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BACKGROUND OF THE INVENTION
[0001] This application is a nonprovisional application of U.S. Provisional Application No. 60/3183,48, filed Sep. 10, 2001.
[0002] The present invention relates to mining and construction cutting bits and holders, the holders being attached to a rotating cutting drum. In the past, rotatable cutting tools have been put to a number of uses, including use as a mine tool in a continuous mining machine. Typically, a continuous mining machine includes a driven rotatable drum having a plurality of support blocks affixed thereto.
[0003] The invention concerns a rotatable cutting bit, as well as the bit holder, wherein the cutting bit has a hard insert at the forward end thereof. The cutting bit rotatably mounts in the bit holder. More specifically, the invention pertains to such a rotatable cutting bit, as well as the bit holder, designed so as to exhibit a reduction in the impediment to rotation, and thereby provide for improved rotation, between the bit and the bit holder. The invention also provides for a rotatable cutting bit, as well as the bit holder, which provides for improved wear protection for the bit holder during operation.
[0004] In the prior art, such as U.S. Pat. No. 6,113,195, to Mercier et al., and U.S. Pat. No. 4,818,027, to Simon, the bit block holder is protected from wear caused by rotation of the cutter bit head and shank by a holding washer element and spring sleeve retainer respectively. In the cutter bit provided with the holding washer element, the clamping sleeve is held tightly enough that the cutter bit with the clamping sleeve can be pushed into the bore of the bit holder even manually over a great portion of its axial dimension, until, for example, the holding element abuts on the insertion side of the bit holder. The cutter bit can be driven to the shoulder of the bit head adjacent the bit holder by means of a hammer blow. By this means, the holding element is slid from the clamping sleeve, and reaches an area of the bit shank free from the clamping sleeve, so that the clamping sleeve, with the clamping force particular to it, can be tensed in the bore of the bit holder, whereby the tension force correspondingly increases with increasing drive-in depth.
[0005] In operation, the drum rotated whereby the rotatable cutting tools impacted the earth formation, such as, for example, coal, so as to cut and break up the earth formation. As can be appreciated, the earlier rotatable cutting bits operated in an environment in which small particles of the earth formation impacted by the bit, such as coal, impinged upon the cutting bit. As the length of operation increased, these contaminants or debris had the tendency to become sandwiched between the rotatable cutting bit and the bit holder. If the amount of contaminants or debris became too great, it impeded the rotation of the cutting bit. Despite prior art designs to allow free rotation, certain cutting applications such as asphalt milling and the continuous mining of coal cause tool rotation to be inhibited by fines accumulating between the mating surfaces of the tool holder and cutter tool. Once the accumulated fines become tightly packed between the tool retainer and the tool body and/or between the tool shoulder and the holder face, rotation is greatly reduced. Following reduced rotation, a wear flat will develop on the hard tip of the tool progressing down onto the steel body. After developing a wear flat, the tool rotation generally stops, whereby the remaining useful tool life is lost.
[0006] During the operation of the earlier cutting bits, the support block experienced wear due to the contact and rotation between the cutting bit and the support block, as well as the impingement of the debris from the cutting operation. In other prior art, such as U.S. Pat. Nos. 6,113,195 and 4,818,027, which incorporate a washer between the cutting bit and support block, the wear to the bit support block is reduced, however, during operation of said prior art and the holding element washer does not remain in a fixed position on the top face of the bit block. The holding washer elements in said prior art have a tendency to rotate on the top face of the bit block due to the contact between the washer and rotating cutter bit.
[0007] While the cutting bit was replaced on a periodic basis after the expiration of the useful life thereof, the support block was typically intended to be functional much longer than the cutting bit. As the bore and front face of the support block became worn, the support block lost its effectiveness due to deformation and wear of the bore and the front face thereof. In the case of the bore, it lost its initial cylindrical shape by becoming out-of-round, oversized or bell-mouthed. In the case of the front face of the support block, it lost its flatness. Each one of these conditions impeded the satisfactory rotation of the cutting bit in the support block.
[0008] In U.S. Pat. No. 5,931,542 to Britzke et al., the cutter bit assembly was designed to prevent rotation of the washer. The cutter bit assembly in Britzke et al. includes a substantially circular wear washer having a radially inwardly directed key. The wear washer key is adapted to fit within the retainer sleeve slot, thereby interlocking the retainer sleeve with the wear washer. This provided the benefit of greatly reducing wear on the top face of the bit block. This prior art design required additional cold work machining of the block and of the washer to form the key. In the field, upon insertion into the bit block, the washer key often became broken off in use or knocked out of its cooperating keyway groove so that the washer would not be fixed in position.
[0009] It is, therefore, apparent that in light of the past experience of earlier cutting bits, it would be beneficial to provide a rotatable cutting bit which has an improved ability to freely rotate during operation.
[0010] It would, therefore, be very advantageous to provide a cutting bit, which, during operation, protects the bore of the bit holder, as well as the front face of the support block, from deformation. By providing this protection, a cutting bit would help prolong the useful life of the support block, as well as help the rotation of the cutting bit.
SUMMARY OF THE INVENTION
[0011] It is an object of the invention to provide a rotatable cutting bit, and rotatable cutting bit-bit holder assembly and washer that have improved wear resistance characteristics.
[0012] It is an object of the invention to provide a rotatable cutting bit, and rotatable cutting bit-bit holder assembly, that has improved rotational characteristics between the cutter bit and top surface of the washer during operation.
[0013] An object of the present invention is to provide an efficient means for protecting holding support blocks, of the type used to hold cutting bits used in pulverizer and rotary drum or wheel machines, from excessive abrasion and impact damage. It is believed that the relative rotation between the rear face of the washer and front of the block face is reduced in the present invention.
[0014] The improved wear resistance properties of the invention reduce the amount of necessary maintenance of rotary drums in the field, resulting in reduced downtime and increased productivity. The invention is also simple to manufacture in a cost effective manner and easy to assemble in the field.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 illustrates a side view of a first embodiment of a cutting bit having a holding washer having ridges and recesses, the holding washer maintains the clamping sleeve in a loaded state with a smaller diameter than the bore in the bit holder block.
[0016] [0016]FIG. 2 illustrates a side view of a second cutting bit assembly embodiment having a holding washer having ridges and recesses inserted into its operating position in a bit holder block wherein the holding washer abuts against the top face of the block and has released the clamping sleeve which is now loaded against the bore of the bit block.
[0017] [0017]FIG. 3 is a bottom perspective view of the holding washer of the first embodiment shown in FIG. 1.
[0018] [0018]FIG. 4 illustrates a top view of the first embodiment of a holding washer illustrated in FIG. 3.
[0019] [0019]FIG. 5 is a cross sectional view along lines 5 - 5 of FIG. 4.
[0020] [0020]FIG. 6 illustrates a side view of the second embodiment illustrated in FIG. 2, wherein the holding washer is maintaining the clamping sleeve in a loaded state prior to insertion into the block with a smaller diameter than the bore in the bit holder block.
[0021] [0021]FIG. 7 is a perspective view of the holding washer of the second embodiment illustrated in FIGS. 2 and 6.
[0022] [0022]FIG. 8 illustrates a top view of the holding washer in the second embodiment.
[0023] [0023]FIG. 9 is a cross sectional view along lines 9 - 9 of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
[0024] In the embodiment shown in FIG. 1, bit shank 14 projects from bit head 11 . The transition between the bit head 11 and bit shank 14 is constructed as collar 12 , which forms the greatest external diameter of bit head 11 . The hard metal insert 8 is inserted into the bit tip in the known manner. The clamping sleeve 17 provided with the longitudinal slot 18 rests in circumferential groove on the bit shank 14 . Clamping sleeve 17 extends over the greatest portion of the axial dimension of bit shank 14 . Stop tabs 16 (in phantom lines) project radially inward for cooperation with a recessed annular groove 15 . The bottom end of the tabs abut against an annular surface of the groove that extends perpendicular to the longitudinal axis of the shank as well-known in the art. A holding washer element 19 is slid onto clamping sleeve 17 . The washer compresses the clamping sleeve 17 to such an extent that its external diameter is equal to or smaller than the diameter of bore 21 in bit holder 20 . Longitudinal slot 18 is wide enough so that clamping sleeve 17 can be pressed together far enough that its internal wall lies on bit shank 14 . Since bore 21 of bit holder 20 is provided with diverging frustoconical opening 22 , the bit shank 14 of cutter bit 10 can be easily inserted into bore 21 . This insertion process can be carried out manually, until holding element 19 strikes the frontal side of the bit holder 20 . Then with increased application of force, for example, by means of a blow from a hammer, the cutter bit 10 can be driven far enough into bore 21 so that collar 12 of bit head 11 , by means of the holding element 19 , is driven to face against the frontal side of bit holder 20 as illustrated in FIG. 2 (second embodiment). In this manner, holding element 19 formed as a holding washer is moved from clamping sleeve 17 down onto the free area 13 of the bit shank 14 between clamping sleeve 17 and the bit head 11 , so that it releases clamping sleeve 17 . Clamping sleeve 17 can now be tensed with the tensing force specific to it, in the bore 21 of bit holder 20 , since it would accommodate, in the unstressed condition, an external diameter which is greater than the diameter of bore 21 of bit holder 20 . The difference between both diameter values determines the tensing force of sleeve 17 , and thereby the force with which the cutter bit 10 is held in bore 21 of bit holder 20 .
[0025] In the embodiment in accordance with FIG. 1, the external diameter of the holding washer corresponds to the maximum external diameter of bit head 11 in the area of collar 12 . The holding washer thereby serves as a protective washer for bit holder 20 , since it cushions the impact forces acting on cutter bit 10 and prevents abrasion and wear of the bit block caused by the cutter bit bearing down upon the bit block as it rotates during operation. If the external diameter of the holding washer is expanded over the maximum external diameter of the bit head 11 , then the entire frontal side of the bit holder 20 is protected against wear, if the holding washer is made of wear-resistant material.
[0026] [0026]FIG. 5 illustrate a cross-sectional view of the holding washer in which each of the front and rear main surfaces 44 , 48 extends from the outer peripheral surface 50 to the inner peripheral surface of the central opening 52 which defines the center hole of the washer. The front main surface 44 is a generally flat shape and has a plurality of evenly spaced arcuate ridge segments 55 . Front face 44 also includes a bevel 56 (e.g., a bevel of 40-50 degrees.) at the intersection with the inner peripheral surface 52 that defines the central opening in the washer. Rear surface 48 is also generally flat and has a plurality of evenly spaced recesses 53 as best seen in FIG. 3. For the purpose of this invention it is not necessary that the rear surface is beveled at 60 or that the front face is beveled 56 .
[0027] Similar to FIG. 2, the holding washer of the first embodiment of FIG. 1 in its operating position is located between the cutting bit shoulder 12 and top face 23 of the bit block. The bottom face 9 of the cutter bit rests upon the top face of the ridges 55 . The top faces of the ridges form a bearing surface about which the cutter bit rotates. In the prior art the bottom horizontal surface 9 of the cutter bit abuts against a horizontal front surface of the washer as illustrated in FIG. 1 of U.S. Pat. No. 4,818,027. This '027 flat washer and a corresponding flat surface of the cutter bit shoulder cooperate to form a large contact area at a significant distance from the cutter bits axis of rotation. With the washer of the invention, only the top surfaces of the ridges 55 contact the bottom flat surface 9 of the cutter bit shoulder. This bearing surface contact between the holding washer and cutter bit bottom reduces torsion friction that inhibits relative rotation between the cutter bit and washer in comparison to a flat washer of the same size.
[0028] In prior art designs of rotating cutter bits, in some cutting applications such as asphalt milling and the continuous mining of coal, cause tool rotation to be inhibited by fines accumulating between the mating surfaces of the tool holder and cutter tool. It is believed the flat section gaps 57 between ridges 55 permit for uninhibited flow of fines and cut particles so as to help reduce accumulation of the fines in some milling and coal operation environments in which accumulation of fines and debris sandwiched between the top mating surface of holder washers and bottom mating surface of the cutting bit is more prevalent. The length of the gap may be varied as well as the height of the gap (i.e. ridge height) to appropriately accommodate the prevailing particle size that causes accumulation problems in certain mining and construction environments. In other mining and construction environments in which sandwiched accumulation of fines and debris between mating surfaces is not a problem, the gaps may not be necessary and a continuous concentric annular ridge may be constructed with smaller gaps or possibly without any gaps (not shown).
[0029] In some prior art designs, such as U.S. Pat. No. 6,113,195, which has a beveled washer, the cutter bit shoulder does not rest flatly on the holding washer element. However, in U.S. Pat. No. 6,113,195, the washer is beveled so that the rear surface of the washer does not rest flatly upon the top face of the block either, but makes minimal contact or line contact with the top face of the bit block about the circumference of the bore close to the cutter's central axis. The rear surface 48 of the invention sits flatly on a flat horizontal top face of the bit block. Hence, the radial outward surface contact between the washer and top face of the bit block is greater than such prior art designs as U.S. Pat. No. 6,113,195. This surface contact area between the washer and top face of the bit block is made at a greater distance from the central axis increasing torsion friction and resistance to relative rotation between the holding washer 19 and bit block face 23 . This reduction in rotation of the washer upon the bit block reduces undesirable wear such as countersinking.
[0030] The rear face 48 of the washer adjacent to the opening includes inner bevel portion 60 that forms an angle between 40-50 degrees with longitudinal axis. Bevel 60 will make surface contact with the holder face frustoconical opening 22 . That surface contact performs the advantage of aiding in the resistance to lateral displacement of the cutter bit 12 since it will abut the bevel 22 of the bore 21 .
[0031] [0031]FIGS. 2 and 6- 9 illustrate a second embodiment of the present invention wherein like and similar parts with the first embodiment are identified with the same numbers in the second embodiment. The holding washer element in FIGS. 2 and 6 is shown in its holding position in which the spring clamp is held in its loaded position prior to being inserted into a bit holder block. As can be seen in FIGS. 2 and 6, the tip 8 of the cutting tool is conical as opposed to the flatter cap shaped tip 8 in FIG. 1. The shape of the tip of the cutter bit should not be limited to just those disclosed in these two embodiments but could alternatively be constructed from a variety of different shapes and geometries well-known in the industry.
[0032] The front face 44 of the washer in FIG. 7 has a plurality of evenly spaced gaps 57 and ridges 55 in the general shape of a U that extends from near the opening 52 of the washer to the outer periphery 50 of the washer. The rear surface of the washer has a U-shape recess 53 corresponding in shape and size to the U-shaped ridge on the top surface. In the inventions described above and illustrated herein, the entire top surface area of all the ridges contacts the bottom face of the cutter bit head. It is contemplated, however, that in some cutting bit assemblies, near the outside diameter of the holding washer the top face of the ridges 55 extend beyond the outside diameter of the bottom surface 9 of the cutter bit head. Therefore, only the radially inward portion of each top face of the ridges 55 provides support and forms a bearing surface for the rotating cutting tool.
[0033] The rear surface 48 of the second embodiment also sits flatly on the top face of the bit block as illustrated in FIG. 2. Hence, the contact between the washer and top face of the bit block is at a greater distance from the axis of rotation of the cutter bit than some prior art designs increasing torsion friction and resistance to relative rotation between the holding washer 19 and bit block face 23 as discussed above.
[0034] The recesses 53 in the holding element washer shown in FIGS. 2 , 6 - 9 also prove to be useful in removing a cutter bit form the bit block. The recesses can be uniform depth, as best illustrated in FIG. 9, or have a tapered undercut to receive a bit removal tool as taught in U.S. Pat. No. 5,374,111, to Den Besten deceased et al., which is herein incorporated by reference in its entirety.
[0035] In a preferred embodiment, the undercuts taper upwardly from the underside surface of the flange toward the conical nose of the cutting bit. The undercuts taper upwardly at an angle of approximately 15 degrees from a line extending transversely from a longitudinal axis of the cutting bit.
[0036] The U-shaped ridges and recesses in the holding washer element disclosed in the second embodiment, FIGS. 2 , 6 - 9 , and the arcuate ridge segments and recesses in the first embodiment, FIGS. 1 , 3 - 5 , are exemplary only. The shape of the ridges and recesses on the holding washer elements should not be limited to just those disclosed in these two embodiments but could alternatively be constructed from a variety of different shapes and geometries.
[0037] The novel holding washer element 19 according to the present invention provides a very effective means for protecting the holding block 20 on which it is installed from abrasion and impact damage, thereby substantially increasing the useful life of the holding block. The holding washer 19 in the disclosed embodiments is generally ring shaped. It should be appreciated that said holding washer could instead have the general shape of a square, hexagon or other geometry. Further, it is not necessary that the holding washer 19 be employed to compress a clamping sleeve 17 . The washer can be used with other rotating cutter bits for the purpose of enhancing rotation and reducing wear to the top face of the holder block.
[0038] The embossed washers of the invention have added strength in comparison to flat washers of the prior art. It is contemplated that as a result of this added strength, the general thickness of the washer from the front face to rear face (not at ridges or recesses) can be reduced, providing for savings in material cost and shaping ease in manufacturing the embossed washer. The embossed washer invention is made from typical Spring Steel employed and well known in the industry. The embossed washer may or may not be heat-treated. A Rockwell hardness value between 43-48 can provide for satisfactory results in some environments, whereas different Rockwell hardness values of the Spring Steel are more suitable for other environments.
[0039] Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departing from the spirit and scope of the invention as disclosed.
[0040] It is to be understood that although the invention disclosed herein is fully capable of achieving the objects and providing the advantages described, the characteristics of the invention described herein are merely illustrative of the preferred embodiment. Accordingly, I do not intend that the scope of my exclusive rights and privileges in the invention be limited to details of the embodiment described. I do intend that equivalents, adaptations and modifications reasonably inferable from the invention described herein be included within the scope of the invention as disclosed. | A rotatable cutting bit, and rotatable cutting bit-bit holder assembly and washer that have increased wear resistance characteristics. The assembly incorporates a new holding washer design that has improved rotational characteristics between the cutter bit and top surface of the washer during operation. The washer includes a front face and a generally flat rear face, said front face has a plurality of ridges, said ridges each have a top face forming a bearing surface for the cutting bit to enhance rotation of the cutter bit and the flat rear face reduces rotation of said washer. The relative rotation between the rear face of the washer and front of the block face is reduced in the present invention. The improved wear resistance properties of the invention reduce the amount of necessary maintenance of rotary drums in the field resulting in reduce downtime and increase productivity. The washer is also simple to manufacture in a cost effective manner and easy to assemble in the field. |
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PRIORITY CLAIM
The present application claims priority to PCT Application EP2008/067307, filed 11 Dec. 2008, which claims priority to European Patent Application No. EP 07123101.3, filed 13 Dec. 2007.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method of creating a wellbore system whereby an expanded tubular element is employed in a wellbore.
BACKGROUND OF THE INVENTION
The technology of radially expanding tubular elements in wellbores finds increasing application in the industry of oil and gas production from subterranean formations. Wellbores are generally provided with one or more casings or liners to provide stability to the wellbore wall, and/or to provide zonal isolation between different earth formation layers. The terms “casing” and “liner” refer to tubular elements for supporting and stabilising the wellbore wall, whereby it is generally understood that casing extends from surface into the wellbore and that a liner extends from a certain depth further into the wellbore. However, in the context of this disclosure the terms “casing” and “liner” are used interchangeably and without such intended distinction.
In conventional wellbore construction, several casings are installed at different depth intervals, in a nested arrangement, whereby each subsequent casing is lowered through the previous casing and therefore has a smaller diameter than the previous casing. As a result, the cross-sectional wellbore size that is available for oil and gas production, decreases with depth. To alleviate this drawback, it has become general practice to radially expand one or more tubular elements at the desired depth in the wellbore, for example to form an expanded casing, expanded liner, or a clad against an existing casing or liner. Also, it has been proposed to radially expand each subsequent casing to substantially the same diameter as the previous casing to form a monobore wellbore. It is thus achieved that the available diameter of the wellbore remains substantially constant along (a portion of) its depth as opposed to the conventional nested arrangement.
EP 1438483 B1 discloses a system for expanding a tubular element in a wellbore whereby the tubular element, in unexpanded state, is initially attached to a drill string during drilling of a new wellbore section.
To expand such wellbore tubular element, generally a conical expander is used with a largest outer diameter substantially equal to the required tubular diameter after expansion. The expander is pumped, pushed or pulled through the tubular element. Such method can lead to high friction forces between the expander and the tubular element. Also, there is a risk that the expander becomes stuck in the tubular element.
EP 0044706 A2 discloses a flexible tube of woven material or cloth that is expanded in a wellbore by eversion to separate drilling fluid pumped into the wellbore from slurry cuttings flowing towards the surface.
However there is a need for an improved method of creating a wellbore system whereby an expanded tubular element is employed.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a method of creating a wellbore system, the method comprising:
a) arranging an expandable tubular element in a wellbore formed in an earth formation whereby a lower end portion of the wall of the tubular element extends radially outward and in axially reverse direction so as to form an expanded tubular section extending around a remaining tubular section of the tubular element;
b) axially extending the expanded tubular section by moving the remaining tubular section downward relative to the expanded tubular section so that said lower end portion of the wall bends radially outward and in axially reverse direction, whereby an annulus is defined between said expanded and remaining tubular sections, the annulus containing a body of fluid;
c) replacing a volume of said fluid by pumping a stream of replacement fluid into the annulus and discharging said volume of fluid from the annulus whereby at least one of said volume of fluid and said stream of replacement fluid flows through a conduit extending into the annulus.
By moving the remaining tubular section downward relative to the expanded tubular section, the tubular element is effectively turned inside out whereby the tubular element is progressively expanded without the need for an expander that is pushed, pulled or pumped through the tubular element. The expanded tubular section can form a casing or liner in the wellbore.
Furthermore, by replacing a portion, or all, of the fluid in the annulus, the fluid pressure in the annulus can be adapted to the wellbore fluid pressure, for example to minimise a pressure difference across the wall of the tubular element in the bending zone. The conduit enables fluid to be circulated into, and out of, the annulus.
Suitably said replacement stream of fluid is pumped into the annulus via the conduit. Furthermore it is preferred that the conduit is a first conduit, and said volume of fluid is discharged through a second conduit extending into the annulus.
To allow fluid streams of different densities to be inserted into the annulus, suitable the first conduit has a fluid outlet in the annulus and the second conduit has a fluid inlet in the annulus, said fluid outlet and fluid inlet being arranged at mutually different vertical levels. For example, if the fluid outlet is arranged at a higher vertical level than said fluid inlet, a layer of fluid can be pumped into the annulus between said inlet and outlet without affecting fluid present in the annulus below the outlet.
To reduce the risk of wellbore fluid leaking into the annulus in case of damage to the wall in the bending zone, whereby the expanded tubular section has an outer surface subjected to an outer fluid pressure and an inner surface subjected to an inner fluid pressure, it is preferred that the stream of fluid is controlled such that, at said lower end portion of the wall, the inner fluid pressure is at least equal to the outer fluid pressure. More preferably the inner fluid pressure exceeds the outer fluid pressure at said lower end portion of the wall. The outer fluid pressure is, for example, exerted to the outer surface by at least one of a drilling fluid present in the wellbore and a pore fluid present in the earth formation.
In some applications, such as during drilling of the wellbore, the outer fluid pressure varies along a length of the expanded tubular section. It is then preferred that the stream of fluid is controlled so that, at each level along said length, the inner fluid pressure is substantially equal to, or exceeds, the outer fluid pressure.
Suitably the step of controlling the stream of fluid comprises controlling the density of the stream of fluid.
In order to achieve that the expanded tubular section retains its expanded form, it is preferred that the wall of the tubular element includes a material that is plastically deformed in the bending zone, so that the expanded tubular section automatically remains expanded as a result of said plastic deformation. Plastic deformation refers in this respect to permanent deformation, as occurring during deformation of various ductile metals upon exceeding the yield strength of the material. Thus, there is no need for an external force or pressure to maintain the expanded form. If, for example, the expanded tubular section has been expanded against the wellbore wall as a result of said bending of the wall, no external radial force or pressure needs to be exerted to the expanded tubular section to keep it against the wellbore wall. Suitably the wall of the tubular element is made of a metal such as steel or any other ductile metal capable of being plastically deformed by eversion of the tubular element. The expanded tubular section then has adequate collapse resistance, for example in the order of 100-150 bars.
In order to induce said movement of the remaining tubular section, preferably the remaining tubular section is subjected to an axially compressive force acting to induce said movement. The axially compressive force preferably at least partly results from the weight of the remaining tubular section. If necessary the weight can be supplemented by an external, downward, force applied to the remaining tubular section to induce said movement. As the length, and hence the weight, of the remaining tubular section increases, an upward force may need to be applied to the remaining tubular section to prevent uncontrolled bending or buckling in the bending zone.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be described hereinafter in more detail and by way of example, with reference to the accompanying drawings in which:
FIG. 1 schematically shows, in longitudinal section, a first embodiment of a wellbore system used with the method of the invention;
FIG. 2 schematically shows, in perspective view, and partly broken away for clarity, an everted liner of the first embodiment;
FIG. 3 schematically shows, in perspective view, and partly broken away for clarity, an everted liner of a second embodiment of a wellbore system used with the method of the invention;
FIG. 4 schematically shows, in perspective view, and partly broken away for clarity, an everted liner of a third embodiment of a wellbore system used with the method of the invention; and
FIG. 5 schematically shows the first embodiment modified in that a drill string is operated to further drill the wellbore.
In the drawings and the description, like reference numerals relate to like components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is shown a first embodiment of a wellbore system used with the method of the invention, whereby a wellbore 1 extends into an earth formation 2 , and whereby a tubular element in the form of liner 4 extends from surface 6 downwardly into the wellbore 1 . The liner 4 has been partially radially expanded by eversion of its wall 5 whereby a radially expanded tubular section 10 of the liner 4 has been formed of outer diameter substantially equal to the wellbore diameter. A remaining tubular section of the liner 4 , in the form of unexpanded liner section 8 , extends from surface 6 concentrically into the expanded tubular section 10 .
The wall 5 of the liner 4 is, due to eversion at its lower end, bent radially outward and in axially reverse (i.e. upward) direction so as to form a U-shaped lower section 11 of the wall 5 interconnecting the unexpanded liner section 8 and the expanded liner section 10 . The U-shaped lower section 11 of the liner 4 defines a bending zone 9 of the liner. The expanded tubular section 10 and the remaining tubular section 8 define an annulus 16 there between, containing a body of fluid 18 exerting an inner fluid pressure to the expanded tubular section 10 , to the U-shaped lower section 11 an to the unexpanded liner section 8 .
