 17 and 18, a six-sided tent 90 is depicted, comprising a base adapted to rest on a support surface arranged in the shape of a three point support when viewed from above in planeform, the base consisting of six elongated support members 92 joined at three apical coupling points 94 and three inner base points 96. A hexagonal-shaped upper support structure is disposed in a plane parallel to the support surface and is elevated a distance H to provide suitable interior space. The upper support comprises three elongated support members 98 joined together at one apical coupling points 100. Extending downwardly to base couplings 102 from upper support structure couplings 100, are three elongated support members 98 which define the vertical structure as three points of a star when viewed from above. Covering fabric 104 may be hung beneath, draped over, or sandwiched in layers around the structure and attached to the respective couplings in like manner to the other embodiments by frame suspension rings and the lower couplings, drawn to define a plurality of curved sections as best illustrated in the sectional view in FIG. 18. A plurality of six-sided tents 90 are joined together into a larger assembly, at common coupling points 106. To complete the structure, additional elongated support members 108 can be added and joined at apical couplings 110 which define intermediate hexagonal-shaped upper support structures coplanar with the upper support structure of each tent 90 itself. Elongated support members 108 extend downwardly from couplings 110 to couplings 106 where adjacent tents 90 are coupled. Covering fabric 104 is added to define inverted pyramidal-shaped areas which assist in geometrically canceling aerodynamic lift components on adjacent tent covering surfaces which may be induced by the wind. The covering fabric creates parabolic curves in the fabric as drawn between the raised points and base support members. For purposes of example only, the tent structure of the instant embodiment employs each connecting member at five foot ten inches.
The present invention has been disclosed in what is considered to be the most practical and preferred embodiment. It is anticipated, however, that departures may be made therefrom, and that obvious modifications will occur to a person skilled in the art. | A modular tent structure capable of withstanding high winds by minimizing the aerodynamic forces on the structure by use of a sectional design which acts through a series of negatively cambered air foils. A covering fabric is suspended between structural supports of the tent to provide a variety of patterns. Each pattern is subsequently based on a four, six, or eight-sided geodetic support member arrangement raised to common apical coupling points. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. patent application No. 60/324,044 filed Sep. 24, 2001 and Swedish patent application No.0103174-9 filed Sep. 24, 2001, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and a method for suction and discharge of material.
BACKGROUND ART
[0003] Apparatus for suction and discharge of material as mentioned above are used, for instance, when making excavations in areas where electricity cables, telecommunication cables and the like are buried in the ground, and where an ordinary excavator may cause damage by breaking such cables by mistake. The material sucked up consists of stones, macadam, gravel, sand, earth etc. Such apparatus can also be used to suck up material in liquid form, such as mud and wet clay. One field of application is to suck up ballast adjacent to the rail when reconditioning railroad lines.
[0004] In a prior-art procedure, the ballast is sucked through a hose into a vacuum container which is placed on a rail vehicle. When the container is full, doors in the sides of the container are opened, and the ballast is discharged along the vehicle sides. There is usually some kind of guide plates arranged at the side of the vehicle below the doors in the container sides to direct the discharge in the desired direction somewhat obliquely away from the container. This prior-art apparatus cannot be used in cases where the sucked-up material is to be discharged behind the vehicle, for example to be able to convey it onto a collecting vessel.
[0005] U.S. Pat. No. 5,709,270 discloses another apparatus arranged on a rail vehicle for drawing in ballast by suction, for example, when renovating railroad lines. The ballast is drawn up by suction to a vacuum container which, when being full, is opened via a door in the bottom of the container. The ballast is discharged onto a conveyor belt running under the vehicle and discharging the ballast at the rear end of the vehicle, optionally onto another conveyor belt and then onto another container.
[0006] A difficulty in this prior-art apparatus is that the conveyor belt for conveying material to the rear end of the vehicle is arranged under the container and the other parts mounted on the vehicle, such as drive means etc, which makes the space for the conveyor belt very limited in the vertical direction. This makes it difficult to reach the conveyor belt for maintenance and repair. Moreover, the belt may easily come to a standstill when material is pinched between the conveyor belt and the lower parts of the superposed devices.
[0007] In all these prior-art apparatus, problems arise when discharging wet material since this sticks to the inner walls of the container, thus making it difficult to entirely empty the container. Low temperatures will also cause inconvenience when discharging, for instance, blue clay. The same problem arises when discharging, for instance, macadam according to the prior-art technique, when the material is stopped at the opening of the container and is retained above the opening owing to so-called bridging in the material according to the principle used to build stone bridges in former times.
[0008] This problem has been solved by arranging vibrators to vibrate the container so as to make the material come loose from the walls. However, this easily results in all the material falling out of the container in an uncontrolled manner, which is unfavourable.
[0009] The fact that the discharging occurs in an uncontrolled manner, both with and without the use of vibrators, means that it is not possible to control the speed of the material flowing out of the container once the door in the bottom of the container or the doors in the sides of the container are open. Nor is it possible to interrupt a discharging process, for instance in the case of a near-accident.
[0010] The uncontrolled discharging may also give rise to great strain on the conveyor belt receiving the material flowing out. In many cases a ketchup effect occurs in discharging, which causes a momentarily very high load on the conveyor belt or other devices receiving the discharged material. Problems with build-up of dust may also arise when dry material is discharged too quickly from the container. Dust build-up may cause negative environmental and health effects.
[0011] In another known procedure, the container is instead tilted for discharging and the material is discharged behind the vehicle. Also in this case, the problems mentioned above in connection with quick emptying may arise. When tilting the container, problems will also arise when driving through tunnels having a limited height, where discharge can be made difficult or prevented by there not being sufficient space in the vertical direction for tilting of the container.
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to obviate the above problems by providing a device for suction and discharge of material, where the discharging operation takes place in a controlled manner, said device being further suited for use in tunnels and for use both for solid and liquid materials.
[0013] According to the present invention, the above object is now achieved by an apparatus having the features stated in claim 1 . The object is also achieved by a method according to claim 16 . Preferred embodiments are defined in the appended claims.
[0014] The invention gives the advantage that discharge takes place in a controllable manner since the discharge speed can easily be controlled by regulating the speed of rotation of the container. Moreover, the discharge operation may be interrupted when necessary and may then be easily started again. Furthermore, both solid and liquid materials, as well as mixtures thereof, can be easily and safely discharged completely from the container. Further no tilting of the container is necessary in the discharge operation.
[0015] The conveying means are preferably at least partly helical. This gives the advantage of easily performing efficient transport of the material to the discharge opening. It also facilitates the manufacture of the apparatus.
[0016] The suction opening is connected to a suction duct preferably via a first connecting means. This gives the advantage of facilitating the supply of the material/air mixture to the container.
[0017] According to an embodiment of the invention, the first connecting means may allow disconnection of the suction duct from the container. This gives the advantage that the entire container can easily be rotated without the suction duct being affected.
[0018] The container can have an exhaust opening for letting out air. This is advantageous since it easily allows the generation of a negative pressure in the container, which ensures efficient drawing-in of material and air by suction.
[0019] The exhaust opening can via a second connecting means be connected to an exhaust duct which communicates with an extractor for air. This gives the advantage of easily generating a negative pressure in the container.
[0020] The extractor preferably comprises at least one vacuum pump. This gives the advantage of ensuring efficient drawing-in of material by suction to the container through the suction opening and also efficient extraction of air from the container through the exhaust opening.
[0021] According to an embodiment of the invention, at least one filter is arranged between the exhaust duct and the extractor, which gives the advantage of efficiently filtering away any entrained particles from the container and separating these before they reach the extractor so as not to interfere with the function of the extractor.
[0022] Preferably the extractor comprises a filter, which gives the advantage of ensuring that only a minimum amount of dust particles can be entrained to those parts, for instance pumps, in the extractor, whose function can be interfered with.
[0023] The second connecting means can, according to an embodiment of the invention, allow disconnection of the exhaust duct from the container. This gives the advantage that the entire container can easily be rotated without affecting the exhaust duct.
[0024] The discharge opening is preferably sealable, which gives the advantage of allowing the generation of a negative pressure in the container, which results in the above-mentioned advantages. It is particularly advantageous if the discharge opening is hermetically sealable.
[0025] The suction and exhaust openings are preferably sealable, which gives the advantage that no material can flow or fall out of the container through the exhaust or suction openings in particular when the container is rotated during discharge. It is particularly preferred to combine this with embodiments involving disconnectible connecting means.
[0026] According to an embodiment of the invention, a conveyor belt is arranged in the vicinity of the discharge opening outside the container for conveying material discharged from the container. This gives the advantage of easily being able to convey material from the apparatus, for instance to a storage container.
[0027] According to a preferred embodiment of the invention, a longitudinal axis of the container is inclined relative to a horizontal plane, the discharge opening being arranged at the upper end of the container. This gives the advantage of minimising the amount of material that possibly falls or flows out of the container at the moment when the discharge opening is opened. A further advantage is that the arrangement of a possible conveyor belt in the vicinity of the discharge opening for removing material is facilitated. This is particularly advantageous in the cases where a plurality of conveyor belts are used.
[0028] The above advantages are achieved also by a method according to the invention, by use of an apparatus according to the invention, as well as by a vehicle according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will now be described in more detail with reference to the accompanying schematic drawings which by way of example illustrate a currently preferred embodiment of the invention.
[0030] [0030]FIG. 1 is a schematic side view of a prior-art apparatus for suction and discharge of material.
[0031] [0031]FIG. 2 is a similar view of a preferred embodiment of the inventive apparatus when used on a rail vehicle.
[0032] [0032]FIG. 3 is a sectional view of a container in the apparatus in FIG. 2.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] [0033]FIG. 1 shows an example of a prior-art apparatus A for suction and discharge of material when used on a rail vehicle B. A conveyor belt C is arranged along the rail vehicle B for conveying material to a collecting tank D arranged at the rear end of the rail vehicle B.
[0034] With reference to FIGS. 2 and 3, an apparatus for suction and discharge according to the invention will now first be described. Then the suction and discharge function of the apparatus will be described.
[0035] [0035]FIG. 2 shows an apparatus 1 for suction and discharge which is used like in FIG. 1 in connection with a rail vehicle 2 . The apparatus 1 comprises an elongate and flexible suction hose 3 communicating with two vacuum pumps 4 connected in parallel. The vacuum pumps 4 are, as shown in FIG. 2, arranged one behind the other on the rail vehicle 2 . A first end 5 of the suction hose 3 is connected to a nozzle 6 . The nozzle 6 is moved along the rail R at the front end of the rail vehicle 2 , according to an imaginary direction of travel in the direction of arrow F, for drawing in material by suction. The nozzle 6 is controlled by an operator by means of an articulated control arm 7 arranged on the rail vehicle 2 . The suction hose 3 is arranged along the longitudinal direction of the rail vehicle 2 and its second end 8 opens in a suction opening 19 in a cylindrical container 9 . The connection between the second end 8 of the suction hose 3 and the container 9 takes place by means of a docking plate 10 detachable from the container 9 .
[0036] The container 9 also has an exhaust opening 20 which is arranged in the vicinity of said suction opening 19 . An exhaust hose 11 is, via the above docking plate 10 , at its one end connected to the exhaust opening 20 of the container 9 . The other end of the exhaust hose 11 communicates with two filters 12 which are connected in parallel and arranged one after the other on the rail vehicle 2 and communicating with the above-mentioned vacuum pumps 4 . Moreover each vacuum pump 4 is provided with an additional filter (not shown), a so-called safety filter. A duct 13 connects the filters 12 to the suction hose 3 .
[0037] The cylindrical container 9 is arranged at the rear end of the rail vehicle 2 and has a longitudinal direction corresponding to that of the rail vehicle 2 . The container 9 has three openings, the suction and the exhaust openings 19 , 20 which are mentioned above and which at a front end 9 a of the container 9 via a docking plate 10 connect the container 9 with the suction and exhaust hoses 3 , 11 , and a sealable discharge opening 14 in the tapering rear part 9 b of the container 9 . The container 9 is inclined so that its longitudinal axis is inclined to an imaginary horizontal plane. The rear end 9 b of the container is thus arranged at a higher level than its front end 9 a . A flange 15 is arranged along the circumference of the rear portion 9 b of the container. The flange 15 is in contact with rolls 16 on the rail vehicle 2 . The container 9 is thus at its rear end 9 b in contact with the rail vehicle 2 via said rolls 16 and at its front end 9 a in contact via a drive shaft 21 . The drive shaft 21 allows rotation of the container 9 .
[0038] The rail vehicle 2 has at its rear end, below the discharge opening 14 of the container 9 , a conveyor belt 17 .
[0039] The function of the apparatus 1 which has been described above can be divided into two phases, a suction phase and a discharge phase. In the suction phase, material is drawn in by suction from the area around the rail via the nozzle 6 to the suction hose 3 . The suction function in the suction hose 3 is generated by the vacuum pumps 4 via the exhaust hose 11 drawing in air from the container 9 . A negative pressure is therefore generated in the container 9 and an influx of material and air can therefore take place to the container 9 through the suction hose 3 . The material falls down in the container and is separated from the air which is extracted from the container 9 by the suction pumps 4 . Then the air passes the two filters 12 to ensure that particles do not reach the vacuum pumps 4 . Any particles that are collected in the filters 12 will, via the duct 13 , between the filters 12 and the suction hose 3 , be moved from the filters 12 to the suction hose 3 and then be discharged into the container 9 . In order to further protect the vacuum pumps 4 from any particles, the air passes, before it reaches the vacuum pumps 4 , safety filters which are arranged in connection with each vacuum pump 4 .
[0040] The suction phase continues as long as is desirable or until the container 9 is filled to a predetermined level. The discharge opening 14 is, during the entire suction phase, hermetically sealed. Also the connection between the docking plate 10 and the container 9 is hermetically sealed. These hermetic seals are necessary to generate the negative pressure in the container 9 that is necessary for a suction function in the suction hose 3 .
[0041] After the suction phase, the discharge phase takes place when the material collected in the container 9 is discharged onto the conveyor belt 17 . The vacuum pumps 4 are then switched off and the docking plate 10 is disconnected from the container 9 . The suction and exhaust openings 19 , 20 of the container 9 are sealed by a door each or by a common door, and the discharge opening 14 is opened. Rotation of the container 9 takes place by means of a drive shaft 21 which is connected to the front end 9 a of the container and arranged on the rail vehicle 2 . During rotation of the container 9 , the material is discharged via the discharge opening 14 onto the conveyor belt 17 .
[0042] The discharge of the material from the container 9 takes place by means of conveying means such as vane-shaped conveyors or flanges 18 which are helically arranged on the inside of the container 9 , as shown in FIG. 3. Thus the flanges 18 convey the material from the front end 9 a of the container to the rear end 9 b thereof and out of the discharge opening 14 . The discharge speed of the material from the container 9 is determined by the speed of the drive shaft 21 in connection with the front end 9 a of the container.
[0043] When the discharge phase is terminated, a new suction phase can be begun. The rotation of the container 9 is stopped, the doors covering the suction and exhaust openings 19 , 20 are removed, the docking plate 10 with the suction and exhaust hoses 3 , 11 is connected to the container 9 and the discharge opening 14 is sealed. Subsequently the vacuum pumps 4 can be started once more.
[0044] It will be appreciated that many modifications of the above-described embodiment of the invention are feasible within the scope of the invention, as defined in the appended claims.
[0045] For instance, the invention is not bound by the number of vacuum pumps or filters. Nor does the entire container 9 have to be rotatable. For instance, the container 9 may consist of two parts, the first end 9 a of the container 9 , which communicates with the suction and exhaust hoses 3 , 11 , being nonrotatable, while the rest of the container 9 is rotatable and is in rotational contact with the front end 9 a of the container. During rotation of the container 9 in the discharge phase, the suction and exhaust hoses 3 , 11 thus need not in this case be disconnected from the container 9 via the docking plate 10 .
[0046] The apparatus may also be used in other applications, such as arranged on a truck, a caterpillar vehicle, a ship or the like, or when placed in a stationary manner, such as in factory premises. | An apparatus for suction and discharge of material comprises a container ( 9 ) with a suction opening ( 19 ) for letting in a sucked-up air/material mixture and a discharge opening ( 14 ) for discharging material. The container ( 9 ) is rotatable and has inner conveying means ( 18 ) which upon rotation of the container ( 9 ) are adapted to convey the material to the discharge opening ( 14 ). |
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FIELD OF THE INVENTION
This invention relates to a bolt unit and frame arrangement. In particular it relates to a lockable bolt unit having a slidable bolt, typically for securing two movable panels together or for securing one movable panel to a fixed frame.
In this specification, "left" and "right" and similar geometric terms refer to parts in their condition of use as illustrated in FIG. 1, unless otherwise specified in relation to a drawing.
The following disclosure will refer to door panels, and for such applications the bolt may be resiliently biassed and with a chamfered end to permit a latching engagement. However, the bolt unit of the invention can be fitted to windows and other movable panels, and for these applications the bolt unit can have for example a non-chamfered bolt and be moved by an actuator to its engaged position.
BACKGROUND OF THE INVENTION
Both sliding and hinged doors need the facility to be made secure against unauthorised opening. Bolt units have therefore been developed which have fittings for attachment to an external surface of the door, specifically with the bolt being slidable in a bolt housing or casing between guides; in use the bolt unit includes a slidable bolt which can be moved into and out of engagement with a keeper secured to a fixed member, usually to the upright of a fixed outer door frame within which the door panel is hingedly mounted.
A door secured by a bolt unit is often vulnerable to unauthorised opening upon "bursting" of the securement, with the bolt being disengaged from its keeper. Such bursting of the bolt can for instance be effected by a blow impacting on the door edge perpendicular to the plane of the door, and which for a hinged door would be delivered in the door opening direction. A bolt is strong against bending and shear forces, but nevertheless if the bolt is mounted in cantilever the inserted (unsupported) and can often be sprung from its keeper by a determined blow.
It is of course desirable that unlawful opening movement of a door generally parallel to its plane (as might occur by use of a housebreaker's jemmy) also be made more difficult. Improved security against bursting movement perpendicular to the door frame should not result in reduced security against unauthorised opening parallel to the door frame; it is an advantage of embodiments of the invention that increased security can be provided against such attempted door openings parallel to its plane.
DISCLOSURE OF THE PRIOR ART
Bolts are widely used as fastening for hinged gates and include a bolt end which can slidably be moved into an aperture in a fixed upright, to prevent the gate swinging on its hinge.
More sophisticated bolt units have long been available in which the bolt is mounted in a housing, perphaps with the bolt fully concealed in the housing when in the retracted, inoperative condition, and with the housing carrying actuating means which can be used to move the bolt into a "holding" position with its one end projecting from the housing; with the housing mounted to a hinged door, if the projecting end of the bolt in this holding condition is fitted into an aperture (for instance in a fixed upright forming part of a frame for the door) then the door is held against swinging about the hinge(s).
The bolt unit will often have a key-controlled lock which can be operated to secure the bolt in its extended "holding" position.
For greater security, fabricated (metal) keepers secured to the upright are used instead of apertures cut in the upright.
Some bolt units have a latching action, in which the bolt is chamfered and biassed towards its holding position by a spring; when such a bolt engages its keeper as by the panel being closed, the chamfer causes the bolt to be retracted into its non-holding position until it enters the keeper aperture. Such latch action bolts can be fitted to the rim of a door and are then referred to as "rim latches"; they can also be secured in the holding position by a lock.
Rim latches are widely used to secure external doors in homes and offices, and for this purpose are mounted to an interior surface of the door; often the lock will be key operated from both inside and from outside the door, but some rim latches can additionally, or alternatively, be opened by rotating a thumb-turn located inside the door so as manually to force the bolt back against the latch spring.
SUMMARY OF THE INVENTION
We seek to provide a bolt unit which when fitted in a frame arrangement is less susceptible to unauthorised opening as by bursting or jemmying than the known bolt units.
According to one feature of the invention we provide a bolt unit which includes a bolt housing, bolt guides in the housing and a bolt slidable between said guides so that one end of the bolt can be outside the housing characterised by a receptor for said one end of the bolt outside of the housing, said receptor being carried by the housing and movable therewith.
Preferably, the bolt unit has resilient bias means in the housing, said resilient bias means acting to urge the said one end of the bolt in a direction away from a non-holding position and towards a first holding position with said one end outside of the housing, and in that said one end of the bolt has a chamfer, with a chamfer angle relative to said direction such that a force against said chamfer and substantially perpendicular to said direction can cause the said one end to move away from said first holding position and towards said non-holding position.
We can also provide a bolt unit which includes a bolt movable between a first holding position and a second holding position. Preferably the bolt should be lockable in the second holding position.
Thus according to a preferred feature of the invention the bolt unit has a first movement means mounted in the housing, the first movement means being adapted to allow one end of the bolt to move in a direction between a non-holding position and a first holding position, said first holding position being outside the housing, and a second movement means mounted in the housing, the second movement means being adapted to allow the said one end of the bolt to move further in said direction and into a second holding position, the said one end of the bolt being engaged with the receptor in said second holding position.
For a latch arrangement, preferably the first movement means restrains movement of the bolt, the bolt being moved by a spring in the said direction when the movement means is removed. Preferably the second movement means drives the bolt further in the said direction. Thus the latch uses a "single throw" bolt movement means.
For bolt withdrawal, preferably the second and first movement means successively drive the bolt in the opposite direction to the said direction, firstly from the second holding position to the first holding position, and then from the first holding position to the bolt retracted position (allowing door opening).
The first and second movement means can be provided by a single component, such as a rotatable actuator perhaps capable of multiple revolutions in both angular directions. In a preferred latching embodiment, the actuator has a permitted angular movement of 200-240 degrees, typically with a rotation of 20-60 degrees to clear the bolt to allow the spring to move the bolt to the first holding position, and a further full 180 degree rotation to move the bolt to the second holding position.
The first and second movement means can however be provided by separate components. For office doors and the like having lockable bolt units, key holders can for instance use their key during the day to move the bolt (or a number of bolts on selected doors) between the first holding position and a withdrawn condition (allowing door opening); security staff can use their key to move the bolt to the second holding position. The lock casing can be of any known design, including for instance one using a split key (with one part of the key being used by the key holder for movement of the bolt between its first holding and non-holding positions, and both parts by security staff for movement of the bolt into and out of its second holding position).
The bolt housing carries a receptor with which the one end of the bolt engages in the second holding position. Thus in the assembled condition and according to a further feature of the invention we provide a frame arrangement which includes a frame member, a panel movable relative to the frame member into a closed condition, and a keeper mounted to the frame member, characterised by a bolt unit as herein defined having the bolt unit mounted to the panel member, the bolt unit carrying a hollow receptor and a bolt having one end movable into the receptor, the keeper having an open-ended aperture to permit in said closed condition said one bolt end to pass into the keeper and then through the keeper and into the receptor.
Usefully the bolt can be key-locked in the second holding position.
The bolt when received in the receptor acts as the releasable arm of a padlock.
In a preferred (latching) arrangement the bolt is resiliently biassed towards an extended condition corresponding to the first holding position as above described; usefully the bolt (one) end is chamfered, and the roof of the keeper is angled to form a ramp directed towards the bolt housing whereby to provide a "slam shut" latching facility. Thus if the bolt is already partly extended from its housing, as the hinged (door) panel is swung towards the closed condition the bolt (one) end can abut the ramp whereby first to ride back against the spring and then to snap-fit (ride forward) into a first holding position within a fixed keeper. If the arrangement is used on a door, the bolt will snap-fit to a standard door holding position upon door closure.
With such slam-shut latching facility, the key or other bolt actuating means needs for example to be turned so as to retract the bolt one end from the keeper, against the spring force, in order that the door or other panel can be opened away from the frame.
Also in a preferred arrangement the bolt can be moved from inside the building to its second holding position by manually rotatable means, such as a thumb turn. Usefully however the manually rotatable means is a key whereby rotation of the key rotates a lock plug within a fixed lock barrel or body to cause an actuator carried by the plug to engage with the bolt; the bolt can only be released from its second holding position by use of the (correct) key or key part, the key also being used to withdraw the bolt from its first holding position to its door-opening retracted position.
The first and second holding positions are usefully determined by a control member pivotally or slidably mounted to the bolt housing, and resiliently biassed towards an operative or rest condition. When the abutment is rotated it can move the control member against a spring to permit a peg carried by, perhaps integral with, the bolt to traverse between spaced peg stops. The control member provides a dead-lock facility.
A cover is assembled over the bolt housing. When so fitted its projects beyond the edge of the panel, and preferably is shaped to soften any inadvertent user and visitor contact; specifically the cover prevents inadvertent contact with the bolt end, which in prior art arrangements for snap-shut latches is sharp-edged and exposed.
The cover can have an opening allowing access (when the panel is in an opened condition) to a screw whereby to permit fitting (and replacement) of the lock.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example with reference to the accompanying schematic drawings, not to scale, in which:
FIG. 1 is a side view of part of a frame arrangement with a bolt unit according to the invention, with the cover and other parts removed, and a cooperating keeper;
FIG. 2 is a side view of a bolt retainer for the unit of FIG. 1;
FIG. 3 is a side view of the control member for the unit of FIG. 1:
FIG. 4 is a reverse view of a bolt unit according to the invention fitted to a panel;
FIG. 5 is a side view of part of another embodiment of bolt unit, with the cover and bolt removed;
FIG. 6 is a view of the rear face of the bolt for the unit of FIG. 5 and showing an axially movable manual retraction rod for the bolt;
FIG. 7 is a view of the front face of the bolt for the unit of FIG. 5;
FIG. 8 is a perspective view of yet another embodiment of bolt unit and keeper arrangement;
FIG. 9 is a sectional view of part of the bolt unit of FIG. 8;
FIG. 10 is a schematic view of the bolt unit and keeper of FIGS. 8 and 9 in use (frame and panel not shown); and
FIG. 11 is a perspective view of a bolt unit and keeper arrangement ready for use, the bolt unit being similar to that of FIG. 5, but of opposite hand.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
The frame arrangement 1 of FIG. 1 includes a bolt unit 10 having a slidable bolt 12 which is located between upper and lower guides 14a,14b in bolt housing 30. Bolt 12 is rectangular in cross section, and has its one end 12a chamfered.
Bolt housing 30 comprises a flat base 31 having a left hand edge 32 and a right hand edge 33, joined by side edges 34. The guides 14a,14b upstand from base 31. As more fully described below, walls 35 upstand along part of the side edges 34 and provide a mounting for a cover 90 (FIG. 4). In an alternative embodiment walls 35 upstand completely around the base periphery.
The base 31 of bolt housing 30 in sue, and as shown in FIG. 1, is secured to a movable panel 36. The securement is usefully by nuts which cooperate with screws which project from a plate (not seen) so as to extend through movable panel 36 and through base plate 31. Movable panel 36 is hingedly mounted to an outer fixed frame, of which fixed upright 38 forms part, so as to swing from the closed position shown in FIG. 1, out of the paper towards a panel open position, for instance to the position of FIG. 4.
In this embodiment movable panel 36 is an external door of a building, and which therefore needs to be securable to prevent unauthorised access into the building, whilst fixed upright 38 is part of the door frame. Bolt unit 10 has a lockable bolt 12 as more fully described below, and is fitted as a lockable rim latch to the exposed inside surface of the door 36. A keeper 22 is mounted to fixed upright 38.
In a preferred embodiment edge 32 will overlie upright 38.
Part way along its length bolt 12 has an abutment surface 16. Guide 14b is cut away so that rotatable actuator 20 can engage this abutment surface.
The bolt unit has a retracted position, as shown in FIG. 1, with the actuator turned clockwise against bolt surface 16 to move the bolt against spring 49 out of the fixed keeper 22. In this position the bolt surface 16 abuts actuator 20 under the bias of spring 49. The door can now be opened, since the bolt end 12a is withdrawn from keeper 22.
With the door 36 closed against frame upright 38, and therefore with bolt 12 aligned with the aperture of keeper 22, the bolt unit has a first holding position wherein the bolt end 12a is receive din the keeper aperture, as commonly provided for in known rim latches. Thus initial anti-clockwise rotation of actuator 20 from its position of FIG. 1 allows spring 49 to move bolt end 12a into the keeper aperture. Subsequent clockwise movement causes actuator 20 to engage bolt surface 16 to effect bolt end 12a removal from the keeper aperture.
In an alternative embodiment, with door 36 in the closed condition and with an anti-clockwise rotation imparted to actuator 20, the actuator 20 itself moves the bolt so as to insert chamfered bolt end 12a into aperture provided by fixed keeper 22.
Actuator 20 can be rotated by a key inserted into the key slot 40 of the lock. The lock body 42 is held against rotation by screw 44 received in spaced threaded members secured to base 31, and in an alternative embodiment also to an extended sidewall 35. In further alternative embodiments actuator 20 can be turned by a thumb grip or a handle, or if the lock is double-ended by a key inserted from outside the door.
The bolt unit of FIG. 1 provides a latching or snap-shut closure action. Thus if the door is in an opened state with the bolt 12 in the first holding position, then if the door 36 is moved towards the closed state (into the paper) bolt end 12a will engage the shaped roof of keeper 22 with a ramp action such that bolt 12 can be pressed to the right against the force of spring 49, until bolt end 12a is aligned with the aperture in the keeper; when so aligned with the keeper aperture the bolt end 12a will be urged by spring 49 into the aperture (latching action). In this embodiment the keeper roof is angled towards the right whereby to provide a cam action with the chamfered bolt end 12a whereby to ease bolt movement rightwards.
It is a disadvantage of the known bolt unit and keeper arrangements having only the features such as those described above and which rely solely on this first holding position with the bolt one end 12a in keeper 22 that the bolt can be burst i.e. if a sufficiently strong (impact) force is applied to the door 36 in the opening direction (from behind the paper), then relative movement of the door and frame can allow bolt end 12a to detach from keeper 22 so that the door can unlawfully be opened even though bolt 12 is locked against rightwards movement relative to door 36.
It is a feature of the embodiment of FIG. 1 that housing 30 carries a receptor 50 which in the door closed condition will fit behind (to the left as viewed in FIG. 1) and aligned with the aperture of keeper 22. Thus in the door closed condition of FIG. 1 the keeper 22 is between the receptor 50 and the guides 14. Receptor 50 is secured to upstanding housing wall 35, which in this embodiment is of U-shape but in an alternative embodiment forms a closed upstanding loop, in both cases with only part of the wall 35 being connect to or integral with housing base plate 31 and in both cases with receptor 50 moving with bolt housing 30 upon hinging of door 36; in another embodiment receptor 50 is additionally or alternatively connected to spaced sections of the peripheral housing wall by upstanding struts or the like.
In use the housing 30 is shielded by a cover 90 (partly seen in FIG. 4) of inverted cup-shape and which fits around and is connected to the peripheral housing wall 35; the cover 90 is connected to wall 35 so as to provide extra strength and support to the upstanding peripheral wall.
Cover 90 in the position of use (FIG. 1) extends over and conceals keeper 22, and so prevents keeper 22 being disabled, as by being unlawfully cut or removed.
The cover 90 has an opening permitting key access to the actuator 20, in this embodiment by way of key slot 40 in a double-acting lock plug, the lock plug being turnable as above described in opposite angular directions within a lock barrel or body by the key.
It is a further feature of the embodiment of FIG. 1 that the cover is slotted or apertured at 92 and that wall 35 of housing 30 is slotted or apertured at 37, whereby to allow access to screw 44 which holds the lock barrel against movement, so that for instance an authorised locksmith can select and fit the lock after the housing components have been assembled. However keeper 22 is extended (downwardly in FIG. 1) at its full height so that access to screw 44 is denied when the door 36 is in the closed condition.
In this embodiment the keeper 22 is secured to the fixed upright 38 by screws in leftwardly extending flat, planar bosses 23; the bosses can have screw holes but preferably will have screw slots permitting the position of the keeper to be adjusted relative to housing 30 if door 36 sags relative to its frame i.e. relative to upright 38. The bosses 23 are vertically spaced by a sufficient distance to receive receptor 50 when door 36 is in the closed condition. The outer edges of the bosses 23 are strengthened by upstanding members 24, which in an alternative embodiment are so positioned and with their upper parts outwardly chamfered so as to act as a guide for the housing 30 as door 36 closes, ensuring that the keeper 22 and receptor 50 are aligned ready to receive bolt 12.
It is another feature of the embodiment of FIG. 1 that the bolt end 12a has two predetermined holding positions. The first holding position as described above is with the bolt end 12a within the keeper 22 whereby to permit a standard level of door retention as with the known rim latches. The second holding position is with the bolt end 12a at a greater extension from the guide 14 such that bolt end 12a is within receptor 50, whereby to permit an improved level of panel retention, both (a) because the shaft of bolt 12 is now within keeper 22 and held thereby, ad (b) because any attempt to force door 36 out of the paper causes the bolt end 12a to abut, or to abut more firmly, against receptor 50, with the bolt unit acting in padlock fashion.
Thus with the bolt unit in the second holding position, upon attempted forcible opening of door 36 the bolt end 12a does not burst from receptor 50, but instead bolt 12 and receptor 50 will move together since each is part of the bolt unit 10, with further movement of bolt 12 (if any) resisted by keeper 22.
The bolt has additional abutment surfaces 56, 58 which can be engaged by actuator 20 when the bolt end 12a has been moved into the keeper 22. The actuator 20 is capable of two complete revolutions, in opposite angular directions, and many key operated locks for instance have this facility; however, in the embodiment as described, the required movement is a part revolution (anti-clockwise from the FIG. 1 retracted position) of between 20 and 60 degrees, and then a single-throw further complete revolution to clear the surfaces 56,58. Further anti-clockwise rotation of actuator 20 is stopped upon engagement with the tail of bolt 12 (to the right as viewed in FIG. 1 of surface 56). The position of the abutment 58 is selected so that in the second holding position the bolt end 12a will fully enter receptor 50, which in this embodiment is backed by the upstanding housing wall, and so is single-ended.
In an alternative embodiment, abutment surfaces 56,58 are positioned to be engaged by a separate actuator, key-operated, preferably by a second key for even greater security. For multi-user facilities the second key can be held by security staff who lock the door(s) whilst copies of the first key can be issued to users who need to open the latched door (from the first holding position).
FIG. 2 is of a bolt retainer 60, of generally L-shape, with a function as described below. In the assembled unit plate arm 62 is secured to the guide 14a whilst plate body 64 is secured to guide 14b. Bolt retainer 60, housing base 31 and guides 14a,14b form an enclosed channel within which a part of bolt 12 can slide and which can help retain bolt 12 in the housing, specifically between guides 14a,b without interfering with the operation of actuator 20.
Between plate arm 62 and plate body 64 is a recess 66 of a size to receive upstanding bolt peg 13 when the bolt end 12a is within the receptor 50, to locate peg 13 and to inhibit lateral banding of bolt 12 during any unauthorised attempt to disable the latch, as by attempted lifting of the door 36 relative to the upright 38.
FIG. 3 is of a control member 70 providing a bolt traverse limiting means. Control member 70 has a through-opening 72 of a size to fit upon the upstanding post 71 of the bolt housing 30; opening 72 is circular, as is the post 71 in cross section, so that the control member 70 can be pivoted about post 71.
Control member 70 is urged clockwise about the post 71 by spring 73 extending between control member post 74 and housing post 75. Pivoting movement of member 70 is restrained by upstanding housing post 76 which is received in a slot 77 of the control member, and in the clockwise direction by a depending plate (not shown) which normally is in contact with the guide 14a.
Control member 70 has openings 82 and 84, joined by a passageway 86 of a size to permit bolt peg 13 to pass from opening 82 to opening 84 whereby to allow bolt end 12a to enter the receptor 50.
Control member 70 has a cam surface 80, adapted with the actuator 20 in the position shown in FIG. 1 to be engaged by the actuator 20 and thus to be lifted against the action of spring 73. Thus in the actuator 20 position of FIG. 1, the control member has been lifted, and bolt peg 13 is against (in an alternative embodiment adjacent) surface 82.
Anti-clockwise rotation of the lock plug will now move actuator 20 out of engagement with cam surface 80 to allow spring 73 to return the control member clockwise to its rest position; bolt 12 is also moved (in this embodiment by spring 49 as above described) until peg 13 abuts surface 83.
Further anti-clockwise rotation of the lock plug during the single throw will cause actuator 20 first to lift surface 80, and then to engage bolt surface 58, whereby the peg 13 can travel along passageway 86 into opening 84 before further rotation of actuator 20 allows spring 73 to cause the control member to return towards its rest position whereby to trap peg 13 in opening 84. Thus control member 70 provides an additional degree of dead-lock security, preventing the bolt retracting from the receptor if for instance the spring 49 is damaged or removed.
Whilst in opening 84 the bolt peg 13 is also in slot 66 of bolt retainer 60, and so cannot inadvertently enter passageway 86.
When the bolt 12 is to be retracted, clockwise movement of actuator 20 lifts control member 70 to an inoperative position before bolt surface 56 (and subsequently on the second actuator rotation bolt surface 16) is contacted.
It is a further feature of the invention that in the door open condition the receptor 50 is spaced inwardly (to the left as viewed in FIG. 1) from the door edge. The receptor in the fully assembled unit is however within the cover 90. The exposed edges of the cover and of the housing upstanding wall, as seen in FIG. 4, will usefully be shaped for increased personal safety; specifically if the bolt is in its first holding position with the door open, the edges of bolt end 12a are also within the cover and not exposed.
FIG. 5 shows an alternative embodiment of bolt unit 110. The bolt unit is mounted in a housing 130, which housing has a through opening 121 into which the keeper (not shown in FIG. 5, but see the keeper of FIG. 8 or 11, for example) can enter.
In an alternative embodiment, the opening is closed to one side, as by the cover of the housing.
The housing 130 has guides 114a,114b to locate and guide bolt 112 (FIGS. 6,7). Integral with the housing 130 is the receptor 150, into which the bolt can project when in its second holding position.
In a recess 169 in the housing 130 is located a plate-like control member 170. The control member 170 has a pair of openings 182,184, joined by a passageway 186, the openings and passageway being adapted to accommodate a peg 113 on the bolt 112 (FIG. 6). The control member is slidable in the recess 169 in a direction transverse to the direction of movement of the bolt 112. The control member can move between a rest or operative position (as shown) in which the peg 113 will be retained in one or other of the openings 182,184, and an inoperative position in which the peg 113 will be able to be moved along the passageway 186 between the openings. Sliding movement of the control member is guided by lugs 172 which fit into suitably-shaped recesses in the housing, and the control member is biassed towards its rest position by spring 173.
The control member 170 has an edge 180 which lies adjacent the barrel of a lock (not shown) which can be fitted into standard opening 141. The lock barrel will carry an actuator (also not shown) which can be rotated in recess 119. The edge 180 is engageable by the actuator, so that the control member can be moved by the actuator to its inoperative position. Depending upon the position of the bolt 112 and the direction of rotation of the lock, the actuator can also engage one or other of surfaces 156 and 158 in the bolt 112 (FIGS. 6,7), so that following movement of the control member to its inoperative position rotation of the lock can cause the actuator to drive the bolt between its first holding position and its second holding position, and vice versa.
It will be understood that in the embodiments of FIGS. 3 and 5 that the respective opening 82,182 in the control member permits movement of the bolt between its first holding position and its non-holding position (and vice versa) without requiring the control member to be pivoted or moved to its inoperative position, i.e. the opening 82,182 is large enough to permit the necessary movement of the respective peg 13,113. Thus, the bolt can be moved from its first holding position to its non-holding position by means other than the lock actuator 20, e.g. by its chamfered end 112a engaging the keeper. However, in order to move the bolt between its first and second holding positions it is necessary for the actuator to move the control member so that the peg can pass along the respective slot 86,186. The control member 70,170 can thus provide additional security to the bolt in its second holding position. It will be understood, however, that the control member could have an additional opening connected to opening 82,182 by a passageway similar to passageway 86,186, so that movement of the bolt between its non-holding and first holding positions also requires prior movement of the control member by the actuator; such a bolt would not have a latching action.
The thickness of the control member 170 is substantially the same as the depth of the recess 169, so that in the assembled condition of the bolt unit the bolt 112 engages the control member 170 as well as housing surface 115 and guides 114a,114b.
The bolt 112 is urged towards its first holding position by a spring (not shown); in this position the peg 113 engages surface 183 of opening 182. However, the bolt 112 has a chamfered end 112a, so that if the bolt unit is closed upon a keeper, the bolt 112 may be forced back against the spring, until the bolt end 112a is able to enter the keeper aperture (during this movement, the peg 113 moves within openings 182, away from surface 183).
Thus, in this embodiment, the bolt unit is spring biassed into its first holding position (to act as a latch), and may be moved to its second holding position only upon rotation of the actuator under the control of the lock. In an alternative embodiment, the bolt is not spring biassed, and movement of the bolt between any of its respective positions can only be effected by rotation of the actuator; in such an embodiment, it will be understood that the bolt unit acts as a "double dead lock", so that the bolt will not be chamfered.
Part of the bolt housing 130 is removed at 129, to save weight and also to permit easier access to the screw which will be required to fix the lock barrel in place. The housing also has a slot 117, to accommodate rod 128 which can be connected to a manually grippable handle or the like, so that the bolt may be moved between its first holding position and its non-holding position by way of the handle as well as (or in some embodiments instead of) the key-operated lock.
As shown in FIG. 7, the bolt 112 also has a detent means 194, which comprises a recess cut into the bolt and which has three wells 195 which can receive a detent lug (not shown) carried by the cover of the housing. The detent lug is manually movable into and out of a respective well, and when fitted into one of the wells 195 can secure the bolt 112 in one of its non-holding, first holding and second holding positions respectively.
The embodiment of FIGS. 8 and 9 shows a bolt unit and keeper for use as a "panic" bolt, in which a button 201 can be pressed to move the bolt 212 between its first holding position (as shown in FIG. 8) and its non-holding position. The button 201 is mounted on a rod 202 which is pivotably attached to a pivot plate 203. Pivot plate 203 is mounted upon fixed pivot 204, and has an end 205 which engages abutment surface 216 of the bolt 212.
The housing 230 includes an opening 221 to receive part of the keeper 222. The keeper includes a keeper aperture 225 which has a projection 226 to either side. When the bolt unit and keeper are brought together, the keeper aperture 225 and the projections 226 enter the opening 221 in the housing 230, with the bolt end 212a entering the keeper aperture 225.
The enlarged form of keeper 222 is used in this embodiment so that it can cooperate with the housing 230 fitted to the inside surface of an outwardly opening door 236, as shown schematically in FIG. 10. Thus, it is necessary for the keeper aperture to be mounted spaced away from the edge 237 of the fixed frame member 238 to which the keeper is secured.
In this embodiment, both of the bolt tip 212a and the keeper 222 are chamfered, the bolt tip 212a being able to ride up the keeper chamfer 227 when the bolt unit and keeper are brought together, to provide a "slam shut" latching facility. Though not shown in the figures, the bolt unit can include a key operated facility, by which it may be moved to its second holding position when required, in which position the button 201 becomes inoperative.
It will be understood that the button 201 can be replaced by a pivoting plate, sometimes referred to as a "paddle".
In FIG. 9, the button 201 is shown to be biassed by a spring 206, though the spring (not shown) which urges the bolt (rightwards in this figure) into its first holding position could alternatively be used to bias the button by way of the plate 203.
In the embodiment of FIG. 11, a bolt unit and keeper arrangement is shown which is suitable for an inwardly opening panel in which the bolt unit is secured to the inside surface of the panel. Such an embodiment is commonplace for the doors of domestic dwellings, for example. In the fitted condition, the housing 330 can have its face 331 secured to the panel by known means, and the keeper 322 can be secured to the edge of a frame member by way of screws or the like passing through holes 328; alternatively, the housing 330 can be morticed into the panel, with the frame being suitable rebated (around the keeper) to receive the receptor 350 and its associated carrying parts.
The housing 330 has an opening to receive a known lock barrel which is double-ended, in that it may be operated by the insertion of a key from both inside and outside of the panel. In addition, the housing 330 has a through opening 321, so that the ends of the keeper projections 326 can pass though the housing. However, in other embodiments the opening is closed at its side opposed to the keeper insertion side, as by the cover for the housing.
It is an advantage of our embodiments that when in the second holding position the bolt unit and keeper has the characteristics of a padlock, with the fixed keeper acting as a sample through which the bolt passes to connect the two sides of the housing 30,130,230,330 e.g. the base 31 and the receptor 50. In certain embodiments therefore, the bolt unit can be used "loose" i.e. not fitted to a panel, the bolt being adapted to secure a hasp to a staple for example. There is the further advantage with our preferred embodiments that the fixed keeper (or hasp) is substantially or fully concealed by the fitted cover when the panel is in its closed position, and so cannot be tampered with when the bolt unit is in the first or second holding position. Thus the provision of the receptor carried by the bolt housing, with the housing able to embrace and surround the fixed keeper for example allows the standard type door lock with a cantilevered bolt end to become equivalent to a concealed padlock with supported ends.
Whilst in this description reference has primarily been made to a hinged door panel, it will be understood that the bolt could be used for sliding panels if the housing is hingedly mounted e.g. to the door panel. The housing would be hinged out of the paper until the panel is closed, and then would be swung to the position of FIG. 1 with the receptor aligned with the keeper.
The bolt unit can be used for other applications, such as a closure for a container panel, and may be lockable from one side only for thick factory doors which might otherwise require a deep lock and a correspondingly large aperture in the door. Also for convenience the panel has been described as securable (against hinged or sliding movement) to a fixed upright, though it could be secured to a horizontal fixed member or to an angled part of an outer fixed frame.
It will be understood that the cooperating parts of the control member 70,170 and its respective bolt 12, 112 could be reversed, with the control member carrying the peg and the openings and passageway(s) being formed in (perhaps recessed into) the bolt.
Thus we provide an advantageous new dead-locked safety lock with the beat features of a rim lock and a padlock, with concealed parts in use. We also provide a bolt unit in which a single bolt member can act as a latch (in its first holding position) and as a dead bolt (in its second holding position), and in which a single actuator can control both of these functions, in place of the separate (and separately actuated) latch member and bolt member which are currently available. | This invention relates to a bolt unit and frame arrangement. In particular it relates to a lockable bolt unit having a slidable bolt, typically for securing two moveable panels together or for securing one moveable panel to a fixed frame. |
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RELATED APPLICATIONS
There are no current co-pending applications.
FIELD OF THE INVENTION
The presently disclosed subject matter is directed toward security devices. More particularly, the present invention relates to security devices for preventing personal items such as purses, clothing, luggage, or the like from being stolen or moved while sitting unattended.
BACKGROUND OF THE INVENTION
Very few leisure time activities rival that of spending warm summer days at the beach. Some enjoy being around a pool with all the comforts of home, while others spend time outside tanning. Whatever the reason, all of these events share common items such as beach towels, beach bags, clothing, or the like. However, when a person wishes to go into the water or otherwise walk away for a few short moments, one runs the risk of having their personal items stolen.
Even if they are not stolen, they can be picked up by someone else and moved to another location where they cannot be easily found. Similar difficulties appear when traveling and personal items such as coats, jackets, luggage, or the like must be left alone for short periods of time.
Accordingly, there exists a need for a means by which easily movable or stolen items can be easily secured against theft or unauthorized movement.
SUMMARY OF THE INVENTION
The principles of the present invention provide for a securable locking clip that can grasp items such as towels, clothing, purses, luggage, or the like in its clasping jaws/or by using a flexible secure cable. The securable locking clip can then be attached to a stationary object to prevent a person from taking or moving the items.
The securable clip is a lock suitable for preventing the theft, loss, or misplacing of beach towels, luggage, purses, or other personal items. One (1) end of the securable clip is hinged and receives a flexible wire cable, while the opposite end has interlocking jaws that can grip a towel or similar item. The securable clip has a movable hasp which squeezes the jaws together and prevents their opening. The hasp is held in place by a conventional padlock which can be secured to a stationary object such as a beach chair, post, table, or similar item using the flexible wire cable. In addition, various items such as purses, luggage, briefcases and the like can be secured in place by passing the flexible steel cable through the handle of the item and then securing it to a stationary object. Additionally, the securable clip can have a label for providing information such as owner's name, room number, and telephone number.
A securable clip in accord with the present invention includes a “C”-shaped clip having a hinge at one (1) end, an upper jaw extending from the hinge and a lower jaw extending the hinge. The upper and lower jaws are biased open by the hinge and they both include a tapered section located adjacent the hinge. The upper jaw and lower jaws also include clamping teeth. Force applied to the tapered section can force the upper jaw and lower jaw closed. The upper jaw also includes latching teeth on an outer surface. The securable clip also includes an adjustable band that is dimensioned to fit over the hinge and to apply a force that closes the jaws when the adjustable band is moved along the tapered section. The adjustable band including an integral hasp having an actuator tab and a locking tip. When the locking tip engages a latching tooth it secures the upper jaw and lower jaw closed.
Beneficially the clip is a molded plastic structure, the adjustable band is hollow and forms a rectangular inner opening, and the upper jaw and lower jaw include aligned padlock apertures. Also beneficially the actuator tab can pivot the locking tip out of contact with the latching tooth. A padlock for passing through the aligned apertures may also be included. A cable may also be included, preferably plastic coated and having an eyelet. An identification label may be attached, preferably on the upper jaw.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is an environmental view of a securable clip assembly 10 that is in accord with a preferred embodiment of the present invention when in-use;
FIG. 2 is another environmental view of the securable clip assembly 10 shown in FIG. 1 when secured to a structure 110 ;
FIG. 3 is a close-up view of an assembled securable clip assembly 10 as shown in FIGS. 1 and 2 ;
FIG. 4 is a section view of the securable clip assembly 10 taken along section line A-A of FIG. 3 ; and,
FIG. 5 is an exploded view of the securable clip assembly 10 shown in FIGS. 1 through 4 .
DESCRIPTIVE KEY
10 securable clip assembly
20 clip
22 hinging end portion
24 upper jaw
26 lower jaw
28 clamping tooth
30 padlock aperture
32 latching tooth
34 identification label
50 adjustable band
52 band
54 band aperture
60 clasp
62 actuator tab
64 locking tip
80 cable
82 eyelet fixture
86 padlock
87 padlock clasp
100 towel
102 personal item
110 structure
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one (1) of the referenced items.
Referring principle to FIG. 1 , the preferred embodiment of the present invention is a securable clip assembly 10 that helps prevent theft of fabric-based items such as, but not limited to, beach towels 100 , blankets, clothing items. The securable clip assembly 10 is also useful for securing personal items 102 such as purses, luggage, and the like to a stationary structure. The securable clip assembly 10 is especially useful in a vacation/beach environment.
Refer now to FIGS. 1 and 2 , environmental views of the securable clip assembly 10 when in-use, and to FIG. 3 , a close-up view of the securable clip assembly 10 . The securable clip assembly 10 includes a clamping clip 20 , an adjustable band 50 , and a length of cable 80 which is secured to the clip 20 using a conventional padlock 86 . The securable clip assembly 10 provides mechanical clamping forces to secure various items such as towels 100 , robes, jackets, purses, suitcases, and the like to a stationary structure 110 . This reduces the possibility of tampering, theft, or misplacement which increases the peace of mind of a user.
Refer now to FIGS. 3 , 4 , and 5 , close-up, sectional, and exploded views of the securable clip assembly 10 . The securable clip assembly 10 uses a generally “C”-shaped clip 20 which is approximately two-and-one-half inches (2½ in.) long and approximately one-and-one-half (1½ in.) inches wide. However, it should be understood that the actual dimensions of the securable clip assembly 10 may vary based upon a user's preference and particular applications. The clip 20 is beneficially a one-piece molded plastic structure that is envisioned as being made using an injection-molding process and as being available in a variety of colors and patterns.
The clip 20 has a molded hinge 22 at one end and a set of tapered jaws at the other. The tapered jaws includes a forward extending upper jaw 24 and a forward extending lower jaw 26 that are biased open by the hinge 22 . The clip 20 is configured to have a downward tapered cross-section around the hinge 22 . The upper jaw 24 and lower jaw 26 also include a plurality of clamping teeth 28 that interlock when the jaws 24 , 26 are forced closed as described below. When not forced closed the upper jaw 24 and the lower jaw 26 are biased open about one inch (1 in.) by the hinge 22 . This allows a user to slide a towel 100 or similar item between the open jaws 24 , 26 .
After the towel 100 or other item is placed between the upper jaw 24 and the lower jaw 26 those jaws 24 , 26 are forced closed by sliding the adjustable band 50 forward along the tapered surfaces of the clip 20 near the hinge 22 . To that end the adjustable band 50 has a hollow rectangular band section 52 that forms a rectangular inner opening that encompasses the tapered surfaces of the clip 20 near the hinge 22 . As the adjustable band 50 slides forward along the clip 20 the jaws 24 , 26 are forced together, thus clamping the towel 100 . The adjustable band 50 is retained in a clamping position by an integral hasp 60 having a user accessible actuator tab 62 at one (1) end and a locking tip 64 at the other. The locking tip 64 engages one (1) of a plurality of latching teeth 32 that are molded into the upper jaw 24 . Engagement of the locking tip 64 into one of the latching teeth 32 secures the hasp 60 in position, which secures the closing of the jaws 24 , 26 .
The jaws 24 , 26 can be easily opened by a user depressing the actuator tab 62 . This pivots the locking tip 64 out of contact with the latching teeth 32 . The hasp 60 can then be rocked back and forth to slide it down the clip 20 taper. This enables the bias force of the hinge 22 to open the jaws 24 , 26 , releasing the item(s) placed between them.
Once the towel 100 or other item is secured within the clip 20 that clip 20 can be secured to a structure 110 (see FIG. 2 ) using the conventional padlock 86 . To that end the clip 20 includes a pair of padlock apertures 30 that are formed through the jaws 24 , 26 behind where the adjustable band 50 locks the jaws 24 , 26 closed. The padlock apertures 30 are aligned and allow the padlock 86 clasp to pass through. The cable 80 , preferably one (1) with a plastic-coating, has a pair of eyelets 82 . The cable 80 is wrapped around or otherwise secured to the structure 110 , the eyelets 82 are secured by the padlock clasp 87 , the padlock clasp 87 is passed though the padlock apertures 30 , and then the padlock 86 is locked.
Additionally, the clip 20 includes an identification label 34 that is affixed to a top surface of the clip 20 . This enables convenient display of information such as owner's name, room number, telephone number, or the like to be applied.
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and while only one particular configuration is shown and described that is for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be used by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the securable clip assembly 10 it would be installed as indicated in FIGS. 1 and 2 .
The method of using the securable clip assembly 10 may be achieved by performing the following steps: procuring the securable clip assembly 10 ; removing the padlock 86 and adjustable band 50 , if previously installed; inserting a towel 100 or similar item between the upper 24 and lower 26 jaws; sliding the adjustable band 52 over the hinge 22 ; sliding the adjustable band 52 along the tapered surfaces of the clip 20 to force the jaws 24 , 26 ; securing the adjustable band 50 in position by allowing the locking tip 64 of the clasp 60 to engage a corresponding latching tooth 32 of the upper jaw 24 ; using the identification label 34 to note information such as an owner's name, room number, telephone number, or the like; wrapping or otherwise securing the cable 80 to a structure 110 , securing the cable 80 to the padlock using the eyelets 82 ; locking the padlock 86 ; and then benefiting from the secure attachment of one's towel 100 or other personal property 102 to the stationary structure 110 .
The cable 80 may be routed through and around suitable personal items 102 and through a stationary structure 110 such as a beach chair, and the padlock claps 87 inserted through the eyelets 82 of the cable 80 , and through the padlock apertures 30 of the clip 20 , thereby providing a means to securely anchor the securable clip assembly 10 and personal items 102 .
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. | A security device to prevent the theft of personal items comprises a plastic clip with an adjustable movable hasp on a first end and interlocking gripping teeth on an opposing second end. The movable hasp squeezes the jaws together and prevents their opening. The hasp is in turn held in place by a padlock which can secure the device to a stationary object such as a beach chair, post, table, or similar item using a flexible cable. |
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This application is a continuation-in-part application of U.S. application Ser. No. 08/189,181 filed Jan. 28, 1994, from which applicants claim priority.
TECHNICAL FIELD
The present invention relates generally to a method and apparatus for controlling the displacement (or vibration) of a structure when subjected to external forces such as an earthquake or wind, the apparatus employing novel damping/coupling devices and mounts therefor; and more particularly to a method and apparatus to adjust the dynamic parameters (mass, damping, stiffness coefficients) of a structure by using new devices mounted in novel manners in accordance with novel processes developed from newly proposed control laws.
BACKGROUND OF THE INVENTION
It is well known that structures can fail when subjected to external forces of sufficient magnitude, as for example high winds or a moderate to strong earthquake. Many proposals have been made for improving the ability of a structure to withstand such forces without damage or failure of the structure. The approaches range from making the structure rigid, making it flexible, to mounting the structure upon the surface of the ground so that it can move relative to the ground, by coupling or uncoupling the structure to a mass to change its resonant frequencies, etc. One such example is shown in U.S. Pat. No. 5,036,633 invented by Kobori wherein an apparatus is disclosed for controlling the response of a structure to external forces such as seismic vibration and/or wind impacting against the structure, the control apparatus including variable stiffness means secured to and bracing the structure, variable damping means interposed between the structure and the variable stiffness means, and a computer which is programmed to monitor external forces impacting against the structure and to control the variable damping means by selecting a coefficient of damping suitable to render the structure non-resonant relative to the monitored external forces. The foregoing patent of Kobori, as well as other patents of Kobori, and patents of others, are based on feedback control principles which include changing stiffness to avoid resonance according to ground motion forecasting, changing damping coefficient according to preset damping standards, and varying the stiffness of a local member by locking or unlocking a device disposed between the ends of a member. The approach of the prior art emphasizes identifying individual structural vibration-reduction-devices, but does not perform an analysis of the whole structural system's behavior. Furthermore, the prior art analysis tends to focus on a single plane of the structure and the analysis is not three dimensional.
SUMMARY AND OBJECTS OF THE INVENTION
The major concept of the present invention is to provide a method and apparatus for controlling a structure to minimize time-varying motion of the structure by a real-time modification of structure parameters to achieve a cost-effective control of structural deformation, internal force, buckling, destructive energy and related damages caused by multi-directional loading such as earthquake, winds, traffic, and/or other type of ambient loading. The control is based upon the use of control devices in accordance with control principles which are non-linear, time dependent, and adaptive; the control devices making the system more robust, and hence more stable. Since this approach actually controls the physical parameters of the structure through adaptive control devices, it is called functional adaptive control, and a structure which is capable of modifying its dynamic performance is called an adaptive structure.
The present invention contemplates changing within an adaptive structure the coefficients of the displacement, velocity and acceleration, namely the stiffness, damping, and mass. In addition, the present invention may also change certain coefficients of the input driving forces. For example, it may change the friction coefficients of base-isolation devices for structures to minimize the input force/energy for ground motion. Since the new approach actually controls the physical parameters of the structures, it therefore controls the characteristics or the functional behavior of the structure through the adaptive devices.
The underlying theory of the present invention is based upon analysis of the whole structural system's behavior, and therefore is innervative (adaptive), and is characterized by the following:
1) Control procedure--System's optimal approach by changing the physical parameters of the structure such as damping, and either mass or stiffness, or both.
2) Control mechanism--Through coupling/uncoupling of certain substructures and/or sub-members by means of functional switches.
3) Control Principle--Minimization of conservative energy through the use of a computer program which will perform a sequence of steps arranged in a hierarchical fashion.
In addition, in the preferred embodiment no actuators apply force to the structure. Therefore, the control is not active.
Each of the functional switches of the control mechanism can be in one of the following states: "on", "off" or "damp". By varying the state of each functional switch, the switches may control the physical parameters of an associated structure such as mass, damping, and stiffness, and the functional switches may also control the input-driving forces.