The expanded liner section 10 is axially fixed to the wellbore wall 14 by virtue of frictional forces between the expanded liner section 10 and the wellbore wall 14 resulting from the expansion process. Alternatively, or additionally, the expanded liner section 10 can be anchored to the wellbore wall by any suitable anchoring means (not shown).
The wellbore 1 has an open-hole lower portion 19 located below the liner 4 , whereby the unexpanded liner section 8 and the open-hole portion 19 contain a volume of wellbore fluid, for example drilling fluid used to drill the wellbore 1 or pore fluid from the surrounding earth formation 2 .
Referring to FIG. 2 there is shown the unexpanded and expanded liner sections 8 , 10 of the first embodiment, with a tube 20 extending from surface 6 into the annulus 16 . The tube 20 has an open lower end 22 positioned in a lower portion of the annulus 16 .
Referring to FIG. 3 there is shown the unexpanded and expanded liner sections 8 , 10 of a second embodiment of the wellbore system used with the method of the invention. The second embodiment is substantially similar to the first embodiment, except that a plurality of tubes 24 , 26 , 28 extend from surface 6 into the annulus 16 . The tubes 24 , 26 , 28 have respective open lower ends 30 , 32 , 34 whereby open end 34 is positioned below open end 30 which, in turn, is positioned below open end 32 .
Referring to FIG. 4 there is shown the unexpanded and expanded liner sections 8 , 10 of a third embodiment of the wellbore system used with the method of the invention. The third embodiment is substantially similar to the first embodiment, except that a pair of tubes 36 , 38 extend from surface 6 into the annulus 16 . The tubes 36 , 38 have respective open lower ends 40 , 42 positioned at mutually different vertical levels in the annulus 16 . Furthermore, the annulus 16 is divided into a lower compartment 44 , a middle compartment 46 and an upper compartment 48 . The open end 40 of tube 36 is located in lower compartment 44 , and the open end 42 of tube 38 is located in middle compartment 46 . The compartments 44 , 46 , 48 are sealed from each other by respective annular seals 50 , 52 positioned in the annulus 16 .
Referring to FIG. 5 there is shown the first embodiment during drilling of the wellbore 1 whereby a drill string 54 extends from surface 6 through the unexpanded liner section 8 to the bottom of the wellbore 1 . The drill string 54 is at its lower end provided with a drill bit 56 comprising a pilot bit 58 with gauge diameter slightly smaller than the internal diameter of the unexpanded liner section 8 , and a reamer section 60 with gauge diameter adapted to drill the wellbore 1 to its nominal diameter. The reamer section 60 is radially retractable to an outer diameter allowing it to pass through unexpanded liner section 8 , so that the drill string 54 can be retrieved through the unexpanded liner section 8 to surface.
During normal operation of the first embodiment ( FIGS. 1 and 2 ), a lower end portion of the liner 4 is initially everted. That is, the lower portion is bent radially outward and in axially reverse direction. The U-shaped lower section 11 and the expanded liner section 10 are thereby initiated. Subsequently, the short length of expanded liner section 10 that has been formed is anchored to the wellbore wall 14 by any suitable anchoring means. Depending on the geometry and/or material properties of the liner 4 , the expanded liner section 10 alternatively can become anchored to the wellbore wall automatically due to friction between the expanded liner section 10 and the wellbore wall 14 .
The unexpanded liner section 8 is then gradually moved downward by application of a sufficiently large downward force F thereto, whereby the unexpanded liner section 8 becomes progressively everted in the bending zone 9 . In this manner the unexpanded liner section 8 is progressively transformed into the expanded liner section 10 . The bending zone 9 moves in downward direction during the eversion process, at approximately half the speed of the unexpanded liner section 8 .
Since the length, and hence the weight, of the unexpanded liner section 8 gradually increases, the magnitude of the downward force F can be gradually lowered in correspondence with the increasing weight of liner section 8 . As the weight increases, the downward force eventually may need to be replaced by an upward force to prevent buckling of liner section 8 .
Simultaneously with downward movement of unexpanded liner section 8 , or at selected time intervals, a stream of fluid is pumped via the tube 20 into the annulus 16 . The fluid density of the fluid stream is selected such that, at the depth-level of the bending zone 9 , the fluid pressure in the annulus 16 is equal to, or exceeds, the fluid pressure in the open-hole portion 19 of the wellbore 1 . This can be achieved, for example, by selecting the fluid density of the stream of fluid to be equal to, or larger than, the fluid density of the wellbore fluid present in the unexpanded liner section 8 and the open-hole portion 19 . If the fluid density of the wellbore fluid varies with depth, the fluid density of the pumped stream of fluid is varied correspondingly. In this manner it is achieved that, in case a leak occurs in the wall 5 during bending in the bending zone, wellbore fluid cannot not escape from the open-hole portion 19 via such leak into the annulus 16 . Pressure control in the wellbore 1 is thereby maintained.
Normal operation of the second embodiment ( FIG. 3 ) is substantially similar to normal operation of the first embodiment, except with regard to the following. Separate stream streams of fluid are pumped via the tubes 24 , 26 , 28 into the annulus 16 , with the fluid density of the stream in conduit 34 being higher than the fluid density of the stream in conduit 30 being higher than the fluid density of the stream in conduit 32 . The body of fluid 18 in the annulus 16 is thereby formed of fluid layers of different densities separated from each other by gravity. The densities are selected such that at the depth-level of the bending zone 9 , the fluid pressure in the annulus 16 is equal to, or exceeds, the fluid pressure in the open-hole portion 19 of the wellbore 1 .
Normal operation of the third embodiment ( FIG. 4 ) is substantially similar to normal operation of the second embodiment, except with regard to the following. Separate stream streams of fluid are pumped via the tubes 36 , 38 into the respective compartments 44 , 46 , whereby the fluid density of the stream in conduit 36 is lower than the fluid density of the stream in conduit 38 . The body of fluid 18 in the annulus 16 is thereby formed of fluid layers of different densities, whereby the fluid densities are selected such that at the depth-level of bending zone 9 , the fluid pressure in the annulus 16 is equal to, or exceeds, the fluid pressure in the open-hole portion 19 of the wellbore 1 . The annular seals 50 , 52 prevent intermixing of the fluids in the different compartments.
Normal operation of the modified first embodiment ( FIG. 5 ) is substantially similar to normal operation of the first embodiment, except with regard to the following. Simultaneously with downward movement of the unexpanded liner section 8 into the wellbore, the drill string 54 is operated to rotate the drill bit 56 whereby the pilot bit 58 drills an initial portion of the borehole and the reamer section 60 enlarges the borehole to the final gauge diameter. The drill string 54 thereby gradually moves downward into the wellbore 1 . The unexpanded liner section 8 is moved downward in a controlled manner and at substantially the same speed as the drill string 54 , so that it is ensured that the bending zone 9 remains at a short distance above the drill bit 56 . Controlled lowering of the unexpanded liner section 8 can be achieved, for example, by controlling the downward force, or upward force, referred to hereinbefore. Suitably, the unexpanded liner section 8 is supported by the drill string 56 , for example by bearing means (not shown) connected to the drill string, which supports the U-shaped lower section 11 . In that case the upward force suitably is applied to the drill string and transmitted via the bearing means to the unexpanded liner section 8 . Furthermore, at least a portion of the weight of the unexpanded liner section 8 can be transferred to the drill string 54 by the bearing means, so as to provide a thrust force to the drill bit 56 .
During the drilling process, drilling fluid is circulated into the wellbore in conventional manner whereby the drilling fluid density is generally increased with increasing depth. As a result the drilling fluid pressure exerted to the wall of the tubular element in the bending zone increases correspondingly. With the method of the invention, the fluid density of the stream of replacement fluid is suitably selected such that the fluid pressure in the annulus 16 at the level of the bending zone 9 is equal to, or slightly exceeds, the drilling fluid pressure at that level.
When it is required to retrieve the drill string 54 to surface, for example when the drill bit 56 is to be replaced or when drilling of the wellbore 1 is complete, the reamer section 60 brought to its radially retracted mode. Subsequently the drill string 54 is retrieved through the unexpanded liner section 8 to surface.
With the wellbore system of the invention, it is achieved that the wellbore is progressively lined with the everted liner directly above the drill bit during the drilling process. As a result, there is only a relatively short open-hole section of the wellbore during the drilling process at all times. The advantages of such short open-hole section will be most pronounced during drilling into a hydrocarbon fluid containing layer of the earth formation. In view thereof, for many applications it will be sufficient if the process of liner eversion during drilling is applied only during drilling into the hydrocarbon fluid reservoir, while other sections of the wellbore are lined or cased in conventional manner. Alternatively, the process of liner eversion during drilling may be commenced at surface or at a selected downhole location, depending on circumstances.
In view of the short open-hole section during drilling, there is a significantly reduced risk that the wellbore fluid pressure gradient exceeds the fracture gradient of the rock formation, or that the wellbore fluid pressure gradient drops below the pore pressure gradient of the rock formation. Therefore, considerably longer intervals can be drilled at a single nominal diameter than in a conventional drilling practice whereby casings of stepwise decreasing diameter must be set at selected intervals.
Also, if the wellbore is drilled through a shale layer, such short open-hole section eliminates possible problems due to a heaving tendency of the shale.
In the above examples, expansion of the liner is started at surface or at a downhole location. In case of an offshore wellbore whereby an offshore platform is positioned above the wellbore, at the water surface, it can be advantageous to start the expansion process at the offshore platform. In such process, the bending zone moves from the offshore platform to the seabed and from there further into the wellbore. Thus, the resulting expanded tubular element not only forms a liner in the wellbore, but also a riser extending from the offshore platform to the seabed. The need for a separate riser is thereby obviated.
Furthermore, conduits such as electric wires or optical fibres for communication with downhole equipment can be extended in the annulus between the expanded and unexpanded sections. Such conduits can be attached to the outer surface of the tubular element before expansion thereof. Also, the expanded and unexpanded liner sections can be used as electricity conductors to transfer data and/or power downhole.
Since any length of unexpanded liner section that is still present in the wellbore after completion of the eversion process, will be subjected to less stringent loading conditions than the expanded liner section, such length of unexpanded liner section may have a smaller wall thickness, or may be of lower quality or steel grade, than the expanded liner section. For example, it may be made of pipe having a relatively low yield strength or relatively low collapse rating.
In order to reduce friction forces between the unexpanded and expanded liner sections during the expansion process, suitably a friction-reducing layer, such as a Teflon layer, is applied between the tube and the unexpanded and expanded liner sections. For example, a friction reducing coating can be applied to the outer surface of the liner before expansion, or to the inner and/or outer surface of the tube.
Instead of expanding the expanded liner section against the wellbore wall (as explained in the detailed description), the expanded liner section can be expanded against the inner surface of another tubular element already present in the wellbore.
The method of the invention also can be used to pump a high temperature fluid, or one or more compounds performing an exothermic reaction, into the annulus so as to heat the wall of the tubular element in the bending zone to improve its bending capability. | A method of creating a wellbore system comprises arranging an expandable tubular element in a wellbore whereby a lower end portion of the wall of the tubular element extends radially outward and in an axially reverse direction so as to form an expanded section extending around a remaining tubular section of the tubular element, and axially extending the expanded section by moving the remaining tubular section downward relative to the expanded section so that said lower end portion of the wall bends radially outward and in an axially reverse direction, whereby an annulus is defined between said expanded and remaining tubular sections, the annulus containing a body of fluid. A volume of the fluid is replaced by pumping a replacement fluid into the annulus and discharging the volume of fluid from the annulus whereby at least one of the volume of fluid and the replacement fluid flows into the annulus. |
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TECHNICAL FIELD
[0001] Embodiments of the invention relate generally to decks and their construction methods. More particularly, the embodiments of the invention relate to a pool-covering putting green over deck apparatus and method of construction.
BACKGROUND
[0002] In the warmer climates, many homes are equipped with outdoor in-ground pools formed from poured concrete. Such pools are often free form, such as the classic kidney shape, rather than the rectangular form preferred for exercise and competition. These swimming pools are usually surrounded by concrete decks which are level with the edge of the pools.
[0003] In addition, many pools are equipped with a decorative ribbon around the inside upper edge of the pool for easier cleaning and for a decorative effect. Such an edge can be textured concrete, plaster, or tiles.
[0004] Homeowners change their minds about the desire for a pool. Sometimes the children who used the pool have grown and no longer reside in the home. Other times, grandchildren appear on the scene and need to be protected from a swimming pool. New homeowners may purchase the home for its indoor characteristics and do not want the outdoor pool. The responsibility for the pool (problems of others gaining access and harming themselves) may weigh heavily on the homeowner.
[0005] Pool maintenance and upkeep include electricity to circulate the water and cleaning devices, chemicals to kill algae and maintain the proper salt balance and pH, water replacement, pool cleaning components such as hoses, pool maintenance charges by contractors, insurance and pool replastering. Current estimates for pool maintenance and upkeep are estimated at about $2,000 per year. Closing off an unwanted pool can save the homeowner significant funds in a few years.
[0006] There are few alternatives for getting rid of the pool. Often pools are filled in, often with the concrete deck that surrounded the pool, and landscaped over. Occasionally people will simply ignore the pool until it turns green, but then it may harbor obnoxious mosquitoes and pose a health hazard. If the pool is filled in with concrete, it cannot be used again because it is extremely difficult to dig out the concrete; replacing the pool is prohibitively expensive. A new pool must be added to a different, less convenient part of the home's yard.
[0007] What is needed is a stricture that can be worked into the existing landscape plan without seriously damaging the swimming pool and permitting it to be “revived” at a later date. Ideally such a structure would be added to completely cover the pool, permitting no-one, even small animals from entering the pool. Preferably the structure would be attached to the pool so as to avoid damaging the expensive decorative ribbon around the top edge of the pool. Moreover, because concrete in-ground pools are built in a myriad of shapes and the structure covering the pool needs to be in a unique shape, there needs to be an efficient way to cut the wood deck members to their proper size and close tolerance with the pool dimensions. Even more useful would be a putting green over the deck structure for the pool-owner to enjoy a new outdoor activity.
SUMMARY OF INVENTION
[0008] In one embodiment, there is provided a putting green whose perimeter is level with the top of a concrete-sided pool having a decorative ribbon along the top of the pool side and an apron surrounding the pool having at least partially flat surface, the putting green overlying a deck including a) a waterproof surface comprising decking surface members having lengths and ends, the lengths being sized to the dimensions of the pool and the surface being at the same level as the pool apron; b) supports including i. cross members which are perpendicular to the lengths of the decking surface members; ii. underlying joists that form a sturdy base for the cross members; and iii. joist hangers being secured to the sides of the pool below the decorative ribbon along the top of the pool side and being sunk into the concrete side of the pool; and c) a putting green comprising at least the layers of gravel, sand and artificial grass.
[0009] In another embodiment of the pool covering structure in accordance with the present invention, a side-mounted beam rests on a pre-existing pool step or pool seat if such has been formed as part of the pool and is at a correct height to accommodate a beam and a beam mount. Where this approach to supporting a beam is used, the beam mount includes pressure treated wood to rest on the pool floor and then the beam rests on the pressure treated wood. The beam is held in place by the rigidity of the structure held together on the top of the beam.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a perspective view of a deck being built to cover a swimming pool. Note that boards have been placed in the bottom of the pool for moving across bottom of pool.
[0011] FIG. 2 is a perspective view of a swimming pool wall on which a joist hanger has been installed below the decorative stripe around the pool. The joist hanger contains a joist and blocks to shim the joist.
[0012] FIG. 3 is another perspective view of a swimming pool wall with decorative tile around its edge and joist hanger installed below the decorative tile and joists being installed
[0013] FIG. 4 is a perspective view of the deck being built to cover the swimming pool. In this view, cross members have been added.
[0014] FIG. 5 is a perspective view showing the start of the deck surface with the placement of a deck surface member.
[0015] FIG. 6 is a perspective view of a partially built deck surface from which the excess lengths of board have been trimmed to fit into the free-form outline of the swimming pool.
[0016] FIG. 7 is a perspective view of the deck surface with access door. The excess board lengths have been trimmed from the deck surface.
[0017] FIG. 8 is an end view of the completed deck surface before it is lowered to the level of the concrete apron around the swimming pool.
[0018] FIG. 9 is a perspective view below the deck structure, showing a jack that is used to raise the deck structure sufficiently to remove the blocks under the joists. The blocks raised up the deck structure for rapid removal of the board ends.
[0019] FIG. 10 is a perspective view of the finished deck structure with its deck surface flush with the surface of the pool apron. The access door is shown open to permit dropping in the pump that drains the pool;
[0020] FIG. 11 is a perspective view of a vertical post connected to a pool floor and to a cross beam in a pool covering structure in accordance with the present invention;
[0021] FIG. 12 is a perspective view of a beam resting in a beam mount which is placed on a pool floor portion of a pool seat or pool step in a pool covering structure in accordance with the present invention; and
[0022] FIG. 13 is a perspective view of metal connectors connecting floor joists to a cross beam in a pool covering structure in accordance with the present invention.
[0023] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustrating specific embodiments in which the invention may be practiced. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of present inventions. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments of the invention is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.
DETAILED DESCRIPTION OF INVENTION
[0024] The current invention incorporates unique features which offer benefits appreciated by the owner of a pool. First of all, the deck is installed in a new configuration, such that the deck contact with the side of the pool is below the decorative rim around the pool. This gives the pool deck a semi-permanence, such that the structure can be removed at a later date, and the pool be returned to working status with a minimum of plastering repair and cost. The plastering is performed mostly below the filled water line. The new plastering is thus less visible when the pool is in use. Thus, replastering can be performed quickly. Were the deck structure installed in the usual manner (higher on the pool wall), the decorative tile rim would be damaged, requiring expensive replacement and delays in returning the pool to service.
[0025] The structures described below can be assembled and installed for a modest investment, having a payback time of less than four years (taking into account the pool maintenance costs mentioned above).
[0026] The embodiments described below are built to normal building standards for floors and decks and usually far exceed structural requirements. In fact, most exceed commercial requirements for floor loading. If one desires to put even heavier loads on the deck, the deck can be easily reinforced for increased loads.
[0027] FIG. 1 shows an empty pool 10 in which several boards 12 a , 12 b , etc. have been placed for workers to walk during construction. This too limits damage to the pool surface and makes easier the rehabilitation of the pool. Such boards 12 a , etc., are preferably left in the pool after construction and can support objects to be stored under the pool cover. Another advantage of the embodiments described below is that there is accessible space under the deck cover for storage of water-proof objects, such as kayaks, old pool equipment, plastic storage boxes, etc.
[0028] FIGS. 2 and 3 show the locations of bolts 40 being placed into the pool side. Note the joist hanger 40 location is below the decorative tile rim 30 of the pool. The joists 50 are placed in these joist hangers 40 and form the base for the pool structure. The joists 50 are shimmed up with blocks 60 a , 60 b , to raise the deck structure above the concrete apron 20 . The blocks 60 a , 60 B, etc. are removed when deck structure (see below) is completed and lowered to concrete apron 20 level.
[0029] FIG. 4 shows the joists 50 in place. Their locations are selected based on the lengths of the cross members 70 they bear. The horizontal joist 50 placement and distances between adjacent joists 50 are determined by well known calculations used in conventional floor and deck design. FIG. 4 also shows some of the cross members 70 in place in the emerging deck structure. These cross members 70 extend across the pool. Their depth is chosen based on conventional deck design in consideration of the weight of deck surface members 80 (discussed below) and other weight they are intended to support. To accommodate greater weights, the joists may be taller or closer together and the cross members also can be taller or closer together.
[0030] FIG. 5 shows a deck surface member 80 placed on the cross members 70 to which it will be affixed with nails, screws or other such fasteners. FIG. 6 shows numerous deck surface members 80 on the cross members. In this embodiment, the deck surface members 80 are initially positioned above the concrete apron 20 . At this height, it is easier to cut deck members 80 to accommodate the pool's outline.
[0031] FIG. 7 shows an access door 90 to the area underneath pool deck. This enables access to the under-deck area for performing final steps of construction and allows access to maintenance of motor pump (not shown) that is required to keep pool empty of water.
[0032] FIG. 8 is a side view of a completed deck 100 , which is raised above concrete apron 20 . The access door also allows entry of items to be stored, such as pool mechanicals, other outdoor equipment or water proof containers.
[0033] FIG. 9 provides a view under deck structure 100 accessed through door 90 . A jack 110 has been placed to raise deck structure 100 a few inches to take pressure off joists 50 and allow removal of blocks 60 a , 60 b , shown in FIG. 2 . Jack 110 then is used to lower the deck structure 100 level to that of the concrete apron 20 .
[0034] FIG. 10 shows completed deck surface 100 flush with surrounding concrete apron 20 . Also shown are the access door 90 and a pump 120 . Through the access door 90 , the pump 120 is lowered and placed at the lowest point of the pool to pump out water from rain or other sources.
[0035] When deck members were individually sized and then attached to the deck, these steps took approximately 3 days for a free-form pool measuring at the maximums 10 feet by 20 feet. When the new pool construction method (using shims and jacks to raise the structure) was invented and used, the construction time decreased to a little over one day. Not only was the time savings huge, but the overall appearance of the deck edge improved. Because the sizing of all the deck members was performed in a smooth, continuous motion, the adjacent deck members had more consistent and attractive blending of edge lines.
EXAMPLE 2
[0036] In this embodiment, a deck structure 100 is constructed as described above, including installing the joist hangers 40 below the decorative tile rim 30 of the pool. However, in this embodiment the joists 50 are placed directly into the hangers without shimming blocks 60 . The rest of the joists are so installed. The cross members are installed the same. However, each deck surface member 80 is individually placed after it has been sized and sawed to the precise length needed at its location on the deck.
EXAMPLE 3
[0037] An additional improvement in the usefulness of the in-pool deck is a reinforced deck capable of accommodating a putting green. Particularly when the pool-using children no longer live at home do the parents' ideas tend to turn to golf. For both their own amusement and the amusement of visitors and to conserve water, people in the southern climates have begun to replace yard structures with artificial putting greens. This is a particularly attractive alternative since artificial grass has greatly improved in appearance and in imitation of a golf course.
[0038] Compared to the above examples, the following changes are contemplated to accommodate a putting green surface over the deck structure. First, the height of the beam hangers needs to be adjusted downward for the height of the overlying structure which may include but is not limited to the following: artificial turf, sand, gravel, crushed granite, a sand impermeable surface, and any height due to reinforcing the structure. The structure may have a plywood floor to create a surface that allows the soil to be supported. Furthermore, additional beam hangers may be needed to accommodate the weight. Moreover, the beam hangers may need to be installed with longer bolts that sink deeper into the pool sides. Additional substructure may be required, such as posts, footings or other structures on or in the pool floor. The deck structure may include some water proofing and a built in slope to allow water to run off to the side.
[0039] On top of the reinforced pool deck surface is placed a mesh to prevent sand from flowing into the pool and disrupting the putting green structure. The mesh permits water to pass through the surface and the deck. On top of the mesh is placed gravel to provide the general contouring for the putting green. On top of the gravel is placed sand to fine-tune the contour. Finally, holes are formed and lined in the surface. Lastly, the artificial grass is laid down. More than one type of artificial grass can be used to give the appearance of a green with surrounding rough or taller grass.
[0040] In another embodiment, there are provided the following layers of deck structure and overlying turf:
1. Vertical posts rest on pool floor and support cross beams. 2. Cross beams span the width of the pool and hang in side hangers. With the infinitely unique shapes of this type of a pool, the cross beams will most likely not be parallel to each other or perpendicular to the side walls. 3. Floor joists rest on the cross beams and run generally the opposite direction as the cross beams. 4. Plywood is placed on top of the floor joists. 5. A waterproof membrane applied to the plywood. 6. Mesh is place at drainage locations to allow water to exit, yet hold in the soil or materials that create the effect of soil under the turf. 7. Artificial turf layers cover the top deck and include, but are not limited to, gravel, sand and artificial grass.
[0048] Decks are made from treated lumber, composite material, Aluminum, Western red cedar, teak, mahogany, and other hardwoods and recycled planks made from high-density polyethylene (HDPE), polystyrene (PS) and PET plastic as well as mixed plastics and wood fiber (often called “composite” lumber).
[0049] A variety of braces, brackets and hangers can be used to support and form the deck structure. For example the bracket that is bolted to the pool wall can be a conventional joist hanger or other conventional bracket used in the industry.
[0050] FIG. 11 is a perspective view of a vertical post 110 connected to a pool floor and to a cross beam in a pool covering structure in accordance with the present invention where cross members rest on a beam or joist which is of sufficient length to require support from beneath at one or more locations between the ends of the beam or joist. A metal connector foot 112 is shown utilizing a bolt with a lag (not visible in the figure) into the plaster and concrete pool floor to connect the vertical post to the pool floor. A metal upper connector 114 fastens the upper end of the vertical post to the beam or joist. FIG. 12 is a perspective view of a beam resting in a beam mount 1116 which is placed on a pool floor portion of a pool seat or pool step 118 (emphasized in the drawing figure with a dotted line) in a pool covering structure in accordance with the present invention where a pre-existing pool step or pool seat has been formed as part of the pool and is at a correct height to accommodate a beam and a beam mount. Where this approach to supporting a beam is used, the beam mount includes pressure treated wood to rest on the pool floor and then the beam rests on the pressure treated wood. The beam is held in place by the rigidity of the structure held together on the top of the beam. In an embodiment in accordance with the present invention, the top of the cross beam holds a tapered shim to give the proper crown and angle to the floor joists.
[0051] FIG. 13 is a perspective view of a metal connector 120 connecting floor joist to a cross beam in a pool covering structure in accordance with the present invention. The floor joists rest on top of the cross beams and are fastened by metal connectors. The metal connectors are used on each end of the floor joist and sometimes on a middle beam if the floor joists are of sufficient length to require same.
[0052] In accordance with an exemplary embodiment of a pool covering structure in accordance with the present invention, a layer of ¾″ tongue and grooved exterior grade plywood is placed over the floor joists and screwed or nailed down. The plywood is placed overlapping the edge of the pool and then carefully cut to fit the shape of the pool. Holes may be cut to accommodate grates, referenced below, which will allow ventilation. A waterproof membrane is placed on top of the plywood and wrinkles removed from the waterproof membrane. The waterproof membrane is typically a one piece sheet of EPDM rubber, or PPL plastic sheet. There may be joints in the waterproof membrane in order to form a single sheet by joining smaller sheets, in which case the seams are glued. A fabric or wire reinforcement is optionally added to the waterproof membrane.
[0053] To provide ventilation, is required by building codes for enclosed spaces, either of two types of ventilation are usable. One type of ventilation employs a grate with a screen mesh placed throughout the surface by framing in the open locations throughout the floor and allowing the membrane to cover the frame perimeter. Another type of ventilation is provided when approximately ¼ to ⅓ of the area is formed as a deck of planks as in a regular deck. The spacing between planks may be set at the maximum amount allowed by the deck plank manufacturer to maximize ventilation for a given deck area. The exemplary pool covering including a deck has a section that is solid and covered in one of several materials as detailed below, and another section which is a traditional deck with deck planks.
[0054] In accordance with the present invention, the pool covering structure may be finished in any of a variety of top covers, in addition to the crushed granite already mentioned above.
[0055] More particularly, in accordance with the present invention, a pool covering structure is provided with a variety of final surface coverings which are similar to one another in the structural support they utilize and which may require a variation in the final height of the plywood layer to which they are applied, so that the overall finished height matches the sides of the swimming pool.
[0056] In one embodiment, a putting green or other turf application is disposed on the previously described layer of plywood. An example of such a product is “Forever Lawn Select LX” brand of turf grass product, available at http://www.foreverlawnarizona.com/LX.html. Other brands and variations could also work in this situation. The turf is placed and cut to size, then stapled or nailed down to the floor. This particular material has a built-in pad which helps cushion the hardness of the floor surface. If this brand is not used, a separate pad may be used under the turf in addition to the layer of turf to provide a cushion. On top of the grass a mixture of special sand and rubber is spread into and mixed into the grass fibers. Additionally, different combinations of putting green grass can be mixed in with the turf listed above. The putting green material is shorter in height, thus allowing the golf ball to roll smoothly. Putting green cups may be placed throughout the deck to provide a challenging choice of putting paths. The turf can also be carried over the edge of the pool covered deck and appear as a continuous extension of the turf, completely hiding the location of the pool.
[0057] In another exemplary embodiment, a putting green is provided on putting green panels. This option is used where a precise putting green is needed. The plywood floor and membrane are the same as other configurations, but the elevation is lowered to accommodate the thickness of the panels. The manufacturer of the panels chosen for this option is “Tour Links” brand, whose website is found at www.tourlinks.net/custom/specs_panels.html. A variety of turfs and putting greens may be used and placed across the deck top with putting green cups and contours to give a challenging choice of putting paths. The contours used would be by the same manufacturer of the putting green panels. This is shown on the web page http://www.tourlinks.net/custom/access_contours.html. The turf may also be carried over the edge of the pool covered deck and appear as a continuous extension of the turf, completely hiding the location of the pool.
[0058] Another exemplary embodiment finishes the pool covering structure as an acrylic deck which is used whenever the final deck surface is desired to imitate a stone or concrete textured surface. The beauty of this product is that it can look exactly like the surrounding surfaces that are placed around the existing pool. It can also bide the existing pool. The manufacturers spec sheet is found on a website at http://westcoat.com/downloads/ALX_Standard_Spec_Sheet.pdf. The available textures and colors are available in a wide range of variety.
[0059] Another exemplary embodiment finishes the pool covering structure in a rubber playground cover, appropriate where a safe playground surface is needed. A swing set or other playground type equipment may be placed upon the deck creating a safe area where children may tumble and play.
[0060] Another exemplary embodiment finishes the pool covering structure as a sport deck similar to the rubber playground. The sport deck is placed down in 12″ squares that link together and are fastened down throughout the surface. This deck provides a surface for balls to bounce on without erratic deflections.
[0061] In another exemplary embodiment of a pool covering structure in accordance with the present invention, a staged installation option is provided to a customer. A first finished installation, which may be, for example, a sport covering having a thickness of ¾ inch, is provided upon a pool covering structure which, by the end of the first finished installation, is positioned with the aid of one or more shims at a height such that the final overall height of the sport covering matches the customer's preference relative to the height of the edge of the pool or the height of the apron. At a later time, at the customer's instance, a second finished installation is provided in which a contoured putting green is provided on top of or as a replacement for the sport covering of the first finished installation. Where the contoured putting green is thicker than the sport covering, the final height of the second finished installation will be equal to that of the first finished installation only if the structure supporting the green is lowered. This is accomplished by removing or replacing one or more of the shims that were left in place in the first finished installation. Jacking may be required in this process. Alternatively, plywood layers of different thicknesses may be provided to accommodate subsequent variations in final surface thickness.
[0062] Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art will appreciate that any arrangement calculated to achieve the same purpose can be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments of the invention. It is to be understood that the above description has been made in an illustrative fashion, and not a restrictive one. Combinations of the above embodiments, and other embodiments not specifically described herein will be apparent to those of skill in the art upon reviewing the above description. The scope of various embodiments of the invention includes any other applications in which the above structures and methods are used. Therefore, the scope of various embodiments of the invention should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.
[0063] It is emphasized that the Abstract is provided to comply with 37 C.F.R § 1.72(b) requiring an Abstract that will allow the reader to quickly ascertain the nature and gist of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
[0064] In the foregoing Detailed Description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Description of Embodiments of the Invention, with each claim standing on its own as a separate preferred embodiment. | A putting green whose perimeter is level with the top of a concrete-sided pool having a decorative ribbon along the top of the pool side and an apron surrounding the pool having at least partially flat surface, the putting green overlying a deck including a) a waterproof surface comprising decking surface members having lengths and ends, the lengths being sized to the dimensions of the pool and the surface being at the same level as the pool apron; b) supports including i. cross members which are perpendicular to the lengths of the decking surface members; ii. underlying joists that form a sturdy base for the cross members; and iii. joist hangers being secured to the sides of the pool below the decorative ribbon along the top of the pool side and being sunk into the concrete side of the pool; and c) a putting green comprising at least the layers of gravel, sand and artificial grass. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to on-site treatment of drilling fluids, mobile systems for treating drilling fluids, methods of their use, and, in certain particular aspects, to such systems and methods that have erectable parts to facilitate fluid processing.
[0003] 2. Description of Related Art
[0004] The prior art discloses a wide variety of systems for treating drilling fluids and methods of their use; for example, and not by way of limitation, see the systems and methods in U.S. Pat. Nos. 7,296,640; 7,022,240; 6,881,349; 6,863,809; 6,808,626; 6,855,261; 6,391,195; 6,193,070; 6,059,977; 5,093,008; 4,595,422; 4,536,286; and 4,474,254—all of said patents incorporated fully herein for all purposes.
[0005] Oil and gas well exploration involves the generation of various fluids and of waste products, including, e.g., fluid wastes, spent drilling fluids, and fracture or return fluids from various operations. Fluids, etc. have been treated and processed both on-site and off-site. U.S. Pat. No. 4,465,598 discloses an off-site method for the precipitation of metals including iron, nickel, chromium, cobalt, and manganese in oil and gas well heavy brines which have been filtered initially to remove solids. U.S. Pat. No. 4,634,533 discloses an oil and gas well brine treatment including an initial oxidizing treatment to convert iron to the ferric state. U.S. Pat. No. 5,814,230 describes an apparatus and method for separation of solids from liquid for use with different processes and describes the separation of solids from a liquid flow using an endless conveyor carrying screen filters which dredge gravity-settled solids from the bottom of a settling tank and filter solids suspended in the flowing liquid. The solids are further dewatered while on the filters using a combination of vibration and air streams. U.S. Pat. No. 4,436,635 describes a filtering process for filtration of oil and gas well treatment fluids.
[0006] Treating fluids, etc., off-site can be uneconomical due to transportation costs. Consequently mobile systems for on-site treatment have been developed, some of which attempt to produce fluid re-usable on-site. U.S. Pat. No. 4,895,665 discloses on-site methods for treating and reclaiming oil and gas well working fluids and the related drilling pits and methods of chemical treatment and filtration of oil and gas well working fluids within associated drilling pits. These methods include preparing a drilling pit for closure through reduction of the fluid content in sludge which is formed in the drilling pit. Treated water can be reused.
[0007] U.S. Pat. No. 5,093,008 describes on-site processes and apparatus for recovering reusable water from waste drilling fluid. The processes involve a dewatering process and apparatus for concurrent reutilization of water in waste drilling fluids from an active drilling operation that includes a storage area, an intermixer for introducing treatment chemicals into the waste drilling fluids, and a centrifuge. Flocculation is chemically induced in the waste drilling fluids as they pass through the intermixing needs for introducing treatment chemicals into the waste drilling fluids. The waste drilling fluids are then transferred to a centrifuge where solid waste is separated from clear, reusable water. The water is returned to the storage area and may be chemically adjusted prior to being returned to the drilling rig.
[0008] U.S. Pat. No. 4,536,286 describes a self-contained, portable waste treatment system for hazardous and non-hazardous waste with a pair of mixing tanks. Solids are removed from fluid waste streams by flocculation and related solids deposition.
[0009] U.S. Pat. No. 7,022,240 discloses an apparatus and method for on-site treatment and reclamation of oil and gas well waste water or fracturing fluids. The mobile treatment process and apparatus provide both chemical precipitation and filtration to treat the drilling fluid waste to a technically and environmentally acceptable level allowing for reuse. Alkaline treating agents are applied to the drilling waste fluids, as they are pumped through the treatment apparatus, to increase the pH of the fluid waste to a preferred pH range and to also cause selective soluble contaminants in the fluids to form a precipitate. The waste fluid is allowed to clarify as the precipitate of insoluble contaminants, through flocculation, settle and form a sludge at the bottom of the drilling pit. The clarified fluids are then filtered to satisfy applicable industry and environmental requirements.
[0010] Single skid mounted apparatus for providing all the components necessary to treat used drilling mud and return a clarified liquid for reuse in an active mud system are disclosed in prior references; e.g., see U.S. Pat. Nos. 4,536,286; 4,474,254; 5,582,727; 6,391,195; and 6,863,809. For example, U.S. Pat. No. 4,536,286 discloses a transportable waste treatment which is completely mobile and capable of treating high mud volumes. This system is self-contained having chemical storage, chemical pumps, sludge pumps, water pumps, laboratory, centrifuge, conveyors etc. and has weight, height and width suitable for highway travel. A skid incorporates three settling tanks and two chemical tanks for flocculation. Waste liquids containing solids enter a first settling tank and are mixed with flocculation chemicals. Solids settle to the tapered bottom of the tank for collection by a suction located at the apex of the tank bottom. Partially clarified liquid from the first settling tank overflows a weir to the next adjacent settling tank and similarly for the second to the third settling tank.
[0011] U.S. Pat. No. 5,582,727 discloses a single structural skid with four settling tanks, each equipped with a shaker and a de-silter. Used drilling mud is routed sequentially from tank to tank. Partially clarified liquid is decanted over weirs to each tank in succession. Fixed suction pumps extract settled solids from the bottom of each tank and route them to the de-silter of each additional and successive tank. Foster does not practice flocculation.
[0012] U.S. Pat. No. 6,391,195 discloses an apparatus for cleaning clearwater drilling muds and a process for treating used drilling mud, particularly that produced during clearwater drilling. A structural and highway transportable skid has two or more settling tanks connected in succession. Flocculation aids settling of solids to the bottom and clarified liquid forms at the surface. Clarified liquid flows from one tank to the next successive tank. Clarified liquid is produced from the last of the successive settling tanks. The tanks have flat bottoms. Passageways extend between each successive tank for gravity-flowing liquid from one tank to successive settling tank. A solids tank or centrifuge is also mounted within the skid. The solids and settling tanks are located for weight-balancing. A rotational suction is positioned in the bottom of each settling tank and having one or more radially extending conduits which rotate about an axis and have inlets at their distal ends which traverse an inscribed circular path about the periphery of the tank's bottom. Collected solids are directed to the solids tank and a drag conveyor transporting solids product outside the skid.
[0013] There has long been a need, recognized by the present inventors, for effective and efficient systems for on-site treatment and processing of well fluids. There has long been a need, recognized by the present inventors, for effective and efficient unitized skid-mounted systems for processing well fluids with centrifuge apparatus.
[0014] U.S. Pat. No. 6,863,809 discloses transportable drilling fluid cleaning systems for removing solids from drilling fluid at a drill site comprises a platform for transporting the system. A bin region on the platform retains solids from the drilling fluid. A settling tank on the platform separates the drilling fluid into an upper fluid fraction having a reduced concentration of solids and a lower solids fraction having a higher concentration of solids as the drilling fluid flows from an inlet chamber for receiving drilling fluid to at least one other chamber. A stand on the platform supports at least one centrifuge for separating the solids from the drilling fluid, the stand being movable between stored and operating positions. The system provides a self-contained unit that is easily transportable on a flat bed truck to provide all the ancillary equipment necessary for solids control at the drill site. In certain aspects such systems include: a platform for transporting the cleaning system to a drill site; a bin region on the platform to retain solids from the drilling fluid; a settling tank on the platform having an inlet chamber to receive drilling fluid and at least one other chamber, the settling tank acting to separate the drilling fluids into an upper fluid fraction having a reduced concentration of solids and a lower solids fraction having a higher concentration of solids as the drilling fluid flows from the inlet chamber to at least one other chamber; and a stand on the platform to support at least one centrifuge for separating the solids from the drilling fluid, the stand being movable between a stored position during transport of the platform and an operating position. In certain of these systems, the platform is skid loadable onto a trailer towable by a vehicle to move the system as a unit.
BRIEF SUMMARY OF THE PRESENT INVENTION
[0015] The present invention discloses, in certain aspects, systems for treating well fluids which are easily transportable; which include erection apparatus for raising system components to facilitate their positioning and operation; and which include removable bracing structures for transport.
[0016] In certain aspects, such systems require no auger apparatus to move material. In certain aspects, such systems employ at least one or one or more cone-bottom tanks with a feed well from which top fluid is skimmed to an adjacent tank via a baffle. The conical bottom converges and concentrates solids for removal or for feed to one, two, or more centrifuges for further processing. In certain particular aspects, using such cone tanks, barite recovery is enhanced since there is one primary suction area or point within the tank. This is also beneficial in oil-based mud solids reduction (stripping) operations to concentrate solids. In such systems, optional agitation enhances chemical and solids/fluid blending and inhibits the accumulation and the undesirable build up of solids on the tank bottoms.
[0017] In certain aspects, systems according to the present invention include raising apparatus for raising a centrifuge support with one or more centrifuges thereon. The centrifuge support has multi-part telescoping vertical legs and the raising apparatus raises the centrifuge support up vertically as the legs telescope out vertically.
[0018] In certain aspects, such systems require relatively less space than certain prior systems. In certain aspects systems according to the present invention weigh about 53,000 pounds, including a centrifuge and can fit on a 43 foot long skid; whereas certain prior systems weigh about 57,000 pounds without a centrifuge.
[0019] Accordingly, the present invention includes features and advantages which are believed to enable it to advance drilling fluid treatment technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.
[0020] What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide:
[0021] New, useful, unique, efficient, non-obvious transportable systems and methods of their use for on-site treatment of well fluids, including drilling fluids and spent drilling fluids with drilled cuttings;
[0022] Such systems and methods with erection apparatus for raising system components vertically to facilitate their positioning and operation; and
[0023] Such systems and methods with the system parts braced with releasable bracing apparatus for stability during movement of the system, e.g. during transport to a remote site.
[0024] Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.
[0025] The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, other purposes and advantages will be appreciated from the following description of certain preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form, changes, or additions of further improvements.
[0026] The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention in any way.
[0027] It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0028] A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or legally equivalent embodiments.
[0029] FIG. 1A is a side view of a system according to the present invention.
[0030] FIG. 1B is a top view of the system of FIG. 1A .
[0031] FIG. 1C is a perspective view of part of the system of FIG. 1A .
[0032] FIG. 1D is a side view of part of the system of FIG. 1A .
[0033] FIG. 1E is a top view of part of the system of FIG. 1A .
[0034] FIG. 1F is a side view of part of the system of FIG. 1A .
[0035] FIG. 1G is a perspective view of part of the system of FIG. 1A .
[0036] FIG. 1H is an end view of the system of FIG. 1A .
[0037] FIG. 1I is an end view of the system of FIG. 1A with part of the system raised.
[0038] FIG. 1J is a perspective view of part of a centrifuge support according to the present invention.
[0039] FIG. 1K is a top view of the support of FIG. 1J .
[0040] FIG. 1L is a perspective view of part of a centrifuge support according to the present invention.
[0041] FIG. 1M is a top view of the support of FIG. 1L .
[0042] FIG. 1N is a perspective view of part of a centrifuge support according to the present invention.
[0043] FIG. 1O is a top view of the support of FIG. 1L .
[0044] FIG. 2 is a perspective view of a tank of the system of FIG. 1A .
[0045] FIG. 3 is a perspective view of part of the system of FIG. 1A .
[0046] FIG. 4 is a perspective view of a shale tank of the system of FIG. 1A .
[0047] FIG. 5A is a side view of a power apparatus for raising a centrifuge support of the system of FIG. 1A .
[0048] FIG. 5B is a side view showing the apparatus of FIG. 5A extended.
[0049] FIG. 5C is a side view showing the apparatus of FIG. 5A extended.
[0050] FIG. 6A is a schematic view of a system according to the present invention.
[0051] FIG. 6B is a schematic view of a system according to the present invention.
[0052] FIG. 6C is a side schematic view of the system of FIG. 6B .
[0053] FIG. 6D is a side cross-section view of part of the system of FIG. 6B .
[0054] FIG. 7 is a side schematic view of a system according to the present invention.
[0055] Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0056] As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein. No feature, aspect, step or element is critical or essential to the invention unless it is specifically referred to herein as “critical” or “essential.”
DETAILED DESCRIPTION OF THE INVENTION
[0057] FIGS. 1A and 1B illustrate a system 10 according to the present invention which has a base which is a skid 12 removably positioned on a trailer 14 . Fluid to be treated (including, but not limited to, spent drilling fluid with drilled cuttings and/or solids therein) is pumped from an active rig system ARS to a first holding tank 30 . A pump 42 pimps fluid from a tank 31 to an active rig pumping system ARS. Flocculant and coagulant is mixed in aqueous solution in the tank 21 with an agitator or impeller 21 a (shown schematically) in the tank. The coagulant, e.g. but not limited to calcium nitrate—CaNO 3 , makes the fluid more of a fluidic semi-solid mixture. A pump or pumps 20 (shown schematically) in a doghouse enclosure 16 pump the fluid-flocculant mixture from the tank 21 to the first holding tank 30 ; and, optionally, to a centrifuge or centrifuges as described below in detail. The doghouse enclosure 16 may also have: pumps for the flocculant mixture 16 a; impeller controls 16 b; hydraulic controls 16 c for power apparatus 78 ; and/or a heater 16 d. Solids that settle down in the tank 30 are pumped by the pump 40 (shown schematically) to a centrifuge 50 (shown schematically, FIGS. 1A , 1 B). Water from the upper part of the tank 30 overflows via water flow apparatus, a baffle 32 , to the tank 31 . Relatively clean water from a feed well 31 w is pumped by the pump 42 , e.g. to storage or to the active rig system ARS. Any desired number of tanks like the tanks 30 and/or 31 may be used.
[0058] A sensor system 42 s signals the pump 42 to control the amount of water sent to the rig system ARS. Solids with some fluid from the lower part of the tank 31 (and from lower the part of the tank 30 ) are pumped by the pump 40 to the centrifuge 50 (one or two or more centrifuges 50 may be used). Relatively clean water from the upper part of the tank 30 flows via the baffle 32 to the tank 31 and is then pumped to the active rig system ARS by the pump 42 . Fluid (including water and some drilling fluid) with solids in it is pumped by the pump 40 to the centrifuge 50 . In one aspect the tanks 30 and 31 have conical bottoms 30 c and 31 c, respectively, to facilitate solids movement and flow.
[0059] Centrifuge underflow (drilled solids separated in the centrifuge by centrifugal force) flows from the centrifuge 50 down into a tank 60 . This underflow is then transferred to a holding tank or pit for storage and/or further treatment.
[0060] The system 10 includes a structure 70 with a plurality of interconnected beams, members, bars, supports and pieces 70 p. Some of these pieces 70 p form upper walkways 70 w and hand rails 70 h.
[0061] To buttress the system 10 and the structure 70 during transport and movement, a removable brace apparatus 80 is releasably connected to the structure 70 and to the skid 12 . The apparatus 80 includes four beams 82 each with an end 83 releasably connected to the skid 12 and with another end 84 releasably connected to the structure 70 . As shown in FIG. 1D a removable pin 85 releasably secures an end 83 to the skid 12 . Pins 87 releasably secure the ends 85 to the structure 60 . The pins are removed and the beams 82 are removed following positioning of the system at a site. Four beams 82 are shown, but two, three, five, six or more can be used. The beams 82 do not prevent erection of the centrifuge support 74 described below.
[0062] As shown in FIG. 1G the structure 70 includes a centrifuge support 74 with legs 75 and 76 . A power apparatus 78 (e.g. an hydraulic piston apparatus powered by an available hydraulic power unit 78 h, shown schematically, FIG. 1I ) can raise the centrifuge support 74 up vertically with respect to lower legs 76 of the structure 70 . FIG. 1I shows the legs 75 raised with respect to the legs 76 . The legs 75 telescope out of and up from the legs 76 .
[0063] FIG. 1H shows the centrifuge support 74 in a lowered position and FIG. 1I shows it in a raised position. An extension ladder 77 extends upwardly as the centrifuge support 74 is raised.
[0064] The centrifuge 50 produces the underflow described above and a stream 52 of clean drilling fluid which can be fed into a line 50 l by gravity flow to the line 31 m for return to the active rig system ARS.
[0065] The tanks 30 , 31 are shown as “cone” tanks with a bottom shaped to converge solids; but it is within the scope of other aspects of the present invention to use other tanks, e.g. with non-conical bottoms or with flat bottoms.
[0066] FIGS. 1J-1O illustrate various possibilities according to the present invention for solids discharge from one or two centrifuges on a support 74 . FIGS. 1J and 1K show a support 74 a for one centrifuge 74 k (shown schematically in dotted lines) with a single solids discharge channel 74 b. FIGS. 1L and 1M show a support 74 c with a single solids discharge channel 74 d. FIGS. 1N and 1O show a support 74 e with two solids discharge channels 74 f, 74 g for centrifuges 74 m, 74 n (in dotted lines) (or alternatively, 74 h, 74 i —shown in dotted lines). Any two discharges shown in FIG. 1O may be used.
[0067] In certain particular aspects the overall footprint of a system according to the present invention is 42 feet by 8 feet and the footprint of one particular old system is 40 feet by 32 feet.
[0068] FIGS. 5A-5C illustrate various positions for the hydraulic ram apparatus 78 .
[0069] FIG. 6A shows schematically a system 100 like the system of FIG. 1A . Two centrifuges 101 , 102 are like the centrifuge 50 ; and tanks 130 , 131 correspond, respectively, to the tanks 30 , 31 . A tank 160 corresponds to the tank 60 ; a pump 142 corresponds to the pump 42 ; and an active rig system ART corresponds to the active rig system ARS.
[0070] As shown in FIG. 6A the system 100 is useful, e.g. in typical drilling operations. A slurry from the active rig system ART fed to the tank 130 with solids material therein is pumped by a pump 151 to the centrifuge 101 in a feed line 137 . The underflow (with solids and drilled solids) from the centrifuge 101 is gravity fed to the tank 160 . The overflow from the centrifuge 101 is gravity fed to the tank 130 or back to the system ART. From the tank 130 , a pump 152 pumps fluid with solids in a feed line 135 to the centrifuge 102 . Overflow from the centrifuge 102 flows by gravity to the active rig system ART or to the tank 130 . Underflow from the centrifuge 102 flows to the tank 160 .
[0071] The tank 130 can overflow to the tank 131 via a baffle 132 .
[0072] The centrifuge overflows of centrifuges 101 and 102 are primarily cleaned fluid and the underflows contain drill solids for return to the tank 160 . Pump suction from the pump 151 and/or the pump 152 is applied to the line 133 to pump from both tanks 130 and 131 .
[0073] Relatively clean fluid is pumped by the pump 142 in a line 144 to the active rig system ART.
[0074] In one particular aspect the system 100 is used for barite recovery, as shown in FIGS. 6B and 6C . A slurry from the active rig system ART with barite material therein is pumped from a line 138 by the pump 151 in the line 137 to the centrifuge 101 . The underflow (primarily barite and/or drilled solids) is jetted by a line 137 and is gravity fed to the system ART in a line 139 . The overflow from the centrifuge 101 is gravity fed in the line 134 to the tank 130 . Material from the tank 130 is pumped by the pump 152 in the line 135 to the centrifuge 102 . Overflow from the centrifuge 102 flows by gravity to the system ART. Underflow from the centrifuge 102 flows to the tank 160 .
[0075] Centrifuge 101 underflow contains recoverable barite which is returnable to the active rig system ART. The jet line 107 is fed by the line 137 . The jet line 107 is a line with pressurized fluid for inhibiting plugging by barite and for moving the barite to the system ART. In one aspect fluid from the line 137 is oil based fluid at about 25 psi. FIG. 6D illustrates the exit of barite solid particles from the centrifuge 101 . This barite flows by gravity or is pumped.
[0076] FIG. 7 shows one particular embodiment for the tanks 30 , 31 and associated pumps 40 and 42 . Slurry from the active rig system is introduced into the tank 30 via an inlet 30 r. The slurry contains drilling fluid, drill solids or drilling solids (desirable solids added to drilling fluid), drilled solids (e.g. drilled cuttings) and debris. The mixture from the tank 21 is fed to the tanks 30 , 31 (“FLOC MIX ENTRY”). The pump 40 pumps a mixture of solids and some other components to the centrifuge(s) 50 . The pump 42 pumps water from the tank 31 back to the active rig system ARS. The pump 42 is connected to, and in fluid communication with, the feed well of the tank 31 . Water pumped by the pump 42 comes to it directly from the feed well of the tank 31 .
[0077] Optionally, agitators ADJ with impellers L agitate the fluid in the tanks.