When a functional switch is "on" portions of the switch are rigidly connected to each other and the switch can connect a heavy mass to add significant mass to the structure. Also, when a functional switch is "on" it can connect members of the structure to increase the stiffness of the structure to reduce the corresponding displacement and thereby increase the natural frequency of the structure. When a switch is "off" the connections are eliminated, thus the opposed portions of the switch are freely movable with respect to each other. When a switch is set at "damp", there is a viscous movement of the opposed portions and the switch can also increase the energy dissipation capacity of the structure. When this state is eliminated, the damping force can be significantly reduced, which may therefore reduce the input driving forces.
Since there are only three output states of a functional switch, the control processes for the operation of the switches can be relatively simple. Thus the calculating speed will be increased significantly, which is a key issue in active or adaptive control.
To better understand the control theory of this invention, a prior art active control system will be considered first. For a linear mechanical vibration system, the following equation may be used to describe its motion:
f(t)=MX"(t)+CX'(t)+KX(t) (1)
where f is the external force, M, C, and K are the mass, damping and stiffness coefficient matrices, X(t), X'(t), and X"(t) are the displacement, velocity and acceleration vectors, and the superscripts ' and " stand for the first and second derivatives with respect to time. In a single degree of freedom (hereinafter SDOF) system, in equation (1), the work done by the internal force MX" can be described as the kinetic energy. The work done by the damping force CX' can be described as dissipated energy. The work done by the spring force KX can be described as the potential energy. The sum of these three energy terms equals the work done by the external force f. This can be stated as:
E.sub.c =E.sub.i -E.sub.d ±E.sub.t ( 2)
where E stands for energy, and the subscripts c, i, d, and t stand for conservative, input, damping, and transfer energy, respectively. (For a pure SDOF system, E t =0. However, if equation (1) is used to describe a vibrational mode of a multi-degree-of-freedom (hereinafter MDOF) structure, E t exists either positively or negatively.) When the mass, damping and stiffness coefficients are fixed, both the kinetic and the potential energy are conservative. Only the damping force dissipates energy.
If the coefficients M, C, K can be changed as they are in real-time structural parameter modification (hereinafter RSM) devices of this invention, neither the kinetic nor the potential energy are completely conservative. Thus equation (1) can be rewritten as follows:
M(t)X"(t)+C(t)X'(t)+K(t)X(t)=F(t) (3)
Comparing equation (3) with equation (1) it is apparent that all parameters have become functions of time. A certain amount of energy may be transferred outside the structure by functional switches. The remaining energy is still conservative. It is intuitive that, to minimize the displacement of the structure, the conservative part of the kinetic and potential energy should be minimized. If the conservative energy is minimized, the displacement keeps the smallest value. This is the essence of the principle of minimal conservative energy. Thus:
E.sub.kc +E.sub.pc =minimized (4)
The energy equation of the entire system can be written as:
W=E.sub.kc +E.sub.kf +E.sub.d +E.sub.df +E.sub.pc +E.sub.pf( 5)
Here, the letter W is the work done by the external forces, and the letter E stands for energy terms. The subscript k stand for kinetic, d for energy to be dissipated by damping force, p means potential, and c means conservative energy. The second subscript f stands for the energy transferred and is dropped later by the functional switches. To minimize the E pc +E kc from the above equation, it can be seen that an optimal result can be achieved by maximizing E kf , E d , E df , and E pf and by minimizing W. Thus minimal E pc is achieved by increasing the energy transfer E kf and E pf , increasing the energy dissipation E d and E df , and also by decreasing the work done by the external force W, which is equally important and is achieved by increasing the instantaneous impedance or the entire structure.
While several SDOF systems may be used to approximate a MDOF structure, in a multiple degree of freedom system (MDOF), minimization of Conservative energy becomes a somewhat more complex task. The complexity arises because the energy transfer between the various modes of vibration of a structure must be considered. The energy transfer among modes of a MDOF structure may be determined through the Complex Energy Theory as proposed by Liang and Lee ("Damping of Structures: Part I: Theory of Complex Damping", NCEER Report 91-0004, 1991).
Under the Complex Energy Theory, systems may be classified as proportionally damped or nonproportionally damped. A proportionally damped system is one in which the damping coefficient may be represented as a proportion of mass and stiffness, that is,
C=(A)M+(B)K (6)
where A and B are constant coefficients, and M and K represent the mass and stiffness matrices of a system respectively. A fundamental characteristic of such a system is that there is no energy transfer between modes during vibration.
However, for a nonproportionally damped system, Equation (6) will not hold. This is of particular relevance to the instant invention because as the stiffness, mass and damping matrices of the structure are modified with time, Equation (6) will not be satisfied, and the system will be classified as nonproportionally damped. Accordingly, energy transfer will occur between modes.
The measure of energy transfer between modes may be expressed by a Modal Energy Transfer Ratio S i , where
S.sub.i ≈W.sub.Ti /4πW.sub.i ( 7)
and W Ti =Energy transferred to the i th mode during one cycle of vibration and W i =Energy stored in the i th mode before the cycle of vibration.
The natural frequency for any given mode in a nonproportionally damped system is also dependent on the transfer of modal energy. The natural frequency, w i , of the i th mode in a nonproportionally damped system accordingly becomes
w.sub.i =w.sub.ni exp(S.sub.i) (8)
where S i is defined by Equation (7) and w ni =the natural frequency of the i th mode if the system was proportionally damped.
In order to minimize conservative energy, it is necessary to minimize the modal energy transfer ratio of Equation (7) for each mode of the structure. This concept will be incorporated into Equation (5) in the Detailed Description section of this application.
From the above it can be seen that one of the objects of the present invention is to provide a design procedure to analyze what kind of real-time structural modification system is needed for the structural control (according to the bare dynamic behavior of the structure), namely what parameters should be modified; to calculate by a novel formula the preliminary design parameters, namely how much the amount of mass, damping and stiffness are needed to be varied; and to check the safety factor of the real-time structural modification.
It is an further object of the present invention to provide a method and apparatus for real-time structural modification of a structure based upon an analysis of the whole structural system's behavior.
It is yet another object of the present invention to provide a novel and more effective energy dissipation control method according to the energy minimization principle.
It is yet another object of the present invention to provide a variational complementary system to realize the aforementioned control method by means of push-pull dual energy dissipation and accommodation devices.
It is yet another object of the present invention to provide innervatively activated hydraulic devices to activate the proper control actions.
It is yet another object of the present invention to provide a novel setup of device and structure coupling/uncoupling to achieve the structural control effect by means of varying structural stiffness-damping parameters or mass-damping stiffness simultaneously to realize the optimal structural physical parameter modification.
It is yet another object of the present invention to provide a computer program which will perform an arranged sequence of steps to treat a MDOF structure subjected to multi-directional input according to the energy minimization principle.
It is yet another object of the present invention to provide a hierarchical process which performs initial local structural control based on velocity and force criteria, a higher level global structural control based on an optimization criteria, and overall override control in the event of control system malfunction.
It is yet another object of the present invention to provide a novel device capable of handling two directional input/output to carry out the command required by the aforementioned logic.
It is yet another object of the present invention to provide a method for controlling the displacement or resonance of a structure by providing energy dissipation devices in non-parallel planes within the structure, by determining the displacement excitations applied to the structure in non-parallel planes, and by controlling the energy dissipation devices in real-time in response to the determined displacement excitations to dissipate energy and control displacement or resonance of the structure.
It is yet another object of the present invention to provide paired energy dissipation devices in a structure, one of the energy dissipation devices being in an "on" stage and the other being in an "off" stage when the structure is subject to movement in a first direction, and the one energy dissipation device being in an "off" stage and the other being in an "on" stage when the structure is subject to movement in an opposite direction.
It is yet another object of the present invention to provide novel control means for controlling paired energy dissipation devices.
It is yet another object of the present invention to provide a novel energy dissipation device.
It is still a further object of the present invention to provide a novel device which can be utilized to couple or uncouple mass into the structure.
It is yet another object of the present invention to provide a novel coupling device which can be used to vary the stiffness of a structure.
The foregoing objects and other objects and advantages of the present invention, as well as the application of the control theory briefly outlined above, will become more apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a building structure which may be deflected by an earthquake, strong winds, etc.
FIG. 2 illustrates the X-Y movement of an earthquake over a period of time.
FIG. 3 illustrates a portion of a building structure to which functional switches have been applied in accordance with the principles of this invention.
FIG. 4A is a schematic diagram of a unidirectional functional switch.
FIG. 4B illustrates the dynamic model of the functional switch shown in FIG. 4A.
FIG. 5 is a graphical flow chart for the control program developed in accordance with this invention.
FIG. 6 is a decision making flowchart of the RSM control process showing the hierarchical control loops.
FIGS. 7A and 7B illustrate a typical arrangement of the control hardware at the initial local structural control level in this invention, FIG. 7A being a front view and FIG. 7B being a side view.
FIG. 8 illustrates the switching of a functional switch while undergoing initial local structural control.
FIG. 9A illustrates the Force vs Displacement plot for a functional switch operating under initial local structural control.
FIG. 9B illustrates the structural overdraft deflection which may occur if initial local structural control is used in the absence of any higher level controls.
FIG. 10 illustrates a structure provided with global loop control which simultaneously checks the status of all functional switches in real-time and issues optimal commands according to a selected principle.
FIG. 11 illustrates a simplified building structure which may be modified in accordance with the principles of this invention.
FIG. 12 illustrates calculations on how the building shown in FIG. 11 would resonate when subjected to the earthquake of FIG. 2.
FIG. 13A and 13B illustrate how the building of FIG. 11 may be modified in accordance with the principles of this invention to reduce its structural deflection during the earthquake of FIG. 2.
FIG. 14 illustrates how the functional switches shown in FIG. 13 will be turned "off" and "on."
FIGS. 15A and 15B show the calculated response of the structure of FIG. 6, FIG. 15A showing the response when modified in accordance with the RSM system of this invention, and FIG. 15B showing the response when modified by using stiff bracing.
FIG. 16 shows actual test results of a test stand structure when either controlled or not controlled by the subject matter of this invention.
FIG. 17 shows how this invention may be applied to a bridge.
FIG. 18 illustrates a bidirectional functional switch which may be employed in the design shown in FIG. 17.
FIGS. 19-21 show how this invention may be applied to other building structures.
FIG. 22 shows yet another application of this invention to a building structure.
FIG. 23 is a diagram showing the results of applying the RSM system to the building Shown in FIG. 22.
FIGS. 24 and 25 show the theoretical and experimental dynamic responses of a prototype switch under certain excitations.
FIG. 26 is a side view of a four-way functional switch.
FIG. 27 is a view taken generally along the line 27--27 in FIG. 26.
FIG. 28 is a sectional view taken generally along the line 28--28 in FIG. 27.
DETAILED DESCRIPTION
First, with reference to FIG. 1, a building structure is indicated generally at 10. The structure illustrated has four generally vertically extending columns 12, 14, 16, and 18. In addition, there are a number of floors formed by horizontal beams 20, 22, 24, and 26. As indicated in this figure, the horizontal beams 22.1, 22.3, 24.1, 24.3, etc., extend in an east-west direction in an X-Z plane; and the beams 22.2, 22.4, 24.2, 24.4, etc., extend in a north-south direction in a Y-Z plane. The structure as shown is provided with a passive control such as the chevron bracing beams 30, 32. When the building 10 is subjected to a wind such as a westerly wind indicated by the arrow 34, the building will deflect towards the east. The wind will input energy into the building, the additional energy being stored within the bending columns, etc. When the velocity of the wind 34 decreases, this energy will be released to restore the building to its normal shape. As can be seen from the structure sketched in FIG. 1, all of the deformation to the building occurs in the X-Z plane, which deformation can be resisted by the chevron bracing beams 30, 32.
When the building 10 is subjected to an earthquake, there will be horizontal movement of the ground in X and Y directions (which may be east-west, and north-south, respectively). In addition, there will be ground waves which are indicated by the sinusoidal waves X and Z in FIG. 1. Because of these motions, during an earthquake the building will be subjected to at least five degrees of movement; namely, movement in the X-Y-Z directions, and rotational movement about the X and Y axes, and perhaps rotational movement about the Z axis. In most earthquakes, the excitation and most other dynamic loadings are typically random. This can best be seen from FIG. 2 which is the E1 Centro Earthquake Response Time History. The building 10, when subjected to such an earthquake, will be deflected and tends to vibrate. The vibration of such a building tends to be destructive.
It has been determined by computer analysis and experimental tests that if the structural physical parameters are modified in real-time that the adaptive structure can withstand a large range vibration magnitudes. Such structural parameter modification may be achieved through the use of functional switches. While many forms of functional switches may be employed, the preferred form is a type which is both bidirectional and which may be used again and again. The functional switch may be set to "off", "on", or "damp" states. Depending upon the application, either a bidirectional or a unidirectional switch may be preferred.
FIG. 3 is a view similar to FIG. 1 showing a portion of the structure shown in FIG. 1 but with an additional vertical column 15 in the Y-Z plane. This figure additionally shows paired unidirectional functional switches indicated generally at 36. (While unidirectional switches are illustrated in FIG. 3, it should be obvious that the preferred bidirectional switches could be employed, the directional switches being discussed below in connection with FIGS. 17, 18, and 26-28.) Thus, as illustrated, there are a pair of unidirectional functional switches 36.1 and 36.2 lying in the Y-Z plane and extending between the column 15 and the horizontal beam 24.2. At the corner of the structure are two additional functional switches 36.3 and 36.4, the functional switch 36.3 lying in the Y-Z plane and extending between the corner column 14 and the horizontal beam 24.2 and the other functional switch 36.4 lying in the X-Z plane and extending between the vertical column 14 and the horizontal beam 24. It is possible for the switches 36.3 and 36.4 to either transfer of dissipate energy from one plane to the other.
A unidirectional reusable functional switch, indicated generally at 36, is illustrated in FIG. 4A, this functional switch including a cylinder 38 and a rod 40 which is received within the cylinder 38. One end of the rod 40 is provided with a suitable eye 42 or the like which can be secured to a suitable fixture (not shown) carried by the beam 24. The end of the cylinder 38 remote from the rod end 42 is provided with a bracket 44 which can be suitably secured to the column 14 or 15 by a link (not shown). In addition to the piston and rod assembly, the unidirectional functional switch 36 may also include a reservoir 46. The reservoir is connected with the fluid chamber 48 within the cylinder 38 through a suitable port 38.1. A fluid circuit extends between port 38.1 and the reservoir 46, the circuit being provided with parallel branch lines 50, 52. A regulator in the form of a variable orifice or restrictor 54 is provided in one of the branch lines 50, and a one-way check valve 56 is provided in the other branch line 52. When the structure 10 is deflected in a manner which may cause the functional switch 36 to be compressed, the check valve 56 will prevent flow through line 52 and the variable orifice may be set to a "damp" condition so that the energy of deflection will be absorbed by the switch. However, if the functional switch were to be extended, fluid may move freely from the reservoir 46 through line 52 and check valve 56, and also through port 38.1, the switch then being in an "off" condition. The variable orifice or restrictor may employ a mechanical controller, as for example by a bell crank which senses movement between the rod 40 and cylinder 38, the bell crank in turn being coupled to a suitable valve. Alternatively, the variable orifice may be controlled by an electro-mechanical device which is coupled to a suitable electronic device. Two unidirectional functional switches may be assembled together so that in both directions one can have "on" "off" and damp functions. A bidirectional functional switch will be discussed later.
In FIG. 4B the dynamic model of the unidirectional functional switch is illustrated. (This model is also valid for a bi-directional assembly.) The connectors and other parts of the assembly always have stiffness and masses, the modified stiffness and masses being denoted K m and M m , respectively. In this figure, the function of the variable orifice 54 is achieved by a variable valve 57 which may be progressively moved from a fully closed position to a fully open position by a suitable control such as a linear electrical device 58. The damping C [equation (1)]is provided by the variable orifice of the valve as it is moved between its extreme positions. However, if the damping must be very high, and the orifice in the variable orifice valve 57 cannot supply such a high range of damping, an additional damping mechanism 59 may be used. However, the stiffness K m and mass M m can be mainly contributed by the switch system itself. The value of C, K m , and M m are determined in the following criteria: The damping C must be high enough to dissipate the energy stored in the switch system during the half cycle when the switch is "off". However, overvalued C will decrease the response speed of the control valve. The value K m is determined in a manner set forth below in connection with equation (9). The value of M m is determined to achieve optimal energy dissipation including optimal work done by the mass against the external force. However it is constrained by the response speed of the switch system. Overvalued M m will also decrease the response speed as does the damping C.
FIG. 5 illustrates a graphical flow chart for a multi-degree of freedom seismic vibration control. According to this scheme, initially all of the switches are set to be "on". The dynamic responses, the internal and external forces, the modal energy status and/or ground motions are measured and calculated when the structure is subjected to multi-dimensional ground motion. The measured and calculated data are stored all the time. A system identification unit may be used to obtain certain modal parameters that are also stored in the storage unit. When the response level exceeds the preset values, the central decision-making unit will give orders to initiate local decision-making units. The preset values are decided as follows:
1) If the RSM system is used together with other conventional controls, the preset values can be higher to allow these controls to perform first; 2) If the RSM system is used alone, the values should be lower, even zero. In this case, the preset values are to lower the required precision of the RSM system to lower the manufacturing cost.
Another important function of the central decision-making unit is to identify the optimal set of specific functional switches and their on/off status with respect to global results. Thus, a local substructure may achieve a minimal response, but this minimal response may lead to very large deformation of another substructure. On the other hand, a local point may show a large deformation and absorb significant amount of vibrational energy and reduce the global vibrational level. After the central unit initiates the orders, the local decision-making units start to calculate the optimal results and give the on/off order to each functional switch individually. According to the orders, each switch is set to be "on" "off" or "damp" to reduce the vibration level. At the next time interval, the vibratory signals are measured again and a new cycle of control is initiated. When the external excitation and the structural vibrational levels are reduced to certain values, the central unit gives orders to stop the entire control process.
The control system described above is implemented by a computer program which will perform a sequence of steps arranged in a hierarchical manner. The program performs local structural controls, global structural controls and safety checks to insure structural integrity in the event of a malfunction. FIG. 6 is a flowchart representation of the sequential control program for RSM.
For the purpose of the flowchart of FIG. 6, it is assumed that a multi-storied structure is equipped with a number of functional switches and that the RSM system is not used with other controls. In this flowchart these switches are deemed to have only two physical states: "on" (stiff member) or "off" (zero stiffness member). The control scheme begins with all functional switches set initially to the "on" position.
The lowest level of control provided by the sequential control program is called the initial local structural control level or H 1 control loop. Each functional switch in the structure is equipped with the necessary control devices to perform H 1 control, and accordingly, each set of H 1 control devices controls only the local functional switch it is associated with.
The general control loop utilized in the H 1 control loop consists of a functional switch, a velocity transducer and control electronics. The velocity transducer may be mounted in a variety of manners with the purpose of measuring the relative velocities between two adjacent floors in a multiple story structure. The functional switch associated with this velocity transducer is mounted between the same two adjacent floors as the velocity transducer.
FIGS. 7A and 7B show a basic arrangement of a single functional switch 36.5 mounted in a structure such as that set forth in FIG. 3. The switch 36.5 may be of the type shown in FIG. 4A. In this figure the switch is connected to a lower horizontal beam 22.2 via a support 60 and to an upper horizontal beam 24.2 via a brace 61 and intermediate frame 62 which supports a mass 63. A velocity transducer 64 extends between the mass 63 and the upper beam 24.2. A force transducer 65 is mounted between the brace 61 and the functional switch 36.5. Finally, an accelerometer 66 is mounted on the frame 62. The velocity transducer measures the relative velocity of the upper floor 24.2 with respect to the lower floor 22.2, and initiates a signal to the H 1 control means or processor 67 which in turn sends a signal to the linear electrical device 58, which in this embodiment is a two position solenoid, to either turn the switch "on" or "off" by operation of valve 57.
The H 1 loop operates in the following fashion. The H 1 processor first analyzes the velocity transducer output and, as the relative velocity approaches zero, the H 1 processor issues a command to the control valve of the functional switch which has the effect of reversing the current status of the device 58, either turning the switch "on" or "off" as required. The performance of the H 1 loop action is shown in FIG. 8. The net result is that the functional switch is alternated between "on" and "off" status at the time when the local velocity of the structure approaches zero.
The control electronics embodied in the H 1 processor which are necessary to execute H 1 control are located near or on the associated functional switch. The electronics consist of a power amplifier to amplify the output of the velocity transducer 64, decision making electronics, and a power amplifier to send a suitable control command to the solenoid 58 of control valve 57 of the functional switch 36.5.
The H 1 control method has been described above as a method for switching stiffness elements "on" and "off" but it may readily be used to switch mass or damping elements. In a very simple form of structural control, the H 1 loop will provide significantly improved energy dissipation characteristics over conventional methods, and it can operate as an independent control system. FIG. 9A displays the results of the H 1 loop as a stand-alone control device on a simple structure. The loop of energy dissipated is ideally a parallelogram. The two sides perpendicular to the x axis stand for the force drop without change of displacement. The other two sides stand for the stiffness of the entire system. It can be proven that, given a certain amount of stiffness, the parallelogram offers the maximum energy dissipation from RSM. In a SDOF system, this energy loop satisfies the Minimum Conservative Potential Energy described in equation (5).
However, to achieve better system performance, hierarchical controls may be implemented to check other system criteria, which other criteria may override the local control of the H 1 loop. A second level of control is known as the H 2 loop. This is similar to the H 1 loop in that it is also a form of local control. FIGS. 7A and 7B also represents the components associated with the use of this loop. A measurement of force is taken from the force transducer 65. The force measurement is taken at the same time as the H 1 loop performs its velocity check. If the H 1 loop determines that the relative velocity is near zero, the H 2 loop will then be activated, and the force measured is compared to a small threshold force stored in the memory of the H 1 processor 67. If the force measured exceeds the threshold force, no action is taken by the controller. After a selected time interval, determined by a timer within the processor 67, the H 1 and H 2 control loops are again called into operation.
The purpose of the H 2 loop is to avoid the development of unbalanced forces in a structure. As explained in the discussion of the H 1 loop, switching occurs at the point where relative velocity approaches zero. For a typical structure, the dynamics of a building under vibration approximate sinusoidal motion. Thus at the instant velocity is zero, displacement will be at a maximum. Since the ground motions of an earthquake are random, there exists the possibility that a functional switch may be commanded to have zero stiffness at the same instant an undesirable external force propagates through the structure. The net effect will be to cause an overdraft in the deformation of the structure if the functional switch is controlled solely by the H 1 loop. This phenomena is shown in FIG. 9B. The H 1 loop will thus override the command of the H 1 loop in this situation, causing the system to pause until the force situation becomes more favorable.
The H 2 loop is intended to act at a local level. Thus each functional switch will have the H2 control loop integrated into its own control electronics, along with the prior discussed H 1 control loop.
The next level of hierarchical control in the sequential control program is in the H 3 loop. This is a global control loop which is responsible for overseeing the control of each functional switch in the structure. After the H 2 loop of each functional switch has performed its comparison, the command to the functional switch must be verified by the H 3 loop before allowing the command to be executed.
The H 3 control loop operates by measuring structural displacement, velocity and acceleration at a number of strategic locations throughout the structure. These measurements are then utilized by the H 3 loop in order to calculate the conservative energy of the structure. The goal of this loop is to minimize the conservative energy. The H 3 loop then analyzes the command from the H 2 loop in order to determine whether or not the H 2 control signal to a given functional switch will tend to decrease the conservative energy of the structure. If the control signal will decrease the conservative energy, then it is sent to the functional switch. If the signal will tend to increase the conservative energy, then the command will not be allowed to issue to the functional switch.
The H 3 loop is a global loop in that it simultaneously checks the status of all functional switches in real time and issues optimal commands according to the principle of minimization of conservative energy. It acts as a central decision making unit. Thus, only one set of control electronics is utilized to implement the H 3 loop. The decision making process of the H 3 loop will be repeated at subsequent time intervals until external excitation and structural vibrations are reduced below pre-established levels.
The application of the H 3 loop can best be appreciated from FIG. 10. This figure is similar to FIG. 3, but additionally shows the various control devices which are necessary for the performance of the H 3 control. In order to measure velocity, chevron bracing beams 30.1, 30.2, 31.1 and 31.2 are provided, these being secured at their lower ends to horizontal beams 22.1 and 22.2. The upper ends of the bracing beams are secured to each other and are interconnected with upper horizontal beams 24.1 and 24.2 via velocity transducers 70. Also mounted on the structure are sensors 73 which are capable of measuring displacement and/or acceleration. The output signals from sensors 70 and 73 are received by a computer 74 which processes the received signals and sends out suitable signals to the H 1 processor 67. The computer 74 also receives feedback signals from the H 1 processors.
The H 3 loop may be implemented through a number of conventional controls, such as proportional-integral-derivative (PID) feedback, state space feedback or various optimization schemes. A neural network control scheme may also be utilized to perform the large number of calculations required to minimize conservative energy. One possible implementation is through the use of a self learning neural network utilizing a modified associative memory modification method.
As an alternative to the principle of conservative energy, the H 3 loop may also utilize a velocity displacement theory as the control criteria for issuing commands to the functional switches. Under this type of control, the H 3 loop would only be activated to oversee those discrete portions of a structure where the velocity and/or displacement measurements provided by strategically located transducers exceed certain preset levels.
The final level of control in this scheme is known as the malfunction control loop or H 4 loop. The purpose of this loop is to take control of all the functional switches in the structure in the event of a major malfunction in the lower control loop and/or control hardware. A number of measurements of displacement, velocity and acceleration are taken throughout the structure in a continuous fashion. The H 4 loop then compares these values to certain maximum preset levels. If the measurements are found to exceed the maximum allowable values, it is indicative of significant malfunctions in the lower level of controls.
In the event that the maximum preset levels are exceeded, the H 4 loop will issue a signal to all of the switches in the structure which overrides the signal of the H 3 loop and will set all of the functional switches to a state so as to insure the safety and stability of the structure to the extent possible without RSM. This may entail either setting all of the switches in the structure "off" or only setting certain switches "off" based on a prior structural analysis. The H 4 loop is considered an independent control loop because it does not continuously monitor the status of each functional switch. Its sole purpose is to provide the appropriate default command signal in the event of system malfunction. The H 4 control does not need any additional hardware than that required for the H 3 control hardware shown in FIG. 10, but it will be necessary to load the computer with a malfunction program which may override the H 3 control output.
Experimental tests were conducted utilizing the functional switch arrangement shown in FIG. 4A on a structure shown in FIGS. 7A and 7B. A shaking table was utilized to simulate ground motion in a two directional manner. The shaking table was operated to simulate two forms of ground motion: sweep sine wave input and random vibration input based on actual recorded earthquake motions. The results of the sweep sine wave input provide information on the equivalent damping ratio of the structure. The earthquake ground motion record is used to measure the effectiveness and capability of this invention.
The results of Tables I-IV represent a comparison of structural response under a number of operating modes. Since these tests represent a single plane application of this invention, only H 1 and H 2 type control were utilized.
Table I, set forth below, compares the experimental results of four prior art structural damping configurations with the results obtained through the use of a damping type functional switch controlled by the H 1 control scheme. The structure was excited with a controlled input acceleration of 0.1 g by the shaker table. The equivalent sinusoidal input displacement to the structure was approximately 4 mm. Configuration 1 represented the structure with one rigid brace with a stiffness equal to that of the functional switch maintained in the "on" position. Configuration 2 represented the structure with one viscous damper as a replacement to the rigid bracing of configuration 1. The damping characteristics were similar to that of the functional switch maintained in the "damp" position. Configuration 3 represented the structure with two viscous dampers mounted in the same plane with damping characteristics each equal to that of the functional switch in the "damp" mode. Configuration 4 is the same as configuration 3 except two conventional viscoelastic dampers were also utilized for vibration control. The "Functional Switch" columns of Table I represents the use of a single damping type functional switch controlled with H 1 type control, the first column being experimental data and the second representing theoretical results. The maximum deflection and damping ratio of the structure are
TABLE I__________________________________________________________________________ Functional Functional Switch Switch Config. 1 Config. 2 Config. 3 Config. 4 Experimental Theoretical__________________________________________________________________________Damping 8.1 13.5 18.6 23.1 33.0 34.0Ratio - (%)Maximum 47.5 28.0 26.9 26.3 11.9 10.0deformation(mm)RSM 75.0 57.5 55.8 54.8reduction(%)__________________________________________________________________________
TABLE II__________________________________________________________________________ Functional Functional Switch Switch Config. 1 Config. 2 Config. 3 Config. 4 Experimental Theoretical__________________________________________________________________________Damping 7.9 12.9 17.2 19.4 32.7 34.0Ratio - (%)Maximum 32.0 15.1 12.6 12.0 8.2 7.5deformation(mm)RSM 74.4 45.7 34.9 31.7reduction(%)__________________________________________________________________________
TABLE III__________________________________________________________________________ Functional Switch Functional Switch Config. 1 Config. 2 Experimental Theoretical__________________________________________________________________________Damping Ratio - (%) 8.3 17.2 32.2 34.0Maximum deforation (mm) 88.2 68.1 25.4 25.0RSM reduction (%) 71.2 62.7__________________________________________________________________________
TABLE IV__________________________________________________________________________ Functional Switch Functional Switch Experimental Theoretical__________________________________________________________________________Damping Ratio - (%) 8.1 35.2 38.0Maximum deforation (mm) 27.2 6.0 6.0RSM reduction (%) 77.3Maximum base shear (lbs) 507.8 127.0RSM reduction (%) 77.0__________________________________________________________________________
listed for comparison and reflect the benefits of the H 1 control of this invention in terms of higher damping ratios and lower structural deflections.
Table II represents the results of a test on the same structure as described above, however the input in this test was a controlled constant sinusoidal displacement of 4 mm. The equivalent input acceleration level at the resonant frequency was approximately 0.1 g. The major difference between the results of Table I and Table II is that Table I shows the results of a feedback controlled acceleration test, whereas Table II shows the results of a feedback controlled displacement test.