[0078] The present invention, therefore, provides in at least certain embodiments, a system for well fluid treatment, the system being transportable, the system including: a base; a support structure on the base; a brace apparatus connected to the base and to the support structure for bracing the support structure during movement of the system, the brace apparatus releasably secured to the support structure and releasably secured to the base; at least one holding tank on the base for holding well fluid to be treated, the well fluid to be treated from an active rig well fluid system and the well fluid to be treated including solids; centrifuge apparatus for centrifuging a mixture of well fluid and solids from the at least one holding tank, producing a reusable component of the well fluid; a first pump apparatus for pumping well fluid and solids from the at least one holding tank to the centrifuge apparatus; and a centrifuge support on the base for supporting the centrifuge apparatus. Such a system may have one or some, in any possible combination, of the following: a mixing tank for mixing materials in aqueous solution for introduction to well fluid in the at least one holding tank, and a second pump apparatus for pumping materials in aqueous solution from the mixing tank to the at least one holding tank; wherein the materials in aqueous solution include flocculant and coagulant; raising apparatus connected to the centrifuge support for raising the centrifuge support and the centrifuge apparatus to a desired height; wherein the raising apparatus raises the centrifuge support up vertically; wherein the raising apparatus includes hydraulically powered piston apparatus for raising the centrifuge support; wherein the at least one holding tank has a conical bottom for facilitating solids concentration and movement; the at least one holding tank is two holding tanks including a first holding tank, a second holding tank adjacent the first holding tank, the second pump apparatus pumping the materials in aqueous solution into the first holding tank, and the first holding tank receiving the well fluid to be treated; water flow apparatus via which water is flowable from the second holding tank to the first holding tank; a third pump apparatus for pumping water from the first holding tank; wherein the third pump apparatus pumps the water to one of the active rig well fluid system and storage; wherein the well fluid to be treated includes drilled solids and the centrifuge apparatus produces an overflow of cleaned well fluid for feed back to the active rig well fluid system, and the centrifuge apparatus produces an underflow of drilled solids; the centrifuge apparatus includes a plurality of centrifuges for processing fluid with solids from the at least one holding tank; wherein the well fluid to be treated contains recoverable barite solids and the centrifuge apparatus produces an underflow with recovered barite solids for feed to the active rig well fluid system, and the centrifuge apparatus produces an overflow for feed to the at lest one holding tank; and/or a jet line for providing fluid under pressure to the recovered barite solids to facilitate flow of the recovered barite solids to the active rig well fluid system.
[0079] The present invention, therefore, provides in at least certain embodiments, a system for well fluid treatment, the system being transportable, the system including: a base; a support structure on the base; a brace apparatus connected to the base and to the support structure for bracing the support structure during movement of the system, the brace apparatus releasably secured to the support structure and releasably secured to the base; at least one holding tank on the base for holding well fluid to be treated, from an active rig well fluid system and the well fluid to be treated including drilling solids and drilled solids; centrifuge apparatus for centrifuging a mixture of well fluid and solids from the at least one holding tank, producing reusable drilling solids; a first pump apparatus for pumping well fluid and drilling solids from the at least one holding tank to the centrifuge apparatus; a centrifuge support on the base for supporting the centrifuge apparatus; a mixing tank for mixing materials in aqueous solution for introduction to well fluid in the at least one holding tank; a second pump apparatus for pumping materials in aqueous solution from the mixing tank to the at least one holding tank; and wherein the materials in aqueous solution include flocculant and coagulant.
[0080] The present invention, therefore, provides in at least certain embodiments, a method for treating well fluid with drilling fluid, drilled solids, and drilling solids therein, the well fluid from an active rig well fluid system, the method including providing well fluid to a well fluid treatment system from an active rig well fluid system, the well fluid treatment system as any described or claim herein according to the present invention, and producing reusable material with the centrifuge apparatus of the well treatment system. Such a method may have one or some, in any possible combination, of the following: the centrifuge apparatus producing a stream of reusable drilling solids, and returning the stream of reusable drilling solids to the active rig well fluid system; and/or the centrifuge apparatus producing a stream of reusable fluid, and returning the stream of reusable fluid to the active rig well fluid system.
[0081] The present invention, therefore, provides in at least certain embodiments, a method for transporting a well fluid treatment system, the well fluid treatment system including well fluid treatment apparatuses secured to a support structure, the support structure secured to a base, the method including connecting bracing apparatus releasably to the base and to the support structure to brace the well fluid treatment system during movement of the well fluid treatment system.
[0082] The present invention, therefore, provides in at least certain embodiments, a method for moving a centrifuge support with centrifuge apparatus thereon of a well fluid treatment system, the method including raising with raising apparatus the centrifuge support with centrifuge apparatus thereon, said raising being raising the centrifuge support up vertically.
[0083] In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. §102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35 U.S.C. §103 and satisfies the conditions for patentability in §103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. §112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | A system for well fluid treatment, the system being transportable, the system including a base, a support structure on the base, a brace apparatus connected to the base and to the support structure for bracing the support structure during movement of the system, the brace apparatus releasably secured to the support structure and releasably secured to the base, at least one holding tank on the base for holding well fluid to be treated, from an active rig well fluid system and the well fluid to be treated including solids, centrifuge apparatus for centrifuging a mixture of well fluid and solids from the at least one holding tank, producing reusable fluid, a first pump apparatus for pumping well fluid and solids from the at least one holding tank to the centrifuge apparatus, and a centrifuge support on the base for supporting the centrifuge apparatus. The system including a mixing tank for mixing materials in aqueous solution for introduction to well fluid in the at least one holding tank, and a second pump apparatus for pumping materials in aqueous solution from the mixing tank to the at least one holding tank. The system wherein the materials in aqueous solution include flocculant and coagulant. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b). |
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[0001] This application claims the benefit of the filing date of and is a continuation-in-part of United States Utility Patent Application having a title of DECORATIVE GRID SYSTEM AND METHOD, filed on Jan. 24, 2006 and assigned Ser. No. 11/338,357.
FIELD OF THE INVENTION
[0002] The technology described herein relates generally to the field windows and more particularly to a decorative grid and muntin system and method.
BACKGROUND OF THE INVENTION
[0003] Muntins are typically used in many types of windows in order to provide decoration for both insulated glass also known as Grill-Between-Glass (“GBG”) and Simulated Divided Lite (“SDL”) windows. Insulated glass (IG) windows are known as multiple panes of glass, typically two panes, being spaced thereby creating an air space between the panes. The panes are sealed, thereby becoming what is considered a single pane of glass having an insulating air space. GBG windows are advantageous because the insulating barrier between the panes results in energy conservation. Prior to sealing the two panes together, muntins are often placed between the panes to provide decoration.
[0004] Typical muntins are metal, plastic or wood. Regardless of the type of material, muntins present several problems in the GBG windows. For example, excessive heating and exposure to sunlight cause the muntins to warp and discolor causing a permanent unaesthetic appearance of the GBG window. Furthermore, the heat and light causes outgassing of the muntins, which is the release of moisture, liquid and/or chemical gases from the material.
[0005] The outgassing causes the moisture to be retained between the panes resulting in permanent clouding on the panes of glass that cannot be removed. For several of the materials used in present muntins, expensive and prolonged treatment, such as painting and heat curing, is required before placement of the muntins between the panes of glass. Muntins can also be used on SDL glass to give the appearance of True Divided Lite (“TDL”) windows, which are typically more difficult and time consuming to manufacture. The use of muntins for SDL windows can also cause similar problems associated with GBG window muntins, such as warping and discoloring, often cause by heat, sunlight and local outgassing.
[0006] These and other problems exist. Previous attempts to solve these and other problems include U.S. Pat. No. 7,318,301.
[0007] The foregoing patent reflects the state of the art of which the inventor is aware and is tendered with a view toward discharging the inventor's acknowledged duty of candor in disclosing information that may be pertinent to the patentability of the technology described herein. It is respectfully stipulated, however, that the foregoing patent and other information do not teach or render obvious, singly or when considered in combination, the inventor's claimed invention.
BRIEF SUMMARY OF THE INVENTION
[0008] In general, the technology described herein features a decorative (muntin) system and method. The muntins are formed from a substrate of expanded cellular polyvinyl chloride (“PVC”) material that has been applied with a desired muntin shape and machined by a computerized numerically controlled (CNC) machine.
[0009] In general, in one aspect, the technology described herein features a window system, including a pane of glass and a window muntin located adjacent the pane of glass, wherein the window muntin is formed from a substrate of expanded cellular polyvinyl chloride (“PVC”) material.
[0010] In one implementation, the substrate of expanded cellular polyvinyl chloride material is ultraviolet (UV) resistive.
[0011] In another implementation, the pane of glass and the muntin are adhered together as an SDL application.
[0012] In another implementation, the system further includes a second pane of glass generally parallel to the pane of glass, the muntin being located therebetween.
[0013] In another implementation, the system further includes a spacer connected along outer edges of the panes of glass and the muntin.
[0014] In another implementation, the panes of glass and the muntin are connected together in a GBG configuration.
[0015] In another aspect, the technology described herein features a method of manufacturing a window muntin, including creating a design of the window muntin, forming a substrate of expanded cellular polyvinyl chloride (“PVC”) material, forming the design of the window muntin on the substrate of the expanded cellular polyvinyl chloride (“PVC”) material and cutting the design of the window muntin from the substrate of the expanded cellular polyvinyl chloride (“PVC”) material.
[0016] In another aspect, the technology described herein features an improved window muntin being positioned between two panes of glass and sealed there-between, wherein the improvement comprises means for eliminating the outgassing and UV deterioration of the muntin.
[0017] In another implementation, the technology described herein features an improved method of forming a window of the type having two panes of glass having a space defined therebetween, the spaces being sealed from external environmental conditions, the improvement comprising forming a muntin for placement within the airspace prior to sealing the airspace, the muntin being formed by a substrate of expanded cellular polyvinyl chloride (“PVC”) material.
[0018] In another aspect, the technology described herein features a window muntin made by the process, including forming a planar sheet from a substrate of expanded cellular polyvinyl chloride (“PVC”) material, forming a decorative grid design on the planar sheet and cutting out the decorative grid design with a computerized numerically controlled (CNC) machine to form the muntin.
[0019] In one implementation, the process further includes optionally smoothing rough portions from the muntin and optionally finishing the muntin with at least one of paint and stain, and optionally air dried.
[0020] In another implementation, the process further includes placing the muntin in a Grill-Between-Glass (GBG) configuration.
[0021] In another implementation, the process further includes placing the muntin in a Simulated Divided Lite (SDL) configuration.
[0022] One advantage of the technology described herein is that it provides a muntin that does not degrade or warp.
[0023] Another advantage of the technology described herein is that it provides a muntin that does not yellow, fade or otherwise discolor.
[0024] Another advantage of the technology described herein is that it provides a muntin that does not require heat curing during production.
[0025] Another advantage of the technology described herein is that it provides a muntin that does not offgas.
[0026] Another advantage of the technology described herein is that it provides a muntin that does not contribute to moisture sealed between double pane windows.
[0027] Another advantage of the technology described herein is that it provides a muntin that does not absorb moisture.
[0028] Another advantage of the technology described herein is that it provides a muntin that can be painted or otherwise coated or not and air dried.
[0029] Another advantage of the technology described herein is that it can easily be beveled, textured or otherwise shaped.
[0030] Another advantage of the technology described herein is that a unitary one piece window muntin can be manufactured.
[0031] Another advantage of the technology described herein is that the methods described herein can be used to form window muntins as well as muntins for doors and other shaped windows.
[0032] There are additional features of the technology that will be described hereinafter and which will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the technology in detail, it is to be understood that the technology described herein is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The technology described herein is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0033] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the technology described herein. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the technology described herein.
[0034] Other objects, advantages and capabilities of the technology described herein are apparent from the following description taken in conjunction with the accompanying drawings showing the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The technology described herein is illustrated with reference to the various drawings, in which like reference numbers denote like system components and/or method steps, respectively, and in which:
[0036] FIG. 1 illustrates an embodiment of a window muntin 100 formed of expanded cellular polyvinyl chloride (“PVC”) material and shaped into a desired configuration;
[0037] FIG. 2A & FIG. 2B illustrate two embodiments of muntin retaining pins;
[0038] FIG. 3 illustrates an end view of an embodiment of the muntin as illustrated in FIG. 1 showing holes drilled into ends; and
[0039] FIG. 4 illustrates an embodiment of a GBG window system.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Before describing the disclosed embodiments of this technology in detail, it is to be understood that the technology is not limited in its application to the details of the particular arrangement shown here since the technology described is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
[0041] The embodiments described herein can be used for a large variety of muntin types, including but not limited to GBG and SDL windows. Regardless of the type of window, the muntin is typically formed by creating a desired muntin pattern on a substrate or board of expanded cellular polyvinyl chloride (“PVC”). The desired pattern is then cut from the board, typically using a CNC overhead router previously drawn on a CAD program. In a typical embodiment, the board used to form the muntins from the computerized numerically controlled (CNC) overhead router is 5′×10′. In addition, the board can generally have a thickness of 0.238-1.27 cm, and having typical thickness of, including but not limited to 0.318, 0.635 and 0.953 cm.
[0042] Typical muntins have a larger variety of shapes and sizes. FIG. 1 illustrates an embodiment of a window muntin 100 formed of expanded cellular polyvinyl chloride (“PVC”) and shaped into a desired configuration. In the embodiment, the muntin 100 has a semi-circular inner rim 105 having terminal ends 110 , 115 and three protruding bars 120 connected generally along the circumference of the inner rim 105 . A patterned outer rim 130 is connected to the ends of the bars 120 , the outer rim 130 being generally concentric with the semi-circular inner rim 105 . The outer rim 130 typically includes terminal ends 135 , 140 . It is appreciated that the rims 105 , 130 and bars 120 are typically an integral piece formed and cut from the expanded cellular polyvinyl chloride (“PVC”), and share a common plane of orientation.
[0043] After the cutting machine has cut out the muntin 100 , the muntin 100 is typically checked for smoothness. If desired, the muntin 100 can be sanded, typically with fine grit sandpaper and then cleaned. When a desired texture is achieved the muntin 100 is optionally painted or stained. When the paint has cured, the muntin 100 can be further processed, the processing depending on the muntin 100 types. For grid between glass (GBG) muntins, as shown with muntin 100 in FIG. 1 , a 0.159 cm ( 1/16 inch) wide hole is typically drilled into the ends of the bars 120 , and the terminal ends 110 , 115 of the inner rim 105 and the terminal ends 135 , 140 , of the outer rim 130 . The holes are drilled parallel to the plane of orientation, to a depth generally ranging from about 0.841 to 1.27 cm. It is understood that a variety of depths are possible depending on the application. A retaining pin 150 is used to connect the muntin 100 to its final position between panes of glass typically to a spacer as described further below, directly into a frame or into other orientation.
[0044] FIG. 2A and FIG. 2B illustrate two embodiments 150 a , 150 b of retaining pins 150 as just described. In one embodiment, the retaining pin 150 a is a pin having a generally planar head 155 , which can be square or rectangular, and a shaft 165 having a depth suitable to fit into holes drilled into the ends 110 , 115 , 135 , 140 as described above. The shaft 165 can further be advantageously tapered at the end in order to provide ease of insertion into the holes and thicker toward the head 155 to provide a snug fit. The head 155 can further include one or more dimples 160 positioned along an upper surface 156 of the head 155 , the dimples 160 generally providing a frictional fit when placed adjacent a spacer as described further below.
[0045] In another embodiment, the retaining pin 150 b is an elongated cylindrical shaft having tapered ends for affixation into the holes of the ends 110 , 115 , 135 , 140 as described above and for insertion into holes provided on window frames when fit directly into structures.
[0046] FIG. 3 illustrates an end view of an embodiment of the muntin 100 as illustrated in FIG. 1 showing holes 111 drilled into ends 110 , 115 .
[0047] FIG. 4 illustrates an embodiment of a GBG window system 200 . The system 200 includes an embodiment of a muntin 100 as described above. The muntin 100 is connected to a spacer 205 that is connected to a window frame 210 . As described above, either embodiment of the connector pins 150 a , 150 b can be used to connect the muntin 100 to the spacer 205 .
[0048] In another implementation, the muntin 100 can be formed as described for GBG use, but be modified for SDL use. For SDL muntins, no holes are typically drilled into the ends 110 , 115 , 135 , 140 . Instead, one side of the SDL muntin is wiped clean providing a clean, smooth and dry surface onto which adhesive, such as two-sided tape can be affixed for subsequent attachment to glass for an SDL window.
[0049] In one embodiment the technology described herein is a window system, comprising: a first pane of glass; a second pane of glass generally parallel to the first pane of glass; a window muntin located therebetween the first pane of glass and the second pane of glass, where the window muntin is formed from a substrate of UV resistive expanded cellular polyvinyl chloride (“PVC”) material, and the first pane of glass, the second pane of glass and the window muntin are adhered together as a Simulated Divided Lite (“SDL”) configuration; and a spacer disposed along outer edges of the panes of glass and the muntin.
[0050] In another embodiment the technology described herein is a window system, comprising: a pane of glass; and a window muntin located proximate the pane of glass, where the window muntin is formed from a substrate of expanded cellular polyvinyl chloride (“PVC”) material. In this window system the pane of glass and the window muntin are adhered together as a Simulated Divided Lite (“SDL”) configuration.
[0051] In another embodiment the technology described herein is a window system, comprising: a pane of glass; and a window muntin located proximate the pane of glass, where the window muntin is formed from a substrate of expanded cellular polyvinyl chloride (“PVC”) material. This window system is further comprised of a second pane of glass generally parallel to the pane of glass, the muntin being located therebetween; it is furthermore comprised of a spacer disposed along outer edges of the panes of glass and the muntin. In one implementation the panes of glass and the muntin are connected together in a GBG configuration and are further comprised of means for eliminating outgassing and UV deterioration of the muntin.
[0052] The technology described herein includes a method of manufacturing a window muntin, the method comprising: creating a design of the window muntin; forming a substrate of expanded cellular polyvinyl chloride (“PVC”); forming the design of the window muntin on the substrate of expanded cellular polyvinyl chloride (“PVC”) material; and cutting the design of the window muntin from the substrate of the expanded cellular polyvinyl chloride (“PVC”) material.
[0053] The technology described herein includes an improved method of forming a window having two panes of glass having an airspace defined therebetween, the airspace being sealed from external environmental conditions, the improvement comprising forming a muntin for placement within the airspace prior to sealing the airspace, the muntin being formed from a substrate of expanded cellular polyvinyl chloride (“PVC”) material.
[0054] The technology described herein includes a window muntin made by the process, comprising: forming a planar sheet from a substrate of expanded cellular polyvinyl chloride (“PVC”) material; programming a CNC machine to form a decorative grid design on the planar sheet; and cutting out the decorative grid design with a CNC machine to form the muntin. This process further comprises: optionally smoothing rough portions from the muntin; and optionally finishing the muntin with a coating chosen from the group consisting of paint and stain. This process further comprises placing the muntin in a Grill-Between-Glass (“GBG”) configuration or placing the muntin in a Simulated Divided Lite (“SDL”) configuration.
[0055] The foregoing description and drawings comprise illustrative embodiments of the technology described herein. Having thus described exemplary embodiments of the technology described herein, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of a method in a certain order does not constitute and limitation on the order of the steps of the method. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the technology described herein will come to mind to one skilled in the art to which this technology described herein pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the technology described herein is not limited to the specific embodiments illustrated herein, but is limited only by the following claims.
[0056] Although this technology has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples can perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the invention and are intended to be covered by the following claims. | A window muntin apparatus and system, and methods for forming the same is disclosed. The muntins are formed from a substrate of expanded cellular polyvinyl chloride (“PVC”) that has been applied with a desired muntin shape and machined by a computerized numerically controlled (CNC) machine such as a 3-axis router. Muntins are then sealed between two pieces of glass to create a sealed insulated glass unit. |
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BACKGROUND OF THE INVENTION
This invention relates to a semi-automatic hydraulic excavator.
In hydraulic excavators such as a loading shovel and a power shovel, a number of control levers such as a boom lever, an arm lever, a bucket lever and a rotation lever are provided. An operator manually operates these control levers to control the corresponding hydraulic control valve and thereby carries out work such as excavating and dumping soil. When a sequence of work, for example, excavating soil, dumping the excavated soil into a dump truck and then bringing the bucket back into the excavation posture for another excavation is to be carried out with a loading shovel, plural operations must be conducted simultaneously, i.e. a compound operation must be performed.
In a conventional hydraulic excavator, an operator is required to carry out such compound operation, and accordingly the operator must be highly skilled and even a highly skilled operator should put forth tremendous efforts which bring about deal of fatigue. It is also disadvantageous that in a large loading shovel in the prior art it is fairly difficult to watch the movement of the bucket from the operator's seat and the bucket is likely to be destroyed by mistakenly hitting against the front part of the track thereof.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to eliminate the above-described disadvantages in conventional hydraulic excavators.
It is another object of this invention to provide a semi-automatic hydraulic excavator wherein the control system of a hydraulic excavator is semi-automatized to such extend that after dumping the excavated soil, the arm cylinder and bucket cylinder are automatically controlled in accordance with an operation of the boom lever so as to bring the bucket back automatically to the excavation posture.
It is still another object of this invention to provide a semi-automatic hydraulic excavator capable of returning the bucket to the excavation posture with small efforts even by a low-skilled operator as well as alleviating operator's fatigue.
It is further object of this invention to provide a semi-automatic hydraulic excavator whose control device is simple in construction, easy to attach to a conventional hydraulic excavation and enables manual control as performed in a conventional excavator together with the above-described automatic control.
These and further objects, features and advantages of this invention will become more obvious from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, one embodiment in accordance with this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is an explanatory diagram showing each part of a hydraulic loading shovel.
FIG. 2 is a block diagram showing one embodiment of a control device for a semi-automatic hydraulic excavator according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of a semi-automatic hydraulic excavator according to this invention is described in detail with reference to the accompanying drawings. For convenience in description, the semi-automatic hydraulic excavator is a loading shovel by way of example.
Referring to FIG. 1, a boom 2, an arm 3 and a bucket 4 are independently controlled by means of a boom cylinder 5, an arm cylinder 6 and a bucket cylinder 7, respectively. A bottom cylinder 8 (shown in a broken line) controls the bucket 4 so as to bring the bottom 4a thereof into a posture 4a' (shown in a chain line) so as to split the bottom 4a of the bucket 4 for dumping excavated soil. In FIG. 1, rotation supporting points of the boom 2, the arm 3 and the bucket 4 are called O, A and B, respectively, and angles between a vertical surface containing the supporting point O and a line segment OA, between an extension of the line segment OA and a line segment AB, and between the extension of the line segment AB and a line segment BC are called a boom angle α, an arm angle β and a bucket angle γ, respectively. Point C represents the edge of the bucket 4.
In this invention, it is so designed that after dumping the excavated soil, the bucket 4 is returned to the original excavation posture by automatically controlling the arm cylinder 6 and the bucket cylinder 7 during the period when the boom cylinder 5 is manually controlled. All of the rest of the operations, namely operations for excavation work, raising the boom after excavation, rotating the rotation body 1a leftward (or rightward) and opening the bucket bottom are designed to be manually controlled.
Referring to FIG. 2, an arm angle detector 60 and a bucket angle detector 61 are provided at the rotation supporting points A and B of the arm 3 and the bucket 4 respectively. These arm angle detector 60 and bucket angle detector 61, which can be, for example, rotary potentiometers, respectively detect the arm angle β and the bucket angle γ and then output the corresponding arm angle signal eβ and bucket angle signal eγ.
Levers 11 to 15 respectively send out lever control signals Ea to Ef corresponding to the operation angle of each lever, and at the same time in case of the levers 13, 14 and 15, in particular, send out signals Vc, Vd and Vf which indicate that the lever is being operated, that is, the lever is not in the neutral position.
A manual-auto changeover switch 16 in a control device 10 is for selecting the control mode of the arm cylinder 6 and the bucket cylinder 7 from manual to automatic and vice versa and sends out signal "0" for the manual mode and "1" for the automatic mode.
A control circuit 20 sends out, when receiving the boom lever control signal Ec, the bottom lever control signal Ed and the rotation lever control signal Ef together with the boom lever operation signal Vc, the bottom lever operation signal Vd and the rotation lever operation signal Vf, an automatic control command signal e c which determines control mode in the operation of the arm 3 and the bucket 4 when bringing the bucket 4 into the original excavation posture after dumping the excavated soil. After the bucket 4 scooped up the excavated soil, raise the bucket 4 and rotate the rotation body 1a up to the dumping place. When the dumping place is located in the right side from the operator's seat, rotate the rotation body rightward and when the dumping place is in the left side, rotate it leftward so as to bring the bucket 4 above the dumping place. Then by operating the bottom lever 14, split the bottom of the bucket 4 so as to dump the excavated soil. After dumping, while operating the rotation lever 15 in the direction opposite to that taken previously, control the boom lever 13 downward. The automatic control command signal e c is produced from the time when the boom lever 13 starts to be operated downwardly until it stops. The rotation lever 15 is brought back to the neutral position for ending the rotation when the rotation body 1a comes to be directed to the original excavation posture.
An arm angle setter 30 is for setting the arm angle β in the excavation posture. That is, when the arm angle at a predetermined excavating posture is βo, the arm angle setter 30 sets this angle βo and sends out the corresponding signal Eβo.
A bucket angle setter 31 is for setting the bucket angle γ in the excavation posture. That is, when the arm angle βo is set in the arm angle setter 30, the bucket angle setter 31 sets the bucket angle γo for said arm angle βo and sends out the corresponding signal Eγo .
Upon receipt of the automatic control command signal e c , manual-auto return switches 36 and 37 of a switch device 35 is switched from contact a to contact b.
When excavation is ready, the boom 2, the arm 3 and the bucket 4 take such relative position to each other as shown in FIG. 1, in which the bottom surface 4b of the bottom 4a of the bucket 4 flatly contacts with the excavation surface. At this time, the bottom cylinder 8 is being expanded and therefore the bottom 4a of the bucket 4 is being closed. The manual-auto changeover switch 16 is being switched to "manual" side and therefore the automatic control selection signal Es is not being sent out. Accordingly, the automatic control command signal e c is not sent out from the control circuit 20 and the manual-auto return switches 36 and 37 of the switch device 35 are switched to contact a, respectively, thereby enabling the bucket 4 to be manually controlled.
In the above state, when an operator operates the arm lever 11 and the bucket lever 12, the lever control signals Ea and Eb are sent out corresponding to the lever angles of these levers 11 and 12, and applied, via amplifiers 40 and 41, to hydraulic control valves 50 and 51, respectively. These hydraulic control valves 50 and 51 expands the arm cylinder 6 and the bucket cylinder 7 according to the signals Ea and Eb, respectively, thereby the bucket 4 is pushed forward horizontally (in the direction of arrow A in FIG. 1) for excavation.