Table III represents the results of a test on the same structure as described above, however the input in this test was a controlled sinusoidal displacement of 12 mm. The equivalent input acceleration-level at the resonant frequency was approximately 0.3 g. Configuration 1 represents the structure with two rigid braces, each having an individual stiffness equal to that of a functional switch maintained in the "on" position. Configuration 2 represented the structure with two viscous dampers as replacements to the rigid bracing of configuration 1. The damping characteristics of each damper were equal to that of a functional switch maintained in the "damp" mode. Two conventional viscoelastic dampers were also utilized in this configuration. The "Functional Switch" column of Table III represented the use of a single functional switch controlled with H 1 type control.
Table IV represents the results of a test on the same structure as described above, except that in this test, two functional switches were employed in a push-pull arrangement instead of a single functional switch. The input in this test was a controlled input acceleration of 0.1 g. The equivalent input constant sinusoidal displacement to the structure was approximately 4 mm. The "Rigid Bracing" column of Table IV represents the structure with two rigid braces, each with a stiffness equal to the stiffness of the functional switches when maintained in the "on" position. The "Functional Switch" column represents the use of two push-pull functional switches controlled by both H 1 and H 2 type control.
An application of the present invention can be appreciated from a consideration of FIG. 11. In this figure, a one-story structural system is shown consisting of three inverted U-shaped frames 68R, 68C, and 68L, the three frames being connected at their tops by suitable beams 69. On top of the frames there are three concrete slabs 69S the size of 3 by 12 meters each. The weight of the concrete and other static and live loads are considered uniformly distributed over the top floor. Since the central frame 68C is to be treated with the real-time structural modification system of this invention, a structural analysis is performed for the frame wherein the weight, lateral stiffness, and natural frequency of the structure is determined. From this analysis, it is found that the total load on the middle frame is 35,100 kg. By carrying out a standard analysis, it is also found that the natural frequency of the frame is about 3 Hz and its horizontal stiffness K is 1,170,000 kg/m.
The displacement response of the frame under the recorded 1940 El Centro earthquake (FIG. 2) is calculated and shown in FIG. 12. It is seen that the peak value of the displacement is about 2 cm, which is 1/250 of the frame height of 5 m. According to building code specification, a horizontal displacement of over 1/700 of the story height will result in certain degrees of inelastic deformation of the building structure. Although this is not intolerable, it is desirable that the structure stay within its elastic deformation range. Therefore, the real-time structural modification system of this invention is used to suppress the vibration level back to the code suggest value. Thus a method is selected for minimizing the displacement response of the structure which is based upon the natural frequency of the structure and the percentage deviation from the building code. Normally two steps must be taken when using the RSM system. First a preliminary design is done by using the estimation formula
X.sub.max =αW/(K+2K.sub.m) (9)
wherein X max is the maximum displacement allowed, αW is the lateral force, K is the stiffness of the frame, and K m is the apparent stiffness contributed by RSM by the application of functional switches. From the above formula we learn that to insure the value of 1/700, K m should be equal to K, namely 1,170,000 kg/m. After the above calculations have been done, structural modification devices are mounted in the structure which are capable of minimizing the displacement of the structure.
In FIG. 13A an RSM system employing push-pull functional switches is somewhat schematically shown installed on the central U-shaped frame 68C, and a push-pull control of the functional switches is shown in FIG. 13B. First, a special steel beam connector, indicated generally at 70, is welded or bolted on the central horizontal beam 68C.2 of the U-shaped frame, not shown in FIG. 13B. Two steel connectors 71 are securely fastened to the lower end of the vertical column portions 68C.1 and 68C.3 of the U-shaped frame 68. Two bracing members 72.1, 72.2, which incorporate functional switches 36.5, 36.6, are installed between the connectors 71 and the special connector 70 as shown in FIG. 13A. The functional switches 36 make the bracing members become adaptive components of the structure. The added functional switches and bracing members provide an additional stiffness which is 100% of the original stiffness contributed by each set of connector, the switch, and the member. The special connector 70 includes a sensor 73 which may be any suitable transducer capable of measuring the displacement, velocity and/or acceleration of the horizontal beam 68c.2 from the base of the columns 68C.1, 68C.3. The sensor 73 is connected to a computer 74 via a suitable electrical cable 75. The computer 74 has available to it stored data and system identification. In addition, as shown in FIG. 13A, each functional switch is provided with a local decision making unit capable of properly operating the associated switch. As the computer receives the information from the sensors, it will process the information and the computer 74 will in turn transmit signals to the local decision making units 76 via lines 78. The system identification and data storage unit is indicated at 80, and the power supply is indicated at 82. Each functional switch may be controlled independently of the other in FIG. 13A. However, in FIG. 13B a control is shown where the switched 36.5 and 36.6 are alternately "on" and "off". Thus the two valves 54 are coupled together by a rigid link 55. When the right hand switch 36.6 is "on" as shown if FIG. 13B, the left hand switch 36.5 will be off. When the right valve is switched to place the right switch in its "off" state, the left will be switched "on". The control command to the functional switches 36.5 and 36.6 mounted as shown in FIG. 13B is approximately shown in FIG. 14. Namely, the functional switches 36.5 and 36.6 are alternatively "on" and "off". Thus, two of the functional switches are used as a push-pull (complementary) pair controlled by adaptive programs to keep the apparent stiffness, damping, and mass unchanged but real stiffness, damping and mass of the structure modified. As a comparison to show the effectiveness of the functional switches as applied to the structure, the same E1 Centro earthquake record is used to calculate the displacement response of the frame with the functional switches applied. It can be seen from FIG. 15A that the peak value of the displacement response is now 0.7 cm., which is about 1/700 of the frame height. This is a 70% improvement over the results shown in FIG. 12 and it agrees with the preliminary design. Also, to illustrate the difference between using simple bracing and the functional switches, another treatment of the frame with simple bracing of 100% original stiffness is studied. The corresponding displacement is given in FIG. 15B. It is seen that the peak displacement is only reduced to about 1.6 cm. This improvement is less than 20%. While calculated results are shown in FIGS. 12, 15A and 15B, actual results comparable to those shown in FIGS. 12 and 15A are shown in FIG. 16.
In the application just discussed in connection with the structure shown in FIGS. 11 and 13, the functional switches have been used to dissipate energy and to modify the stiffness of the structure in a single plane. However, it should be obvious from FIG. 3 that the functional switches may be used to dissipate energy in more than a single plane. Thus the functional switches 36.3 and 36.4 lie in differing planes. These devices are responsive to variable control (either mechanical or electrical) which is responsive to a measured displacement for controlling the energy displacement device or functional switch in response to the measured displacement to cause the functional switch to dissipate energy and control displacement.
While one design of a functional switch has been shown in FIG. 4A, other designs may be employed. For example, a one-time purely mechanical functional switch may be used in some applications. In its simplest form it may consist of a tube coupled to a rod by a shear-pin. Such a device is suitable for both linear and rotational movement. The device shown in FIG. 4A is unidirectional in the sense that the rod is free to move to the left, the return from the reservoir 46 to the chamber 48 being unrestricted through the one-way valve 56. Thus, the switch is always "off" in one direction, but may be set at "off" "on" or "damp" in the other direction. The shear pin functional switch may also be coupled with a variable rate spring. This design is particularly suitable for small structures mounted on rigid substructures, such as mobil homes mounted on concrete piers.
FIG. 17 shows a typical embodiment of the present invention used on a bridge. This embodiment includes a bridge 83 slidably mounted on base 84, and fixtures 85.1 and 85.2 which connect a bidirectional functional switch, indicated generally at 86, to the bridge 83 and base 84. In addition sensors 87 are provided which measure input signals such as displacement, velocity, acceleration, strain, etc. of the system. The sensors are connected to a computer 72 which controls the switch 86 in response to the signals received from the sensors. The switch may be nearly instantaneously switched between "on" "off" and "damp" states by the computer. It should be obvious from an inspection of FIG. 17 that the energy from the ground to the bridge, or vice versa, may be controlled. In addition, it should also be obvious that the structural parameters of the bridge may be varied. For example, the mass of the bridge may be varied by coupling or uncoupling the mass of the base to the bridge. Additionally, the stiffness of the switch may be varied, or the relative movements of the bridge and base may be damped. Thus, the bridge as modified in FIG. 17 is an adaptive structure.
A design of a bidirectional reusable functional switch is illustrated in FIG. 18, the switch being indicated generally at 86. This design consists of two unidirectional switches of the type generally illustrated in FIG. 4A, with the cylinders 38a and 38b being mounted end to end with their rods 40a and 40b extending in opposite directions. The rods are connected together by means of a yoke assembly which includes two transversely extending bars 88 held in place on the threaded ends 40a.1 and 40b.1 of the rods by means of nuts 89. The bars are in turn coupled together by means of shafts 90, opposite ends of each shaft being suitably connected to an end of an associated bar 88. The yoke assembly may be suitably connected to a fixture 85.2, or any other suitable connector. The cylinders 38 are each provided with brackets 91 which may be coupled to a suitable fixture 85.1 or the like. Each of the cylinders is provided with a port 38a.1 or 38b.1, the ports being in communication with a reservoir 46 via a three position valve 92. The position of the valve may be determined by an electrical controller 58 which is in turn preferably coupled to a computer 72. While the bidirectional switch 86 may act as a damper when the valve is in its damp position, additional dampers 59 (not shown) may be provided. While the mechanism for controlling the valve may be electrical, a variable orifice valve may be used which can be controlled electrically or through a mechanical device, for example a bell crank which senses movement between the cylinder 38 and the rod 40, or the structures to which the cylinder and rod are connected. If controlled electrically, there is typically only a single "damp" setting in order to improve the response time. While in FIGS. 3, 13, and 17 the functional switches are shown being mounted for tension-compression, the functional switches may also be mounted for bending, torsion, or shear.
Added damping and stiffness (ADAS) has been used in the prior art to modify a building structure to improve its deflection characteristics. However, it is well known that fixed higher stiffness and fixed higher damping does not always help a structure to reduce its vibration level. Varying damping stiffness and damping can achieve much better results. Besides, functional switches can also change the mass of a structure, which can also help to reduce the vibration level. Therefore, by utilizing the functional switches disclosed above, it is possible to modify structural parameters of mass, damping, and stiffness in real-time.
With reference now to FIG. 19, a two story structure is shown having vertical columns 93 and a roof truss 94. Functional switches 36 are mounted between intermediate columns 93.2 and 93.3 in the manner indicated. By setting the functional switches "on" or "off" the central columns are either strongly braced or are not braced at all. Therefore the stiffness of the frame can be changed. The functional switches can also be connected to dampers instead of rigid members. Therefore, the physical parameters of mass, damping and stiffness can be changed simultaneously. The functional switches shown in FIG. 19 may be designed to be subject to extension forces only. Therefore, no buckling caused by compression forces will happen. In this way the links and support for the functional switches need much less cross sectional area so that the cost may be lowered.
FIG. 20 illustrates a tall building mounted upon a base isolation unit. The tall building is indicated generally at 10, the base at 96, the base including a hard surface 96.1 and the building including rigid base 10b. Rollers 98 or the like are disposed between the rigid base 10b and the hard surface 96.1 so that the building structure 10 can move relative to the base 96. A functional switch 86 extends between the building 10 and the base 96. This system is different from the design shown in FIG. 19 because it changes the force transfer path and capability from external sources whereas the design shown in FIG. 19 changes the mass, damping, and stiffness of a structure. However, the basic principle is the same as changing the physical parameters of the structure only.
FIG. 21 shows another concept of changing mass. In this design a building structure 10, which is mounted directly upon a base 96, is coupled to a mass 100 by means of a functional switch 86. The mass may be another building. As the building 10 and the mass may have different movements (different frequencies, different phases, and different amplitudes) and may be connected or disconnected by means of functional switch 86, the vibrations of the two objects may cancel each other to a certain degree.
While the control theory of this invention has been referred to in the objects and summary of the invention, it may perhaps be better understood from a consideration of FIG. 22. Shown in FIG. 22 is a building structure which includes shear walls 102, 104, two spaced apart vertical columns 106, and a mass 108 supported by the columns 106. In addition, a first functional switch 110 is positioned between a column 106 and the shear wall 102, and a second functional switch 112 is positioned between the other column 106 and the shear wall 104. The first functional switch 110 is connected to associated shear wall and column by links 114 and 116, and the second functional switch is connected to the associated shear wall 104 and column 106 by links 118 and 120. Each of the shear walls has a stiffness, the stiffness of shear-wall 102 being expressed as K 1 , and the stiffness of shear wall 104 being expressed as K 2 . According to the principle of minimal conservative potential energy a simple and very effective algorithm is established by switching the stiffness between K 1 and K 2 to achieve maximum energy drop and minimum displacement. Assuming K 1 =K 2 switching between the two shear walls 102 and 104 maintains the apparent stiffness constant as K+K 1 or K+K 2 keeps constant. However, the two additional stiffness K 1 and K 2 , stores and drops potential energy alternately. When the mass 108 is caused to move in the direction of arrow 122 the functional switch 110 is switched "on" while the functional switch 112 is switched "off". If the maximum displacement of the mass caused by the ground motion in the direction of the arrow 122 is x 1 , the energy stored in the additional stiffness is K 1 x 1 2 /2. When the mass starts to move in the direction of the arrow 124 the switch 110 is switched to its "off" position, and the switch 112 is switched "on". At this time the stiffness K 1 can move freely and release the energy stored. Thus, the stored energy K 1 x 1 2 /2 is released. An energy dissipation mechanism, associated with the functional switch 110 dissipates this amount of energy within the duration of the movement of the mass in the direction of the arrow 124. Meanwhile, since the functional switch 112 is "on", the stiffness K 2 of shear wall 104 starts to work together with the stiffness K of the main frame 106. That is to say that the stiffness of shear wall 104 (K 2 ) starts to restore the potential energy until the mass reaches the maximum displacement in the direction of the arrow 124, the maximum displacement being denoted by x 2 . Similarly, this amount of energy is equal to K 2 x 2 2 /2 which is to be dropped in the next movement of the mass 108 in the direction of the arrow 122. The time history of this algorithm is conceptually shown in FIG. 23. In this figure the solid line 126 shows the deformation when the functional switch 110 is "on" and the functional switch 112 is "off". The dotted line 128 shows the deformation when the functional switch 110 is "off" and the functional switch 112 is "on".
While the equation previously set forth at (5) is applicable to a single degree of freedom system, in a multi-degree of freedom structure the situation becomes a little more complicated. Thus equation (5) becomes
E.sup.i.sub.kc +E.sup.i.sub.kf +E.sup.i.sub.d +E.sup.i.sub.df +E.sup.i.sub.pc +E.sup.i.sub.pf =W.sup.i =T.sup.i (10)
Here, comparing with equation (5), the newly introduced superscript i describes the i th mode and the letter T stands for the energy transferred from modes other than the i th mode. The term T i can be either positive or negative. However, referring to the first mode, or even the first several modes, the term T i is positive in most cases [Liang and Lee, "Damping of structures: part I theory of complex damping", NCEER report 91-0004, 1991]. Therefore, the task to minimize the modal conservative potential energy includes minimizing the modal energy transferal also.
This principle is that M, C, and K must be changed in such a way that the minimal conservative energy must be achieved. In other words, during the external excitation, the total external energy is treated as follows: prevent a portion of the energy from entering the structure; allow the remaining in, then damp some, and keep some which will be used later to do certain work to prevent external energy from getting in the next step. In a MDOF system, an arrangement that only satisfies equation (5) may not be enough, another amount of energy, the modal energy transfer, should be taken into consideration.
In FIG. 24, the theoretical response of a switch is shown. At point 1, the switch starts to be compressed, since the orifice is set to be "on" no fluid can pass the orifice. At point 2, the force reaches its maximum value without any displacement allowed. However, when the force begins to change its direction, the orifice is suddenly released, the "off" condition is achieved and the switch is allowed to move, in a very short period, the force is dropped to its minimum value at point 3 and the maximum displacement between the switch is achieved, which equals to the maximum allowed displacement of the structure at the specific points where the functional switch is mounted. Shortly after the point 3, the switch is still in free movement of "off" condition but the displacement begins to decrease until the next compression begins at point 1. Note that, if the excitation is random, instead of sinusoidal, the response will not look like the experimental response shown in FIG. 25. It can be seen that the theoretical estimate of FIG. 24 agrees the experimental data shown in FIG. 25 very well.
A four-way switch system is shown in FIGS. 26-28, which system can be operated in two modes to allow the switches act in both X and Y directions. In FIG. 27, 131 is an oil reservoir; 132 is a mounting housing; 133 is a brake housing; 134 is a turning disk; 135 is a sliding channel; 136 is a slider; 137 is a right plunger; 138 is a right cylinder; 139 is a right oil chamber; 140 is a left plunger; and 141 is a left oil chamber. In FIG. 26, 142 is a bearing of upper cover 143; 144 is a sliding bearing; 145 is a bearing of sliding channel 135; 146.1 is a left pipe; 146.2 is a right pipe; and 147 is a control valve. In FIG. 28, 148 is an electromagnetic brake; 149 is an electromagnet for brake; and 150 is an electromagnet for control valve 147.
When a voltage is applied to the electromagnet 149, the brake 148 prevents the disk 134 from turning. Therefore, no relative turning movement between the two ends of the bearing device occurs. When no voltage is applied, the brake does not act, the disk can turn freely due to external torque.
When the electromagnet 150 receives the voltage, it pushes to close the control valve 147. Thus, no oil can pass through pipes 146 and valve 147. Therefore, neither plunger 137 nor plunger 140 can move. The position of the slider 136 is fixed. When no voltage is applied, the slider 136 can be moved by external force but receive certain resistance from the control valve 147. Namely, when the valve is opened with larger orifice, less resistance will occur; when the valve is slightly opened with small orifice, heavy resistance will appear.
As described above, the brake-disk works as a turning switch. When it is allowed to turn freely, zero torsion stiffness is achieved. When no turning movement is allowed, heavy torsion stiffness will apply. The value of the stiffness is designed according to specific structures. Also, the slider works as a translational switch. When it can be moved freely, no stiffness is added to the structure. However, certain amount damping will be made by adjusting the resistance from the orifice of the control valve 147. When it is fixed, certain value of stiffness is achieved according to specific needs.
The opening of the orifice of the control valve is adjusted to achieve certain resistance. The resistance is determined in this way: 1) The slider 136 must be stopped at certain position in desired duration of time (it is allowable to take shorter time duration), otherwise the cylinder cannot be used in the next step. 2) The damping ratio of the cylinder-plunger system should be at least 70%, otherwise the energy dissipation will not be enough to drop the energy from the entire structure.
While a preferred form of this invention has been described above and shown in the accompanying drawings, it should be understood that the applicant does not intend to be limited to the particular details described above and illustrated in the accompanying drawings, but intends to be limited only to the scope of the invention as defined by the following claims. | A method and apparatus for structural deflection control, as well as associated sequential controls that are based on new control laws. The apparatus of this invention is of relatively low cost and performs better than prior art devices. The essence of the invention is to adjust the dynamic parameters (mass, damping, stiffness coefficients of the structure and/or input forcing coefficients) adaptive to input dynamic loads, by using the new devices and the suggested control laws. In so doing, the structure performs an adaptive function to effectively counter the effects induced by multi-directional external excitations. The required control power can be nil, or many times lower than prior art active control devices, and the effectiveness can be equivalent or even better than the current state-of-the-art active controls. The devices used by the apparatus of this invention can readily be manufactured for immediate application in structures, buildings and contents, and other constructed facilities. |
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FIELD OF THE INVENTION
This invention lies in the field of construction. One embodiment of the invention, for example, relates to a stringer and tread combination for use in the construction of a staircase, ramp or walkway. The scope of the invention extends to the stringer and the tread and to a method of establishing a staircase, ramp or a walkway.
Another embodiment of invention, however, is also useful in creating seating structures, and in particular, seating structures which are applicable for the manufacture of grand stands or seating arrangements for theatres, both open air and indoor, although primarily the former.
The concept of the invention can be further extended to creating ladders or very steep staircases or step ways. The steepest staircase allowed by official building regulations is inclined at approximately 40° to the horizontal. At angles of inclination greater than 40°, the structure can conveniently be referred to either as a very steep staircase or preferably referred to as a ladder.
This invention provides structural building components which may be precast and applied in all of the above mentioned areas.
SURVEY OF RELATED ART
Staircases present many on-site problems for the builder. Floor-to-floor heights vary, as do riser and tread dimensions. Typically, skilled carpenters set out and build the shuttering (i.e., concrete form) with extensive propping and specially designed reinforcing which are required before the concrete is poured. Space is needed for storing the reinforcing and shuttering material. Further, concrete spills resulting from bleeding and inadvertantly kicking shuttering and careless barrow-handling add to the general mess and congestion in the very place where easy access to upper floors would enhance efficiency and project completion.
Proposals for prefabricated staircases have been made and examples can be found in the art.
French Patent No. 90 10433 describes a stringer and tread construction for a staircase in which the stringers have a substantially conventional stepped construction for supporting a tread on each step. A radius of curvature on the upper surface of each step is matched by a similar radius of curvature on the lower surface of each tread by which only a very limited amount of adjustment of the tread, so as to be perfectly level, can be achieved. However, the teaching of the French patent is confined to faciliating only limited adjustment of the treads for the purpose of levelling them.
Rather similarly, the U.S. Pat. No. 3,986,579 also teaches only the possibility for accurately levelling the steps at the job site after the stringers have been installed. Angular rotation is described as being quite limited, as is shown in the view of FIG. 3 where a bolt 8 must move within a slotted hole 41 of limited dimension.
SUMMARY OF THE INVENTION
By contrast, the object of the present invention is to permit the same stringers and treads to be used to provide not only a staircase of any angle of inclination, but even down to horizontal, that is, to serve as a walkway and all other angles between horizontal and normal maximum for a staircase of about 40° inclination. The system can also be used to produce ramps, that is, to provide a smooth surface that rises on an incline.
Special embodiments of the invention can be extended to provide very steep staircases or ladders.
This underlying principle of the invention can also be applied to provide seating ramps for theatres and stadiums.
In accordance with the present invention, a stringer and tread combination is provided in which the stringer is lengthwise provided with successive integrally formed scallops, each of which has a lengthwise shape conforming to the arc of a circle and each of which scallops can accommodate at least part of an underside of a tread, which underside has a co-acting shape to that of the scallops.
By "integrally", it is meant that the scallops and the stringer form one component, i.e., the scallops have not been separately added to the stringer.
It is a characteristic of this invention that each scallop begins and ends on the same longitudinal line of the stringer, or substantially so.
The transverse shape of each scallop may be linear.
It is an important feature of the invention that the same stringer and tread combination can be used in the manufacture of a stairway, walkway and ramp.
Generally, two stringers will support a plurality of treads. However, in an embodiment of the invention in which the scallops are provided in the top surface of the stringer, a single stringer can be employed in creating a walkway, ramp or staircase using treads having suitable lengths.
In another embodiment of the invention in which the combination comprises two opposed, spaced apart and generally parallel stringers, an inner side surface of each stringer includes scallop shaped corbels for supporting the end portions of the treads. A single projection constituting a plurality of corbels may be provided on the inner side of the stringer. Alternatively, a plurality of projections, each of which constitute a corbel, may be provided on the inner side of the stringer.
Preferably, the treads and the stringers are manufactured of precast concrete.
Generally, each of the scallops must have the same pitch to comply with good practice and official building regulations.
In a preferred embodiment, an underside, or at least part of the underside, of each tread is secured in a scallop by means of glue. Glues which may be employed include those of the epoxy type and of the poly-sulphide type. The applicant has found that the epoxy type of glues provide a rigid joint whereas the poly-sulphide types provide a more flexible joint which is preferred for staircases where only the rear portion of the tread overlaps with the stringer and the front portion forms a cantilever which is stepped on during use and provides a better impact strength. Alternative ways of securing the treads to a stringer are envisaged and include mechanical keys, for example dove-tail joints, and bolt and nut connections. The dove-tail joint may include an aluminum extrusion suitably cast into the stringer.
To render the treads more resistant to tensile stresses, the treads may be provided with reinforcements, for example, metal bars cast into the treads, especially in the overlap mentioned above.
To reduce the mass of a stringer, it may be provided with holes extending from side to side, which holes are open to the outside. The holes also facilitate transportation of the stringers because a means, for example a crowbar or a sling, can be located there through. The holes also facilitate fixing the stringers, e.g., to columns, etc.
The stringer may be provided with inner reinforcements rendering the stringer more resistant to tensile stresses. The reinforcements are preferably located between the holes and the top surface and between the holes and the bottom surface of the stringer. Metal bars cast into the stringers are preferred.
An advantage of the invention is that in the construction of a staircase, the scallops allow the stringer(s) to be raked to any suitable angle. After having raked the stringer(s) to the required angle, the treads are located in the scallops and the upper tread surfaces levelled. Alternatively, the treads can be simultaneously raised with the stringers after treads have been rotated and secured in the scallops so that the upper tread surfaces become level when the stringers have been raised.
Preferably, each tread has a generally flat upper surface.
The scallops in the stringer(s) allow the treads to be secured parallel to the stringer(s) for creating a walkway or a ramp.
An end portion of the stringer may be provided with half a scallop such that two stringers having such end portions can be mated in an end to end configuration which will provide a full scallop. The applicant has found that such stringers can be used where a change in the direction of a walkway or a ramp is desired. It will be appreciated that where the change in direction occurs a gap is generated between the two successive treads. A suitable landing may be used to fill this gap.
An end portion of a tread may be adapted for mounting a stanchion. For example, the end portion may be provided with a suitable hole, preferably formed during casting. Stanchions may alternatively be secured to stringers.
It will be appreciated that the invention provides a versatile stringer and tread combination.
The scope of the invention extends to the stringer alone, the tread alone and to methods of manufacturing the stringer and tread, each of which methods preferably includes a step of casting the stringer or tread using a suitable concrete.
Each tread may have a riser added to it which preferably depends from the front underside of the tread. The tread and the riser may be integrally cast of concrete. Alternatively, the riser may be a separate component which fits into a groove provided in the front underside of the tread. Otherwise the risers may be open.
In accordance with the present invention, there is provided a method of establishing a staircase or a ramp, which staircase or ramp uses the stringer and tread combination of the invention.
The method includes a step of raking the stringer(s) to a required angle and a step of securing at least part of an underside of each tread in a scallop after the stringer(s) has been raked to the required angle. The upper tread surfaces are then levelled in the case of the staircase. In the case of a ramp or walkway, the upper tread surfaces are then arranged so that they are generally located in a plane.
The scope of the invention extends to a method of establishing a horizontal walkway using the stringer and tread combination. The method includes a step of arranging the stringer(s) in a horizontal position. The method further includes a step of securing at least part of an underside of each tread in a scallop after the stringer(s) has been arranged horizontally and the upper tread surfaces levelled.
The stringers will be designed (e.g., in suitable steel reinforced concrete) to serve as end-supported beams, in most applications. However, the lengths of the stringers can also be bedded in soil or concrete to provide staircases, ramps or walkways on soil or concrete ramps or beds.
This basic structure can also be applied to the manufacture of grand stands since, in simple form, they are conceptually equivalent to a large scale staircase where the riser height in staircases corresponds to the height of the seat and the tread in staircases corresponds to the seat itself. In grandstand applications, preferably sufficient space is provided behind a seated person for the feet of the next user to gain access to the next seating place.
The principle is thus also applicable to providing seating in theatres and similar buildings and also stepped surfaces in theatres and similar buildings for providing conventional seating rows on such stepped surfaces in theatres.
In a typical grand stand application, seat heights may vary from 300 mm to 500 mm high. Outside this range, the comfort zone may be exceeded. A suitable seat including access behind it, should be on the order of 800 mm wide, or in the range between 780 mm to 850 mm.
The invention can be implemented with materials other than concrete, for example, timber and plastic. The aesthetic possibilities inherent in the invention can, for example be realized with particular attractiveness in timber. Technological adaptations of the principle to timber would include the possibility that the treads would be glued and screwed to the stringers.
Furthermore, in the case of timber, a corbel could be separately fabricated and fastened to the stringer by nailing, screwing and/or gluing, for example. A further interesting possibility, which is perhaps particularly apt with the use of timber, is to raise the angle of the staircase towards 90° when it becomes tantamount to a ladder. This application could, of course, also be implemented in concrete and other materials.
The application of the invention in plastics materials could be employed by techniques in which the tread is extruded. The stringers could be manufactured in modular form and then assembled. Fiber re-inforcement techniques of the plastic could be useful in both the stringers and the treads.
In the application of the invention to grand stands and similar applications as discussed herein, the scale of the modular component such as the stringers and seats or seating platforms may well result in the components having to be placed in situ on a building site by means of suitable cranes. Thus, these applications are in contrast to the application for staircases where the components can, in many cases, be small enough to be manhandled into place.
The principle of the invention can furthermore be extended, as has been stated, to provide ladders or very steep staircases, that is, at angles greater than is conventionally permitted, for example by standard building regulations for staircases, around 40° or 45°.
Prior art proposals have been made for stringer and tread combinations in which, even if the tread is given a hemi-cylindrical under surface, the stringers do not have merely circular scallops. Instead, the stringers have more complicated indentations, notches or other formations for receiving the treads, thus giving them support on steeper angles of inclination. The shortcoming of these known proposals is that such stringers cannot be used over a wide range of angles of inclination from the horizontal. Indeed, such stringers may be used only over a very small range of variation of a few degrees, for example, and certainly may not be used to the point where the stringer and tread combination can be used to provide a walkway or ramp. For these purposes, these known proposals of which the inventor is aware are quite unsuitable.
A further object of this invention is therefore to further extend the concepts described thus far to allow the stringer to be used at any angle between horizontal and an angle very close to vertical.
In accordance with this invention, the essential feature is that the scallop diameter is less than the pitch between treads, and that the arc of the scallops is close to a semi-circle (i.e., 180°). In the preferred embodiment, this feature will be met by means of short straight portions, parallel to the length of the stringer, between scallops.