When the excavation ends, the operator stops operating the arm lever 11 and the bucket lever 12, and then starts operating the boom lever 13 and the rotation lever 15. The lever control signals Ec and Ef are sent out corresponding to the operation of these levers and are applied to amplifiers 42 and 44. Hydraulic control valves 52 and 54 are actuated in accordance with the signal Ec and Ef which are amplified through the amplifiers 42 and 44. These valves 52 and 54 then drive the boom cylinder 5, the rotation cylinder (not shown in the drawings) so as to raise the bucket 4 to a predetermined height while rotating it in the direction where a dump truck (not shown in the drawings) is waiting in the predetermined place, thus bringing the bucket 4 right above the dump truck.
Then the operator operates the bottom lever 15 to the bottom split position. In response to this lever operation, the signal Ed is output, which actuates hydraulic control valve 53 and drives the bottom cylinder 8, thereby splitting the bottom of the bucket 4 so as to dump the soil on said dump truck.
By taking the procedure as described above, the work from excavation through dumping is carried out.
When the semi-automatic control according to this invention is to be performed for the operation to return the bucket from the dumping posture to the original excavation posture, the manual-auto changeover switch 16 should be switched to "auto". After completion of the dumping, the operator controls only the bottom lever 14, the rotation lever 15 and the boom lever 13 so as to close the bottom of the bucket 4 and lower the boom 2 while rotating the rotation body 1a. With the aid of the arm angle setter 30 and the bucket angle setter 31 which memorize the original excavation position of the bucket, the bucket 4 can be brought back into the original excavation posture.
The detail of the control circuit 20 is shown in FIG. 2 in which a comparator 20a compares the lever operation signal Vc of the boom lever 13 with a first set value and sends out output "1" when the boom 2 is made in the downward condition and a comparator 20b compares the lever operation signal Vd of the bottom lever 14 with a second set value and sends out output "1" when the bottom of the bucket is opened. Comparators 20c and 20d input the lever operation signal Vf of the rotation lever 15 and compare this signal Vf, in case of the comparator 20c, with a third set value and sends out output "1" when the rotation lever 15 is operated for rightward rotation and in case of the comparator 20d, with a fourth set value and sends out output "1" when the rotation lever 15 is operated for leftward rotation.
Each one of the two input terminals of AND circuits 20e to 20h is respectively connected to the output of the comparator 20a to 20d and each of the other input terminals of the AND circuit 20e and 20f is connected. to be applied to the operation signal Vc of the boom lever 13 and the operation signal Vd of the bottom lever 14, respectively. Both of the other input terminals of the AND circuit 20g and 20h are connected to be applied to the operation signal Vf of the rotation lever 15. The output terminals of these AND circuits 20f, 20g and 20h are connected, via NOT circuits 20i, 20l and 20m, to the set inputs of flip-flop circuits F1, F1 and F3, respectively. Each of the set outputs of these flip-flop circuits F1 to F3 and the output of the AND circuit 20e are applied to the input of an AND circuit 20k. These flip-flop circuits are a type which is triggered with the input signal "0". All of the flip-flop circuits are made reset when the output of the AND circuit 20e becomes "0". The remaining one input terminal of the AND circuit 20k is connected to the output of the manual-auto changeover switch 16. This switch 16 is being switched so as to produce output signal "1" when the semi-automatic excavation-posture return according to this invention is desired to be performed.
Let us assume the case in which the dumping place is located on the right side from the excavation place. When the rightward rotation is performed with the rotation lever 15, the output of the comparator 20c becomes "1" as well as the operation signal Vf, then the output of the AND circuit 20g becomes "1" and the flip-flop circuit F2 turns into the set state. Subsequent to this, when the bucket 4 comes to the dumping place, the rotation lever 15 is set to the neutral position and the bottom lever 14 is operated so as to split the bottom of the bucket 4. Then the output of the comparator 20b become "1" as well as operation signal Vd, thereby the output of AND circuit 20f becomes "1", which, being inverted through the NOT circuit 20i, turns the flip-flop circuit F1 to the set state. After completion of the dumping, leftward rotation is performed by means of the rotation lever 15. By this operation the output of the comparator 20d becomes "1", which, being inverted through the AND circuit 20h and NOT circuit 20m, turns the flip-flop circuit F3 to the set state. Therefore, when the boom lever 13 is controlled downward, the output of the comparator 20a becomes "1" and thereby the output of the AND circuit 20e becomes "1" thus the output of the AND circuit 20k becomes "1", that is, the automatic control command signal e c becomes produced. This signal e c switches the switches 36 and 37 to the position as shown in FIG. 2 so as to enable automatic control of the arm cylinder 6 and bucket cylinder 7. That is to say, the arm cylinder 6 and the bucket cylinder 7 are automatically controlled in accordance with a deviation signal Δeβ corresponding to the deviation between outputs of an arm angle detector 60 and the arm angle setter 30, and a deviation signal Δeγ between a bucket angle detector 61 and the bucket angle setter 31, respectively.
When the rotation body 1a returns to the original excavation posture, the rotation lever 15 is set to the neutral position and when the bucket 4 is brought back to the original excavation posture, the boom lever 13 is set to the neutral position. Then, the operation signal Vc becomes "0" and the output of the AND circuit 20e becomes "0", thereby all of the flip-flop circuits F1 to F3 are made to the reset state and consequently the output of the AND circuit 20k becomes "0".
By taking the above-described procedures, the bucket is swiftly brought back to the original excavation posture, thus becoming ready for another excavation. | A semi-automatic hydraulic excavator capable of automatically controlling arm and bucket angles when bringing the bucket back to the original excavation posture after completion of dumping excavated soil. For this purpose, arm and bucket angle detectors are provided therein and the automatic control is performed by negatively feeding back values detected by these detectors to minimize deviations between these values and preset values produced from arm and bucket angle setters corresponding to the arm and bucket angles in the original excavation posture. The automatic control mode is selected by a signal from an automatic control command signal producing circuit. With this system, the bucket is swiftly brought back to the original excavation posture from the dumping posture without requiring much operator's skill and efforts. |
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BACKGROUND OF THE INVENTION
[0001] The transportation of hydrocarbons produced from subsea wells is an integral part of offshore hydrocarbon production operations. In a typical offshore production arrangement, as shown in FIG. 1, a plurality of subsea wells (not shown) are drilled from an offshore drilling and production platform 1 . Once the targeted formations (not shown) have been reached through drilling operations, production tubing (not shown) is typically set in place and further procedures including, for example, the perforation of the production tubing in selected target zones, are performed to produce hydrocarbons from the well. The offshore drilling and production platform 1 may include storage facilities 2 for the temporary storage of hydrocarbons produced from wells (not shown).
[0002] Delivery of hydrocarbons produced from subsea wells may be performed with any of several techniques known in the art. For example, hydrocarbons may be produced from a remote subsea wellhead (e.g., the subsea wellhead may be positioned at a subsea location that is some distance away from the location of the offshore drilling and production platform 1 ) and then piped to the offshore drilling and production platform 1 . Alternatively, the hydrocarbons produced from subsea wells may be routed from a subsea wellhead directly to land locations through a pipeline, as long as the wellhead is located sufficiently close to the shore.
[0003] Hydrocarbons may also be produced from a subsea well and then transferred through a pipeline 3 to a moored floating production, storage, and offloading tanker (FPSO tanker) 4 .
[0004] Regardless of the technique used to deliver hydrocarbons from the well to transportation facilities, the hydrocarbons must be processed before being transported to other facilities for further refining or delivery. An important requirement for the transportation of liquid hydrocarbons is that low pressure flash gas must be removed from the liquid hydrocarbons so that the vapor pressure of the liquid hydrocarbons is reduced. Reduced vapor pressure ensures that low pressure flash gas will not “evolve,” or come out of solution, while the hydrocarbons are being transported. For standard tanker transport, the vapor pressure of the transported hydrocarbons must be near or below atmospheric pressure (14.7 psia) in order to minimize gas evolution during loading of the tanker. Evolving flash gas can pose a safety hazard for transporters and for the environment.
[0005] Hydrocarbon processing to remove low pressure flash gas may be performed at land based facilities for producing wells that are located close to the shore. Deepwater wells that are located significant distances offshore provide a more complicated processing issue. For example, processing of hydrocarbons to remove low pressure flash gas may be performed at production platforms or at FPSOs. Processing at either of these locations, however, requires the presence of shuttle tankers to transport the processed hydrocarbon (e.g., the hydrocarbon with a reduced vapor pressure) to other facilities. For example, production platforms and FPSOs have a limited storage capacity for holding processed hydrocarbons. The problem is particularly relevant for FPSOs because the storage capacity of an FPSO is limited by the volume of the hold of the ship (which is further limited because of the space required to house the processing equipment). Thus, if shuttle tankers are unavailable due to, for example, poor weather conditions, processing must be interrupted when all storage facilities are full. Processing interruptions or slowdowns may have adverse economic consequences because of the high cost of operating and maintaining offshore facilities.
[0006] An alternative method includes processing hydrocarbons with a subsea separation system. Subsea separation systems are known in the art, and staged separation is the most common technique used in the industry for hydrocarbon stabilization. Preferably, pressure at the last stage of a staged separation system is at or near atmospheric pressure so that a desired level of hydrocarbon stabilization may be achieved without excessive heating (e.g., because heating liquid hydrocarbons increases the vapor pressure and facilitates removal of flash gas). Therefore, flash gas extracted from the hydrocarbons in the last stage of the staged separation system is typically also at or near atmospheric pressure. Generation of the low pressure at the last stage of separation typically requires the use of a mechanical compressor installed near the separation equipment on the seafloor because the separation system is located at great depth. The mechanical compressor typically requires an independent power source, and the mechanical compressor must be regularly maintained. Further, the low pressure flash gas may require a pressure boost to provide a pressure differential so that the flash gas can overcome pipe friction and the static pressure in a pipeline and flow to the surface (e.g., the ocean surface). As a result, prior art systems typically include boosting the pressure of the extracted low pressure flash gas with a mechanical compressor. Once the low pressure flash gas reaches the surface, the flash gas may be disposed of via a flare or may be separately transported.
[0007] An alternative to boosting the flash gas pressure with a compressor is to forego subsea processing and transport the hydrocarbon with an elevated vapor pressure directly to the surface. Transport to the surface is facilitated by operating the last stage of the subsea separation process at a sufficiently high pressure to provide the necessary pressure differential required to boost the hydrocarbon to the surface. However, this “live” hydrocarbon still contains flash gas at a higher than atmospheric pressure and the “live” hydrocarbon must be processed, as previously mentioned, before being loaded onto shuttle tankers.
SUMMARY OF THE INVENTION
[0008] One aspect of the invention is a system for subsea flash gas compression comprising a first separator adapted to remove high pressure flash gas from a hydrocarbon product and a second separator is adapted to remove low pressure flash gas from the hydrocarbon product after removal of the high pressure flash gas therefrom. An ejector is coupled at a high pressure input thereof to a high pressure flash gas output of the first separator and at a low pressure input thereof to a low pressure flash gas output of the second separator. An output of the ejector is coupled to an outlet pipeline extending from proximate the sea bottom to the sea surface.
[0009] In another aspect, the invention comprises a method of separating flash gas from a hydrocarbon product. The method comprises separating high pressure flash gas from the hydrocarbon product in a first separator, and a flash gas output of the first separator is coupled to a high pressure input of an ejector. Low pressure flash gas is separated from the hydrocarbon product after removal of the high pressure flash gas therefrom in a second separator, and a flash gas output of the second separator is coupled to a low pressure input of the ejector. An output of the ejector is conducted from proximate the second separator on the sea bottom to the sea surface.
[0010] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 shows a prior art drilling and production system.
[0012] [0012]FIG. 2 shows an embodiment of a passive low pressure flash gas compression system.
[0013] [0013]FIG. 3 shows a simplified view of a subsea ejector of an embodiment of the invention
DETAILED DESCRIPTION
[0014] An embodiment of the invention comprises a system for removing low pressure flash gas from hydrocarbons produced from subsea wells. The invention comprises a low maintenance solution by passively removing low pressure flash gas using the motive force extractable from pressurized gas evolved from crude hydrocarbons to boost the low pressure flash gas to the surface without the use of, for example, a mechanical compressor.
[0015] An embodiment of the invention, as shown generally at 10 in FIG. 2, comprises a subsea, two stage oil and gas separation system. The embodiment shown in FIG. 2 comprises a high pressure separator 16 , a low pressure separator 18 , and an ejector 14 coupled to both the high pressure separator 16 and the low pressure separator 18 . Hydrocarbons produced from a well (not shown) flow into an input of the high pressure separator 16 through a pipeline 20 that may be regulated by a valve (not shown). The high pressure separator 16 (e.g., a first stage of the separation) operates at a pressure of, for example, 500 psi. However, 500 psi is only a typical operating pressure and is not intended to limit the invention.
[0016] When the hydrocarbon flow is passed though the high pressure separator 16 , high pressure flash gas evolves from the flow and is transported out of the high pressure separator 16 through a high pressure output 26 . The high pressure flash gas flows through the high pressure output 26 to the ejector 14 , as will be described in detail below. The processed liquid hydrocarbon flow is transmitted from a liquid hydrocarbon outlet of the high pressure separator 16 to an inlet of the low pressure separator 18 through a piping system 22 . A flow control device, such as a valve 24 , may be positioned between the high pressure separator 16 and the low pressure separator 18 to regulate the processed hydrocarbon flow.
[0017] In the second stage of the separation, low pressure flash gas is extracted from the processed hydrocarbon flow in the low pressure separator 18 . The low pressure separator 18 operates at a pressure of at most atmospheric pressure (14.7 psia), but typically operates below atmospheric pressure, as will be further explained. As a result, the low pressure flash gas extracted in the low pressure separator 18 is typically at or below atmospheric pressure. The low pressure flash gas moves to a low pressure input of the ejector 14 through a low pressure gas output 28 . The processed liquid hydrocarbon flows out of the low pressure separator 18 through, for example, a boosting pump 32 and a hydrocarbon outlet pipeline 30 .
[0018] The ejector 14 , which may also be referred to as an “eductor” or a “jet pump,” comprises structure that is known in the art. The ejector 14 , as shown in FIG. 3, comprises a nozzle 50 , a diffuser 52 , a high pressure input 54 , and a low pressure input 56 . In an embodiment of the invention, high pressure flash gas from the first separator is conducted to the high pressure input 54 . The high pressure flash gas comprises a “motive gas” for operating the ejector ( 14 in FIG. 3), and the high gas pressure is converted into kinetic energy (velocity) as it flows through the nozzle ( 50 in FIG. 3).
[0019] In an embodiment of the invention, low pressure flash gas from the second separator is conducted to the low pressure input ( 56 in FIG. 3). The relatively high pressure, high velocity flow of the high pressure input ( 54 in FIG. 3) (e.g., the flow is of a relatively high pressure and velocity when compared to the pressure and velocity of the flow of the low pressure input ( 56 in FIG. 3)) through the nozzle ( 50 in FIG. 3) creates a low pressure region ( 60 in FIG. 3) that induces flow from the low pressure output ( 28 in FIG. 2) into the low pressure region ( 60 in FIG. 3).
[0020] Flow induction into the low pressure region ( 60 in FIG. 3) is caused by the Venturi effect, where the flow from the low pressure input ( 56 in FIG. 3) is drawn to the low pressure region ( 60 in FIG. 3) proximate the nozzle ( 50 in FIG. 3) exit. The low pressure flash gas from the low pressure input ( 56 in FIG. 3) mixes with the high pressure flash gas from the high pressure input ( 54 in FIG. 3) in the low pressure region ( 60 in FIG. 3). The two flows combine to produce an ejector outlet flow ( 58 in FIG. 3) through the diffuser ( 52 in FIG. 3) with a pressure below that of the high pressure input ( 54 in FIG. 3) flow but above that of the low pressure input ( 56 in FIG. 3) flow.
[0021] The combination of the relative mass flow rates of the flash gas in the high pressure input ( 54 in FIG. 3) and the low pressure input ( 56 in FIG. 3) determine the mass flow rate of the ejector outlet flow ( 58 in FIG. 3). The pressure of the ejector outlet flow ( 58 in FIG. 3) and the geometry of the ejector ( 14 in FIG. 3) determine the level of compression of the ejector outlet flow ( 58 in FIG. 3) as it passes through the diffuser ( 52 in FIG. 3). By properly selecting geometric parameters of the ejector ( 14 in FIG. 3) components and by controlling the pressure in an outlet pipeline, such as a surface pipeline ( 36 in FIG. 2), the operating pressures of the high pressure separator ( 16 in FIG. 2) and the low pressure separator ( 18 in FIG. 2) may “self-adjust” and seek equilibrium operating levels. In this manner, using a surface control valve ( 38 in FIG. 2) to change the pressure in the surface pipeline ( 36 in FIG. 2) can maintain a selected pressure at the low pressure input to the ejector ( 14 in FIG. 2). Further, geometric parameters of the ejector ( 14 in FIG. 3) such as the cross-sectional areas of the nozzle ( 50 in FIG. 3), the diffuser ( 52 in FIG. 3), the high pressure input ( 54 in FIG. 3), and the low pressure input ( 56 in FIG. 3) may be adjusted to achieve optimum operating pressures.
[0022] Regulation of the pressure in the surface pipeline ( 36 in FIG. 2) with the surface pressure control valve ( 38 in FIG. 2), in combination with the self-adjusting nature of the passive low pressure flash gas compression system ( 10 in FIG. 2), means that active subsea control is not generally required. Therefore, the low pressure flash gas compression system ( 10 in FIG. 2) comprises a passive flash gas separation system that transports extracted flash gas to the surface while not requiring the same level of regular maintenance as a subsea compressor. Specifically, the pressure in the surface pipeline ( 36 in FIG. 2) is boosted by the ejector outlet flow ( 58 in FIG. 3), and a mechanical compressor is not required.
[0023] After the flash gas has been transported through the outlet pipeline, such as the surface pipeline ( 36 in FIG. 2) of an embodiment of the invention, the flash gas may be disposed of by any method known in the art. For example, the gas may be burned off in a flare at the ocean surface or may be collected and transported to an alternate location. Alternatively, the flash gas may be transported to a storage facility and held for later disposal. The passive low pressure flash gas compression system ( 10 in FIG. 2) is cooled by ambient seawater cooling.
[0024] The processed hydrocarbon in the hydrocarbon outlet pipeline ( 30 in FIG. 2) may be distributed in several ways. For example, the processed hydrocarbons may be loaded directly onto shuttle tankers if the hydrocarbon outlet pipeline ( 30 in FIG. 2) is attached to a buoyant docking station ( 5 in FIG. 1) that may be accessed from the ocean surface. The processed hydrocarbons may also be routed to a drilling and production platform ( 1 in FIG. 1) for offloading onto shuttle tankers. If required, a boosting pump ( 32 in FIG. 2) may be located proximate the hydrocarbon outlet pipeline ( 30 in FIG. 2) to increase the pressure of the processed hydrocarbon flow.
[0025] Alternatively, the processed hydrocarbons may be stored in a facility such as a submerged storage tank as described in U.S. patent application Ser. No. ______ entitled “Seabed Storage and Tanker Offtake System,” assigned to the assignee of the present invention, filed herewith, and incorporated by reference in its entirety. The storage tank described in the aforementioned application can be used to store the processed hydrocarbons for later offloading onto, for example, shuttle tankers. The storage tank, in combination with the passive low pressure flash gas compression system, provides a system by which hydrocarbons (with a substantially atmospheric vapor pressure) may be produced substantially continuously and then stored until shuttle tankers are available for transport. As a result, there is no need to halt production during adverse weather conditions or other times when shuttle tankers are unavailable. Less downtime may increase the rate at which hydrocarbons may be produced from wells and, as a result, may increase the profitability of offshore production operations.
[0026] Moreover, the entire low pressure flash gas compression system may be regulated by any method known in the art. The regulation of the pressure in the surface pipeline is only disclosed as an example and is not intended to limit the invention. Other methods, such as using remotely operated subsea valves to control flow pressures, can also be used in various embodiments of the invention.
[0027] Moreover, as previously mentioned, the operating pressures of the separators may be varied as long as the vapor pressure of the processed liquid hydrocarbons at the hydrocarbon outlet pipeline is at or near atmospheric pressure.
[0028] Those skilled in the art will appreciate that other embodiments of the invention can be devised which do not depart from the spirit of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | A subsea passive flash gas compression system that includes a first separator that removes high pressure flash gas from a hydrocarbon product, a second separator that removes low pressure flash gas from the hydrocarbon product after the high pressure flash gas has been removed, and an ejector. The ejector includes a high pressure input that is coupled to a high pressure flash gas output of the first separator. The ejector also includes a low pressure input that is coupled to a low pressure flash gas output of the second separator. An output of the ejector is coupled to an outlet pipeline that extends from proximate the sea bottom to the sea surface. |
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REFERENCE TO RELATED APPLICATIONS
This application is a division of my copending U.S. patent application Ser. No. 08/925,762, filed Sep. 9, 1997, now U.S. Pat. No. 5,946,875.
This invention has to do with a bracket and fastener assembly offering quick-connect fastening of parts or components whether or not the parts are perfectly aligned. More particularly, the invention relates to the ready installation and support of clean room ceilings, to filter units for clean room ceilings which are readily mounted with the bracket and fastener assembly, and to novel bracket and fastener assemblies. In this last aspect, the invention relates to brackets and assemblies of these brackets with fasteners for the installation of filter units in clean room ceilings, and in other mounting situations where misalignments of parts or components may be prevalent and interfittment of many units is required.
BACKGROUND OF THE INVENTION
Clean room ceilings, which term includes ceiling sections, and enclosed area walls and floors with a similar purpose, typically comprise a plurality of high efficiency filter units, e.g. HEPA and ULPA and similar filter units, arranged in rows and columns and supported by a suspension attached to an adjacent support surface, most commonly the true ceiling of room in which the clean room is located.
In an installation of a great number of filter units tolerances in the dimensions of the units may stack, resulting in misalignment of the filters with their suspension components, making completion of the installation difficult and problematical.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide an improved filter unit mounting system for clean room ceiling installations. It is another object to provide a variable, self-adjusting bracket and fastener assembly-based mounting system for these installations and for other purposes. A further object is to provide a clean room ceiling installation in which the individual filter units are supported by suspension rods which are fixed, the filter units having brackets according to the invention to allow for discrepancies in the registration or alignment of the mounting rods and brackets in effecting filter unit mounting. It is a further object to provide a bracket having a fixed opening and a movable opening for reception and retention of the suspension rod in mounting the filter unit in its place. A further object is the provision of a bracket and fastener assembly that enables the snap interfittment of two or more components by simply passing the fastener fixed to one component through an opening in the other component, the opening suitably being variable in location without change in interfittment capability for ready interfittment of the components in a variety of relative positions.
These and other objects of the invention to become apparent hereinafter are realized in a bracket for interconnecting a fixed unit, such as a suspension rod, and a movable unit subject to variable alignments, such as a filter unit, the bracket comprising a fixed bracket member defining a fixed opening connectable to the movable unit and a movable bracket member defining a movable opening variably registerable with the fixed opening by relative movement of the fixed and movable bracket members, the movable member opening being connectable with the fixed unit through the fixed member opening in different alignments of the fixed unit and the fixed opening to compensate for variations in the location of the fixed unit and the movable unit during their interconnection.
In this and like embodiments, typically: the movable bracket member is loosely captured on the fixed bracket member; the fixed bracket member and the movable bracket member define cooperating slots and ears for connection in loosely captured relation; or the movable member partially encloses and slides on the fixed member in loosely captured relation.
More particularly, in accordance with the invention, in a clean room ceiling embodiment, the movable unit typically comprises a filter unit comprising a filter pack in a frame having a wall, the fixed unit is a filter unit suspension rod fixed to a support surface, the filter unit wall defining the fixed bracket member and its the fixed opening opposite the suspension rod, the movable bracket member being loosely captured on the filter pack frame wall for movement to register with the suspension rod for engagement therewith when the fixed opening is out of registration with the suspension rod to suspend the filter unit from the suspension rod.
In this and like embodiments, typically, the filter unit wall defines a pair of transverse slots, the movable bracket member defines ears cooperating with the slots to loosely capture the movable bracket member; the movable unit comprises a filter unit comprising a filter pack in a frame having a wall, the fixed unit is a filter unit suspension rod fixed to a support surface, the bracket being mounted to the filter unit wall with its the fixed member fixed opening opposite the suspension rod in receiving relation, the bracket movable member lying parallel to and adjacent the fixed bracket member and loosely captured thereon by inturned flanges of the movable bracket member for movement to register with the suspension rod for engagement therewith when the fixed opening is out of registration with the suspension rod to suspend the filter unit from the suspension rod.
In a further embodiment, the invention provides a bracket for supporting a movable unit from a fixed unit, the bracket comprising a fixed bracket member having a fixed opening and a movable bracket member having a movable opening, the movable opening being variably registerable with the fixed opening in different alignments to compensate for variations in the location of the fixed opening.
In a further embodiment, the invention provides a bracket for suspending a clean room ceiling filter unit comprising a filter pack and a wall from a support surface with a support rod and fastener, the bracket comprising a fixed bracket member having a fixed opening and a movable bracket member having a movable opening, the movable opening being variably registerable with the fixed opening and adapted to retain the support rod and fastener in filter unit supporting relation, the fixed opening being adapted for receiving the movable opening retained support rod in different alignments to compensate for variations in the location of the fixed opening relative to the support rod and fastener.
The invention further includes in combination: the above bracket, and a fastener adapted to pass through the movable opening of the bracket in shaft supported relation in one direction only, such as a fastener comprising a lock body and a movable latch. In this and like embodiments, typically, the fastener comprises a lock body smaller than said movable opening, and at least one spring latch adapted to spring-project from the lock body against passage of the lock body through the movable opening.
There is further provided according to the invention an assembly of a bracket and fastener in which the bracket comprises a fixed bracket member having an fixed opening and a movable bracket member having a movable opening, the fastener comprising a lock body too large to pass through the movable bracket member opening but which will pass through the fixed member fixed opening, the bracket and fastener lock body being mounted on a common shaft.
In this and like embodiments, typically, the movable bracket member and the fixed bracket member define cooperating mounting structure for loosely capturing the movable bracket member on the fixed bracket member for relative movement to enable centering of the movable bracket member opening on the common shaft without the fixed bracket member opening being also centered on the shaft; the fastener lock body includes at least one spring latch within the lock body, the spring latch being adapted to fold into the body when the lock body passes through the movable bracket opening, and to project from the latch body once the lock body has passed through the movable bracket opening to block return passage of the lock body.