A secondary effect of this approach is that the treads have a relatively deep profile which can, of course, advantageously increase bending strength in the cases of long spans or in canti-lever arrangements for the tread.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of various examples with reference to the accompanying drawings in which:
FIG. 1 is a partial side view of a stringer and tread combination in accordance with the present invention;
FIG. 2 is a partial side view of a staircase comprising the combination shown in FIG. 1;
FIG. 3 is a cross-sectional end view of the combination along m--m in FIG. 1;
FIG. 4 is a partial side view of another stringer and tread combination in accordance with the present invention;
FIG. 5 is a partial side view of a staircase comprising the combination shown in FIG. 4, but with three different types of treads;
FIG. 6 is a cross-section of the combination along VI--VI in FIG. 4 in which a tread is shown having a mirror image to that of the tread shown in FIG. 4;
FIG. 7 is a side view of a stringer and tread combination used to show how a pitch of the scallops can be calculated;
FIG. 8 is a side elevation showing grand stand seating;
FIG. 9 is a side view of a tread;
FIG. 10 is a side view of a stringer;
FIG. 11 is a side view of treads and stringers of the kind shown to provide a steep staircase at 45°;
FIG. 12 shows treads and stringers combined to provide a ladder at 60°;
FIG. 13 shows tread and stringers combined to provide a ladder at 80°;
FIG. 14 is a plan view showing a walkway landing;
FIG. 15 is a side elevation showing a capital and support column;
FIG. 16 is a side elevation from the other side of the capital and support column;
FIG. 17 is a front elevation of the capital and support column;
FIG. 18 is a side view of the capital and support column supporting an alternative stringer;
FIG. 19 is a side view from the other side of the capital and support column and stringer;
FIG. 20 is a front elevation of a stanchion with hand rail and knee rail attached to a stringer;
FIG. 21 is a side elevation of the stanchion of FIG. 20 showing alternative angles of inclination of the stringer;
FIG. 22 is a front elevation showing a stanchion with hand rail and knee rail attached to a tread;
FIG. 23 is a side elevation showing the stanchion of FIG. 22 attached to a tread, with the stringers being arranged at various angles; and
FIG. 24 is an enlarged detail showing a connection between a hand rail and stanchion; and
FIG. 25 shows an exploded view of various applications of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 the reference numeral 10 generally indicates a stringer and tread combination in accordance with a first embodiment of the present invention. The stringer and tread combination 10 comprises a precast concrete stringer 12 and a plurality of precast concrete treads 13 each having an upper tread surface 14.
The top surface 15 of the stringer 12 is lengthwise provided with successive scallops 16. Lengthwise, the shape of each scallop 16 conforms to the arc of a circle as shown in FIG. 1. In the transverse direction the shape of each scallop 16 is linear. A gap 18 is provided between each of the scallops 16 and an adjacent scallop. FIG. 1 shows that the shape of the underside of each tread 13 co-acts (mates) with the shape of the scallops 16. Every scallop (i.e., the arc of each scallop) begins and ends on the same longitudinal line 200.
FIG. 3 shows that the stringer 12 has a trapezoid shaped cross-section which the applicant has found to be advantageous for casting and for removal of the stringer 12 from a mold after having been cast. The shape is useful in providing a greater width at the top to bear compressive stress. Tensile stress at the bottom is born by steel re-inforcing, in beam loading.
The stringer 12 is provided with a plurality of side to side holes 20 extending through the stringer 12. The holes 20 reduce the mass of the stringer 12 and facilitate transportation thereof. Crowbars can be located through the holes 20 thus enabling the stringer 12 to be carried. For raising the stringer 12, a sling and crane can be used with the sling located through the hole 20 and fastened to the stringer 12.
Each tread 13 can be secured parallel with the line 200 defined by the ends of the scallops 16 of the stringer 12 as shown in FIG. 1. More specifically, the upper tread surface 14 is generally parallel with the bottom surface 23 of the stringer 12. This embodiment of the combination 10 can thus be used to construct a horizontal walkway or a ramp.
To establish a horizontal walkway, a ramp or a staircase the stringer(s) 12 can simply be laid onto a surface or the bottom surface 23 of the stringer 12 can be embedded in the ground. Overhead walkways and ramps can be constructed by using supports, for example poles or columns, which may be secured to the stringers 12 via the respective holes 20. After having arranged the stringer(s) 12 as aforementioned, the treads 13 are arranged in the scallops 16 and the upper tread surfaces 14 levelled (i.e., are made to be parallel with one another) when a walkway or staircase is constructed. For a ramp, the upper tread surfaces 14 are arranged so that they are generally coplanar. The treads 13 are then secured to the stringer(s) 12 by gluing their undersides to their respective scallops 16.
An end portion 24 of the stringer 12 is provided with half a scallop 25 which allows two stringers 12 to be mated in an end to end configuration. The mated end portions 24 will thus provide a full scallop, akin to the scallop 16, into which a tread 13 can be located. A walkway or a ramp having a change in direction can also be constructed using a plurality of the stringers 12. Viewing such a walkway or ramp from above will show that a gap is formed between two successive treads 13 where a change in direction occurs. A suitable landing can be used to fill this gap (See, e.g., FIG. 14).
FIG. 2 shows a staircase 30 which has been constructed using the same stringer and tread combination 10 shown in FIG. 1. The staircase 30 has been established by raking the stringer 12 to an angle of 30 degrees. The treads 13 have been rotated in the scallops 16 to render the upper tread surfaces 14 level. After having been levelled, the underside of each tread 13 in contact with the scallops 16 is secured to the stringer 12 in the scallops 16 by means of gluing. Installing the staircase 30 may be accomplished by, preferably, first raking the stringer 12 to the required angle and then locating the treads 13 in their respective scallops 16. Alternatively, the treads 13 can be simultaneously raised with the stringers 12 after the treads 13 have been rotated and secured by means of gluing in the scallops 16 so that the upper surface 14 of each tread 13 becomes level when the stringers 12 have been raised.
It will be appreciated that the walkway, ramp and staircase 30 may comprise one or more stringers 12 for supporting the treads 13. Referring to FIG. 3, a cross-section is shown of a ramp or walkway using only one stringer 12. This type of stringer 12, which passes beneath the treads 13, allows the treads 13 to form cantilevers as is evident from FIG. 3.
FIGS. 1, 2 and 3 show that the stringer 12 and tread 13 have been provided with cast in re-inforcements in the form of metal bars 26, 27, 28. The bar 26 is located between the holes 20 and the top surface 15 of the stringer 12 while the bar 27 is located between the holes and the bottom surface 23 of the stringer 12. The bars 28 are provided in the overlap 29 of each tread 13 to render the treads 13 more resistant to tensile stresses during stepping onto the upper tread surface 14 of the overlap 29.
FIG. 4 shows another embodiment of a stringer and tread combination which is generally indicated by the reference numeral 50. The stringer and tread combination 50 comprises a precast concrete stringer 52 and a plurality of precast concrete treads 54 each having a generally flat upper tread surface 55.
The stringer 52 is provided with a single projection constituting a plurality of corbels 56. Each corbel 56 defines a scallop 58 having the same shape as that of the scallops 16 shown in FIGS. 1 and 2. A gap 60 is provided between each scallop 58. FIG. 4 shows that the underside of each tread 54 has a co-acting (mating) shape to that of the scallops 58.
The stringer 52 is further provided with a plurality of holes 61 serving the same purpose as the holes 20 of the first embodiment stringer 12.
The combination in FIG. 4 can be used to construct a horizontal walkway, a ramp or a staircase. As shown in FIG. 6, at least two stringers must be employed, the one being the stringer 52 and another stringer 62 having the mirror image of the stringer 52. These stringers 52, 62 are used in pairs, as shown in FIG. 6, with the stringers 52 and 62 arranged opposite, spaced apart and generally parallel to one another. As was the case with the stringer(s) 12, the mentioned pairs of stringers 52, 62 can simply be laid onto a surface or with the bottom surface 63 embedded in the ground. Overhead walkways and ramps can also be constructed by using supports, for example poles or columns, which may be secured to the stringers via the respective holes 61. After having located the stringers 52, 62 as aforementioned, the end portions 63 of the treads 54 are located in the respective scallops 58 and the upper tread surfaces 55 are leveled when a walkway or staircase is constructed. For a ramp, the upper tread surfaces 55 are arranged so that they are generally coplanar. The treads 54 are then secured to the stringers 52 by gluing their undersides at their end portions 63 to their respective scallops 58.
An end portion 64 of the stringer 52 is provided with half a scallop 65 which serves the same purpose as the half scallop 25 discussed previously.
A staircase can be constructed by using the stringer and tread combination 50 shown in FIG. 4 together with a stringer 62 shown in FIG. 6. The staircase is established by raking the stringers 56, 62 to a required angle, for example 30 degrees as shown in FIG. 5, and arranging them opposite one another, suitably spaced apart and generally parallel to one another. The end portions 63 of the treads 54 are located in their respective scallops 58 and the upper tread surfaces 55 are leveled. The underside of each end portion 63 which is in contact with the scallops 58 is then secured to the respective stringers 52, 62 in the scallops 58 by means of gluing. FIG. 5 shows a partial view of a staircase 70.
The treads 54 are re-inforced in the same way as the treads 13 using metal bars 28 in the overlap 72. A metal bar re-inforcement 74 is further provided in the stringer 52, 62.
FIG. 5 shows that the staircase 70 comprises three different types of treads 54, 76, 78. Each of the treads 76, 78 has added to it a riser 80, 82 which depends from the front underside of the tread 76, 78. The tread 76 and riser 80 element has been integrally cast using concrete. The riser 82 is a separate concrete casting which fits into a groove 84 in the underside of the tread 78.
To have comfortable stairs, the Neufert formula, in which twice the riser plus the tread width equals 600 to 650 mm, is applied. Using a riser of 200 mm and a tread width of 250 mm which is the steepest stair allowed by official building regulations in R.S.A. and applying the Neufert formula we get (2×200)r 250=650 mm which satisfies the criterion for comfortable stair design. FIG. 7 shows the riser 89 of 200 mm and the tread width of 250 mm, where the tread width is defined as the distance between the point 90 and the nose 92 of the tread 13.
Referring to FIG. 7 and applying Pythagoras' theorem a diagonal distance of 320 mm is generated from tread nose 92 of a first tread 13, 54 to the tread nose 94 of an adjacent tread 13, 54. The pitch of the scallops 16, 58 is taken as 320 mm.
The tread width 96 shown in FIGS. 1 and 4 is 310 mm when the stringer 12, 52 is horizontal and with the upper tread surfaces 14, 55 level or with the stringer 12, 52 inclined and with the upper tread surfaces 14, 55 generally located in the same plane. The gap 18, 60 is taken as 10 mm.
Using the dimensions above, the minimum required overlap 98 (FIG. 7) is obtained when the rake comes down to 27 degrees with the riser being 147 mm.
It will be appreciated that the riser 89, the tread width 96 and the overlap 98 will vary with a change in the rake.
The view in FIG. 8 of the drawings is a side elevation of a stringer 90 and seat 100 supported on it in a grandstand. The stringer is at 30° which is appropriate for grand stand seating and the stringer is provided with scallops on a 750 mm radius which is matched, of course, by the lower surfaces of the seats 100. The scallops are spaced on the stringers 90 with a 900 mm pitch along the length of the stringers 90. A clear width of each seat 100, that is, the sections of the seats 100 which are not overlapped by the next succeeding seat, is 774 mm in this arrangement. The height between seats is 460 mm. These features are indicated on the sketch. Holes in the stringer are of some interest for aesthetic and/or weight advantages.
With these considerations in mind the inventor has suggested a choice of a pitch (measured along the length of the stringer) in the region of 900 mm for the scallops and with this choice the following range is covered:
______________________________________SEAT HEIGHT SEAT WIDTH ANGLE______________________________________300 849 19.4310 844 20.1320 811 20.8330 837 21.5340 833 22.1350 829 22.8360 825 23.5370 820 24.3380 816 24.9390 811 25.6400 806 26.3410 801 27.1420 796 27.8430 791 28.5440 785 29.2450 779 30.0460 774 30.7470 767 31.4480 761 32.2490 754 32.9500 748 33.7______________________________________
The radius used for the scallops is determined by the following factors:
1. The structural depth required for the seat.
2. The length of interface between stringer and tread required to give an adequate bond of seat to the stringer.
3. The need for seats to overlap slightly when viewed in plan. The larger the radius, the thinner the structural depth of the seat segment and the smaller the bond interface at steeper angles.
A radius of 750 mm would probably optimise these criteria.
As reflected in the above table, typical angles for grand stand seats are somewhat lower than is typical for staircases, for example in the range of 20° to 30° measured to the horizontal.
As shown in FIG. 9, the typical tread 101 has an under (lower) surface 102 which is hemi-cylindrical, the upper surface 103 being flat for stepping on. The under surface 102 has a radius of curvature 104 which, by way of example, is 130 mm. This can be contrasted with the fact that the pitch 105 between treads is in this example 320 mm. The width 106 of the tread in this example is 230 mm.
Thus the stringer 107 shown in FIG. 10 for use with these treads 101 has scallops 108 which have a radius of curvature 109 exactly equal to the radius of curvature 104 of the under surface of the treads 101, namely, in this example, 130 mm. Thus, the diameter of the scallops (and of course of the under surface of the treads) is 260 mm is smaller than the pitch 105 of 320 mm between the treads 101 in the assembled stairs or ladder. As can be seen in FIG. 10, the pitch 105 is the length of the pattern of two consecutive scallops 108, which is successively repeated along the length of the stringer 107.
Holes 110 are shown in the stringer as a lightening or attachment convenience. At the ends of the stringer a half scallop 111 is provided which permits the stringers to be joined end to end for providing walkways.
A staircase and a ladder made with these treads and stringers are shown in FIGS. 11 and 12, respectively, where the same numerals are used for the various features discussed with reference to FIGS. 9 and 10. In FIG. 11 the angle is 45° and in FIGS. 12 and 13, the angles are 60° and 80° respectively. Thus, the embodiment shown in FIG. 11 can be described as a very steep staircase and the embodiments shown in FIGS. 12 and 13 can be described as ladders.
Another important feature of the invention, which is preferably adopted, is that the center 112 on which the circular shape of each scallop is generated is co-linear with the upper edge 114 of the stringer so that a full semi-circular (i.e., 180°) scallop is available for placing the tread 101 in position. This means that the cantilever portion 102 of the tread 101 is quite reduced and, as will be seen with reference to the following FIGS. 12 and 13, still within acceptable limits even on the steepest use of the tread 101 and stringer combination of this invention. The short straight portions 114 between scallops could be reduced by increasing the diameter of the scallops, but not to a diameter greater than the pitch 105 between scallops. This would have the advantage that if the stringer is placed horizontally to make a walkway, then the edges or the treads will be contiguous to provide a walkway without gaps.
As shown in FIGS. 12 and 13 this tread and stringer combination is amenable to very steep inclinations, as shown for example in FIGS. 12 and 13 of 60° and 80°, respectively.
FIG. 14 shows a landing 150 to accommodate a change of direction of a walkway, having half scallops 151 and 152 to mate with co-acting half scallops at the abutting ends of stringers (e.g., as shown in FIG. 1, the half scallop 25) to carry a tread.
FIGS. 15 to 17 show the use of a capital and column type support for walkways and staircases. The capital comprises cylindrical body 120 with a groove for carrying a pin 121 which passes through a hole 122 of the stringer 123. A face 124 of the capital is cut away to permit the stringer 123 to be mounted at an inclination (in this example of up to 38°). After installation, grout is applied in the spaces visible in the view of FIG. 16.
The use of the same capital for the type of stringer in which the scallops are placed in the upper surface of the stringer is shown in FIGS. 18 and 19, the same reference numerals have being used. With the arrangement shown, left hand and right hand capitals are provided for alternate sides of the stringers.
FIGS. 20 and 21 show the mounting of a stanchion 125 by means of a flange 128 on to the side of a stringer 129. Hand rail 126 and knee rail 127 are carried by the stanchion 125. The detail in FIG. 24 shows how the hand rail 126 is fixed to the top of the stanchion 125 by means of a steel rod of mild steel 130 which can be bent on site to the required angle thus co-operating in this way with the flexibility of the system in being able to adopt any suitable angle of rake.
FIGS. 22 and 23 show a stanchion 131 carrying a hand rail 132 and knee rail 133. However, in this case the stanchion 131 is mounted, at its base 134, to a tread 135 which is provided with a suitable hole 136 for this purpose. A bolt projects from the lower end of the stanchion 131, at its base 134, passes through the hole 136, and is bolted in position.
FIG. 25 shows at 120 a staircase structured using two stringers and a plurality of treads and also showing hand rails fixed to the treads.
The feature at 121 shows two stringers in this case with the scallops formed on inwardly facing corbels on each stringer and with the treads showing an integrally formed riser depending from each tread so as to close the space between treads.
The feature at 122 shows a horizontal walkway using the same stringers and treads as shown in the previous drawings, illustrating the versatility of the apparatus.
The feature at 123 shows again the same stringers and treads forming an inclined ramp.
The Neufert formula permits the pitch distance between the noses of the treads, and accordingly the pitch distance of the scallops in the stringers, to be made. Thus, in accordance with the invention, a preferred pitched distance is 320 mm or lies between, for example 290 and 330 mm. Standardizing on this dimension of pitch for the scallops in the stringers allows a system for staircases, walkways and ramps to be offered to the public which can be employed in all the different ways described in this invention. In the installation of a staircase, a fixed dimension is the pitch of 320 mm. This allows the variation of the rise dimension, the tread dimension or the angle of the staircase in any particular application.
Most frequently, because the floor to floor height for a particular staircase is pre-determined by the building, a riser height must be chosen as the starting point. The following example illustrates how the method is then applied:
Example: Given a floor to floor height of 2 635 mm
1. Choose the number of risers (say 14) 2 635/14=188.214 mm riser
2. The tread length by Pythagoras (using 320 for the hypotenuse) will be ##EQU1## 3. The angle by cosine will be 258.796/320=0.809=36°
4. The going distance in true plan will be: 13 [email protected] mm/tread=3 364 mm
The same stringers and treads of the invention can be illustrated in the following tabulation of the various options available to the designer.
__________________________________________________________________________RISER TREAD ANGLE 2 R + T STEP CLIMBING EFFECT SPECIAL CAUTION__________________________________________________________________________110 30 20°05 520 Easy going mincing step 20°∠120 297 22°00 537 Easy going mincing steps Angles below 20°130 292 24°35 552 Easy going mincing steps may be better served140 288 25°57 568 Easy going mincing steps by Winstep ramps.150 283 27°56 583 Easy going mincing steps 28°∠ WINTEC does not recommend the use160 277 30°00 597 Comfort zone 30°∠ of rake angles greater170 271 32°58 611 Comfort zone than 40°.180 265 34°14 625 Comfort zone190 258 36°25 638 Comfort zone Rake angles greater than 38°41' do not200 250 38°41 650 Comfort zone 38°∠ comply with NationalSee special caution for angles over 40° Building Regulations210 241 41°04 661 Steep big strides 41°∠ SABS 0400 and fall220 232 43°26 672 Steep big strides outside stair design226 226 45°00 679 Steep big strides 45°∠ comfort zones.__________________________________________________________________________
As can be seen from the foregoing tabulation, the angles of staircases using the apparatus for this invention are infinitely variable between 0° and 40°, or even 45°.
A system of stringers and treads with other dimensions can be provided for very steep staircases or ladders above 45°, as described. | Prefabricated, preferably pre-cast concrete, stringers and treads can be employed to provide either a staircase of any required inclination, a horizontal walkway or a ramp of a required inclination. In all these applications, the same standardized stringers and treads can be effectively used. Stanchions can be added as required. Further embodiments can be used for providing ladders and for providing seating for grand stands or theaters. |
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FIELD OF THE INVENTION
The present invention relates to a system for transport of at least one span by a road vehicle and for laying the span from the vehicle over a dry gap in order to enable any road vehicle to cross the dry gap by driving over the span laid over this gap.
BACKGROUND
Such systems are known, for example, from French Patent No. 2 666 772 and French Patent No. 2 683 837 in the name of the applicant.
However, these known systems are not suitable for crossing wet gaps, that is to say gaps filled with water, whose width is such that the span cannot cover them.
Also known is the use of modular floating bridges which can be put end-to-end in order to cover all widths of wet gaps and enable them to be crossed by any road vehicle. However, these floating bridges cannot be used for crossing dry gaps.
SUMMARY OF THE INVENTION
The present invention aims to eliminate the disadvantages above by proposing a system for transport of at least one span by an amphibious road vehicle so that it is used either for laying the span over a dry gap, or as a floating ferry or bridge for crossing a wet gap regardless of the width of the latter.
To this effect, according to the invention, the system for transport of at least one span by a road vehicle and for laying the span from the vehicle over a dry gap in order to enable any road vehicle to cross the gap is characterized by the fact that the vehicle for transporting the span is amphibious in order to enable any road vehicle to cross a gap filled with water by transferring and transporting this vehicle on the span resting on the amphibious vehicle functioning as a floating ferry.
The amphibious vehicle is preferably provided with one or more inflatable lateral ballasts, of the tubular type, making it possible to increase the floatability and stability of the amphibious vehicle.
The suspensions, hydraulic in particular, of the amphibious vehicle can be operated so as to raise the axles of the vehicle which has a turbine device for its aquatic propulsion.
The span extends longitudinally with respect to the transport vehicle and comprises two twinned parallel, roughly parallelepiped boxes defining two upper tracks and two ramps for access to the tracks, which are respectively articulated to the two ends of the boxes around a transverse pin, and a means is provided so as to make possible the pivoting of each ramp from an inactive position folded over the corresponding box to an active deployed position in extension of the box in which the access ramp is maintained when the span is used for crossing a dry gap or in which the access ramp can be adjusted to a determined angular position on either side of its position in extension of the box when the vehicle is used as floating ferry in such a way as to adapt the ramp to the profile of the bank of the gap filled with water when the ramp must rest on this bank for the transfer of any vehicle from the bank onto the span or the transfer of the vehicle from the span onto the bank.
Preferably, the means for pivoting of each access ramp comprises an actuating cylinder mounted in the corresponding box of the span and two connecting rods having two of their ends articulated together at the end of the rod of the cylinder and their opposite ends articulated respectively to the inner surface of the upper track wall of the parallelepiped box and to the inner surface of the lower wall of the box of the ramp.
The span of the vehicle functioning as floating ferry can be connected end-to-end in a removable manner by a connecting means to another identical span of another vehicle functioning as floating ferry in order to form a longer floating bridge.
The connecting means makes it possible to connect end-to-end the ends of the two deployed access ramps of a given end of the span of the amphibious vehicle respectively to the ends of the two deployed access ramps of a given end of the span of the other amphibious vehicle.
The connecting means comprises an articulating hinge of which the knuckles of the ends of one of the access ramps engage respectively in conjugate recesses of the end of the other opposite access ramp, a pin passing through the recesses and the knuckles so as to assemble the ends of the ramps together, and sets of connecting rods arranged on each side of the ramps put end-to-end, including a central connecting rod connected to a corresponding end of the pin while extending below the ramps and two lateral connecting rods connected, on one hand, to the end of the central connecting rod on the opposite side from the pin, and on the other hand, respectively to the corresponding sides of the ramps.
According to an embodiment variant, the connecting means makes it possible to connect end-to-end the ends of two access ramps of a given end of the span of the amphibious vehicle and occupying their position folded over the span respectively to the ends of the two access ramps of a given end of the span of the other amphibious vehicle and also occupying their position folded over this span.
According to yet another embodiment variant, the connecting means makes it possible to connect, by overlapping, the ends of the two deployed access ramps of a given end of the span of the amphibious vehicle to the ends of the two deployed access ramps of a given end of the span of the other amphibious vehicle.
Advantageously, the two ramps of a given end of the span are provided with a plate arranged between the two ramps and whose free end is raised in the manner of a ski.
For laying the span over a dry gap, the system has a beam for support and launching of the span arranged approximately in the longitudinal axis of the vehicle, which can be moved relative to the vehicle according to this axis between an inactive position resting on the vehicle and a launching position projecting with respect to the vehicle in which the span is moved by translation guided on the launching beam also to a position projecting with respect to the launching beam which is supported by an underframe which can be oriented, while being able to translate in a guided manner on it, the underframe tilting around a fixed horizontal pin in order to enable the beam to pivot to the point that the span comes to rest first by its projecting end on the edge of the gap on the opposite side from that situated on the vehicle side, and then by its opposite end on the edge of the gap on the vehicle side, the launching beam then being disengaged from the span which is laid over the gap.
The system advantageously has at least one thrust cylinder situated at the rear of the vehicle under the beam and of which the body is attached to the chassis of the vehicle and the rod rests in a sliding manner under the beam, with it possible for the cylinder to be operated so as to make the beam tilt downward around the pivot pin of the titling underframe so as also to bring the end of the span to rest on the corresponding edge of the gap to be crossed.
The system also has a means for fastening of the beam to the chassis of the vehicle that comprises a rigid frame connected perpendicularly to the chassis and two jaws mounted articulated to the frame and controlled by a cylinder mounted on the frame in such a way that each jaw can squeeze a corresponding lower part of the beam.
The system can be transported by airplane.
The vehicle in its front has a stabilization foot which can come to rest on the ground during laying of the span over the dry gap and during which the vehicle rests on its axles.
The invention also relates to a process for transfer and transport of a vehicle on a span borne by an amphibious vehicle for crossing a gap filled with water and using the system as described in the preceding, and includes bringing the amphibious vehicle close to one of the banks of the gap, deploying the inflatable lateral ballasts of the amphibious vehicle, deploying the end ramps of the span in horizontal position in the extension of the two boxes of the latter, operating the hydraulic suspensions of the amphibious vehicle in order to raise its axles, orienting the two ramps of a given end of the span relative to the two boxes in order to bring them to rest on the bank of the gap where the vehicle to be brought on board is situated, bringing the vehicle on board the span in such a way that it is situated roughly in the middle of the span, raising the two ramps to their horizontal position, moving the amphibious vehicle towards the opposite bank, orienting the two ramps of the other end of the span relative to the two boxes in order to bring them to rest on the opposite bank of the gap, landing the transported vehicle on the opposite bank and of raising the two ramps to their horizontal position.
BRIEF DESCRIPTION OF DRAWING FIGURES
The invention will be better understood and other aims, characteristics, details and advantages of it will appear more clearly in the following explanatory description in reference to the appended diagrammatic drawings given only by way of example, illustrating an embodiment of the invention and in which:
FIG. 1 is a view in perspective of an amphibious road vehicle of the invention carrying a span making it possible to cross a dry gap or a wet gap;
FIG. 2 is a view in perspective of the vehicle of FIG. 1 provided with its system making it possible to lay the span over a dry gap;
FIG. 3 is a view in perspective of the vehicle of FIG. 1 used as a floating ferry for crossing a wet gap;
FIG. 4 is a side view representing two amphibious vehicles of FIG. 1 whose spans are joined end-to-end in order to form a longer floating ferry, making it possible to cross corresponding wet gaps;
FIG. 5 is a bottom view of the amphibious vehicle of FIG. 1 ;
FIG. 6 is a side view of the amphibious vehicle functioning as floating ferry;
FIG. 7 is a partial view in perspective of the span showing the means making possible the pivoting of each access ramp relative to the span;
FIG. 8 is a view in perspective of a set consisting of a beam for support and launching of a span and an underframe for tilting of this beam;
FIG. 9 is a view in perspective representing the span of the amphibious vehicle of FIG. 1 in deployed position;
FIG. 10 is a partial view in perspective of the ends of two access ramps which can be coupled to one another in an articulated manner;
FIG. 11 is a side view representing the articulated connection of the ends of the two spans of FIG. 10 by a set of connecting rods;
FIG. 12 is an enlarged view in perspective of the rear part of the amphibious vehicle of FIG. 1 and showing thrust and fastening means;
FIG. 13 is an enlarged view in perspective of the fastening means of FIG. 12 ;
FIGS. 14A to 14I represent the different steps making it possible to lay a span over a dry or wet gap whose width is less than the width of the deployed span; and
FIGS. 15A to 15J represent the different steps making it possible to cross very wide wet gaps.
DETAILED DESCRIPTION
In reference to FIGS. 1 to 15 , reference 1 designates a road vehicle, such as a truck, enabling one to transport span 2 towards a gap that needs to be crossed by vehicles VT, for example, military vehicles.
Vehicle 1 has armored cab 3 extended in the rear by longitudinal chassis 4 which supports the system for laying span 2 over gap B.
This system has beam 5 for support and launching of span 2 arranged in resting position on chassis 4 of the vehicle in its longitudinal axis and which can be moved relative to the vehicle according to this axis between its inactive position resting on the vehicle and a launching position projecting with respect to the vehicle.
Beam 5 is made up of a strong structure with an I-shaped cross section and is mounted on an underframe in the form of girder 6 which can tilt around fixed horizontal pin 7 relative to the chassis of vehicle 1 in order to make possible the tilting of the beam from its horizontal position projecting with respect to the vehicle downward during laying of span 2 .
The tilting of underframe 6 around pin 7 is controlled by two lateral hydraulic jacks 8 , body 9 of each cylinder 8 being attached in an articulated manner to the chassis of the vehicle and rod 10 of the cylinder being connected in an articulated manner to tilting underframe 6 to the rear of the latter.
Beam 5 can move by translation along tilting underframe 6 , and for this purpose, beam 5 can be connected to tilting underframe 6 by a dove tail connection.
Although it is not represented, the means for moving beam 5 by translation relative to tilting underframe 6 can include an electric or hydraulic motor attached under the tilting underframe, a rack attached longitudinally under the launching beam and a drive gear driven by the rotating shaft of the motor, engaged with the rack.
Span 2 has a driving structure consisting of two twinned parallel, roughly parallelepiped boxes 11 defining two upper tracks and two access ramps 12 , each consisting of a box and articulated respectively at the two ends of a given side of the two boxes 11 of the driving structure around transverse hinge pin 13 . Each ramp 12 has a slope which enables any vehicle to access the tracks of boxes 11 and to leave them easily.
Span 2 moreover has a set of rollers 14 and connecting arms 15 for boxes 11 , arranged transversely between boxes 11 and which make possible the positioning of span 2 on launching beam 5 and facilitate the translation of span 2 with respect to this beam. Connecting arms 15 and end rollers 14 also make it possible to retrieve and lay down span 2 .
Rollers 14 of connecting arms 15 can slide in guide rails 16 of launching beam 5 , and although it is not represented, the means for translating span 2 on launching beam 5 comprises an electric or hydraulic motor connected to beam 5 and a rack connected with the span, on which a drive gear engages, which is driven by the rotating shaft of the electric or hydraulic motor.
The system for laying a span over a gap and for retrieving it as described in the preceding corresponds to the system described in particular in French Patent No. 2 666 772 in the name of the applicant, and it is sufficient to refer to this patent in order to understand the details of its structure and functioning.
According to the invention, vehicle 1 is amphibious so as to enable any other road vehicle VT to cross a very wide gap filled with water as will be seen later on.
The suspensions of amphibious vehicle 1 can be operated, for example, by the driver of the vehicle, in such a way as to raise axles 17 of the vehicle which is moreover provided with an aquatic propulsion device, for example, a turbine or pump-jet device 18 , which is known in itself.
Amphibious vehicle 1 is also provided with one or more inflatable lateral ballasts 19 , of the tubular type, which increase the floatability and stability of the amphibious vehicle. As emerges more clearly from FIG. 5 , two lateral inflatable tubes 19 are provided on each side of the vehicle arranged under a chassis part forming lateral wing 20 of the vehicle.
Vehicle 1 moreover has a device for deployment of the ramps by tilting around their respective hinge pins 13 from their transport or driving position in which ramps 12 occupy a position folded over the driving structure with boxes 11 with the track of each ramp resting on the corresponding track of the box.
Preferably, this deployment device includes actuating cylinder 21 mounted in each box 11 of span 2 and two connecting rods 22 having two of their ends articulated together at A 1 at the end of rod 23 of cylinder 21 and their opposite ends articulated respectively at A 2 and A 3 to the inner surface of the upper wall forming the track of box 11 and to the inner surface of the lower wall of the box of ramp 12 . The end part opposite rod 23 of cylindrical body 24 of each cylinder 21 is connected in an articulated manner at A 4 to the corresponding box 11 of span 2 .
Of course, the four jacks 21 associated respectively with the four ramps 12 can be operated simultaneously or separately in pairs in order to make possible the pivoting of each ramp 12 from its inactive position folded over the corresponding box 11 to an active deployed position in extension of the box in which access ramp 12 is maintained when span 2 is used for crossing a dry gap or in which ramp 12 can be adjusted to a determined angular position on either side of its position in extension of box 11 when the vehicle is used as floating ferry in such a way as to adapt ramp 12 to the profile of the bank of the gap filled with water when the ramp has to rest on this bank for the transfer of any vehicle from the bank onto span 2 or the transfer of the vehicle from span 2 onto the bank. For this purpose, each cylinder 21 and its two connecting rods 22 make it possible for each access ramp 12 to perform rotations of 200° of angle around pivot pin 13 so that in a floating ferry or bridge mode of vehicle 1 , the angular position of ramps 12 can be adjusted to more or less 20° of angle with respect to the position of each ramp 12 in extension of the box. When span 2 is used for crossing dry gaps in such a way as to form a fixed bridge, once ramps 12 are positioned in extension of their respective boxes 11 , each cylinder 21 is immobilized in this position by a known complementary mechanical locking means, whereas in the floating ferry or bridge mode of this vehicle, each cylinder 21 is immobilized in the position for adjustment of ramp 12 in the range of more or less 20° of angle depending on the profile of the bank where the ramp is placed, quite simply by maintaining the pressure of the operating fluid in this cylinder.
The jacks housed in the driving structure of span 2 are operated hydraulically by an automatic connection embodied in this driving structure.
Span 2 of vehicle 1 functioning as a floating ferry can be connected end-to-end in a removable manner by a connecting means to another identical span of another vehicle functioning also as a floating ferry, in such a way as to form a longer floating bridge.
Preferably, this connecting means makes it possible to connect end-to-end the ends of the two deployed access ramps 12 of a given end of span 2 of the amphibious vehicle respectively to the ends of the two deployed access ramps 12 of a given end of span 2 of the other amphibious vehicle 1 .
For this purpose, as emerges more clearly from FIGS. 10 and 11 , this connecting means comprises articulating hinge 25 of which knuckles 26 of the end of one of access ramps 12 of the vehicle 1 engage respectively in conjugate recesses 27 of the end of the other opposite access ramp 12 of the other vehicle. This means moreover comprises pin 28 passing through knuckles 26 and recesses 27 in order to assemble together the ends of the two ramps 12 facing one another of span 2 , and two sets of connecting rods arranged on each side of the ramps put end-to-end and making it possible to absorb the bending moments. Each set of connecting rods has central connecting rod 29 connected to a corresponding end of pin 28 while extending below and roughly perpendicularly to ramps 12 when they are in extension of one another, and two lateral connecting rods 30 connected, on one hand, at A 5 to the end of central connecting rod 29 on the opposite side from pin 28 , and on the other hand, respectively to the corresponding sides of the two ramps 12 at A 6 . Pins 28 and connecting rods 29 , 30 are positioned and locked manually, and the connection is symmetrical so as to allow locking of two spans end-to-end regardless of the end of the floating ferry or bridge that is presented.
As a variant, the connecting means can connect end-to-end the ends of the two access ramps of a given end of the span of the vehicle, which occupy their position folded over span 2 , respectively to the ends of the two access ramps 12 of a given end of span 2 of the other amphibious vehicle, also occupying their position folded over this span. Such a connecting means is described in French Patent No. 2 666 772 in the name of the applicant.
According to another variant, the connecting means enables one to connect, by overlapping, the ends of the two deployed access ramps 12 of a given end of span 2 of the amphibious vehicle to the ends of the two deployed access ramps 12 of a given end of span 2 of the other amphibious vehicle as described in French Patent No. 2 683 837 in the name of the applicant.
Advantageously, the two ramps 12 of a given end of span 2 are provided with plate 31 , visible in FIGS. 14B to 14I , which is arranged between the two ramps 12 and whose free end is raised in the manner of a ski. These ski plates 31 facilitate translation of span 2 in particular on an opposite bank on a lower level relative to the vehicle during laying of the span over dry gaps and enable one to rest the span on the two reinforced parts of the ends of access ramps 12 . These ski plates can be attached in a removable manner to ramps 12 just before laying of the span over the dry gap, and in any case, they are arranged so as not to disturb the boarding of any vehicle on the span in bridge mode laid over the dry gap.
Vehicle 1 is also provided with cylinder 32 , visible in FIG. 12 , which is situated in the rear of the vehicle under beam 5 and makes it possible to absorb the forces, that is to say to distribute the loads between the front and the rear of the vehicle, loads which are connected with the assembly which includes launching beams 5 , span 2 and vehicle VT transported on span 2 when the vehicle functions in floating ferry or bridge mode. To this effect, body 33 of cylinder 32 is attached to chassis 4 of the vehicle, extending roughly perpendicularly to the body, and rod 34 of cylinder 32 rests with the ability to slide, by plate 35 forming a pad which is connected with the end of rod 34 , under beam 5 . Furthermore, cylinder 32 can be operated so as to make beam 5 tilt around pivot pin 7 of tilting underframe 6 downward in order also to bring the end of access ramps 12 to rest on the corresponding edge of the gap to be crossed, in addition to the adjustment of the relative angular position of ramps 12 relative to boxes 11 by the assembly consisting of jacks 21 and connecting rods 22 , in floating ferry or bridge mode of vehicle 1 . This thus facilitates access by the rear of the amphibious vehicle in floating ferry or bridge mode by inclining span 2 downward in a simultaneous action with tilting underframe 6 .
Vehicle 1 can also be equipped with means 36 for fastening beam 5 to chassis 4 of the vehicle and which can be seen more clearly in FIG. 13 .
This fastening means comprises rigid frame 37 , generally H-shaped, whose lower feet 37 a are connected with chassis 4 , and two jaws 38 mounted, articulated to the upper end parts of two upper arms 37 b of H-shaped frame 37 and which can be controlled by cylinder 39 arranged essentially transversely above the transverse limb of H-shaped frame 37 , in such a way that each jaw 38 can be closed in order to squeeze a corresponding lower part of beam 5 which can consist of lower longitudinal rim 5 a of beam 5 .
Rod 40 of cylinder 39 is connected, articulated to the lower end of lever 41 mounted so as to pivot on one of arms 37 b of frame 37 around horizontal pin 42 , and its body 43 is connected, articulated to the lower end of second lever 41 mounted so as to pivot on the other opposite arm 37 b of frame 37 around pin 42 . The upper end of each lever 41 is curved and provided with jaw 44 which can come to face fixed jaw 45 connected with the upper end of the corresponding arm 37 b of frame 37 in order to immobilize, in the manner of a vise, the corresponding rim part 5 a of beam 5 which is therefore held rigidly on chassis 4 of the vehicle in transport mode.
Vehicle 1 , in front, has stabilization foot 46 which occupies an inactive position stowed under the vehicle and which can be deployed to its active stabilization position resting on the ground during laying of span 2 over a dry gap, during which vehicle 1 rests on its axles.
The dimensions and weight of vehicle 1 equipped with its span and system for laying it are such that this assembly can be transported by any airplane capable of receiving accommodating vehicle 1 .
Of course, vehicle 1 and its equipment can itself drive over a span in the form of a fixed bridge arranged over a dry gap or can be transported by another similar vehicle used in a floating ferry or bridge mode.
FIGS. 14A to 14I show the different steps for laying span 2 over a dry or wet gap, but whose length is somewhat less than the length of the span intended for forming a fixed bridge for crossing gap B, whose edge or bank on the opposite side from where vehicle 1 is situated is in this case at a lower level, with it understood that it can be at the same level or at a higher level.
The sequence for launching and laying of span 2 takes place as follows.
First of all, vehicle 1 equipped with its span 2 positions itself on the launching bank ( FIG. 14A ).
Then, stabilization foot 46 is deployed so as to rest on the ground in the vicinity of the bank of gap B, ramps 12 are deployed from their position folded over their respective boxes 11 ( FIG. 14B ) and are locked in horizontal position in extension of the driving structure consisting of boxes 11 ( FIG. 14C ).
Span 2 is then moved by translation, on one hand, by beam 5 moving relative to vehicle 1 , and on the other hand, by the means for moving span 2 relative to beam 5 to the position represented in FIG. 14D . Tilting underframe 6 is operated so as to tilt beam S and span 4 [sic] in such a way as to lay the end of ramp 12 on the opposite bank at a lower level ( FIG. 14E ), the translation of span 2 being facilitated by the use of plate 31 in the form of a ski.
Span 2 is then moved towards the front of the vehicle relative to beam 5 in order to hook rear connecting arm 15 at the end of beam 5 ( FIG. 14F ).
Tilting underframe 6 is operated so as to pivot again around its pin 17 and to lay the end of ramps 12 on the bank situated on the vehicle 1 side ( FIG. 14G ).
Launching beam 5 is then disengaged by rotation of tilting underframe 6 in the reverse direction around pin 7 and movement backward of beam 5 ( FIG. 14H ).
Finally, stabilization foot 46 is retracted in the front of vehicle 1 , and the assembly consisting of beam 5 and titling underframe 6 is returned to its transport position on the chassis of the vehicle ( FIG. 14I ).
Thus, the vehicles can drive over span 2 in order to cross gap B, and vehicle 1 finally itself crosses the gap in order to retrieve span 2 on the opposite bank.
These different steps for laying and retrieving span 2 are already described in detail in the prior art consisting, for example, of French Patent No. 2 666 772 and French Patent No. 2 683 837 in the name of the applicant.
FIGS. 15A to 15J illustrate the different steps enabling vehicles VT to cross gap B filled with water from one bank to the other, and whose width is greater than the length of span 2 occupying its deployed position.
As represented in FIG. 15A , vehicle 1 approaches the bank of gap B in reverse, but the vehicle can just as well approach these banks in forward.
Inflatable lateral ballasts 19 are operated so that they are inflated and provide additional floatability and stability for the amphibious vehicle in the water ( FIG. 15B ).
FIGS. 15C and 15D show that the amphibious vehicle forming a floating bridge has entered the water of gap B. It should be noted that from this stage, there are two operators who come out of the armored cab of vehicle 1 , for example, through trap doors on the roof of the cab, and they board the pedestrian walkways arranged in the upper part of the ballasts as emerges more clearly from FIG. 3 . These people then direct the following actions using an exterior control box.
Thus, as shown by FIG. 15E , access ramps 12 are deployed so that they are arranged horizontally in the extension of the driving structure consisting of boxes 11 .
The axles of floating vehicle 1 are raised by operation of its hydraulic suspensions, and access ramps 12 situated on the side of the bank where vehicle 1 is situated are oriented angularly relative to boxes 11 around their respective hinge pins 13 so as to come to rest on this bank situated at a lower level with respect to ramp 12 ( FIG. 15F ).
Vehicle VT to be transported can then board floating vehicle 1 by driving first over access ramps 12 and then over the driving structure until coming approximately to the middle of the latter ( FIGS. 15G and 15H ). At this stage, articulated ramps 12 are immobilized in position, and the whole pivots around the end support of these ramps on the bank, while keeping a regulation freeboard distance, thanks to the additional floatability provided by inflatable ballasts 19 . The length of the ramps makes it possible to have a sufficient water level without risking grounding, even once vehicle VT has boarded.
Once vehicle VT is on board in the middle of the floating bridge, boarding ramp 12 is raised to its horizontal position ( FIG. 15I ), and amphibious vehicle 1 crosses gap B ( FIG. 15J ) so that ramps 12 on the opposite side of 2 can be laid in the direction of the opposite bank, and transported vehicle VT can land with orientation of the corresponding ramps 12 so that they come to rest on the bank, ramps which are returned to their horizontal position once vehicle VT has landed.
If necessary, two similar amphibious vehicles 1 can be used for putting two spans 2 end-to-end and thus forming a floating bridge which is long enough to cover the whole width of a gap filled with water as represented in FIG. 4 .
Of course, it is possible to assemble as many amphibious vehicles as are necessary for covering any width of wet gap B. | A system for transporting a span on a road vehicle capable of being transformed into an amphibious vehicle, enabling crossing of a dry or water-filled gap by any road vehicle. The vehicle for transporting the span is amphibious to allow any vehicle to cross a gap filled with water by transferring and transporting the vehicle on the span supported on the amphibious vehicle operating as a floating ferry. The invention is particularly applicable in the field of civil or military engineering. |
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09/848,406, filed May 04, 2001.
FIELD OF THE INVENTION
[0002] This invention relates to a solar blanket roller assembly and, in particular, a solar blanket roller assembly which is intended to be installed and stored below the surface of the surrounding deck of a pool.
BACKGROUND OF THE INVENTION
[0003] In the past, solar blankets have been used to cover swimming pools in order to reduce the amount of heat lost from the pool. Typically, the solar blanket consists of a floating plastic or foam mat which is cut to a size and shape generally corresponding to the surface of the pool. The solar blanket is stretched over the surface of the pool during periods when the pool is not in use. When the pool is intended to be used, the solar blanket is often stored on a roller assembly which consists of an elongated roller shaft which mounts a wheel at each of its ends, with one end of the blanket physically coupled to the shaft by a series of flexible straps. Typically, the solar blanket is removed from the pool surface by winding it for storage about the elongated roller shaft. The wheels provided at each end of the roller shaft enable the shaft, together with the solar blanket stored thereon, to roll along the top of the pool deck. Once the solar blanket has been removed from the pool surface, the entire roller assembly is moved via the wheels away from the pool area for storage. To return the solar blanket back onto the surface of the pool, the entire roller assembly is again rolled back into a position adjacent to the pool surface, and the solar blanket is unrolled from the roller shaft and onto the surface of the pool.
[0004] Because the roller assembly rests directly on the top of the pool deck, it is an inconvenience to move the entire roller assembly away from and back to the pool area. Furthermore, the roller assembly may disadvantageously hinder movement about the pool and could present an obstruction which could otherwise injure a pool user.
[0005] In addition, the placement of conventional roller assemblies on top of the deck takes up room that could otherwise be used for other activities, and also may be aesthetically unpleasing either when the solar blanket is rolled up for storage or when it is deployed over the pool surface.
[0006] In colder climates conventional solar blanket storage assemblies present a further disadvantage in that given their size, they are often difficult to store during the winter months. Often the roller shaft may be fifteen feet or more in length, necessitating that the solar blanket be either stored outside with the roller assembly, or detached therefrom and stored elsewhere.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is an object of this invention to at least partially overcome the disadvantages of the prior art. Thus, it is an object of this invention to provide an improved type of solar blanket roller assembly which is installed below the grade or deck of a pool.
[0008] Another object of the invention is to provide a roller assembly for a solar blanket which permits simplified deployment and storage of the solar blanket over the surface of an in-ground pool.
[0009] A further aspect of the invention is to provide a solar blanket assembly which enables a solar blanket to be stored immediately adjacent to the edge of a pool without otherwise obstructing or hindering movement about the pool deck area.
[0010] Another object of the invention is to provide a method by which a roller assembly for a swimming pool solar blanket may be installed easily and quickly in a position substantially below the grade of the surface or deck surrounding the pool.
[0011] The present invention includes a solar blanket and roller assembly for use with an in-ground swimming pool. The roller assembly comprises a longitudinally elongated housing which, most preferably, has a length selected at least one to two feet longer than the lateral width of the pool. The housing defines an elongated interior cavity having a dimension selected to enable the storage of the solar blanket in a rolled configuration therein. A rotatable roller shaft or spindle is provided within the housing. The spindle has a length corresponding to or greater than the width of the blanket and is configured to be manually electrically, pneumatically and/or hydraulically journalled in rotation. Thus the solar blanket may be coupled to the spindle and wound into the housing by selectively rotating the spindle.
[0012] An elongated opening extends substantially the longitudinal length of the housing and allows the solar blanket to be drawn from or wound into the housing for deployment or storage. Optionally, a lid or cover may be provided which may be opened or closed to permit or prevent access into the housing interior.
[0013] In use, the housing is recessed into the ground and positioned with its elongated opening oriented upward so that the housing opening is generally flush with the grade or deck surface immediately surrounding the pool.
[0014] Accordingly, in one aspect, this invention resides in a below-deck solar blanket roller assembly comprising: a rotatable roller shaft for rolling and unrolling a solar blanket, the shaft having first and second ends and a longitudinal axis extending in a longitudinal direction; a non-rotatable protective housing or casing having first and second ends, wherein the housing is spaced radially from the roller shaft, surrounds the roller shaft, and extends in the longitudinal direction, and wherein the housing has an elongated opening extending in the longitudinal direction; first end support supporting the first shaft end and positioning the first shaft end inside and relative to the housing; second end shaft support supporting the second shaft end and positioning the second shaft end inside and relative to the housing; first end wall closing the first end of the casing; second end wall closing the second end of the housing; a drive coupler engaging a portion of the roller shaft for receiving rotational energy from a source to rotate the roller shaft.
[0015] In another aspect the present invention resides in a below-deck solar blanket roller assembly comprising:
[0016] a rotatable roller shaft for rolling and unrolling a solar blanket, the shaft having first and second ends and a longitudinal axis extending in a longitudinal direction;
[0017] a non-rotatable protective casing having first and second ends and extending in the longitudinal direction, the casing has a diameter selected such that the casing is spaced radially from the roller shaft, and wherein the casing has a knock-out portion removable to form an elongated opening extending in the longitudinal direction;
[0018] a first end support for supporting the first shaft end and positioning the first shaft end inside and relative to the casing;
[0019] a second end shaft support for supporting the second shaft end and positioning the second shaft end inside and relative to the casing;
[0020] a power coupler at an end of the roller shaft for receiving power from a source to rotate the roller shaft.
[0021] In a further aspect the present invention resides in a solar blanket roller assembly for installation substantially below the deck of a pool, comprising:
[0022] a rotatable roller shaft for rolling and unrolling a solar blanket, the shaft having first and second ends and a longitudinal axis extending in a longitudinal direction;
[0023] a non-rotatable protective casing having first and second ends, the casing being elongated in the longitudinal direction and being spaced radially from said roller shaft, said casing further comprising,
[0024] at least one extruded segment being elongated along an axis having a longitudinally extending knock-out portion in an upper region thereof which is removable to form part of an elongated opening, and
[0025] a first end support for supporting and positioning the first shaft end inside the casing,
[0026] a second end support for supporting and positioning said second shaft end inside the casing, and
[0027] a drive spaced towards one end of said roller shaft and being selectively operable to rotate said roller shaft.
[0028] In yet another aspect the present invention resides in a method of installing a below-deck solar blanket roller assembly for a swimming pool, the roller assembly comprising,
[0029] a roller shaft for rolling and unrolling a solar blanket thereon, said roller shaft extending along a longitudinal axis from a first end to a second end,
[0030] a non-rotatable protective casing having first and second end portions, the casing being elongated in the longitudinal direction and being spaced radially from said roller shaft, said casing further comprising,
[0031] a first extruded segment and a second extruded segment, each of said first and second segments having a longitudinally extending knock-out portion in an upper region thereof which is removable to form part of an elongated opening,
[0032] a first end support for supporting and positioning the first shaft end inside the casing,
[0033] a second end support for supporting and positioning said second shaft end inside the casing, and
[0034] a drive spaced towards one end of said roller shaft and being selectively operable to rotate said roller shaft,
[0035] the roller assembly being installed by,
[0036] coupling said first extruded segment to said second extruded segment with the knockout portion of said first segment substantially aligned with said knock-out portion of said second segment,
[0037] positioning said casing in a trench adjacent the pool with the knock-out portions oriented upwardly and substantially flush with a surface of the deck,
[0038] backfilling about the casing, and
[0039] removing said knock-out portions to form an elongated opening.
[0040] More preferably, the casing further includes a lid, and said method further comprises,
[0041] hingely coupling said lid at a position adjacent to said first segment knock-out portion and said second segment knock-out portion, so as to be pivotally movable between first and second positions to substantially close or open said elongated opening; and wherein
[0042] the step of backfilling about said casing comprises pouring a settable concrete about said casing, and
[0043] following backfilling about the casing, the hinge is moved from said first position to the second position.
[0044] Further aspects of the invention will become apparent upon reading the following detailed description and drawings which illustrate the invention and preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] In the drawings, which illustrate embodiments of the invention:
[0046] [0046]FIG. 1 shows a partial cross-sectional end view of a first embodiment of a solar blanket roller assembly installed recessed flush with a swimming pool deck, and with a solar blanket housed therein in a storage position;
[0047] [0047]FIG. 2 shows the cross-sectional view of FIG. 1 with the solar blanket deployed from within the roller assembly and overlying the surface of the pool.
[0048] [0048]FIG. 3 is a partial perspective end view of a first idler end of the solar blanket roller assembly shown in FIG. 1 with the solar blanket removed for clarity;
[0049] [0049]FIG. 4 is a partial schematic front view of a solar blanket roller assembly of FIG. 1 with the solar blanket removed for clarity;
[0050] [0050]FIG. 5 illustrates an enlarged partial schematic end view of the second other drive end assembly used in the roller assembly of FIG. 1;
[0051] [0051]FIG. 6 illustrates a schematic exploded view of the drive assembly of FIG. 5;
[0052] [0052]FIG. 7 illustrates an enlarged partial schematic end view of the idler end assembly used in the roller assembly of FIG. 1;
[0053] [0053]FIG. 8 illustrates an enlarged end view of the retaining clamp used in coupling the solar blanket to the roller assembly spindle;
[0054] [0054]FIG. 9 illustrates a perspective view of the hand crank used in the operation of the roller assembly;
[0055] [0055]FIG. 10 is a partial schematic view of a roller assembly in accordance with a second embodiment of the invention;
[0056] [0056]FIG. 11 is a partial perspective cut-away view of a solar blanket roller assembly housing in accordance with another embodiment of the invention with the solar blanket removed for clarity;
[0057] [0057]FIG. 12 is a partial perspective cut-away view of a solar blanket roller assembly in accordance with another embodiment of the invention, with the solar blanket removed for clarity;
[0058] [0058]FIG. 13 is a cross-sectional end view of a solar blanket roller assembly housing in accordance with a further embodiment of the invention;
[0059] [0059]FIG. 14 is a partial cross-sectional view showing one way in which the roller assembly of FIG. 12 may be installed;
[0060] [0060]FIG. 15 is a partial cross-sectional view showing another way in which the solar blanket roller assembly of the present invention may be installed;
[0061] [0061]FIG. 16 is a perspective end view of the roller assembly housing illustrating a housing levelling bracket in accordance with a further embodiment of the invention;
[0062] [0062]FIG. 17 is a schematic side view of a roller assembly and spindle housing sections prior to assembly and packaged as part of a kit;
[0063] [0063]FIG. 18 is a cross-sectional end view of the housing section shown in FIG. 17 taken along line 18 - 18 ′;
[0064] [0064]FIG. 19 is an exploded view of the roller assembly housing, lid, hinge and drive assembly; and
[0065] [0065]FIGS. 20 a and 20 b illustrate a side and end view of a cardboard insert used in the initial installation of the roller assembly housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] [0066]FIG. 1 illustrates a cross-sectional view of the portion of a concrete patio or deck 4 which borders and most typically surrounds an in-ground swimming pool 6 . As will be described hereafter, a roller assembly 10 for use in storing and deploying a solar blanket 8 is recessed into the deck 4 adjacent to the end 7 of the pool 6 . Although final positioning may vary, most preferably the solar blanket roller assembly 10 is positioned so that its uppermost surface is substantially flush with the surface of the deck 4 , and approximately 0.5 to 3 feet from the pool end 7 . When rolled for storage, the solar blanket 8 is thus stored in a position recessed below the surface of the deck 4 so as not to present a tripping hazard, or otherwise create an aesthetically unsightly appearance.
[0067] The solar blanket 8 may be of a conventional design, typically consisting of a flexible plastic membrane which has a series of discreet air pockets integrally formed therein to provide the blanket 8 with sufficient buoyancy to enable it to be floated on the water surface 9 of the swimming pool 6 . The roller assembly 10 is configured to enable the solar blanket 8 to be coiled for storage therein so that the blanket 8 is contained entirely within the solar blanket roller assembly 10 beneath the surface of the deck 4 .
[0068] As is shown in FIG. 2, the solar blanket roller assembly 10 enables the solar blanket 8 to be selectively unwound from the coiled storage position shown in FIG. 1, and stretched across the water surface 9 when the pool 6 is not in use.
[0069] [0069]FIGS. 2 and 4 show best the construction of the roller assembly 10 . Preferably, the entire solar blanket roller assembly 10 extends in a longitudinal direction LD one to two feet past each edge of the pool end 7 , and in the case of a typical residential pool installation will have a length of between about 14 and 26 feet, so as to permit the solar blanket 8 to be housed therein. The roller assembly 10 includes an elongated cylindrical roller spindle or shaft 12 , an elongated generally cylindrical casing or housing 18 and a spindle drive assembly 13 . The shaft 12 is rotatably mounted at each of its ends at 14 , 16 (shown best in FIGS. 5 and 7) within the elongated generally cylindrical housing 18 . The roller shaft 12 or spindle is formed from a number of hollow extruded aluminum spindle segments 12 a , 12 b (FIG. 4) which are each typically about 6 to 12 feet in length. The shaft segments 12 a , 12 b are joined to each other by inserting a cylindrical connector segment 23 into the adjacent open ends of each shaft segment 12 a , 12 b , and thereafter inserting screws (not shown) to couple each segment 12 a , 12 b to the connector 23 . Once the spindle segments 12 a , 12 b are assembled, the completed roller shaft 12 extends in the longitudinal direction LD from its first end 14 to the second end 16 along longitudinal axis L A (FIG. 4). It is to be appreciated that although the tubular spindle segments 12 a , 12 b most preferably have a length selected at between about 6 and 12 feet for shipping convenience, the number of tube segments 12 a , 12 b and final length of the shaft 12 will ultimately depend upon the width of the solar blanket 8 which is to be installed.
[0070] A rearward most edge 15 (FIG. 2) of the solar blanket 8 is attached directly to the spindle 12 . The blanket 8 may be attached to the spindle 12 by suitable means including rivets, screws, glues, touch fasteners or ties.
[0071] Most preferably, however, the edge 15 of the blanket 8 is secured to the shaft 12 in a clamp-fit arrangement by means of an elongated aluminum retaining bar 19 (FIG. 8) which is coupled to the spindle 12 by screws 21 . As will be described, in use of the roller assembly 10 , the solar blanket 8 is coiled about the spindle 12 through its selective rotation by the drive assembly 13 .
[0072] As shown best in FIGS. 2 and 4, the housing 18 has a generally cylindrical profile and extends in the longitudinal direction LD (FIG. 4), a marginal distance past each spindle end 14 , 16 . In a preferred embodiment, the housing 18 formed from a series of extruded metal, PVC or other plastic segments or sections 18 a , 18 b (see FIG. 4) which are joined in axial alignment. In the cross-section shown in FIG. 2, the housing 18 is illustrated having radial diameter D which is marginally greater than the maximum diameter d 1 (see FIG. 1) of the solar blanket 8 when rolled for storage about the spindle 12 . With roller assemblies for use with most residential pools, the housing 18 will have a radial diameter of between about 1 and 2 feet, and more preferably about 15 inches. As a result, the housing 18 is spaced radially about and generally surrounds the roller shaft 12 .
[0073] An elongated opening 24 is provided through the uppermost extent of the housing 18 . The opening 24 extends in the longitudinal direction LD a distance at least as wide as the lateral width of the blanket 8 . The opening 24 is sized to enable the blanket to be unwound from the coiled position about the roller shaft 12 and stretched across the water surface 9 as for example is shown in FIG. 2. Preferably, the opening 24 has a width of between about 3 and 8 inches and more preferably approximately 5.5 inches.
[0074] The edge portions of the housing extrusion which define the longitudinal sides of the opening 24 extend away from each other as a pair of outwardly extending flanges 25 a , 25 b . In addition to defining an uppermost surface of the housing 18 , the flanges 25 a , 25 b provide a lip under which concrete is backfilled to assist in anchoring the housing 18 in the desired position recessed into the pool deck 4 (FIG. 2).
[0075] [0075]FIG. 4 shows best each longitudinal end 20 , 22 of the housing 18 being sealingly closed by an end cover 34 , 36 . It is to be appreciated that the end covers 34 , 36 have a profile selected to correspond to the interior cross-sectional profile of each extruded housing section 18 a , 18 b . The end covers 34 , 36 may be formed of PVC or other plastics and/or metals and secured in place by an appropriate plastic cement, or by mechanical fasteners such as screws or the like.