The invention further contemplates the combination of a filter unit and the invention bracket.
In yet another embodiment of the invention there is provided in combination: a clean room filter unit comprising a filter pack and a frame enclosing the filter pack; and a bracket for mounting the filter unit with a support rod and fastener to a support surface in varying alignments, the bracket comprising a fixed bracket member defining a fixed opening connectable to the movable unit and a movable bracket member defining a movable opening variably registerable with the fixed opening by relative movement of the fixed and movable bracket members, the movable member opening being connectable with the support rod and fastener through the fixed member opening in different alignments of the fixed unit and the fixed opening to compensate for variations in the location of the support rod and fastener and the filter unit during their interconnection.
In this and like embodiments, typically: the fixed bracket member is fixed to the filter unit frame, the movable bracket member being loosely captured on the fixed bracket member, and the filter unit frame has a wall portion defining the fixed bracket member, and the fixed and movable bracket members define cooperating slots and ears for their interconnection in loosely captured relation. Or, the filter unit frame has a wall portion, the bracket being fixed to the frame wall portion in spaced relation, and the bracket movable member partially encloses and slides on the bracket fixed member in loosely captured relation.
In a further embodiment there is provided a clean room ceiling comprising multiple filter units suspended from a support surface by a series of fixed suspension rods and fasteners, the filter units comprising a filter pack in a frame having a wall, each filter unit wall defining a fixed bracket member and a fixed opening therein opposite a suspension rod, a movable bracket member defining a movable opening, the movable bracket member being loosely captured on the fixed bracket member for movement to register its movable opening with the suspension rod for engagement therewith when the fixed opening is out of registration with the suspension rod to suspend the filter unit from the suspension rod in the clean room ceiling.
In this and like embodiments, typically: the fixed bracket member is an integral portion of the filter frame wall and defines a pair of transverse slots, the movable bracket member defining ears cooperating with the slots to loosely capture the movable bracket member on the frame wall portion, or the fixed bracket member is separately formed from the filter frame wall and mounted on the wall with a fixed opening opposite the suspension rod in receiving relation, the movable bracket member lying parallel to and adjacent the fixed bracket member and loosely captured thereon by inturned flanges of the movable bracket member for movement to register with the suspension rod for engagement therewith when the fixed opening is out of registration with the suspension rod to suspend the filter unit from the suspension rod.
Additionally, typically, the fastener comprises a lock body, and a movable latch finger mounted in the lock body under resilient force to be shiftable into and out from the lock body to pass through the fixed opening and the movable opening when shifted into the lock body and to block movement through the movable opening when shifted out from the lock body, the fastener may be threaded, or the fastener may be free of threaded attachment to the suspension rod, and there is also included a fastening nut threaded onto the suspension rod to support the fastener in place on the suspension rod.
In yet a further embodiment, the invention provides a clean room filter unit and mounting bracket for supporting the filter unit from a suspension rod attached to a support surface, the bracket comprising a fixed bracket member having a fixed opening and a movable bracket member having a movable opening, the movable opening being variably registerable with the fixed opening in different alignments to compensate for variations in the location of the fixed opening relative to the suspension rods.
In this and like embodiments, typically: the filter unit comprises a pair of filter packs, the filter unit frame has a perimetrical wall laterally enclosing the filter packs, the frame wall further comprises a divider separating the filter packs, the divider comprising a box-like member defining the fixed bracket member and its fixed opening opposite a suspension rod, the divider having an interior volume adapted to receive a suspension rod and a fastener; the movable bracket member lying generally within the divider interior volume, and the bracket structure flanges or ears lying outside the divider portion member volume, or the filter unit comprises a pair of filter packs, the filter unit frame has a perimetrical wall laterally enclosing the filter packs and a further wall portion for mounting the bracket, the bracket fixed member being generally U-shaped and having terminal flanges for attachment to the frame further wall portion, the movable bracket member being slidably secured to the bracket fixed member in spaced relation to the bracket fixed member flanges.
In another embodiment there is provided a clean room filter unit comprising a filter unit pack and a filter unit wall adjacent the filter pack, and a bracket for mounting the filter unit with a suspension rod and fastener to a support surface, the bracket comprising a filter a unit wall-supported bracket structure having a fixed member with a fixed opening and a relatively movable member with an opening variably registerable with the fixed opening, the fixed opening being adapted for receiving and retaining the suspension rod in different alignments to compensate for variations in the location of the fixed opening relative to the suspension rod.
In a still further embodiment, the invention provides a clean room filter ceiling comprising a plurality of individual filter units arranged for delivery of filtered air to a clean room, each of the filter units having a suspension assembly comprising a suspension rod extending from a support surface, a plate extending transversely of the suspension rod, a plurality of subsuspension rods extending from the plate to the filter units, the subsuspension rods being unshared with any other filter unit, whereby each filter unit is shiftable to and from the array independently of shifting the position or orientation of any other filter units or altering their respective suspension assemblies.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described as to an illustrative embodiment in conjunction with the attached drawings, in which:
FIG. 1 is a perspective view of a clean room ceiling according to the invention;
FIG. 2 is a fragmentary detail view of the invention bracket and filter unit assembly;
FIG. 3 a view taken on line 3--3 in FIG. 2;
FIG. 4 is a view taken on line 4--4 in FIG. 3;
FIG. 5 is a view like FIG. 1 showing an alternate bracket and filter unit arrangement;
FIG. 6 is a view like FIG. 2 but of the alternate form of the invention, and including the invention bracket and fastener subassembly;
FIG. 7 is a view taken on line 7--7 in FIG. 6;
FIG. 8 is a view taken on line 8--8 in FIG. 7; and,
FIG. 9 is a view like FIG. 1, showing an alternate form of suspension rod mounting of clean room ceiling filter units.
DETAILED DESCRIPTION OF THE INVENTION
As set forth above, the invention provides a bracket to accommodate misalignments of intended-to-be-interfitted components resulting from small discrepancies in dimensions or hardware mountings such as occurs in a series of filter units in a suspended clean room ceiling. These ceilings employ suspension rods as the suspending means, so as to maintain the separate mounting and demounting of the individual filter units. While built to specifications, filter units will vary in their dimensions and added hardware mounting points may not be always perfectly positioned. These construction errors, while minor, are cumulative, and in a ceiling which will embrace hundreds of filter units, mounting rods may not register with the filter units. Installation then becomes problematic. For example, with the filter units using fixed dividers as the mounting point, there is no opportunity to shift the mounting point to register with the suspension rods. In the invention, the mounting locus, defined by the divider mounting opening, or a fixed bracket member opening, is enlarged to accommodate a greater variation of relative placement of the filter unit and suspension rod. But the diametrical size of the fastener is limited and cannot be comparably enlarged and still fit within the divider, and be operative to anchor the filter unit in place. Accordingly, the invention provides a smaller and movable opening adapted to shift from concentricity with the fixed opening to register with the suspension rod, and engage the fastener, without having to adjust the intended position of the filter unit. The invention assembly of the bracket and fastener is used particularly for filter unit mounting in a clean room situation as an illustrative embodiment.
With reference now to the drawings in detail, FIGS. 1-4 show a first embodiment in which a clean room ceiling 10 is suspended above a clean room space 12 and below a support surface 14 which is typically the true ceiling in the room. The clean room ceiling 10 comprise multiple rows and columns of filter units 16. Each filter unit 16 comprises a pair of filter packs 18, comprising HEPA or ULPA filters, typically, a surrounding frame 20 having a sealing rib 21 running perimetrically about the frame and aiding sealing together of adjacent filter units. The filter unit frame 20 includes a perimetrical wall 22 which laterally encloses the filter packs 18, and a divider 24 which separates the filter packs and extends transversely of the filter unit 16. First and second openings 26, 28 are formed in the divider 24 at its upper wall 30 for the purpose of receiving in registered relation support rods 32 depending from support surface 14 and their associated fasteners 34. Fasteners 34 are internally threaded to thread-connect to rods 32, or may be smooth bored to slide upon rods 32, and be held in place by a fastening nut 106. See FIGS. 7 and 8.
The openings 26, 28 are oversized relative to fastener 34 and will not retain the fastener in place. See FIG. 3. The openings 26, 28 further are sized to receive rods 32 in various alignments of the rod axis to the axis of the opening 26 or 28. See FIGS. 3 and 4. In a perfect alignment of the axes of the rods 32 and the openings 26, 28 are coaxial. In many, if not most, installation situations the alignments of the openings 26, 28 and the rods 32 will not be perfect. Typically, the rods 32 will register imperfectly with the openings 26, 28, either to one side or the other, so that they are paraxial, not coaxial. In this event, the greater diameter of the openings 26, 28, a diameter large enough that the fasteners 34 will pass through in either direction, and typically more than twice or more the diameter of the rods 32 passing therethrough, will allow the rods to be left in their place as installed and the filter units 16 to be installed where they fall in the assembly of the clean room ceiling rows and columns of filter units.
As noted, the fasteners 34 will not be retained in the openings 26, 28. The fasteners 34 comprise a lock body 36 having a plurality of latch fingers 38, which are pivotally mounted within slots 42 of the lock body and outwardly biased by compression springs 48. In assembly of the clean room ceiling, the fasteners 34 are threaded or otherwise connected to the rods 32. The filter units 16 are urged upward toward the rods 32 with their divider openings 26, 28 aligned with the fasteners 34 on the rods. The fasteners 34 pass through the openings 26, 28 and if the openings are small enough or the fastener 34 large enough, the fasteners will latch to the wall edge margin 44 surrounding the openings 26, 28 by virtue of the latch fingers 38 springing out after being compressed inward by passage through the opening. The latch fingers 38 thus support the filter unit 16 where those latch fingers extend far enough to engage the wall edge margin 44.
In the embodiment shown in FIGS. 1-4, the openings 26, 28 are too large for even the latch fingers 38 to engage the wall edge margin 44. The invention provides for supporting engagement of the latch fingers 38 and a further element, a generally shallow U-shaped member 52 having ears 54 and a central opening 56. Member 52 and the upper divider wall 30 form a bracket according to the invention. The upper wall 30 is a fixed bracket member; the member 52 is a movable bracket member. Opening 56 is movable since the member 52 is movable. The member 52 lies generally parallel to and adjacent the divider upper wall 30. Member ears 54 are inserted in slots 58, 60 formed in the divider upper wall 30 on either side of the openings 26, 28, respectively. Slots 58, 60 are larger than the ears 54 so that the member 52 will shift parallel to the long axis of the divider upper wall 30 or transversely thereto. The slots 58, 60 are not so large that the ears 54 will separate from the slots in the installed condition of member 52. The member 52 is loosely captured by being able to shift in position relative to its mounting slots 58, 60, but not escape from that mounting locus. The central opening 56 is thus registered with the opening 26 or 28 but not precisely except when the two openings are concentric. Any other form of mounting the movable bracket member 52 to the fixed bracket member, divider upper wall 30, can be used in place of the ears 54 and slots 58, 60 arrangement shown, provided a degree of movability is retained sufficient to accommodate the expected variations in perfection of registration, and the structure is strong enough to support the filter units 16.
In practice, the member 52 will shift approximately 1/8-1/4 inch or more or less, longitudinally or transversely, depending on the design, moving its central opening 56 accordingly. The central opening 56 is sized to just receive the fastener 34 with the latch fingers 38 closed into the lock body 36. Upon full passage of the fastener 34 through the central opening 56 (it has already passed the opening 26 or 28), the latch fingers 38 open, engaging the edge margin 62 surrounding the opening 56. The filter unit 16 is thus supported.
In FIGS. 5-8 a second embodiment of the invention is shown. The general assembly, shown in FIG. 5 is similar to the embodiment of FIG. 1 with the filter units 16 being supported from a support surface 14 by a series of support rods 32. In this embodiment, the filter divider upper wall 30 is not apertured with openings such as openings 26, 28 in the earlier embodiment. Instead, a separate bracket 72 is provided, attached to the divider upper wall 30 by screws, rivets or other common fastener, or glued in place. The bracket 72 has a fixed member 74, generally U-shaped, having a first leg 76, a second leg 78 and a flange 82 on the first leg flat to the divider upper wall 30 and secured there by screws 84 or the like. The member 74 second leg 78 butts against the flange 86 defined by the freeboard of the filter unit perimetrical wall 22 above the tops of the filter packs 18, contoured as necessary to fit wall lip 92 and fastened by screws 94. Bracket wall 70 defines a too large opening 96 (like divider openings 26, 28) in the sense that the fastener 34 will pass through and not securely engage this opening even with the latch fingers 38 deployed.
Bracket 72 has a movable member in the form of clip 98, a typically metal member defining a movable opening 102 variously registerable with bracket opening 96 in the manner of previously discussed opening 56. The clip 98 is loosely captured on the bracket fixed wall member 70 so as to slide back and forth and in and out all while engaged in sliding relation with the wall. The clip 98 has inturned flanges 104 which are crimped to enclose the fixed member wall 70 parallel to and adjacent to the wall and with its movable opening 102 in various registrations with opening 96. In practice, the fastener 341, alike to fastener 34 except in having a smooth interior bore rather than a threaded bore, is mounted on the rod 32 and secured there with a fastener nut 106. Pushing the filter unit 16 to the rod 32 aligned with the openings 96 and 102, depresses the latch fingers 38, and allows the filter unit to be mounted to the rod by the bracket 72. The movable opening 102 is centered on the fastener by the latch finger 38 action, the necessary movement of the movable opening relative to the bracket fixed opening 96 being accommodated by the sliding of the clip 98 on the bracket wall 70. The use of brackets 70 with openings 96, 102, rather than a series of divider wall openings 26, 28, increases manufacturing flexibility and enables the use of the individually supported filter units 16 in situations where access to the divider wall is limited, as in filters having associated housings, or hooks where it is desired to support the filter unit from its edges rather than from a center divider.
In FIG. 9, the rods 321 are subsuspension rods and are shown to depend from plates 108 which are in turn supported by a lesser number of supports 110 anchored to the ceiling/support surface 14. This manner of support/rod deployment requires fewer attachments to the ceiling and is less costly than the deployment in manner shown in FIGS. 1 and 5.
The invention thus provides an improved filter unit mounting system for clean room ceiling installations, using a variable bracket mounting system to allow for discrepancies in the registration or alignment of the mounting rods and brackets in effecting filter unit mounting, the bracket having a fixed opening and a movable opening for reception and retention of the suspension rod in mounting the filter unit in its place. | A clean room filter unit mounting system including a bracket, a bracket and fastener assembly, and individually mounted filter units. The bracket and fastener assembly includes a bracket having a relatively fixed member and a relatively movable member to allow misaligned mounting of parts such as the filter units in a clean room ceiling to fixed suspension rods without perfect registration of the bracket fixed member with the suspension rods, and a fastener able to pass through both bracket members in a first arrangement and to block such passage in a second disposition. |
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This application is a continuation, of application Ser. No. 07/965,568, filed Oct. 23, 1991; now abandoned which is a continuation of application Ser. No. 07/695,098, filed May 3, 1991; now abandoned which is a division of application Ser. No. 07/518,320, filed May 7, 1990 U.S. Pat. No. 5,013,389, which is a continuation of application Ser. No. 07/224,709, filed Jul. 27, 1988 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a process of taping joints between adjacent pieces of wallboard and an apparatus for effecting such taping of the joints. More particularly, the present invention is directed to a process and apparatus whereby a finished joint between adjacent pieces of wallboard may be completed in one step.
2. Description of the Prior Art
Wallboard (also known as drywall) has become the dominant material in the production of interior building partitions. In particular, interior building partitions generally comprise a studwall of spaced parallel vertical members (studs) which are used as a support for preformed panels (wallboard) which are attached to the studwall by screws, nails, adhesive or any other conventional attachment system. Obviously, joints exist between adjacent preformed panels. In order to provide a continuous flat surface to the wall, it is necessary to "finish" the joint between adjacent panels. Generally, such "finishing" requires the building up of multiple layers of a mastic material (joint compound) and the blending of this joint compound into the panel surface so as to form the desired flat and contiguous wall surface. In order to facilitate this finishing of the joints, most manufacturers bevel the longitudinal edges of the wallboard panels so as to allow a buildup of mastic material which will then match the level of the major surface area of the preformed panel. Typically, the buildup of the mastic material in the joint area comprises the application of a first layer of mastic material, the embedding of a wallboard tape (for example a paper tape or a fiberglass tape) in the first layer of mastic material and then the overcoating of the tape with one or more, generally two layers of additional mastic material. This finishing of the joints is a time consuming process, since it is generally necessary to wait 24 hours between each application of a coat of mastic material in order to allow the coat to dry before the application of an overcoat of an additional layer of mastic material. Moreover, it is then necessary generally to sand the joint area so as to produce a finish which will match the major portion of the surface area of the wallboard panels. The "finishing" process thus is both time-consuming and labor-intensive.
In this regard, numerous attempts have been made to speed up and/or reduce the labor involved in the finishing products. In this regard, attention is directed to U.S. Pat. Nos. 2,666,323 and 2,824,442, to Ames, which disclose a tool designed to apply a layer of mastic to a wallboard joint.
U.S. Pat. No. 3,007,837, to Goode, Jr., discloses a tape and joint compound dispensing wallboard taping machine which uses air pressure to supply joint compound to the head of the tool where it is applied to one side of the tape which side of the tape is then applied to the wall.
U.S. Pat. No. 3,131,108, to Kennard, discloses a wallboard taping machine which may have interchangeable heads for different conditions, e.g. flat joints versus corner joints.
U.S. Pat. No. 3,343,202, to Ames, discloses a tool for applying mastic to wallboard which includes a swingable arcuate trawling blade.
U.S. Pat. No. 3,404,060, to Taylor, Jr., discloses a wallboard taping machine including a supply of both joint compound and tape. The device includes a tape cutting knife which is automatically retractable and the tape has the joint compound applied on one side thereof.
U.S. Pat. No. 3,707,427, to Erickson, discloses a tape and joint compound dispenser wherein the tape is drawn through a joint compound reservoir so that the joint compound is applied on one side thereof. The quantity of joint compound in the dispensing chamber is automatically regulated.
U.S. Pat. No. 3,880,701, to Moree, discloses a tape and joint applying tool including applicator rolls and a blade for cutting the tape.
U.S. Pat. No. 3,925,145 discloses a tool for embedding tape into mastic at the corner of a room after the mastic and tape have been previously applied to the corner joint of the room.
U.S. Pat. No. 3,960,643, to Dargitz et al., discloses a device to apply a tape and covering finish plaster to a drywall seam in a single pass lengthwise thereover, wherein a relatively lightweight, hand supported frame has a unit thereon operative to first apply glue to a length of tape and then glue-affix the tape to the drywall over the seam and another unit on the frame operative, but trailing the tape gluing and applying unit, the apply a thin, smooth, layer of joint compound over the then-in-place tape.
U.S. Pat. No. 4,080,240 to Dysart, discloses a device for applying tape to wallboard and including valve-controlled mud supply. The device also includes a severing knife and a retractable V-shaped roller.
U.S. Pat. No. 4,086,121, to Ames, discloses a self-contained drywall taper having a hollow elongated body for holding mastic and supports a roll of tape with tape feeding means to deliver the tape to tape applying wheels then in turn apply it to cover a joint between two wallboard sections. A piston is slidably mounted in the hollow body and is automatically moved by a mechanism actuated by the rotating wheels, as they are moved over the wallboard surface, to force a layer of mastic onto the tape just prior to it being applied to the surface.
U.S. Pat. No. 4,090,914, to Hauk et al., discloses an apparatus for applying tape and adhesive to wallboard joints which is then convertible to deposit adhesive over the previously applied tape.
U.S. Pat. No. 4,196,028, to Mills, discloses a joint compound and tape applying tool having the provision of a following corner roller.
U.S. Pat. No. 4,208,239, to Lass, discloses a drywall taping machine including a flexible resilient wiper blade which presses the cement-laden tape into engagement with the wall and, in addition, feathers the cement onto the drywall along both side edges of the tape in a single pass. A backpack support for the joint compound supply is disclosed.
U.S. Pat. No. 4,309,238, to Hauk, discloses a drywall taping device which has a control for adjusting the tensioning force applied to toothed traction wheels thereof.
U.S. Pat. No. 4,358,337, to Johnson et al., discloses a tape applicator which utilizes a replaceable joint compound cartridge system.
U.S. Pat. No. 4,452,663, discloses a wallboard joint taping apparatus including an elongated frame having a tape press wheel mounted on the forward end with a compound reservoir mounted on the frame, intermediate the ends, with aligned slots through the lower edge of the wall with a source of tape mounted on the other end of the frame with the tape passing through the slots in the compound container for picking up taping compound on the surface thereof and passing over the roller for application and pressing by the press wheel into a joint between adjacent wallboard panels.
U.S. Pat. No. 4,516,868, to Molnar, discloses a device designed to apply a layer of joint compound over an already installed length of tape.
U.S. Pat. No. 4,592,797, to Carlson, discloses a tube including a cylindrical roller for applying pressure to embed a tape in adhesive, the roller being designed to allow the mud which is on the underside of the tape to flow over the top of the tape and coat that surface as well.
U.S. Pat. No. 4,608,116, to Braselton, discloses a baseboard edge taping tool which includes a severing knife and which is specifically designed to enable cutting operations at a corner.
Other references relating to tape dispensing and mastic dispensing include U.S. Pat. No. 2,972,428, to Dubbs, which discloses a tape applicator including microswitch controls for advancing, severing and applying a pressure sensitive tape. Movements of the tape are controlled incrementally on a cyclicable basis.
U.S. Pat. No. 3,785,535, to Ames, discloses a mastic supply pump outlet for filling different types of mastic-applying tools.
U.S. Pat. No. 4,406,247, to Baughman et al., discloses control of the flow of adhesive in an adhesive dispensing system wherein a logic control unit receives signals indicative of various process conditions and in response thereto controls adhesive dispensing.
U.S. Pat. No. 4,477,304, to Westermann, discloses a tool designed to apply a predetermined quantity of adhesive on a workpiece.
U.S. Pat. No. 4,584,047, to Vanderpool et al., discloses a hand-held labeling device which senses the position of the web of labels and controls other operation in response to this sensed condition.
Despite the great efforts which have been applied to reduce the labor and time involved in wallboard finishing, there is still a marked need for an efficient and useful tool which is easy to operate and which will allow a one-step finishing of wallboard.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a process for wallboard finishing which requires only a single step.
It is a further object of the present invention to provide an apparatus for effecting such a single step process.
As will become readily apparent hereinafter, the above objects of the invention are achieved by the provision of a method for taping joints between pieces of wallboard comprising the substantially simultaneous steps of: (a) applying a first layer of a joint compound to a joint between pieces of wallboard, the first layer of the joint compound having a first predetermined width, the first layer of the joint compound being substantially centered, widthwise, on the joint; (b) embedding a wallboard tape in the first layer of the joint compound, the wallboard tape having a width substantially equal to the first predetermined width, the wallboard tape being substantially centered, widthwise, on the joint; (c) overcoating the embedded wallboard tape with at least one additional layer of the joint compound, the at least one additional layer of the joint compound having a width greater than the first predetermined width, the at least one additional layer of the joint compound being substantially centered, widthwise, on the joint.
In a preferred embodiment of the method of the present invention, the step (c) comprises the substantially simultaneous sub-steps of: (c-1) overcoating the embedded wallboard tape with a second layer of the joint compound, the second layer of the joint compound having a second predetermined width, the second predetermined width being greater than the first predetermined width, the second layer of the joint compound being substantially centered, widthwise, on the joint; and (c-2) overcoating the second layer of the joint compound with a third layer of the joint compound, the third layer of the joint compound having a third predetermined width, the third predetermined width being greater than the second predetermined width, the third layer of the joint compound being substantially centered, widthwise, on the joint.
In a particularly preferred embodiment of the present method, the method comprises the further step (d) of imprinting a surface pattern on the third layer of the joint compound, preferably, the surface pattern matches a surface pattern on the wallboard.
The present invention also provides a novel joint compound, which is quick-setting, so as to allow for substantially simultaneous application of multiple layers of joint compound to a given joint. The joint compound comprises about 45% by weight of calcium sulfate, about 35% by weight of a room temperature evaporable alcohol, about 10% by weight of polyvinyl alcohol, about 5% by weight of polyvinyl acetate, about 3% by weight talc and about 2% by weight mica.
The present invention also provides an apparatus for taping joints between pieces of wallboard comprising a taping head, slidingly contactable with a wall, for in rapid succession applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in the first layer of the joint compound and overcoating the embedded wallboard tape with at least one additional layer of the joint compound; a handle, connected to the taping head, for supporting the taping head, the handle being manually graspable by an operator, the handle having a fluid conduit formed therein for passing joint compound to the taping head; a tape supply mounted on the handle for supplying wallboard tape to the taping head; a backpack, wearable by the operator, for supporting a supply of the joint compound and for producing a pressurized stream of the joint compound; a flexible connection for fluidically interconnecting the backpack and the fluid conduit to pass the pressurized stream of the joint compound from the backpack to the fluid conduit.
In a preferred embodiment of the apparatus according to the present invention, the taping head comprises a first support plate, attached to the handle; a guide means, attached to the first support plate, for guiding a wallboard tape of predetermined width being applied to a joint; first orifice means, attached to the first support plate, for feeding a first layer of joint compound to a surface of the wallboard tape intermediate the joint and the wallboard tape, the first orifice means fluidically connected to the fluid conduit means; a second support plate, releasably attachable to the handle; biasing means, attached to the second support plate, for yieldably urging the wallboard tape and, hence, the first layer of joint compound, into contact with the wall, when the taping head is in contact with the wall, to embed the wallboard tape in the first layer of joint compound; second orifice means, formed in the second support plate proximate the first support plate, for overcoating the wallboard tape with a second layer of the joint compound, the second orifice means having a width greater than the wallboard tape, the second orifice means being centered, widthwise, with respect to the guide means; first passage means, formed in the second support plate, for fluidically connecting the second orifice means and the fluid conduit means; first gate means, pivotally connected to the second support plate for pivotal movement between a first position and a second position, the first gate means preventing flow of joint compound through the second orifice means when in the first position and allowing flow of joint compound through the second orifice means when in the second position; second biasing means for yieldably urging the first gate means to the first position; third orifice means, formed in the second support plate remote from the first support plate, for overcoating the second layer of the joint compound with a third layer of the joint compound, the third orifice means having a width greater than the second orifice means, the third orifice means being centered, widthwise, with respect to the guide means; second passage means, formed in the second support plate, for fluidically connecting the third orifice means and the fluid conduit means; second gate means, pivotally connected to the second support plate for pivotal movement between a first position and a second position, the second gate means preventing flow of joint compound through the third orifice means when in the first position and allowing flow of joint compound through the third orifice means when in the second position; third biasing means for yieldably urging the second gate means to the first position; first resilient wiper means, mounted on the second support plate intermediate the second orifice means and the third orifice means, for spreading and smoothing the second layer of the joint compound; second resilient wiper blade means, mounted on the second support plate on the opposite side of the third orifice means from the first resilient wiper blade means, for spreading and smoothing the third layer of the joint compound.