[0076] As shown best in FIGS. 1 and 2, an extruded aluminium cover or lid 50 is provided over the opening 24 . The lid 50 is connected to the edge of the opening 24 which is furthest from the pool 6 by one or more piano hinges 27 . Although not essential, for ease of shipment, the lid 50 preferably is also formed from a series of extruded aluminium segments each having a length of between about 7 and 12 feet and which are connected by a series of splines. The lid 50 covers the elongated opening 24 in the housing 18 . The lid 50 is movable relative to the hinge 27 from a first position (as shown in FIG. 1) where the elongated opening 24 in the housing 18 is closed to a second position where the lid 50 is moved to an orientation extending radially outward of the housing 18 where the elongated opening 24 in the housing 18 is open (as shown in FIG. 14) to permit access into the interior of the housing. As shown in FIG. 1, the lid 50 and the piano hinges 27 have a profile selected so that when closed, the lid 50 lies substantially flush with both the flanges 25 a , 25 b and the surface of the deck 4 when the solar blanket 8 is coiled about the spindle 12 in a storage configuration.
[0077] The roller spindle 12 is rotatably supported within the housing 18 by means of a pair of spindle end supports 26 , 30 . The first end supports 26 the first shaft end 14 and also positions the first shaft end 14 inside the housing 18 in approximately coaxial alignment therewith. Preferably the first end support 26 supports the first end 14 through a bearing assembly 28 or other suitable device to permit easy rotation of the roller shaft 12 . Similarly, the second end shaft support 30 supports the second shaft end 16 and which positions the second shaft end 16 inside the housing 18 in coaxial alignment therewith. Once again, a bearing assembly 32 or other suitable device is provided to permit easy rotation of the roller shaft 12 about the axis LA.
[0078] In a simplified construction, as shown in FIGS. 5 and 7, the bearing assemblies 28 , 32 each consist of a galvanized steel L bracket 31 which in assembly, are mounted to a plate 41 (FIG. 2) supported by a pair of flanges 27 a , 27 b (FIG. 18) which are integrally formed with the housing extrusion. Each of the bearing assemblies 28 , 32 further include a respective bushing 29 , 33 which rotatably supports a stainless steel pivot shaft 35 positioned so as to project axially from each end 14 , 16 of the spindle 12 . As is shown best in FIG. 2, in the preferred embodiment of the invention, the plate 41 used in the first end support 26 comprises a rigid piece of galvanized metal extending from first extended flange 27 a formed on the inner peripheral wall of the housing 18 to the second flange 27 b on the inner peripheral wall of the housing 18 which is opposite thereto. Similarly, the plate 41 used in the second end support 30 is comprised of a similar rigid piece of galvanized metal extending from the flange 27 a at a longitudinally displaced position on the inner peripheral wall of the housing 18 to an opposing position on the flange 27 b . It is to be appreciated that the housing 18 extrusion may alternately include an axially extending extruded boss, groove, ridge or the like to assist in locating and retaining the plate 41 within the housing 18 .
[0079] Preferably, the rigid plates 41 of each support 26 , 30 are aligned in a plane parallel to a plane defined by the longitudinal axis LA and an axis orthogonal to the longitudinal axis. In a more preferred embodiment of the invention, in the final assembly of the roller assembly 10 each of the plates 41 is provided in a generally horizontal arrangement, as for example is shown in FIG. 2.
[0080] [0080]FIG. 5 illustrates best the drive assembly 13 as including a nylon horizontal bevel gear 37 , a second nylon bevel gear 39 and drive shaft 40 . The horizontal bevel gear 37 is rotatably mounted to the bracket 31 of the bearing assembly 28 for rotation about a vertical axis A 2 -A 2 . The second bevel gear 39 is fixedly mounted to the pivot shaft 35 which projects from the spindle end 14 in meshing engagement with the gear 37 . The drive shaft is coupled to the horizontal bevel gear 37 in alignment with the vertical axis A 2 -A 2 whereby the rotation of the shaft 40 about the axis A 2 -A 2 rotates the gears and turns the spindle 12 about the axis LA. As shown best in FIG. 9, a hand crank 43 is provided to permit the manual rotation of the drive shaft 40 . The hand crank 43 has at its lowermost end a socket 45 for use in engaging the uppermost end of the shaft 40 . More preferably, the tooth spacing of the bevel gears 37 , 39 is selected to rotate the spindle 12 360° with every 2 to 3 turns of the crank 43 .
[0081] To permit the drainage of any water which may enter into the housing 18 as the solar blanket 8 is coiled for storage, a series of drain holes 47 (FIG. 2) are formed at spaced locations along the bottom of the housing 18 . It is to be appreciated that the drain holes 47 allow any pool water which is carried into the housing 18 with the solar blanket 8 to flow outwardly from the housing interior and into a weeping bed of crushed gravel 39 and tile 41 (FIG. 1). The sealing of the housing ends 20 , 22 and drain holes 47 are preferred in order to keep as much dirt and other debris as possible from entering the housing 18 after the housing 18 has been installed, and thereafter to permit the periodic cleaning of the roller assembly 10 .
[0082] With the roller assembly 10 configuration of FIGS. 1 to 9 to move the solar blanket 8 to a storage position coiled about the spindle 12 and contained within the housing 18 , a user would open the lid 50 and fit the socket 45 of hand crank 43 over the drive shaft 40 . With the hand crank 43 so positioned, the crank 43 would be turned in a horizontal plain to rotate the bevel gears 37 , 39 and spindle 12 . As the spindle 12 turns, the solar blanket 8 is pulled from the pool surface 9 into the housing 18 coiling about the spindle 12 to the storage position shown in FIG. 1. Once the solar blanket 8 is coiled in the housing 18 , the lid 50 is thereafter closed, clearing the surface of the deck 4 from any obstructions or tripping hazards. It is to be appreciated that in deploying the solar blanket 8 , the lid 50 is simply reopened, and the user grasps and pulls the free edge of the solar blanket 8 unrolling it off the spindle 12 and across pool 6 .
[0083] Although FIGS. 1 to 9 describe the roller assembly 10 as being operated by means of a hand crank 43 , the invention is not so limited. Other power sources used to return the blanket 8 to a rolled position may also be used. By way of on-limiting example, an alternate embodiment of the invention is shown in FIG. 10. In FIG. 10, the power source could be a suitable electric motor, such as a low voltage electrical motor 90 . The electric motor 90 could be positioned within the housing 18 or outside the housing 18 . In either case, there would be suitable power linkage 92 from the electric motor 90 used to translate rotational power to the pivot shaft 35 .
[0084] The power linkage 92 may be any suitable power coupler, including something as simple as a hole in the end of the roller shaft 12 to receive a similarly-shaped insert from the output shaft of the motor 90 . Also, the power linkage 92 could further include a sprocket, gear, or longitudinal extender.
[0085] In an alternative embodiment shown in FIG. 10, the roller shaft 12 and the housing 18 are substantially the same as discussed above and shown in FIGS. 1 and 9 with the exception of the supports used to rotatably mount the first end support 126 as shown in FIG. 10 is comprised of a support member 142 which is aligned in a plane defined by two axes which are orthogonal to each other and also orthogonal to the longitudinal axis LA. For example, as shown in FIG. 10, the two axes which are orthogonal to each other are the vertical axis YA and the Z axis ZA which comes transversely out of the paper of FIG. 10. In this embodiment, the second end support 130 similarly comprises a rigid support member 148 which is aligned in a plane defined by two axes which are orthogonal to each other and also orthogonal to the longitudinal axis. Also, in order to have roller shaft 12 rotate most easily, each of the support members 142 , 148 support bearing assemblies 128 .
[0086] As may be seen in FIG. 11, in still a further embodiment of the invention, the housing 18 may further include a number or longitudinally spaced reinforcing ribs 55 . The reinforcing ribs 55 provide the housing 18 with increased rigidity and assist in anchoring the housing 18 against movement. In FIG. 11, the opening 24 in the housing 18 is defined by first edge 52 and second edge 54 in place of flanges 25 a , 25 b . As may be seen in FIG. 12, the lid 50 may be hinged to the housing 18 in the area adjacent to the first edge 52 .
[0087] Optionally, a blanket protector 56 may be hinged to the housing 18 in an area adjacent to the second edge 54 . The blanket protector 56 rotatably moves from a first position located substantially within the housing 18 to a second position radially outward from the housing 18 as shown in FIG. 12 during the deployment or storage of the blanket 8 .
[0088] As is shown in FIG. 14, blanket protector 56 protects the solar blanket 8 as the solar blanket 8 is either unwound from the roller shaft 12 or wound back up onto the roller shaft 12 . In particular, in use, the lid 50 and protector 56 are both moved to their respective open position shown in FIG. 14 when the operator desires to either unroll the solar blanket 8 from the roller shaft 12 and place the solar blanket over the surface of the pool 6 or, alternatively, when an operator wants to roll the solar blanket 8 back onto the roller shaft 12 . When the solar blanket 8 is either entirely rolled onto the roller shaft 12 or when the solar blanket 8 is positioned over the pool surface, the operator will typically close the lid 50 so as to cover the elongated opening 24 , primarily for safety reasons but also for aesthetic reasons.
[0089] Although not essential, the lid 50 may also have a “V” shape cross-section so that it wedges into the opening 24 and is at least partially supported by the first and second edges 52 and 54 of the opening 24 . Alternatively, the lid 50 could be partially supported by the flanges 25 a , 25 b (as shown in FIG. 2).
[0090] In a preferred embodiment, the housing 18 is formed from PVC plastic, primarily to provide strength and rigidity to the housing 18 . Alternatively, in another embodiment, the housing 18 could be formed from an aluminium or other plastic extrusion, as well as galvanized steel or other corrosive-resistant metal. In this embodiment, the casing need not be circular in cross-section. For example, the housing 18 could have a generally square or hexagonal lateral cross-sectional shape as shown in FIG. 13, or some other suitable cross-sectional shape.
[0091] In a pool 6 that is at least partially surrounded by a deck 4 , the roller assembly 10 is intended to be installed substantially below the deck surface 4 . The housing 18 is oriented such that the opening 24 in the housing 18 is either substantially flush with the deck surface 4 or is otherwise aligned with an opening 66 (FIG. 14) in the deck 4 . In one embodiment, the opening 66 in the deck 62 is spaced away from a portion of the deck 68 which is immediately adjacent to the pool 64 . Preferably the portion of the deck 68 immediately adjacent to the pool 64 is supported by the pool wall 70 . In a more preferred embodiment of the invention, the opening 66 in the deck is spaced between the portion of the deck 68 immediately adjacent to the pool 64 and a deck portion 72 distant from the pool 64 . In one possible construction, the deck portion 72 distant from the pool 64 is supported by a deck support 74 .
[0092] In another embodiment of the invention shown in FIG. 15, the housing 18 is oriented such that the opening 24 in the housing 18 is aligned with an opening 76 in the pool wall 70 .
[0093] In FIG. 1, the housing 18 is shown as being supported on a pair of extruded support legs 58 , however, other support constructions are also possible. In the embodiment shown in FIG. 16, the housing 18 is supported by a pair of casing supports 178 comprised of a suitable block, concrete or brick structure underneath each of the first and second end of the housing 18 . For example, in FIG. 16, the casing support 178 comprises a vertical concrete support member 180 . Preferably, the vertical concrete support member 180 is formed by pouring concrete into a plastic tube or sonotube, and wherein the vertical concrete support member 180 is supported by a suitable footing 182 .
[0094] Preferably, each casing support 178 furthermore has a casing leveller. In one embodiment, the casing leveller, as shown in FIG. 16, comprises a relatively short length of pipe 184 which is moveable up and down on the vertical concrete support member 180 . The top portion 186 of the pipe 184 is shaped to receive the housing 18 . The pipe 184 can be moved up and down on the vertical concrete support member 180 to adjust the height of the particular end of the housing 18 . Adjustable screws 186 are tightened and forced into the vertical concrete support member 180 to fix the pipe 184 and the housing 18 at the desired height. Other support configurations are, however, possible.
[0095] The roller assembly 10 of the present invention lends itself to sale in kit form and its installation and assembly together with a solar blanket 8 at a swimming pool site is described best with reference to FIGS. 1 and 17 to 20 .
[0096] Following or concurrently with the installation of the pool 6 , a trench approximately 18 inches wide and 20 inches deep is formed parallel to the pool end 7 (FIG. 1), approximately 12 to 24 inches from the edge of the pool 6 . The bottom of the trench is either lined with drainage tile 51 and/or a sufficient deep layer of crushed gravel 48 to provide an effective weeping bed to remove and accumulate water from within or around the roller assembly 10 .
[0097] Although not essential, in a preferred embodiment, the roller assembly 10 is shipped as a partially pre-assembled kit. In kit form, each of spindle sections 12 a and 12 b have their respective ends 14 , 16 and the drive assembly 13 pre-mounted on their respective supports 26 , 30 which have also been pre-attached to a respective housing section 18 a , 18 b . FIG. 17 shows the partially pre-assembled kit for the spindle section 12 a as being pre-mounted within housing section 18 a , and packaged within a cardboard box 82 for shipment. Within the box 82 are also packaged the connector 23 used to couple the spindle sections 12 a , 12 b together, the hand crank 43 and miscellaneous connecting hardware (not shown). As is shown, the end cap 34 has also been factory positioned over the end 20 of the housing section. Although not shown, it is to be appreciated that the remaining spindle section 12 b and housing section 18 b would be packaged in a like manner.
[0098] The free ends of the spindle sections 12 a , 12 b are held in place by a respective corrugated cardboard form 80 shown best in FIGS. 17 and 20 a and 20 b . The cardboard form has a profile which corresponds to the internal cross-section profile of the housing 18 . The cardboard forms 80 maintain the proper alignment of the spindle sections 12 a , 12 b and provide additional lateral support to the housing 18 to offset any lateral pressure which occurs following the pouring of concrete 166 into place about the housing 18 .
[0099] Initially, the individual housing sections 18 a , 18 b are unpacked from the box 82 and axially aligned with the open ends of each section 18 a , 18 b which are remote from the covered ends 20 , 22 juxtaposed. The housing sections 18 a , 18 b are secured to each other by inserting fasteners through either welded or co-extruded loops 86 (FIG. 18) formed along the outer sides of the sections 18 a , 18 b . As shown best in FIG. 18, at the time of this extrusion, each section 18 a , 18 b extends continuously in the redial direction and further includes a planar PVC cut-out or knock-out portion or piece 88 . The knock-out portion 88 is integrally formed with the extrusion and seals the opening 24 along its length. In addition to preventing debris and/or concrete from entering the housing 18 during installation, the use of a knock-out piece 88 and the formation of the housing 18 as a radially continuous extrusion, provides the housing sections 18 a , 18 b with increased structural integrity which resists deformation or distortion during installation.
[0100] Following the assembly of the housing 18 , the aluminium lid 50 is next installed. The lid 50 may be a unitary construction, but more preferably consist of a number of individual sections having the identical cross-sectional profile, and which for ease of storage and shipping have an elongated length corresponding to that of the housing sections 18 a , 18 b . The sections of the lid 50 are assembled to the housing 18 by means of the hinges 27 . Alternately, the lid sections could be pre-assembled to an individual housing section 18 a , 18 b prior to shipping of the roller assembly 10 to the end consumer. Simultaneously with the coupling of the housing 18 , lid sections are joined together by inserting a spline (not shown) in a dovetail profile groove 89 (FIG. 2) extruded in the aluminium lid 50 .
[0101] Following the assembly of the housing 18 and lid 50 , the housing 18 is lowered into the trench with its lower positioning brackets 58 resting on the gravel bed 58 . Once the housing 18 is so positioned, final adjustment is made to ensure that the upper flanges 25 a , 25 b are level with the deck surface 4 , and the longitudinal axis of the housing 18 is aligned with the pool edge 7 . Concrete 166 (or other suitable backfill material) is then poured as backfill about the housing 18 , over the brackets 58 and under the flanges 25 a , 25 b to permanently secure the housing 18 in place.
[0102] Immediately following the pouring of the concrete 166 , the lid 50 is opened and moved to a vertical orientation. It has been found that the movement of the lid 50 about the knuckle of the hinge 27 acts to straighten the PVC housing 18 and remove any twisting or bending. The PVC knock-out 88 is left in place until the concrete 166 has set both to maximize the rigidity of the housing 18 and to prevent concrete from entering the housing and otherwise fouling the spindle 12 or drive assembly 13 .
[0103] Following the setting of the concrete 166 , the knockout 88 is removed by either punching out, trimming with a knife or cutting with a circular or other power saw to thereby clear the opening 24 . After the knock-out 88 is removed, the cardboard braces 80 are next removed from the housing interior. The spindle sections 12 a , 12 b are then joined by inserting the connector segment 23 in the open end of each spindle section 12 a , 12 b in the manner described.
[0104] Following the assembly of the spindle 12 , the end 15 of a sheet of solar blanket material which is sized larger than that of the surface of the pool 6 is fastened to the spindle 12 by the clamping bar 19 (FIG. 8). With the end 15 of the blanket so secured, the spindle 12 is positioned in the desired rotatably mounted position within the housing 18 with the pivot shaft 35 at each of its ends 14 , 16 rotatably coupled to a respective end support 26 , 30 . The solar blanket form is then stretched across the pool 6 and is thereafter trimmed to exactly follow the contour of the pool surface 9 . Following trimming, the solar blanket 8 and roller assembly 10 is thereafter ready for use.
[0105] It will be understood that, although various features of the invention have been described with respect to one or another of the embodiments of the invention, the various features and embodiments of the invention may be combined or used in conjunction with other features and embodiments of the invention as described and illustrated herein.
[0106] Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to these particular embodiments. Rather, the invention includes all embodiments which are functional or mechanical equivalents of the specific embodiments and features that have been described and illustrated herein. For a definition of the invention, reference may be had to the appended claims. | A below-deck solar blanket roller assembly is installed below the deck of a pool. The roller assembly includes a rotatable roller shaft for rolling and unrolling a solar blanket and a non-rotatable protective casing which surrounds the roller shaft. The roller assembly is intended to be installed below the deck of a pool. This invention at least partially overcomes some of the disadvantages of typical solar blanket rollers that are installed on the surface of the pool deck, such as inconvenience in moving the entire above-deck assembly away from and back to the pool area. The below-deck solar blanket roller assembly provides an aesthetically pleasing and safe alternative to solar blanket roller assemblies installed above the pool deck. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is in the field of rotating cutting tools used for milling downhole metal members in a well bore, and rotating cutting tools used for drilling a well bore through an earth formation.
2. Background Information
Various milling applications and drilling applications have, over the years, suffered from the problem of a “dead” spot in the center of the mill or drill bit. As the mill or drill bit rotates, it revolves around a central axis. At the point where that central axis passes through the cutting face of the mill or drill bit, the cutting structure is degraded and quickly becomes ineffective. Ultimately, a core, or depression, is worn into the cutting matrix. As the core wears further into the matrix, fluid circulation in the area is reduced, and cuttings resulting from the milling or drilling operation are no longer effectively removed. The reason for this problem is that on the cutting face, at the point where the central axis passes through the cutting face, the cutting elements have essentially a zero cutting surface speed.
In a typical milling situation, for instance, a segment of metal tubing may be stuck in the well bore. The tubing will usually be bent and leaning against the sides of the casing or well bore. In this situation, a rotating metal milling tool will typically be run downhole to mill away the bent metal tubing. As the milling tool progresses downwardly, milling away the bent tubing, there will be a number of times when the wall of the bent tubing is positioned against the center of the face of the milling tool. This results in a zero relative speed of the cutting elements across the bent tubing at the center point, with little effective cutting taking place. This generates considerable heat at the center point, which can soften the cutting matrix, leading to rapid deterioration of the matrix at the center point. Ultimately, this can create a deep depression or cone in the center of the face of the milling tool. When the depression deepens to the point of reaching the body of the milling tool, which is typically made of steel, no further milling progress can be made.
A similar problem can occur in the drilling of a well bore through an earth formation. Coning of the drill bit can occur at the center point, resulting in slowing or even stalling of drilling progress, requiring the drilling operation to be stopped until a new bit is installed. It is the object of the present invention to provide a design, which can be incorporated into either a milling tool or a drill bit, which will not have a zero cutting speed anywhere on the cutting face of the tool, thereby eliminating the coning problem and allowing a full depth milling or drilling operation to be accomplished.
BRIEF SUMMARY OF THE INVENTION
Whether embodied in a milling tool or a drill bit, the tool of the present invention has a cutting assembly consisting of one or two cutting structures, with at least one of the cutting structures being rotated about an axis offset from the axis of the borehole. The tool is connectable to the lower end of a drill string or coiled tubing, for positioning in a well bore. Use of the term “drill string” herein is intended to include all types of tubular strings, including coiled tubing, where the context allows. The cutting assembly as a whole rotates about its longitudinal axis. Further, each of the cutting structures rotates about its own longitudinal axis. The longitudinal axis of at least one cutting structure is offset from, but parallel to the longitudinal axis of the cutting assembly, and this cutting structure spans the longitudinal axis of the cutting assembly. Therefore, as the cutting assembly rotates, the offset cutting structure rotates independently, insuring that the center point of the cutting assembly does not have a zero cutting surface speed. This prevents coning of the cutting structures at the center point. Where a second cutting structure is present in the cutting assembly, it can also have an offset axis, or its axis can coincide with the axis of the cutting assembly.
In one embodiment, the cutting assembly can be mounted on the lower end of a housing connected to a drill string or coiled tubing, with a first cutting structure being fixedly mounted to the housing and a second cutting structure rotatably mounted to the housing. The rotational axis of the first cutting structure coincides with the axis of the housing, while the rotational axis of the second cutting structure is offset from the axis of the housing. In this embodiment, the first cutting structure is rotated by rotation of the housing, while the second cutting structure is independently rotated by a drill motor mounted within the housing. Rotation of the cutting assembly as a whole is accomplished by rotating the drill string to rotate the housing and cutting assembly, or by rotation of the housing and cutting assembly with a drill motor. The cutting assembly can be centered on the axis of the well bore or casing within which the apparatus is positioned.
In a second embodiment, the cutting assembly can be mounted on the lower end of a drill motor connected to a drill string or coiled tubing, with each of two cutting structures being independently rotated by the drill motor. Independent rotation of the cutting structures with a single drill motor can be accomplished by use of a single input, dual output transmission. Rotation of the cutting assembly as a whole is accomplished by rotating the drill string to rotate the drill motor and cutting assembly, or by rotation of the drill motor and cutting assembly with a drill motor. As with the first embodiment, the cutting assembly can be centered on the axis of the well bore or casing within which the apparatus is positioned.
In a third embodiment, a drill motor is fitted with clamp-on eccentric stabilizers which offset the axis of the drill motor from the axis of the borehole or casing. The drill motor is connected to a drill string or coiled tubing. Where the drill motor is connected to a rotatable drill string, the eccentric stabilizers contact the walls of the borehole or casing. Where the drill motor is connected to coiled tubing, the motor and stabilizers can be located within a rotatable housing which essentially aligns with the borehole or casing axis. In either case, the cutting assembly consists of a single cutting structure driven by the drill motor. This cutting structure can be aligned with the axis of the drill motor, with the result that the cutting assembly is offset from the axis of the well bore or casing. In this embodiment, the single cutting structure is rotated by the drill motor, while rotation of the motor and cutting assembly as a whole is accomplished by rotating the drill string, or by rotating the motor and cutting assembly with a drill motor.
In any of the embodiments where rotation of the apparatus is accomplished by a drill motor, a second drill motor may be used, or a secondary drive off a single drill motor may rotate the apparatus.
The novel features of this invention, as well as the invention itself, will be best understood from the attached drawings, taken along with the following description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic longitudinal section view of a first embodiment of the apparatus of the present invention;
FIG. 2 is a schematic end view of the cutting assembly mounted on the lower end of the apparatus shown in FIG. 1;
FIG. 3 is a schematic longitudinal section view of a second embodiment of the apparatus of the present invention;
FIG. 4 is a schematic end view of the cutting assembly mounted on the lower end of the apparatus shown in FIG. 3;
FIG. 5 is a schematic longitudinal section view of a third embodiment of the apparatus of the present invention; and
FIG. 6 is a schematic end view of the cutting assembly mounted on the lower end of the apparatus shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, a first embodiment of the tool 10 of the present invention includes a housing 12 , a drill motor 14 , and a cutting assembly 18 . The housing 12 is connectable to the lower end of a drill string or coiled tubing DS. The housing 12 is rotatable about its longitudinal axis 26 , either by rotation of the drill string DS, or by being driven by a separate drill motor (not shown), above the housing 12 on the drill string DS. Alternatively, the housing 12 can be rotated by a secondary drive (not shown) off the drill motor 14 . The drill motor 14 can be driven by drilling fluid, or by compressed air, or by any other suitable means. The drill motor 14 can be mounted, and centered if desired, in the housing 12 by means of one or more mounts or centralizers 16 .
The cutting assembly 18 is mounted on the lower end of the housing 12 , for rotation by means of rotation of the housing 12 . The longitudinal axis of rotation 26 of the housing 12 is also the longitudinal axis of rotation 26 of the cutting assembly 18 . The cutting assembly 18 comprises a first cutting structure 19 , which is fixedly mounted to the lower end of the housing 12 , and a second cutting structure 20 , which is rotatably mounted to the lower end of the housing 12 . The longitudinal axis of rotation 26 of the housing 12 and the cutting assembly 18 is also the longitudinal axis of rotation 26 of the first cutting structure 19 . The second cutting structure 20 is independently rotatable about its longitudinal axis 28 , which is parallel to, but laterally offset from, the longitudinal axis 26 of the cutting assembly 18 . The second cutting structure 20 is driven by the drill motor 14 , via one or more coupling mechanisms or universal joints 22 , 24 if required. The second cutting structure 20 spans the longitudinal axis 26 of the cutting assembly 18 , since the longitudinal axis 26 of the cutting assembly 1 8 passes through the second cutting structure 20 .
As shown in FIG. 2, the first cutting structure 19 can incorporate a plurality of blades, or it could be a crescent shaped structure with a flat lower face similar to the lower face shown on the second cutting structure 20 . In either case, the first cutting structure 19 is dressed with cutting elements. The axis of rotation 26 of the housing 12 , the cutting assembly 18 , and the first cutting structure 19 passes through the center point 30 of the lower face of the cutting assembly 18 . The second cutting structure 20 can be a circular structure with a flat lower face as shown, or it could incorporate blades similar to the blades shown on the first cutting structure 19 . In either case, the second cutting structure 20 is dressed with cutting elements. The axis of rotation 28 of the second cutting structure 20 is parallel to, but laterally offset from, the axis of rotation 26 of the cutting assembly 18 . Therefore, although the second cutting structure 20 spans the longitudinal axis 26 of the cutting assembly 18 , the axis of rotation 28 of the second cutting structure 20 does not pass through the center point 30 of the lower face of the cutting assembly 18 . Instead, as the second cutting structure 20 independently rotates about its axis 28 , the cutting elements on the second cutting structure 20 continually sweep the center point 30 . It can be seen, therefore, that there is no point on the lower face of the cutting assembly 18 which has a zero cutting speed at any time.
As shown in FIG. 3, a second embodiment of the tool 110 of the present invention includes a drill motor 114 , and a cutting assembly 118 . The drill motor 114 is connectable to the lower end of a drill string or coiled tubing DS. The drill motor 114 is rotatable about its longitudinal axis 126 , either by rotation of the drill string DS, or by being driven by a separate drill motor (not shown), above the drill motor 114 on the drill string DS. Alternatively, the drill motor 114 can be rotated by a secondary drive (not shown) off the drill motor 114 . The drill motor 114 can be driven by drilling fluid, or by compressed air, or by any other suitable means.
The cutting assembly 118 is mounted on the lower end of the tool 110 , for rotation as a unit, by means of rotation of the entire drill motor 114 , as described above. The longitudinal axis of rotation 126 of the drill motor 114 is also the longitudinal axis of rotation 126 of the entire cutting assembly 118 . The cutting assembly 118 comprises a first cutting structure 119 , which is independently rotatably mounted to the lower end of the tool 110 , and a second cutting structure 120 , which is also independently rotatably mounted to the lower end of the tool 110 . The first cutting structure 119 is independently rotatable about its longitudinal axis 129 , which is parallel to, but laterally offset from, the longitudinal axis 126 of the cutting assembly 118 . The first cutting structure 119 is driven by the drill motor 114 , via one output of a single input, dual output transmission 122 . The second cutting structure 120 is independently rotatable about its longitudinal axis 128 , which is parallel to, but laterally offset from, the longitudinal axis 126 of the cutting assembly 118 . The second cutting structure 120 is also driven by the drill motor 114 , via a second output of the single input, dual output transmission 122 . Alternatively, each cutting structure 119 , 120 could be independently driven by a separate drill motor or air motor. The second cutting structure 120 spans the longitudinal axis 126 of the cutting assembly 118 , since the longitudinal axis 126 of the cutting assembly 118 passes through the second cutting structure 120 .
As shown in FIG. 4, the first cutting structure 119 can be a circular structure with a flat lower face as shown, or it could incorporate blades similar to the blades shown on the first cutting structure 19 in FIG. 2 . In either case, the first cutting structure 119 is dressed with cutting elements. The axis of rotation 126 of the drill motor 114 and the cutting assembly 118 passes through the center point 130 of the lower face of the cutting assembly 118 . The axis of rotation 129 of the first cutting structure 119 is parallel to, but laterally offset from, the axis of rotation 126 of the cutting assembly 118 . The second cutting structure 120 also can be a circular structure with a flat lower face as shown, or it could incorporate blades similar to the blades shown on the first cutting structure 19 in FIG. 2 . In either case, the second cutting structure 120 is dressed with cutting elements. The axis of rotation 128 of the second cutting structure 120 is parallel to, but laterally offset from, the axis of rotation 126 of the cutting assembly 118 . Therefore, although the second cutting structure 120 spans the longitudinal axis 126 of the cutting assembly 118 , the axis of rotation 128 of the second cutting structure 120 does not pass through the center point 130 of the lower face of the cutting assembly 118 . Instead, as the second cutting structure 120 independently rotates about its axis 128 , the cutting elements on the second cutting structure 120 continually sweep the center point 130 . It can be seen, therefore, that there is no point on the lower face of the cutting assembly 118 which has a zero cutting speed at any time.