In a particularly preferred embodiment, the taping head further comprises roller means, mounted on the second support plate, for imprinting a surface pattern on the third layer of the joint compound, wherein the imprinted surface pattern preferably matches a surface pattern on the wallboard.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a partially cutaway view of the right hand side of the backpack unit according to the present invention.
FIG. 1B is a left hand view of the backpack unit according to the present invention.
FIG. 2 is a partially exploded view of the backpack unit showing the pumping mechanism.
FIG. 3 illustrates a section of the handle according to the present invention.
FIG. 4 illustrates another section of the handle according to the present invention.
FIG. 5 is a perspective view of a portion of the handle section illustrated in FIG. 3.
FIG. 6 is a perspective view of a portion of the handle section illustrated in FIG. 4.
FIG. 7 is a partially exploded view of certain elements of the handle section illustrated in FIG. 4.
FIG. 8 is a bottom view of the taping head unit.
FIG. 9 is a partially cutaway view of the taping head unit.
FIG. 10 is a perspective view of the underside of an alternative taping head unit.
FIG. 11 is a side view of the backpack unit shown in FIG. 1 connected to the handle section shown in FIGS. 3-9.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawing figures, FIGS. 1A and 1B (a right hand view and a left hand view, respectively) illustrate the backpack portion of the present invention. In particular, the backpack comprises a support frame 1 which is adapted to be fitted with suitable webbing (not shown) so as to allow the backpack to be worn on the back of an operator. A container support 3 is attached to the support frame by brackets 5 which may be screwed to or welded to support frame 1 and container support 3. Container support 3 comprises an upper section 7 in the form of a box open at its top which is receivable of a unit container 11 of joint compound. The container support also comprises a lower section 9 which contains pumps 13 and 15 and related equipment, as will be described hereinafter.
The unit container 11 is fitted with a pair of grommets 17 and 19 which define puncturable portions of the bottom wall of the container 11. When the container 11 is placed within the upper section 7, a pair of upstanding pipe portions 21 and 23, which are cut at an angle so as to form a "sharpened" edge, are aligned with the grommets 17 and 19, respectively, and insertion of the container 11 fully into the upper section 7 causes these upstanding pipe sections 21 and 23 to pierce the wall of the container and provide fluid communication between the container and the pumps as will be described hereinafter.
As may best be seen in FIG. 2, pipe section 21 is connected through elbow 25 and pipe 27 to the inlet 29 of pump 15. Likewise, pipe 23 is connected through elbow 31 and pipe 33 to the inlet 35 of pump 13. In turn, the outlet 37 of pump 15 is connected via elbow 39 and pipe 41 to outlet fitting 43. Likewise, the outlet 45 of pump 13 is connected via pipe 47, elbow 49 and pipe 51 to the outlet fitting 43. The outlet fitting 43 and/or the pipes 41 and 51 may be supported by a bracket 53 mounted on the support frame 1. The outlet fitting 43 is detachably connectable to an inlet fitting 55 of flexible hose 57.
Pumps 13 and 15, which are preferably positive displacement pumps, and most preferably rotary flexible impeller (vane) pumps, are driven by motors 59 and 61, respectively. Motors 59 and 61 are preferably electric motors driven by 120 V electrical supply. The electrical motors 59 and 61 may be supplied with power by a flexible electrical cable connected to a suitable source of power.
Joint compound which is pumped from unit container 11, via pumps 13 and 15, to flexible hose 57 is passed to the handle assembly. The handle assembly comprises a control section 65 (as shown in FIG. 3) and a delivery section 67 (as shown in FIG. 4).
The control section 65 comprises a handgrip 69 and a tape supply element 71. A fluid passageway 73 (as shown in dotted lines in FIG. 3) passes through the control section 65 from a socket 75, where flexible hose 57 is fluidically connected to the fluid passage 73, to a socket 77 wherein a plug 79 of the delivery section 67 may be received so as to fluidically connect with the delivery section 67. The handgrip 69 is fitted with switches (in the form of buttons 81-86) for operation of the various functions of the apparatus, as will be disclosed hereinafter. The handgrip 69 is also fitted with a socket 87 for electrical connection of the switches to the various electrical elements in the backpack unit. Additionally, the handgrip 69 is also fitted with an additional socket (not shown) for connection (via a cable connection) to the various electrical devices in the delivery section 67.
The tape supply element 71 is shaped substantially as a hollow rectangle (as best seen in FIG. 5) and comprises first and second cross members, 89 and 91, and first and second connecting members 93 and 95. A first disc 97 is rotatably mounted on connecting member 93. A second disc 99 is rotatably mounted on connecting member 95. The mounting of discs 97 and 99 is such that the discs are rotatably mounted substantially coaxially. Disc 97 is provided with a radially extending flange 101 and disc 99 is provided with a radially extending flange 103. At least one of the discs 97 and 99 is moveable axially with respect to the other disc by being supported for rotation on a pin 105 or 107, respectively, received within a corresponding bore 109 or 111 formed in cross member 93 or 95. A spring (not shown) may be fitted in bore 109 and/or 111 so as to yieldably urge at least one of discs 97 and 99 axially toward the other disc. The discs are of such a diameter as to be received within the core of a roll of wallboard tape, whereby a roll of wallboard tape may be supported on the discs for rotation so as to supply tape through the delivery section 67 of the handle.
The delivery section 67 substantially comprises a fluid conduit assembly 113 and a support plate 115. The fluid conduit assembly, as best seen in FIG. 7, comprises the plug 79 which is fluidically connected to a chamber 117 which in turn is connected to three fluid supply pipes 119, 121 and 123. Pipe 121 is fluidically connected to supply nozzle 125 and pipe 123 is fluidically connected to supply nozzle 127. Pipe 119 is fluidically connected via elbow 129, pipe 131 and valve 133 to tape supply nozzle 135, which when assembled is disposed in region 137 of the support plate 115.
A first stepping motor 139 is mounted on chamber 117 and connected via flexible drive cable 141 to a first bevel gear 143. First bevel gear 143 mates with a second bevel gear 145 which is mounted for rotation with a first shaft 147, shaft 147 having a screw thread formed on the outer periphery thereof. A slider 149 is slidably mounted on rails 151 and 153 with a knife edge (not shown) depending in the gap between rails 151 and 153. Connection member 155 is connected to slider 149 and is fitted with a screw threaded bore corresponding to the screw thread formed on the outer periphery of the first shaft 147, whereby rotation of the first shaft will cause movement of the slider 149 along rails 151 and 153, thereby drawing the knife edge across plate 115. Reversal of the rotation of the first shaft 147 by reversal of the rotation of the first stepping motor 139 will drawn the slider, and hence the knife edge, back across plate 115. By alternating the direction of rotation of first stepping motor 139, the knife edge may be drawn back and forth across plate 115 as needed.
A second stepping motor 157 is also mounted on chamber 117 and is connected via flexible drive cable 159 to gear box 161. Gear box 161, in turn, contains gears to drive second shaft 163 upon which friction rollers 165, 167 are mounted for rotation therewith. Plate 115 is fitted with guide rails 169 and 171 so as to guide wallboard tape beneath rollers 165 and 167, beneath rails 151 and 153 as well as shaft 147 and over tape supply nozzle 135.
In operation, a tape passing between guide rails 169 and 171 on plate 115 may be advanced a predetermined amount by actuation of stepping motor 157 so as to cause a predetermined rotation of shaft 163 and the friction rollers 165 and 167 mounted thereon. Likewise, the tape may be cut by actuation of the stepping motor 139 and the concomitant rotation of shaft 147 causing slider 149 (which is fitted with a knife edge) to slide across the width of the tape on plate 115. In this regard, for example, switch 81 on handgrip 69 can actuate stepping motor 157 so as to cause the tape to advance in a predetermined amount. Likewise, switch 84 can be connected to stepping motor 139 so as to cause movement of slider 149 across the tape. It should be noted, however, that switch 84 alternatively changes the polarity of electrical current fed to stepping motor 139 so as to alternately draw the slider across and then back across the plate 115. As the tape passes over tape supply nozzle 135 joint compound is applied to the lower face 173 of the tape 175.
Turning now to FIGS. 8 and 9, a second plate 177 is releasably attachable to the delivery section 67 of the handle. In this regard, as may best be seen in FIG. 9, supply nozzles 125 and 127 may be respectively received in passages 179 and 181 in a snap-fit or force-fit manner. Passage 179 communicates with an orifice 183 formed in plate 177. The orifice 183 is fitted with a gate 185 which is pivotally mounted on plate 177 so as to be moveable from a first position in which fluid passage through the orifice is prevented to a second position (as shown in FIG. 9) wherein fluid passage through orifice 183 is permitted. The gate may be biased, by a torsion spring 187, so as to be yieldably urged to the first position.
In a similar manner, passage 181 communicates with an orifice 189 formed in plate 177. Orifice 189 is also fitted with a gate 191 pivotally connected to plate 177 so as to be moveable from a first position in which fluid flow through the orifice is prevented and a second position in which fluid flow through the orifice is permitted. Gate 191 may also be biased, as by torsion spring 193, so as to yieldably urge the gate to the first position. Rollers 195, 197 and 199 may be supported on a shaft 201 which in turn is journaled in a support member 203 carried in bore 205 formed in the plate 177. A biasing spring 207 yieldably urges the rollers downwardly so as to force the lower side 173 of tape 175 into contact with wallboard 209. A first resilient wiper blade 211 adjustably mounted in the plate 177 as by a screw support 213 smoothes and spreads joint compound delivered through the orifice 183. A second flexible wiper blade 215 adjustably mounted in plate 177 as by screw support 217 moves and spreads the joint compound delivered to the wallboard through orifice 189. A printing roller 219 may be provided with a surface pattern matching the surface pattern of the wallboard 209 so as to aid in disguising the position of the seams formed by the present apparatus. The roller 219 may be supported by support 221 which in turn is pivotally attached to plate 177 and may be biased into contact with the seam surface as by a torsion spring 223.
As shown in FIG. 10, the second support plate may also be formed in other configurations so as to allow specialized taping operations, e.g. the taping of inside corners. In this regard, the plate is formed in two sections 177A and 177B which are at right angles to one another. A pair of printing rollers 219A and 219B is also provided, each of the rollers being disposed so as to imprint one side of the seam. Likewise, a pair of rollers 195A and 195B are also provided so as to bias the tape into contact with the respective sides of the seam. A pair of orifices 183A and 183B are provided so as to place a first coat of joint compound on the upper surface of the tape and these orifices are controlled in a manner similar to the flat taping head shown in FIGS. 8 and 9 by the provision of gates 185A and 185B. Likewise, a pair of second orifices 189A and 189B are also provided so as to place a second coat of joint compound on the tape. Although not shown in FIG. 10, a pair of gates analogous to gate 191 in the flat taping head may also be provided to control the flow of joint compound through orifice 189A and orifice 189B. A first wiper 211' and a second wiper 215' are also provided so as to spread and smooth the respective coats of joint compound.
In operation, the operator will turn on the apparatus as by the depression of switch 82 which causes power to be supplied to motor 59 which drives pump 13. However, the pressure developed by pump 13 is insufficient by itself to overcome the biasing action of springs 187 and 193 in maintaining gates 185 and 191 in the closed position. However, joint compound will be supplied through tape supply nozzle 135 to the underside of the wallboard tape. Immediately upon turning on the apparatus, the operator will then activate the wallboard tape advance so as to cause the coating of the bottom portion of a predetermined length of wallboard tape which will then be placed into contact with the wallboard 209 by pressure from rollers 195, 197 and 199. The wallboard tape which is so pressed against the wallboard is effectively adhesively adhered to the wallboard and the operator may now move the taping head downwardly (or upwardly) along the wall so as to draw tape from the tape supply wheel (the rollers 165 and 167 permitting such passage of the tape slidingly thereover). With the beginning of motion of the taping head across the wall, the operator may then activate motor 61 driving pump 15 so as to overcome the bias of springs 187 and 198 holding gates 185 and 191 shut. By controlling the operation of pump 15, the operator may control the amount of joint compound being fed to the head so as to suit the particular application conditions being dealt with. When the operator comes to the end of the stroke, the knife edge carried on slider 149 may be activated so as to cut the tape off and allow the operator to finish the end of the tape. This cycle may then be repeated in taping the next seam in the operation.
In the case where the operator is merely patching nail or screw holes in the wallboard, e.g. or in those situations where no tape feed is desired, the valve 133 may be closed so as to prevent the feed of joint compound through tape supply nozzle 135 and joint compound may be fed exclusively through orifice 183 and orifice 189.
In order to effectuate the process and apparatus of the present invention, it is necessary to utilize a fast-drying joint compound so as to allow multiple coats to be disposed one upon the other in a substantially simultaneous manner. In this regard, Applicant has developed a joint compound comprising about 45% by weight of calcium sulfate, about 35% by weight of a room temperature, evaporable alcohol, about 10% by weight of polyvinyl alcohol, about 5% by weight of polyvinyl acetate, about 3% by weight talc, and about 2% by weight mica.
By room temperature evaporable alcohol is meant an alcohol which will readily evaporate under conventional room temperatures in the building trades. Methyl, ethyl and propyl alcohols having been suitable for this use. Preferably, the alcohol comprises commercially denatured ethyl alcohol.
As previously noted, the present apparatus allows for the taping of joints between pieces of wallboard by the substantially simultaneous steps of (a) applying a first layer of a joint compound to the joint between pieces of wallboard, the first layer of joint compound having a first predetermined width, the first layer of the joint compound being substantially centered, widthwise, on the joint; (b) embedding a wallboard tape in the first layer of the joint compound, the wallboard tape having a width substantially equal to the first predetermined width, the wallboard tape being substantially centered, widthwise, on the joint; and (c) overcoating of the embedded wallboard tape with at least one additional layer of the joint compound, the at least one additional layer of joint compound having a width greater than the first predetermined width, the at least one additional layer of the joint compound being substantially centered, widthwise, on the joint. | An apparatus for taping joints between pieces of wallboard comprises a taping head, slidingly contactable with a wall, for substantially simultaneously applying a first layer of a joint compound to a joint between pieces of wallboard, embedding a wallboard tape in the first layer of the joint compound, and overcoating the embedded wallboard tape with at least one additional layer of the joint compound; a handle, connected to the taping head, for supporting the taping head, the handle being manually graspable by an operator, the handle having a fluid conduit formed therein for passing joint compound to the taping head; a tape supply mounted on the handle for supplying wallboard tape to the taping head; a backpack, wearable by the operator, for supporting a supply of the joint compound and for producing a pressurized stream of the joint compound; and a flexible connecting means for fluidically interconnecting the backpack and the fluid conduit to pass the pressurized stream of the joint compound from the backpack to the fluid conduit. |
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FIELD OF THE INVENTION
[0001] The present invention relates generally to underground boring machines and methods for controlling underground boring. More particularly, the present invention relates to underground boring machines for use in horizontal directional drilling and to an improved method of, and apparatus for, automatic control of boring functions.
BACKGROUND OF THE INVENTION
[0002] Utility lines for water, electricity, gas, telephone and cable television are often run underground for reasons of safety and aesthetics. Sometimes, the underground utilities are buried in a trench that is then back filled. However, trenching can be time consuming and can cause substantial damage to existing structures or roadways. Consequently, alternative techniques such as horizontal directional drilling (“HDD”) are becoming increasingly popular.
[0003] A typical horizontal directional drilling machine includes a frame on which is mounted a rotational drive mechanism that can be slidably moved along the longitudinal axis of the frame, to rotate a drill string about its longitudinal axis while sliding along the frame to advance the drill sting into, or withdraw it from, the ground. The drill string comprises one or more drill rods attached together in a string.
[0004] A boring tool is installed onto the end of the drill string furthest away from the horizontal HDD machine. For example, a drill bit is used when the drill string is being advanced into the ground where there is no existing hole. Similarly, a back reamer is used to enlarge a bored hole and is used when the drill string is being withdrawn after a hole is cut. These boring tools may include a wide variety of soil cutting devices tailored for specific formations. Examples include cutting edges that shear the soil and compression elements that concentrate longitudinal force from the drill string onto a concentrated area to fracture the ground when boring in rock conditions. In either case, the operation of the boring tools includes both rotational and longitudinal (or thrust) motion.
[0005] Boring machines include controls that allow the operator to control both the rotational movement and the longitudinal movement, also referred to as thrust, of the drill string and consequently of the boring tool. Typically, the magnitude of the rotational movement and thrust movement are proportional to the position of the controls. The optimum setting of rotational movement and thrust movement depends on various factors such as the soil conditions, the formation, and the type of boring tool. It is therefore necessary for the operator to establish the optimum setting based on each unique boring situation. However, in some situations the soil conditions can change rapidly, particularly as the boring tool advances through the soil and encounters soils of different densities and types, such as clay soil and rocks. Under these circumstances, an operator may be not be able to adjust the settings quickly enough to compensate for these variations. U.S. Pat. No. 5,746,278, to Bischel, herein incorporated by reference, discloses a control system that automatically adjusts the rotational movement and thrust movement settings, independently from the inputs of the operator.
[0006] In some conditions, the boring process requires maintaining consistent values of the rotational and thrust movement settings, which in turn requires the operator to maintain the controls in the appropriate position for relatively long periods of time. It can be difficult, however, for the operator to accurately maintain the positions of the controls for relatively long periods of time without becoming fatigued or losing attentiveness. In these conditions, the control system can be set to automatically maintain the boring parameters once the operator has determined the optimum levels of rotation and thrust. A control system configured in this way allows the operator to first manually set the desired rotational movement and thrust movement parameters, and then to maintain this state by depressing a separate control (such as a switch) that causes the control system to maintain these settings when the operator lets go of the controls. Although the controls typically return to their neutral positions (the position where the rotational and thrust movement are set to zero), the rotation and thrust movement settings are maintained automatically at the preferred operating state.
[0007] The boring operation must generally, however, be periodically interrupted, such as when a drill rod needs to be added to the drill string during boring or when a drill rod needs to be removed from the drill string during backreaming. When the boring process is resumed, the drill bit must be transitioned from a stationary state to a drilling state. A drilling state may generally be defined as including rotation and thrust against the soil. To accomplish this, the control system may further be configured to resume the rotational movement and thrust movement parameters that were present before the boring operation was interrupted. However, when the control system attempts to quickly resume the rotational and thrust movement settings, high loads can be encountered in the boring tool and drill string. These high loads can damage the boring tool and drill string and lead to poor drilling performance. Therefore, there is a need for an optimized boring resumption process and an apparatus for implementing the same.
SUMMARY OF THE INVENTION
[0008] One aspect of the invention includes a method for controlling an underground boring tool. The method includes setting a rate of rotation of the boring tool and setting an axial thrust of the boring tool. As indicated above, the set rate of rotation and axial thrust of the boring tool are generally interrupted periodically, such as to add a drill rod to the drill string. Following the interruption, the set rate of rotation of the boring tool is resumed first before the set axial thrust of the boring tool is resumed at a set rate of increasing axial thrust. While the term periodically is used herein to describe the interruptions in the drilling state, it will be appreciated, however, only one such interruption of the drilling state and a resumption is necessary to practice the principles of the present invention.
[0009] A further aspect of the invention includes an apparatus for controlling an underground boring tool. The apparatus includes a hydraulic system for imparting rotational motion to the drill string at a controllable speed of rotation or to generate a controllable level of torque, in response to the position of a first control, and thrusting motion at a controllable speed or to generate a controllable level of axial thrust force, in response to the position of a second control, to a boring tool at the distal end of the drill string. The apparatus also includes a third control for generating a rotation setting signal and a thrust setting signal in response to the position of the controls, an indicator for generating an automatic boring mode signal, and a fourth control for generating an automatic boring mode cancel signal. Furthermore, the apparatus includes a controller for receiving input signals including rotation and thrust setting signals, automatic boring mode signals, and automatic boring mode cancel signals from the controls, for generating rotational motion and thrusting motion control signals in response to the input signals, and for communicating said motion control signals to operatively control said hydraulic system.
[0010] Yet another aspect of the invention includes an apparatus for controlling an underground boring tool. The apparatus includes a hydraulic system for imparting rotational motion at a controllable speed of rotation or to generate a controllable level of torque, in response to the position of a first control, and thrusting motion at a controllable speed or to generate a controllable level of axial thrust, in response to the position of a second control, to a boring tool. The apparatus also includes a third control for generating a rotation setting signal and a thrust setting signal in response to the position of the controls, a fourth operator actuated control that generates a signal for incrementing and decrementing a rotational motion setting, and a fifth operator actuated control that generates a signal for incrementing and decrementing an axial thrust setting. The apparatus also includes a controller for receiving input signals from the first, second, third, fourth, and fifth operator actuated controls, for generating rotational motion and axial thrust control signals in response to the input signals, and for communicating said motion control signals to operatively control said hydraulic system.
[0011] While the invention will be described with respect to preferred embodiment configurations and with respect to particular devices used therein, it will be understood that the invention is not to be construed as limited in any manner by either such configuration or components described herein. Also, while the particular types of hydraulic pumps and motors are described herein, it will be understood that such particular mechanisms are not to be construed in a limiting manner. Instead, the principles of this invention extend to any environment in which automatically maintaining and/or resumption of a drilling state with predetermined rotation and axial thrust settings are desired. These and other variations of the invention will become apparent to those skilled in the art upon a more detailed description of the invention.
[0012] The advantages and features which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. For a better understanding of the invention, however, reference should be had to the drawings which form a part hereof and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate several aspects of the invention and together with the description, serve to explain the principles of the invention. A brief description of the drawings is as follows:
[0014] FIG. 1 illustrates a horizontal directional drilling machine;
[0015] FIG. 2 illustrates the operator control station of a horizontal directional drilling machine according to the principles of the present invention;
[0016] FIG. 3 illustrates a control lever of the operator control station of FIG. 2 ;
[0017] FIG. 4 illustrates a label identifying the function of the controls found on the control lever of FIG. 3 ;
[0018] FIG. 5 illustrates controls found on the right side of the operator control station of FIG. 2 ;
[0019] FIG. 6 illustrates a display according to the principles of the present invention;
[0020] FIG. 7 illustrates the rates of increase of rotational movement and axial thrust when a boring process is resumed; and
[0021] FIG. 8 is a flow diagram of a method of resuming automatic control of boring functions.
DETAILED DESCRIPTION
[0022] With reference now to the various drawing figures in which identical elements are numbered identically throughout, a description of various exemplary aspects of the present invention will now be provided. The preferred embodiments are shown in the drawings and described with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the embodiments disclosed.
[0023] A horizontal directional drilling machine 20 , illustrated in FIG. 1 , includes a frame 22 on which is mounted a rotational drive mechanism 30 that is slidably moved along a longitudinal axis of the frame 22 . In one embodiment, horizontal directional drilling machine 20 includes a rear stabilizer 26 and front stabilizer 27 for positioning and stabilizing the machine 20 at the drilling site, and a wheel assembly 24 for supporting the machine during transport between job sites. A drill string 18 comprises a boring tool 42 designed to engage the soil and one of more drilling rods 38 that transmit forces from machine 20 to the boring tool 42 . The rotational drive mechanism 30 typically includes a gearbox and a drive spindle that rotates the drill string 18 about its longitudinal axis, the rotational power being preferably provided by hydraulic motor 216 . The horizontal directional drilling machine 20 also includes a thrust drive mechanism 28 that typically includes gears or sprockets to move the drive mechanism 28 up and down the frame 22 to advance the drill sting 18 into, or withdraw it from, the soil. The thrust power is preferably provided by hydraulic motor 217 . In some embodiments, an engine 36 drives hydraulic pumps 16 and 17 , which pressurize fluid that is transferred to hydraulic motors 216 and 217 .
[0024] The hydraulic systems can be either open loop where the fluid is transferred from a hydraulic reservoir 14 through the pumps to the motors 216 , 217 and back to the reservoir 14 , or they can be hydrostatic where the fluid is substantially in a closed loop—being transferred between the pump and the motor. In either system the pumps 16 , 17 and motors 216 , 217 are matched, such that by controlling the flow rate of the hydraulic fluid, the speed of rotation of the output shafts of the motors is controlled and can be inferred. The pumps are typically variable displacement pumps capable of producing variable output flow rates, proportional to an electrical current provided by a control system. The output speed of the pumps is proportional to the output flow rates. While the speed can be controlled, the pressure of the hydraulic fluid can be monitored to infer the torque being generated by the motor, which is directly proportional to the longitudinal force or rotational torque being generated. Other embodiments are possible, for instance wherein rotational and thrust drive mechanisms could be actuated by different hydraulic drives (e.g., such as hydraulic cylinders).
[0025] Some embodiments may also include a water flow mechanism that transmits water through the drill string 18 to the vicinity of the boring tool 42 , where the water flow entrains cut soil particles and removes them from the hole. The horizontal directional drilling machine 20 may also include a greaser for lubricating various moving components (not shown).
[0026] FIG. 2 illustrates an exemplary operator control station 100 for a horizontal directional drilling machine 20 . Operator control station 100 includes rotational control 110 and thrust control 130 that provide inputs to a controller 150 . Many embodiments of controls 110 and 130 are usable. For example, in one usable embodiment, each of controls 110 and 130 comprise a control lever. In such an embodiment, control levers 110 , 130 each produce an electrical signal that is proportional to the position of the control lever relative to a center position. The electrical signal is provided as an input to a controller 150 .