As shown in FIG. 5, a third embodiment of the tool 210 of the present invention includes a drill motor 214 , and a cutting assembly 218 . It can also include a housing which essentially aligns with the borehole or casing BH within which the apparatus is positioned. The housing or drill motor 214 is connectable to the lower end of a drill string or coiled tubing DS. The tool 210 is rotatable about its longitudinal axis 226 , either by rotation of the drill string DS. or by being driven by a separate drill motor (not shown), above the tool 210 on the drill string DS. Alternatively, the tool 210 can be rotated by a secondary drive (not shown) off the drill motor 214 . The drill motor 214 can be driven by drilling fluid, or by compressed air, or by any other suitable means. Whether or not the housing is present, the drill motor 214 is held in a position laterally offset from the longitudinal axis of the tool 210 by one or more eccentric stabilizers 216 , which can be the clamp-on type.
The cutting assembly 218 comprises a single cutting structure which is rotatable about its longitudinal axis 228 , which is parallel to, but laterally offset from, the longitudinal axis 226 of the tool 210 . The cutting structure 218 is driven about its axis 228 by the drill motor 214 . Further, the cutting structure 218 is rotated about the axis 226 of the tool 210 by rotation of the tool 210 , either by turning of the drill string DS, by use of a second drill motor (not shown), or by means of a secondary drive (not shown) off the drill motor 214 . The cutting structure 218 spans the longitudinal axis 226 of the tool 210 , since the longitudinal axis 226 of the tool 210 passes through the cutting structure 218 .
As shown in FIGS. 5 and 6, the cutting structure 218 can incorporate a plurality of blades, or it could have a flat lower face similar to the lower face shown on the second cutting structure 20 in FIG. 2 . In either case, the cutting structure 218 is dressed with cutting elements. The axis of rotation 228 of the cutting structure 218 is parallel to, but laterally offset from, the axis of rotation 226 of the tool 210 . Therefore, although the cutting structure 218 spans the longitudinal axis 226 of the tool 210 , the axis of rotation 228 of the cutting structure 218 does not pass through the center point 230 of the lower face of the tool 210 . Instead, as the cutting structure 218 independently rotates about its axis 228 , the cutting elements on the cutting structure 218 continually sweep the center point 230 . It can be seen. therefore, that there is no point on the lower face of the cutting assembly 218 which has a zero cutting speed at any time.
Any of these embodiments, by preventing the occurrence of a zero speed point anywhere on the lower face of the cutting assembly 18 , 118 , 218 , prevents coning of the matrix material and deterioration of the central portion of the face of the cutting assembly 18 , 118 , 218 .
While the particular invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages hereinbefore stated, it is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended other than as described in the appended claims. | A rotating tool for milling or drilling in a well bore, having one or more rotating cutting structures, with each cutting structure rotating about its own axis, and with the cutting structures rotating about the axis of the tool. The rotational axis of the tool is offset from the axis of at least one cutting structure, with the axis of the tool passing through that cutting structure. This ensures that the cutting structure which spans the axis of the tool rotates independently of the tool, to prevent the existence of a zero velocity point on the cutting face of the tool. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/809,036, filed Mar. 25, 2004, which claims benefit of Great Britain patent application serial number GB 0306774.1, filed Mar. 25, 2003, and Great Britain patent application serial number GB 0312278.5, filed May 29, 2003. Each of the aforementioned related patent applications is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to tubing expansion. In particular, but not exclusively, the invention relates to diametric expansion of tubing downhole.
2. Description of the Related Art
One of the most significant recent developments in the oil and gas exploration and production industry has been the introduction of technology which allows for expansion of extended sections of tubing downhole. The tubing may take different forms, including but not restricted to: expandable casing, liner, sandscreen, straddles, packers and hangers. A variety of expansion methods have been proposed, including use of expansion cones or mandrels which are forced through the tubing. One difficulty which has been experienced with cone expansion is the high level of friction and wear between the surface of the cone and the inner surface of the tubing to be expanded.
It is among the objectives of embodiments of the present invention to obviate or mitigate this difficulty.
SUMMARY OF THE INVENTION
According to the present invention there is provided a method of expanding tubing, the method comprising:
locating an expansion device in tubing to be expanded; vibrating at least one of the tubing and the expansion device; and translating the expansion device relative to the tubing.
The vibration of at least one of the tubing and the expansion device preferably acts to reduce friction between the tubing and the device.
In conventional tubing expansion operations an expansion device which slides relative to the tubing to be expanded, such as a cone or mandrel, will tend to progress through the tubing incrementally in a series of small steps. From a static condition, the load on the cone is increased until the load is sufficient to drive the cone through the tubing. In addition to the forces required to expand the tubing diametrically, it is also necessary to overcome the static friction between the contacting surfaces of the cone and the tubing before the cone will move relative to the tubing. Once static friction has been overcome, frictional resistance to movement typically decreases sharply due to the lower dynamic friction between the contacting surfaces, such that the initial movement of the cone will tend to be relatively rapid. As the cone moves forward rapidly relative to the tubing, the driving force being applied to the cone will tend to fall, the inertia of the cone-driving arrangement being such that the cone-driving arrangement will typically fail to keep pace with the cone. Thus, after the initial rapid movement, the cone will tend to stall as the driving force decreases. The driving force applied to the cone then increases once more, moving the cone forward again once static friction between the cone and tube is overcome. For brevity, this form of movement will hereinafter be referred to as “stick-slip”.
With the present invention, the vibration of one or both of the expansion device and the tubing is intended such that there will be little or no static friction experienced between the contacting surfaces, and the conventional stick-slip progression of the expansion device relative to the tubing should be avoided. The driving force necessary to drive the expansion device through the tubing should therefore remain relatively constant, as the frictional forces remain at a relatively constant, and relatively low, level.
Furthermore, the reduction in friction between the expansion device and the tubing should tend to decrease the wear experienced by the expansion device, which in conventional expansion operations may place limits on the length of tubing which can be expanded in a single expansion operation.
Of course, in downhole applications, the vibration may also serve to assist in reducing the occurrence of differential sticking between the tubing and the surrounding bore wall.
The frequency and amplitude of vibration may be selected to suit each particular application. Furthermore, the direction of vibration may be selected as appropriate: for example, the vibration may be random, multi-directional, axial, transverse or rotational. In one embodiment of the invention the vibration is substantially perpendicular to the surface of the expansion device, and in another embodiment the vibration takes the form of torsional oscillations.
Where the expansion device is vibrated, all or a major portion of the device may be subject to vibration. Alternatively, only a selected portion of the device may be subject to vibration, for example only a surface portion of the device, or only a selected area of the surface of the device, may be subject to vibration. Portions of the expansion device may also experience different degrees or forms of vibration.
If the tubing is vibrated, all or a substantial portion of the tubing may be vibrated. Alternatively, only a selected portion of the tubing may be vibrated. For example, only a portion of the tubing at or adjacent the expansion device may be vibrated, or only a surface portion of the tubing may be vibrated.
The vibration of the expansion device or tubing may induce physical movement of the device or tubing. Alternatively, or in addition, the vibration of the device or tubing may induce contraction and expansion of all or a portion of the device or the tubing. For example, the vibration may take the form of one or more waves traveling through the device or tubing.
The vibration of the expansion device or tubing may induce physical movement of the device or tubing. Alternatively, or in addition, the vibration of the device or tubing may induce contraction and expansion of all or a portion of the device or the tubing. For example, the vibration may take the form of one or more waves traveling through the device or tubing.
The vibration may be induced or created locally relative to the expansion device or the tubing being expanded, or may be created remotely, for example a wave form oscillation may be created remote from the expansion device location, and then travel along or through the tubing wall, or travel to the expansion location via another medium.
The vibration may be created by any appropriate means, including: an oscillating or otherwise moving mass; creating a varying or cyclic restriction to fluid flowing through the expansion device or tubing; an electromagnetic oscillator; varying the pressure of fluid operatively associated with the device or tubing; creating pressure pulses in a fluid; or injecting gas or liquid or a mixture of both into fluid operatively associated with the device or tubing.
The source of vibration or oscillation may be directly or indirectly coupled to one or both of the expansion device and the tubing.
The vibration may be of a constant, varying or substantially random nature, that is the amplitude, direction, frequency and form of the vibration may be constant, varying or random.
The vibration or oscillation may be of high frequency, for example ultrasonic. Such vibration may not be apparent as physical movement, as the vibration may be at a molecular or macromolecular level, or at least at a level below that of readily detectable physical movement of the device or tubing. Such vibration may be induced electromagnetically, for example by a varying electromagnetic field, or a varying or alternating current or voltage. Alternatively, or in addition, the vibration or oscillation may be of relatively low frequency, for example in the range of 1 to 100 Hz. If desired, the vibration may comprise a plurality of different components, for example a low frequency component and a high frequency component.
The vibration may be selected to coincide with a natural frequency of the expansion device or the tubing, or another element of apparatus. Alternatively, the vibration may be selected to avoid such natural frequency or frequencies.
The expansion device may be translated relative to the tubing by any appropriate means. The device may be mounted on a support which allows the device to be pushed, pulled or otherwise driven through the tubing. The support may extend from a downhole location to surface, where a pushing, pulling or torsional force may be applied. Alternatively, the expansion device may be coupled to a tractor or other driving arrangement located downhole. Alternatively, or in addition, fluid pressure may be utilised to move the device relative to the tubing.
The expansion device may take any appropriate form and may utilise any appropriate expansion mechanism, or a combination of different expansion mechanisms. An expansion cone or mandrel may be utilised with an expansion surface adapted for sliding or rolling contact with the tubing wall. The cone may be adapted for axial movement relative to the tubing, but may also be adapted for rotation. Alternatively, or in addition, a rotary expander may be utilised, that is a device which is rotated within the tubing with at least one expansion member, typically a roller, moving around the surface of the tubing and creating localised compressive yield in the tubing wall, the resulting reduction in wall thickness leading to an increase in tubing diameter.
The expansion device may define a fixed diameter, or a variable diameter. The device may be compliant, that is the device has a degree of flexibility to permit the device to, for example, negotiate sections of the tubing which cannot be expanded to a desired larger diameter or form. Alternatively, the expansion device may define a fixed diameter and may be non-compliant. In certain embodiments, the expansion device may feature both fixed and compliant elements.
References herein to expansion are primarily intended to relate to diametric expansion achieved by thinning of tubing wall. However, embodiments of the invention may also relate to tubing which is expanded by reforming a tubing wall, for example by straightening or smoothing a corrugated tubing wall, or other expansion mechanisms.
In other embodiments of the invention the expansion process may be supplemented by the application of an elevated fluid pressure, and in particular a varying fluid pressure, to the tubing.
The varying fluid pressure preferably acts across the wall of the tubing. The variation in pressure may be achieved by any appropriate means, and one or both of the fluid pressure within the tubing and the fluid pressure externally of the tubing may be varied. A body of varying volume may be located in a volume of fluid operatively associated with the tubing. Alternatively, or in addition, the volume of a body of fluid operatively associated with the tubing may be varied by movement of a wall portion defining a boundary of the volume, which wall portion may be operatively associated with an oscillator or a percussive or hammer device. In other embodiments a pressurised fluid source may be provided, and the fluid may be supplied at varying pressure from the source or the manner in which the fluid is delivered to the tubing from the source may be such as to vary the fluid pressure. An increase in pressure within the tubing may be accompanied by a reduction in pressure externally of the tubing, or a reduction of pressure externally of the tubing may occur independently of any variations in the internal pressure, which may remain substantially constant.
In one embodiment, in a downhole application, the fluid pressure externally of the tubing may be maintained at a relatively low level by providing a relatively low density fluid externally of the tubing. Thus, the hydrostatic pressure produced by the column of fluid above the tubing will be relatively low. This may be achieved by injecting gas or low density fluid into fluid surrounding the tubing. Alternatively, or in addition, a volume of fluid externally of the tubing may be at least partially isolated from the head of fluid above the tubing, for example by means of a seal or seals between the tubing and a surrounding bore or tubing wall, or by providing pumping means above the tubing.
Alternatively, or in addition, the fluid pressure internally of the tubing may be maintained at a relatively high level by providing a relatively high density fluid internally of the tubing.
Tubing expansion operations are typically carried out using conventional, readily available fluids, such as seawater or completion brine, which may have a specific gravity (SG) of approximately 1.025. However, the SG of fluids used in downhole operations of course varies depending on, for example, the choice of base fluid and the presence of weight materials or other additives, and may range from 0.85 to 2.2. Thus, references herein to high and low density fluids should be related primarily to fluids utilised in conventional tubing expansion operations and other downhole operations where the fluid is selected with reference primarily to other requirements, including availability and ease of handling. Accordingly, by way of example, with reference to expansion operations which, using conventional expansion techniques, would be carried out in the presence of completion brine, a high density fluid may be one having an SG in excess of around 1.025 and a low density fluid may be one having an SG less than around 1.025. In other cases, the density of a fluid present within tubing to be expanded may be considered to be relatively high if the fluid has been selected with reference to the lower density of the fluid in the annulus surrounding the tubing. Similarly, the density of a fluid in the annulus may be considered to be relatively low if the density is lower than the density of the fluid present within the tubing to be expanded. Of course the invention is not limited to use with liquids, and in some cases one or both of the fluids, particularly where a lower density fluid is required, may be a gas such as natural gas or air, or a multiphase fluid.
The portion of tubing to be expanded may be isolated from ambient fluid by one or more appropriate seals, and a varying pressure differential may be maintained across each seal. However, in accordance with a further aspect of the invention a degree of leakage past the seals may be permissible, and in some cases may even be desirable, particularly if means for providing or creating a cycling fluid pressure is being utilised; if the frequency or rate of pressure variation is sufficiently high, a degree of leakage, and the corresponding pressure decay, will not adversely affect the expansion process and may assist in providing the desired pressure cycling when combined with an appropriate source of pressure. In particular, the method may include the step of producing a pressure pulse, and thus an elevated fluid pressure, which then reduces or decays, as leakage occurs across the seal. Furthermore, the ability to utilise “leaky” seals tends to facilitate use of the expansion method, as there are difficulties involved in providing a fully effective seal in many environments: when expanding tubing downhole, the tubing will often not be perfectly cylindrical, and the tubing diameter may be variable; the tubing surface is unlikely to be perfectly smooth, and may include profiles; the ambient fluid in the tubing may contain particulates and contaminants; and in preferred embodiments the seal will move relative to the tubing as the tubing is expanded, which movement would of course result in wear to one or both of the seal and the tubing, and which movement would have to overcome friction, which could be considerable if a leak-free seal was provided or required. Also, the leakage of fluid around and over the seal will provide lubrication, facilitating relative movement between the seal and the tubing.
The seal may take any appropriate form, but is preferably in the form of a labyrinth seal. Typically, the seal comprises a plurality of seal members, each seal member adapted to maintain a proportion of the total pressure differential across the seal. The number of seal members may be selected depending upon a number of considerations, including the form of the seal members, tubing form and condition, ambient conditions, the pressure differential to be maintained, tubing diameter, and the frequency or rate of variation of the fluid pressure. Of course such a seal configuration may also be suitable for use in situations where the fluid pressure is substantially constant, or is maintained above at least a minimum level, provided of course that means is provided for maintaining the expansion pressure at the desired level, despite leakage past the seal. Thus, perhaps five, ten, fifteen or more seal members may be provided, as appropriate. The number of seal members may be selected to provide for redundancy, such that failure or damage of one or more seal members will not adversely affect the expansion process.
The fluid pressure may be maintained at a base pressure, for example at 70% of the yield pressure of the wall of the tubing, upon which base pressure additional pressure pulses or spikes are superimposed, taking the fluid pressure to or in excess of 100% of the yield pressure, to induce plastic deformation of the tubing.
The mechanical expansion or reforming device, such as an expansion cone, mandrel or die, or a rotary expansion device, may exert only a small expansion force, and may merely serve to stabilise the expansion process and assist in achieving a desired expanded form, for example achieving a desired expanded diameter and avoiding ovality. Alternatively, or in addition, the mechanical expansion or reforming device may serve to retain expansion induced by the elevated fluid pressure. In one embodiment, a shallow angle cone may be advanced through the expanding tubing, the cone preferably being advanced in concert with the periods of elevated pressure. The cone angle may be selected depending upon the particular application, but for downhole tubulars of conventional form it has been found that an 11 degree cone angle results in a cone which retains expansion, that is the cone may be advanced into the tubing expanded by the elevated pressure, and is then retained in the advanced position as the tubing contracts on decay of the fluid pressure below the tubing wall yield pressure. It is anticipated that by cycling the fluid pressure at a rate of around 5 Hertz the cone will advance at a rate of approximately 6 to 8 feet per minute. Of course the rate or frequency of fluid pressure variation may be selected to suit local conditions and equipment. Such advancement may be achieved by providing separate mechanical drive means but may be conveniently achieved by virtue of the pressure differential over a seal coupled to the cone; as the pressure peaks, causing expansion of the tubing, the axial differential pressure acting force across the seal will also peak. Where the cone is located between seals, in particular a leading seal and a trailing seal, the leading seal may be mounted on the cone or otherwise coupled to the cone such that any pressure differential across the seal will tend to urge the cone forward. The trailing seal may be located at some point behind the cone, such that the cone is located within an isolated fluid volume between the seals. The trailing seal may be fixable or securable relative to the tubing or may be floating. The trailing seal may be retained in position mechanically or, alternatively or additionally, by fluid pressure, for example by a column of fluid above the seal, which column may be pressurised by appropriate pumps on surface. The variations in pressure are preferably applied to the isolated fluid volume between the seals, and may be created by a pulse generator located within the isolated volume, or by supplying elevated pressure fluid or pressure pulses from a source externally of the isolated volume. In other embodiments, variations in pressure may also be applied to one or both of the fluid volumes above and below the isolated volume.
Of course the presence of fluid will facilitate movement of any expansion device present relative to the tubing, in particular by serving as a lubricant between the contacting surfaces of the expansion device and the tubing. The fluid may be selected for its lubricating properties. This is particularly the case in embodiments where the fluid surrounding the expansion device is at least partially isolated from the ambient fluid, and as such a smaller volume of fluid selected for its particular properties may be provided. Leakage past isolating seals may be accommodated by providing a larger initial volume, or by supplying further fluid to the volume. Of course the fluid may be selected with properties other than lubrication in mind, for example the fluid may comprise or include a relatively viscous element, for example a grease, to minimize the rate of leakage and pressure decay. Downhole expansion may be accomplished either top down or bottom up, that is expansion process moves downwardly or upwardly through the tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the present invention will now be described, by way of example, with reference to the accompanying drawing drawings.
FIG. 1 a schematic illustration of a tubing expansion operation, in accordance with an embodiment of the present invention;
FIG. 2 is a schematic illustration of tubing being expanded downhole in accordance with an embodiment of the present invention; and
FIG. 3 is a schematic illustration of tubing being expanded downhole in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The figure illustrates a subterranean bore 10 , such as may be drilled to gain access to a subsurface hydrocarbon reservoir. After drilling, the bore 10 may be lined with metal tubing, sometimes known as liner or casing. In the illustrated embodiment, a section of expandable casing 12 has been run into the bore 10 , and once located in the bore 10 the casing 12 is expanded from a smaller first diameter D 1 to a larger second diameter D 2 .
The expansion is achieved by means of driving an expansion cone 14 down through the casing 12 , the cone 14 being mounted on a string of drill pipe 16 which extends to surface. The force necessary to drive the cone 14 through the casing 12 while expanding the casing 12 is considerable: the force must be sufficient to deform the casing 12 and also to overcome the friction between the contacting surfaces of the cone 14 and the casing 12 . In conventional cone expansion operations the level of friction experienced is such that the cone 14 will tend to progress with an inefficient stick-slip movement, due in part to the differences in static and dynamic friction experienced by the cone 14 as it is moved through the casing 12 . However, in the present invention, this difficulty is substantially avoided due to the vibration of the cone 14 by means of an oscillator 18 mounted to the cone 14 . In use, the oscillator 18 , which is powered from surface via an appropriate control line, produces oscillations at ultrasonic frequencies, which vibrations or oscillations are transferred to the cone 14 . This high frequency of vibration of the cone 14 is such that there is substantially constant relative movement between the contacting surfaces of the cone 14 and the casing 12 , such that there is no static friction experienced between the contacting surfaces. Thus, the level of friction between the cone 14 and the casing is relatively low, allowing the cone 14 to progress through the casing 12 at a relatively constant rate, in response to a relatively constant applied force.
It will be apparent to those of skill in the art that the above-described embodiment is merely exemplary of the present invention, and that various modifications and improvements may be made thereto without departing from the scope of the present invention.
In other embodiments, the casing 12 rather than the cone 14 may be vibrated, and the manner in which the vibration or oscillation is created may be varied. For example, fluid may be pumped through the drill pipe 16 and the fluid flow path may be interrupted or varied to induce vibration. Alternatively, a stream of gas may be injected into the fluid surrounding the cone 14 , causing vibration of one or both of the cone 14 and the casing 12 .
In other embodiments of the invention translation of the cone 14 through the casing may be achieved at least in part by application of a fluid pressure, which fluid pressure may also assist in expanding the casing 12 . The fluid pressure may be varied such as to vibrate one or both of the cone 14 or casing, or to assist in the expansion of the casing, as described in greater detail in our patent application GB 0306774.1 entitled “Hydraulically Assisted Tubing Expansion”, the disclosure of which is incorporated herein by reference.
FIG. 2 of the drawings illustrates a tubing in the form of a bore lining casing 30 located in a drilled bore 12 , such as may be utilised to gain access to a subterranean hydrocarbon reservoir. The casing 30 is run into the bore 12 in a smaller diameter first condition, of diameter D 1 , and is subsequently expanded to a larger second diameter D 2 .
Expansion of the casing 30 is achieved using expansion apparatus 34 mounted on the lower end of a string of drill pipe 36 , which extends to surface. The expansion apparatus 34 comprises a semi-compliant expansion cone 38 , that is a cone of relatively hard material which defines an outer expansion surface 20 and which defines a maximum expansion diameter corresponding to the expanded tubing diameter D 2 . However, the cone 38 is arranged such that the expansion surface may be deflected radially inwardly to a limited extent to accommodate situations where, for example, the casing 30 cannot be expanded to the diameter D 2 . A variable volume pulse generator 22 is mounted to the cone 38 and is supplied with power via a control line (not shown) that extends to surface.
The volume of fluid surrounding the cone 38 and the oscillator 22 is isolated from the remaining fluid in the casing 30 by seals 24 , 26 , the leading seal 24 being mounted on the leading end or nose of the cone 38 , while the trailing seal 26 is mounted to the trailing end of the oscillator 22 . Each seal 24 , 26 comprises a plurality of seal members 24 a , 24 b , 24 c , 26 a , 26 b , 26 c as will be described, and in use the seal members 24 a - c , 26 a - c permit a degree of leakage thereacross. In this example, each seal member is in the form of a split ring, of a somewhat similar form to a piston ring. Thus, a small volume of fluid may pass between the ends of each seal member. However, the number of seal members provided is such that only minimal leakage occurs past each seal 24 , 26 . Of course other embodiments of the invention may comprise different forms of seal member, for example porous members or members which are intended to allow a degree of leakage between the seal member surface and the tubing surface.
In use, the volume of fluid V 1 in the casing 30 above the seals 26 is at pressure P 1 . The volume V 1 is filled with a relatively high density fluid, resulting in a relatively high hydrostatic pressure above the seals 26 . In addition, pumps may be utilised to further increase the pressure above the seals 26 .
The volume of fluid V 3 beneath the leading seal 24 is isolated from the high density fluid and is at a significantly lower pressure P 3 than P 1 .
The volume of fluid V 2 between the seals 24 , 26 is maintained at an elevated base pressure P 2 , which pressure is achieved by means of pumps, which will typically be located on surface, and which communicate with the volume V 2 via the drill pipe string 36 and a one-way valve provided in the string 36 . The base pressure P 2 may be the same as or more than the pressure P 1 above the seal 26 .
Each individual seal member 24 a , 24 b , 24 c , 26 a , 26 b , 26 c will only maintain a pressure differential which is less than the pressure differential between volumes V 1 and V 2 or V 2 and V 3 . However, collectively the seal members 24 a - c , 26 a - c are effective to maintain the rate of leakage or pressure decay at a relatively low level.
The pressure P 2 is selected such that the differential pressure across the wall of the casing 30 is below the yield pressure of the casing 30 , for example the pressure P 2 may be 70% of the yield pressure. However, operation of the pulse generator 22 creates pressure pulses that exceed the yield pressure of the casing 30 , such that the casing 30 will tend to expand when exposed to the pressure pulses.
The weight of the string 36 and the expansion apparatus 34 , and the fluid pressure forces acting on the apparatus 34 , and thus on the cone 38 , also results in a mechanical expansion force being applied to the casing 30 by the cone 38 , such that the cone 38 will tend to advance and expand a short length of the casing 30 with each pressure pulse. In particular, the pulsing pressure P 2 creates a corresponding differential pressure pulse across the seal 24 , and thus creates a pulsing axial force tending to advance the cone 38 . Of course this pulsing force will coincide with the maximum pressure, above the casing yield pressure, within the volume V 2 , when the force required to advance the cone 38 , and thus mechanically expand the casing 30 , will be at a minimum.
If desired, the pressure P 1 above the expansion apparatus 34 may also be pulsed, to apply an additional motive force to the apparatus 34 , and to counteract any differential pressure experienced across the seal 26 which might tend to urge the apparatus in the opposite direction.
The cone angle is selected such that the forces acting between the cone surface and the casing 30 will retain the forward travel of the cone 38 following a pressure pulse. In this manner, the casing 30 may be extended in a series of small steps. However, expansion may still take place relatively rapidly. For example, with the pressure between the seals pulsing at 5 hertz, the cone will progress at a rate of approximately six to eight feet per minute.
The presence of fluid around the cone 38 minimises friction between the contacting surfaces of the cone 38 and casing 30 , and furthermore the small degree of leakage across the seal members also serves to provide lubrication for movement of the seals 24 , 26 through the casing 30 .
In addition to the pressure pulses which may be present in the pressure P 1 and P 2 as noted above, a further pressure variation may be applied to the casing 30 or apparatus 34 with a view to inducing vibration in one or both of the casing 30 or apparatus 34 . Such vibration may be utilised to reduce the friction between the apparatus 34 and the tubing 30 . This vibration may be the result of further applied fluid pressure pulses, typically of relatively high frequency. Alternatively, the rate of variation of pressure P 2 may be selected to provide both expansion and friction-reducing vibration. These features of the invention are more fully described in our application entitled “Tubing Expansion”, being filed concurrently herewith.
Reference is now made to FIG. 3 of the drawings, which illustrates expansion apparatus 114 in accordance with a further embodiment of the present invention. The apparatus 114 shares many features with the apparatus 34 described above, and operates in a broadly similar manner.
In addition to the leading and trailing seals 124 , 126 , swab cups 50 are provided ahead of the leading seal 124 , which swab cups 50 , in addition to a sealing function, serve to condition the inner surface of the casing 110 ahead of the seal 124 , and also assist in stabilising the expansion cone 118 .
The oscillator 122 is in the form of reciprocating piston pump, a rotary drive 52 being converted to axial movement of the pump piston 54 by an appropriate transfer arrangement 56 , such as those described in WO 02\14028, U.S. Pat. No. 5,042,385, U.S. Pat. No. 5,513,709, the disclosures of which are incorporated herein by reference.
Upward movement of the piston 54 draws fluid from the volume beyond the swab cup 50 into the piston cylinder 58 via a conduit 60 incorporating a one-way valve 62 . Downward movement of the piston 54 pumps the fluid from the cylinder 58 through a further one-way valve 64 and then through a plurality of conduits 66 to fluid outlets 68 provided in the cone surface 120 .
In use, the fluid pressure above the seal 124 , that is the pressure between the seals 124 , 126 and also above the trailing seal 126 , is maintained at a base pressure corresponding to approximately 70% of the yield pressure of the casing 110 , in this example this being around 3000 psi (the yield pressure of the casing 110 is 3700 psi). The oscillator 122 is then operated to pump fluid into the volume V 02 between the seals 124 , 126 to create short duration 4000 psi pressure pulses within the volume V 02 , during which the fluid pressure in the small volume around the cone 118 exceeds the casing yield pressure. With each pressure pulse the casing 110 expands by a small degree, in this example, the expansion resulting in a 10 cc increase the volume V 02 .
A substantially constant weight or force is being applied to the cone 118 , for example by provision of a downhole tractor coupled to the string, while the pressure in the volume V 02 is pulsed, and at each pulse the cone 118 will advance a short distance to occupy the newly expanded casing 118 . The main proportion of the expansion is a result of plastic deformation of the casing 110 , while a smaller degree of deformation is elastic, such that the casing 110 will tend to contract to some extent with the decay of the pressure within the volume V 02 from the peak pressure produced at each pulse. However, the cone angle is relatively shallow (the cone angle is shown somewhat exaggerated in the Figure) such that the cone 118 will tend to retain any elastic deformation. Thus, following completion of an expansion operation, it may be necessary to apply a tension to the cone 118 while the pressure in the volume V 02 is being pulsed in order to remove the cone 118 , if this is desired or necessary: in some cases the cone 118 may be left in the casing 110 .
As will be apparent to those of skill in the art, the operation of the oscillator 122 combined with the application of weight to the cone 118 will result in relatively rapid expansion of the casing 110 .
Those of skill in the art will recognise that the above described embodiments are merely examples of the present invention, and that various modifications and improvements may be made thereto, without departing from the scope of the invention. | A method of expanding tubing comprises locating an expansion device in tubing to be expanded, vibrating one or both of the tubing and the expansion device, and translating the expansion device relative to the tubing, the vibration acting to reduce friction between the tubing and the device. |
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