[0027] In one embodiment, when the control lever 110 , 130 is moved away from the center position, the electrical signal that is generated corresponds to increased rotational torque (and/or rate of rotational movement) or axial thrust force (and/or rate of axial movement), respectively. As the control lever 110 , 130 is moved closer toward the center position, the generated electrical signal corresponds to decreased rotational torque (and/or rate of rotational movement) or axial thrust force (and/or rate of axial movement), respectively. In one embodiment, when the control lever 110 is moved in the forward direction, away from the operator (best seen in FIG. 3 , with the direction designated at 200 ), the generated electrical signal corresponds to counter-clockwise rotational movement of the drill string, as viewed looking at the end of the drill string. Alternatively, when the control lever 110 is moved in the backwards direction, toward the operator (best seen in FIG. 3 , with the direction designated at 201 ), the electrical signal that is generated corresponds to the opposite direction, clockwise rotational movement. Likewise, in one embodiment, when control lever 130 is moved forward, away from the operator, the electrical signal that is generated corresponds to forward movement of the drill string into the soil. Alternatively, when control lever 130 is moved in the backwards direction, toward the operator, the electrical signal that is generated corresponds to backwards movement of the drill string back toward the machine.
[0028] When either of control lever 110 , 130 is in the center position, the electrical signal that is generated corresponds to a neutral condition where the rotational or thrust movement respectively is set to zero. A spring or other biasing mechanism is provided to return each of the control levers to the center position, so that if an operator does not hold the lever, it returns to its centered, neutral position such that the rotational or thrust motion settings are set to zero.
[0029] The controller 150 generates outputs, in response to various inputs, to control the hydraulic system. The system includes the hydraulic pumps 16 and 17 of the drilling machine 20 . The hydraulic motors 216 , 217 are driven by the hydraulic fluid in a known manner to create rotational and thrust movement of the boring tool 42 and drill string 18 . As noted above, this control is typically a variable electrical current, wherein a certain electrical current will cause the pump to create a certain hydraulic flow rate. The output shaft of the motor thereby rotates at a certain speed of rotation. This is typically independent of the pressure in the fluid. The control systems are typically designed to provide speed control that is independent of load. The control systems typically further include pressure transducers 226 and 227 that provide feedback to the control system indicating the pressure in the circuits, and can further include speed sensors 236 and 237 for measuring the output speed of the motors 216 and 217 , respectively.
[0030] FIG. 3 illustrates the rotational movement control 110 in more detail, showing the various control switches that are mounted on the control, as well as the forward 200 and backward 201 directions. FIG. 4 illustrates a visually perceptible display (e.g., a sign) that indicates the functions of each of the control switches located on the control 110 to the operator. Control 110 includes switches 112 , 118 , 120 , and 122 , each of which generates an electrical signal when actuated, such as by being pressed. Control switch 112 may be called a SET switch. When SET switch 112 is actuated, an electrical signal is sent to controller 150 activating an automatic boring mode (also called auto boring mode). When controller 150 receives a signal from SET switch 112 , the rotational movement and thrust movement parameters are set within the controller to the values established by the positions of controls 110 , 130 at the time that the SET switch 112 is actuated. The preferred technique includes setting a value for the speed of rotation, while setting a value for the pressure in the axial thrust circuit, as will be explained in more detail later. Thereafter, controller 150 automatically maintains the boring parameters of rotational movement and thrust movement at the set values without further input from the operator. Preferably, the operator then may release control levers 110 , 130 , which will then automatically return to the neutral position within a short period of time, without affecting the boring operation, thereby reducing operator fatigue. The auto boring mode will be deactivated if either the rotation handle 110 or the thrust handle 130 is subsequently moved from the neutral position. It will be appreciated that as an alternative embodiment or as an option, it may be possible to deactivate the system by actuating the SET switch (or some other switch), when the system is currently activated.
[0031] In one embodiment, rotational movement control 110 also includes control switches 114 and 116 which control the water flow functions for injecting water into a bored hole to remove cuttings from the hole. Rotational movement control 110 also includes control switches 118 and 120 to control the speed of the engine 36 , and control switch 122 to control a greaser (not shown).
[0032] FIG. 6 illustrates a display 170 for the control system that includes a light 172 that is energized when an auto boring mode is active (e.g., to help alert the user on the status of the system). This light 172 is energized after the SET switch 112 is activated and a rotation setting and a thrust setting are defined, so as to enter the auto boring mode. Light 172 is deactivated if the auto boring mode is not active.
[0033] FIG. 5 illustrates additional control switches on the right side of the operator control station 100 . In one embodiment, control station 100 includes switches 140 , 142 that are in electrical communication with controller 150 . Switch 140 has a neutral position, a first operative position, and a second operative position. In one embodiment, switch 140 is spring-loaded to the neutral position, so that when the switch is placed in either the first or second operative positions and then released, switch 140 will return to the neutral position. When switch 140 is in the neutral position, switch 140 has no effect on the boring operation. When switch 140 is placed in the first operative position, such as where switch 140 is rotated clockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller 150 to increase the rotational pressure or movement setting by a predefined increment. Similarly, when switch 140 is placed in the second operative position, such as where switch 140 is rotated counterclockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller 150 to decrease the rotational pressure or movement setting by a predefined decrement.
[0034] Operation of switch 142 is similar. Switch 142 has a neutral position, a first operative position, and a second operative position. In one embodiment, switch 142 is spring-loaded to the neutral position, so that when the switch is placed in either the first or second operative positions and then released, switch 142 will return to the neutral position. When switch 142 is in the neutral position, switch 142 has no effect on the boring operation. When switch 142 is placed in the first operative position, such as where switch 142 is rotated clockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller 150 to increase the axial thrust pressure setting by a predefined increment. Similarly, when switch 142 is placed in the second operative position, such as where switch 142 is rotated counterclockwise away from the neutral position, and when the auto bore mode is activated, an electrical signal is sent to controller 150 to decrease the axial thrust pressure setting by a predefined decrement.
[0035] During the boring or backreaming processes the system then acts to maintain rotation of the drill string at the selected speed of rotation, independent of the rotational pressure setting and axial pressure setting, and will automatically vary the axial thrust speed as necessary to attempt to maintain the selected pressure in the rotation circuit, or to maintain a set amount of force at the boring tool. In consistent formations maintaining a constant force on the drill bit will result in a constant/consistent torque on the drill bit, and will maximize drilling efficiency. In formations that vary, this same control technique is also effective.
[0036] It may be necessary to interrupt the auto boring mode, such as when it is required to add or remove a drill rod from the drill string. There are several ways in which the auto boring mode may be interrupted. The machine 20 may be configured so that when the auto boring mode is activated, as indicated by light 172 , any further motion of controls 110 , 130 sends an electrical signal to controller 150 that causes controller 150 to interrupt the auto boring mode. Alternatively, other switches or controls may be provided or adapted so as to provide an electrical signal to the controller 150 to interrupt the auto boring mode. One example is a control function related to breaking the connection between the drive chuck of the rotational drive 30 and the drill string. When a drill rod has been completely inserted, and the rotational drive is at the end of the frame 22 , then the rotational drive must be unthreaded from the drill string and moved back to the opposite end of the frame so that another drill rod can be added. This action is required when the rotational drive is located at certain positions along the frame, for instance at the extreme opposite ends. Thus, an interrupt signal can be provided automatically by a sensor that measures the position of the thrust drive. When the interrupt signal is received it may also automatically cancel other functions such as the water flow.
[0037] The operator control station 100 also includes switch 144 that is in electrical communication with controller 150 . Switch 144 may be called a RESUME switch. When the auto boring mode has been interrupted, the operator may actuate switch 144 to resume the auto boring mode. Switch 144 then sends an electrical signal to controller 150 that causes controller 150 to resume the auto boring mode at the same settings as existed prior to the auto boring mode being interrupted.
[0038] A preferred method which implements the principles of the present invention is shown in FIG. 8 , where the method is generally designated at 800 . At block 801 , a rate of rotation is of the boring tool 42 is set. The axial thrust of the boring tool 42 is set at block 802 . At block 803 , the set rates of rotation and axial thrust are interrupted, while at block 804 , the resume process is implemented.
[0039] Many embodiments of the resume process are usable. The resume process of the present invention initiates drilling operation in a manner that minimizes unnecessary vibration and stress in the drill string and drilling tool. FIGS. 7 and 8 illustrate one usable embodiment of the resume process. The resume process begins (at time equal to 0 seconds) when the switch 144 is depressed to initiate the resume process, sending an electrical signal to the controller 150 . The controller 150 will activate the rotational drive mechanism so as to bring the boring tool to the set value of rotational movement, the set rate of rotation. At the same time, preferably the water flow is automatically restarted (not shown). The resumption of rotational movement occurs rather quickly, usually in about one second. During the time that the rotation is being resumed, controller 150 does not activate the thrust drive mechanism. In this way, the boring tool 42 will resume rotation to the set rate of rotation while there is little or no longitudinal thrust loading or movement. This operation is advantageous because it produces a smooth rotational acceleration without shock loading of the boring tool and drill string. There are additional benefits to reestablish water flow to the cutting tool prior to new cuttings being generated from axial movement of the drill string.
[0040] After the rotational movement setting is attained, approximately one second after the rotation is started, the controller 150 then beings to apply thrust force to the drill string. However, rather than rapidly increasing the thrust force to the set value, the thrust force is increased from zero to the set value, the set axial thrust, at a predetermined rate. In one usable embodiment, the thrust force is applied at a first constant rate of 25% of the set axial thrust force setting per second for three seconds, from the time of one second after the resume process is initiated to the time of four seconds after the resume process is initiated. Thus, having increased by 25% of the thrust force setting for three (3) seconds, the amount of thrust force applied at this point will be 75% of the thrust force setting. The thrust force is then applied at a second constant rate of 12.5% per second for two seconds. Under this resumption example, from the time of four (4) seconds after the resume process is initiated to the time of six (6) seconds after the resume process is initiated, the thrust force is increased from 75% of the set value to 100% of the set value. Thus, at six (6) seconds after the resume process is initiated, the boring tool will be operating both at the set rate of rotation and the set axial thrust.
[0041] An alternative embodiment includes increasing the axial thrust force at a single predetermined rate, such as 25% of the set axial thrust force per second for four (4) seconds. It will be appreciated that other rates may also be used, and that the rates provided herein are presented as preferred embodiments, and not as limitations.
[0042] While particular embodiments of the invention have been described with respect to its application, it will be understood by those skilled in the art that the invention is not limited by such application or embodiment or the particular components disclosed and described herein. It will be appreciated by those skilled in the art that other components that embody the principles of this invention and other applications therefor other than as described herein can be configured within the spirit and intent of this invention. The arrangement described herein is provided as only one example of an embodiment that incorporates and practices the principles of this invention. Other modifications and alterations are well within the knowledge of those skilled in the art and are to be included within the broad scope of the appended claims. | A method and system for controlling a horizontal directional drilling machine having a boring tool. A rate of rotation and a rate of thrust are selected by an operator. Controls allow an automatic boring operation mode to be initiated to maintain the selected rate of rotation and thrust without further input from the operator. Periodically, when the rotation and thrust are interrupted, such as to modify the drill string, the automatic boring operation mode is interrupted. The automatic boring operation mode may be resumed without requiring the operator to select the rate of rotation and rate of thrust. The rate of rotation is resumed before the rate of thrust to reduce drill string shock loads and increase drilling performance. |
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FIELD OF THE INVENTION
This invention relates to an improved method to cement a wellbore.
BACKGROUND OF THE INVENTION
Casings are typically cemented into wellbores by circulating a cement slurry through the inside of a casing, out the bottom of the casing and up the annulus between the outside of the casing and the wellbore until a cement slurry level outside the casing is reached to which the wellbore is to be cemented. The cement then hardens to form a seal around the casing. Because the column of cement slurry must be fluid until the last of the cement slurry is forced into the annulus around the casing from the bottom, this method requires that the cement slurry is of a density that does not exceed the hydraulic fracture gradient of the formation around the wellbore. If this gradient is exceeded, the formation can fracture and cause the cement to be lost into the fracture. A cement slurry of a density that exceeds the formation hydraulic fracture gradient may be desired because such slurries can have greater mechanical strength, better bonding to the casing and the formation, better tolerance to elevated temperatures and greater thermal conductivity.
Further, the cement slurry must be of a density that is great enough to provide a wellbore pressure that exceeds the formation pore pressure to prevent formation fluids from invading the wellbore and interfering with the setting of the cement. It is occasionally difficult to match the density of the cement slurry to the range of densities that will satisfy these requirements.
To prevent lost circulation, when it is desirable to use a cement slurry that has a density that exceeds the fracture gradient of the formation, the cement slurry can be placed in stages directly into an annulus between the casing and the formation using a coiled tubing. An apparatus for injection of a coiled tubing into such an annulus is disclosed in, for example, U.S. Pat. No. 4,673,035. Placement of cement slurry in stages is time consuming because each stage must gel before a stage can be set above it. This makes placement of cement in stages very expensive due to equipment rental costs and the delay in completion of the well.
Conventional placement of cement from the bottom of the casing and up the annulus requires that the cement set relatively slowly because the entire annulus must be filled with cement slurry before the first cement placed in the annulus starts to become hard. When the formation within which a casing is to be cemented causes significant water loss from the cement slurry, the top of the column of cement will settle a significant amount between the time the cement slurry is placed and the time the column of cement slurry is fully hardened. This settling can be attributed to water loss from the cement slurry. Water loss additives can be added to the cement slurry, but water loss additives can be expensive and some settling will typically occur even when water loss additives are included in the cement slurry. Water loss alters the chemistry of the cement slurry resulting in inconsistent and suboptimal set cement properties. The final height of the cement is also unpredictable.
Injection of cements and curing agents through separate conduits within a casing is disclosed in, for example, the abstract of Russian Patent No. 465,583. This Russian patent abstract discloses such a method in order to provide a quickly setting cement in permafrost conditions.
Separate injection of grouts and curing agents through conduits within the casing is disclosed in U.S. Pat. Nos. 4,302,132 and 4,449,856. These grouts are intended to fill voids and thief zones within a formation with a quickly setting grout. The methods of these patents could not be used to place cement in a significant length of wellbore annulus because they are discharged from the bottom of the casing and will become hard before a significant portion of the annulus could be filled.
It is therefore an object of the present invention to provide a method to place cement in a wellbore wherein the cement hardens sufficiently fast that significant water loss from the cement does not occur. It is a further object of the present invention to provide such a method wherein the cement can be placed in a formation that has a hydraulic fracture gradient significantly less than the static head that would be formed by the cement slurry. It is another object to provide such a method wherein the cement can be placed over an extended length of the wellbore in a single continuous operation.
SUMMARY OF THE INVENTION
These and other objects are accomplished by a method for providing a set cement within a volume in a wellbore, the method comprising the steps of: providing two conduits, each conduit having an end terminating in a lower portion of the volume in the wellbore to be cemented; providing two fluids that when combined, form a cement slurry that hardens within a short time; passing the two fluids to the lower portion of the volume in the wellbore through the two conduits so that the two fluids combine in the volume in the wellbore creating a rising level of cement slurry in the volume in the wellbore; raising the ends of the two conduits within the volume in the wellbore at about the same rate as a level of the cement rises within the volume to be cemented; and allowing the cement to harden within the volume within the wellbore.
The fluids are preferably a known wellbore cement and an accelerator. The amount of accelerator is preferably sufficient to result in the cement slurry hardening within about thirty minutes. The two conduits are preferably concentric tubes that are placed within the wellbore from a coiled tubing unit.
In a preferred embodiment of the present invention, the level of cement slurry in the wellbore is monitored and the ends of the conduits are raised as the level of cement slurry is increased so that the ends of the conduits are maintained within about five to about thirty feet below the top level of the slurry. Monitoring the level prevents the ends of the conduits from becoming too deep within the slurry and possibly being within hardening slurry or being too far above the slurry level and trapping drilling fluids and causing voids within the slurry. The level can be monitored independently of the conduits, for example, by a wireline detector suspended within the casing, or the level could be monitored by detectors attached to one of the conduits such as one or more conductivity sensors attached to the conduit.
The fluids that can be combined may be selected from a wide variety of fluids, such as, for example, epoxies and crosslinking agents, blast furnace slag and sodium carbonate accelerator solution, Portland cement and a cement accelerator, or a high alumina cement and a sodium aluminate or lithium hydroxide accelerator.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is preferably utilized to place cement in a wellbore in an annulus between the formation and a casing. The two conduits may be placed within the wellbore from two coiled tubing units. Alternatively, and preferably, a small tube may be threaded inside of a larger tube, and injected from a single coiled tubing unit. The ends of each conduit may be connected to a static mixer so that the combined fluids pass through the static mixer. This ensures uniform mixing of the two fluids before entering the wellbore region. The conduits could be secured together and lowered from a typical drilling or workover rig, but this is not preferred because it would take a considerably longer time to place the cement if joints of tube would have to be removed continually in order to raise the tube as the volume to be cemented is filled with cement slurry.
The fluids that are combined to form a cement slurry that hardens within a short time to form a hardened cement may be selected from a wide variety of compositions. Conventional Portland wellbore cement slurries may be used in conjunction with know accelerators. Blast furnace slag wellbore cements are preferred in the practice of the present invention because blast furnace slag cement slurries can be prepared with retarders such as lignosulfates that cause the slurry to remain pumpable for long periods of time, but harden quickly when combined with accelerators such as sodium carbonate, sodium hydroxide, or mixtures thereof.
Fluids can be used in the practice of the present invention that are not typically considered to be wellbore cements because of the elimination of the need to delay the development of gel strength. For example, epoxies and crosslinking agents could be combined. Such epoxies may optionally be provided with aggregates or fillers. Polymers or solutions of polymers that can be crosslinked at functional sites, such as many ionomers, may be used with crosslinking agents. Phosphates may be combined with metal oxides to quickly form solids by combining slurries or solutions of these components in the wellbore. When fluids are combined in the wellbore that set quickly, it is particularly preferred to monitor the interface of the fluids and to keep the end of the conduits near the interface to prevent the conduits from becoming stuck in the cement.
The advantages of the present invention can be particularly significant when a wellbore cement is required that is very dense. For example, high alumina cements are preferred when the wellbore will be exposed to elevated temperatures. Such cements can be operated at temperatures exceeding 2000° F., but are preferably prepared from very dense slurries. Setting of such slurries may be effectively accelerated by adding a sodium aluminate or lithium hydroxide solution to the slurry. Less than 0.1 percent by weight of sodium aluminate based on the dry weight of the alumina cement can result in set times of less than fifteen minutes. The slurry without the accelerator will not set for hours. Placement of a quickly setting slurry by the method of the present invention prevents the reservoir from being fractured and loss of cement into those fractures because the formation is not exposed to an excessive static head due to the column of cement slurry in the wellbore.
The level of the cement slurry within the wellbore is preferably monitored to ensure that the end of the fluid conduits are maintained within a desired distance below the surface of the cement. If the ends of the fluid conduits are above the slurry level, the slurry may be diluted with drilling fluids. If the ends of the fluids conduits are too far below the ends of the conduits, the conduits may become trapped in the cement. Commercially available well logging services are capable of providing such monitoring from inside the casing. An NFD (non-focused density or nuclear fluid density) log available from Schlumberger is an example. This is a gamma ray log that can be logged inside the casing. The cement slurry will have higher density (fewer detector counts) than drilling mud. The NFD has maximum sensitivity to the annular space outside of the casing. This method of monitoring the slurry level is accurate but is also relatively expensive.
Slurry levels may alternatively be monitored from inside of a casing by sonic or ultrasonic methods that are well known in the art. A series of ultrasonic level detectors may be suspended from a wireline within a casing, or a single detector may be raised and lowered to monitor the location of the slurry level.
Alternatively, conductivity sensors could be attached to the lower end of one of the conduits. A single conductivity detector could be placed a distance above the lower ends of the conduits, and the conduit raised a set distance, for example ten feet, when the conductivity of the cement slurry is detected by the sensors. Raising the conduits will then lift the conductivity detectors from the cement slurry and into the drilling fluid or drilling mud above the cement slurry and the detected conductivity will change. Typically, because of the lower water content, the cement slurry will have lower conductivity than the drilling mud.
Another measurement device would be differential pressure sensors outside of the conduit. The pressure differential will be proportional to the average density of any drilling mud and cement slurry between the sensing locations. The sensing locations could be spaced, for example, between about five and about thirty feet above the bottom of the conduits.
It is preferred that the ends of the conduits be maintained between about five and about thirty feet below the surface of the cement slurry in the wellbore. At this distance the conduits are not likely to become stuck in the cement. The ends of the conduits are preferably keep below the level of the cement slurry because the cement slurry will then more fully displace wellbore fluids and provide a continuous cement seal around the casing.
The fluids combined within the borehole in the practice of the present invention form a set cement within a short time. This short time can vary depending upon the requirements of the particular operation, but will typically be less than about two hours. It is preferred that the fluids set in about ten to about sixty minutes and more preferably between about ten and about thirty minutes. The cement does not have to become as hard as it will eventually become in order for it to be set according to the present invention. Many cements continue to increase in strength for weeks. The cement is preferably set within the short time to a gel strength that results in the weight of a column of cement slurry above the set cement to be transferred to the wellbore and not to the wellbore contents below the set cement.
EXAMPLES
The advantages of the present invention were demonstrated in cementing two 300 foot deep wellbores, one with an accelerator being injected with a high alumina cement, and one being cemented without the accelerator. Both wellbores penetrated a combination of sands and shales. The cement slurry injected with the accelerator had a weight of about 22 pounds per gallon, and the slurry injected with no accelerator had a weight of about 19.8 pounds per gallon. The cement was injected into both wellbores through a 1.2 inch internal diameter tube from a coiled tube injector. The cement was a "SECAR" 80 cement (available from LaFarge) with a high alumina "MULCOA-60" aggregate (available from C-E Minerals). The cement slurry solids consisted of about forty percent by weight "SECAR 80" and about sixty percent by weight "MULCOA-60" aggregate. About one half of a pound of "XCD" (a xanthan gum available from Kelco) per barrel of slurry was also included in the composition as a thickener and a retarder to prevent setting prior to the combination of the cement with the accelerator. The accelerator was a 0.5 percent by weight aqueous solution of lithium hydroxide. The accelerator solution was injected to form a final slurry in the wellbore of about 0.15 percent by weight of lithium hydroxide based on the water in the slurry. To provide a conduit for injection of the accelerator solution, a 0.5 inch outside diameter stainless steel tube was threaded through the entire coiled tubing. The end of the accelerator solution conduit was fixed to a Kenics static mixer (available from Chemineer, Inc, N. Andover, Mass.) at the end of the coiled tubing, and the static mixer was welded to the end of the coiled tube.
The coiled tubing was placed in the first 300 foot deep well and the cement slurry and accelerator solutions were co-injected as the tubing was raised. The level of the cement slurry was monitored by a non-focused density log (NFD log available from Schlumberger) run inside of the casing. The end of the static mixer was kept between about 6 and about 10 feet below the top level of the cement slurry in the wellbore. The second well was cemented using the same procedure except the accelerator was not co-injected with the cement slurry. After the cement had set, the level of the cement in the first well was the same as it was immediately following the placement of the cement slurry in the wellbore. Before the cement had hardened in the second wellbore, the top level of the cement had settled by over five and one half feet, or about two percent of the total height of cement even though a lower density slurry was used.
The preceding examples and described embodiments are exemplary and reference to the following claims should be made to determine the full scope of the present invention. | A method to cement a wellbore is provided wherein two fluids are transported into the wellbore through separate conduits, and combined within the volume to be cemented. The two fluids set to become a hardened cement after a short time period. The two fluids are preferably passed through a static mixer at the ends of the conduits within the wellbore to provide uniform contact between the two fluids. The two fluids are preferably a wellbore cement and an accelerator for that cement. Because the cement sets within a short time period, fluid loss from the wellbore is minimal. Additionally, the static head to which the formation is exposed is not excessive, even if a cement slurry having a density that exceeds the hydraulic fracture gradient of the formation is used. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 14/591,673, filed Jan. 7, 2015 and entitled “Shading device for an architectural opening and method for adjusting an end stop position of the shading device”, which claims priority to Netherlands Patent Application No. 1040593, filed on Jan. 8, 2014, and entitled “Shading device for an architectural opening and method for adjusting an end stop position of the shading device”, which applications are hereby incorporated in their entirety by reference as though fully disclosed herein.
FIELD
[0002] The invention relates to a shading device for an architectural opening comprising a shade, a drive unit for extending and retracting the shade between a first and second end position, a spindle, a first end stop, stationary connected to the spindle near a first end of the spindle; at least one travelling nut, movably arranged on the spindle and operatively connected to the drive unit so as to move towards, respectively away from the first end stop as the shade is extended, respectively retracted.
BACKGROUND
[0003] A respective shading device, as disclosed in applicant's European Application EP 2 216 492 A1, is equipped with a mechanical end stop system. Such mechanical end stop systems are known as so-called spindle & nut end stop systems. A spindle & nut end stop system may comprise a threaded shaft as the spindle, a wandering or travelling nut threaded on the shaft and at least one or two end stop members fixed on the shaft.
[0004] A drawback of the known mechanical end stop system is that the travelling nut has to be screwed on the spindle before installing the last end stop. This limits the amount of possible constructions of the spindle with the end stops. Particularly at least on end stop has to be releasable in regard to the spindle.
[0005] A further drawback of the known mechanical end stop system is that each end stop is designed as a separate part which needs to be fixed to the shaft such that the end positions of the shade are set as desired. Furthermore, for mounting the end stop member to the shaft a fixing means, preferably screws, pins or rivet, is needed. The end stop member may consist of two separate halves which have to be connected at the shaft. Thus, known mechanical end stop systems consist of several parts leading to a complex construction. As a consequence the assembling and/or adjusting of the shading device may be complex and time consuming.
SUMMARY
[0006] It is a principal object of the present invention to enhance a shading device as mentioned in the preceding introduction and/or a travelling nut for such a shading device such that the assembling and/or arranging of a travelling nut around and/or onto a spindle is simplified.
[0007] Preferably it is a further object of the present invention that the assembling and/or adjusting of the shading device, particularly the end stop assembly, is simplified.
[0008] It is a further object of the present invention to provide a simple method for arranging a travelling nut on and/or around a spindle.
[0009] Preferably it is a further object of the present invention to provide a simple method for adjusting the lower end stop position and/or upper end stop position of a shade providing a shade device according to the invention with at least one travelling nut moveably arranged on the spindle between the first and second end stop, whereby the first end stop, the second end stop and the spindle form an end stop assembly.
[0010] The object of the invention is accomplished by a shading device as mentioned in the preceding introduction and/or a travelling nut for such a shading device, wherein the travelling nut comprises at least two segments for arranging the travelling nut around the spindle.
[0011] As an advantageous result the travelling nut can be arranged around and/or onto a spindle in a quick and/or easy way. A travelling nut formed of at least two segments can be arranged around the spindle independent of the end stops. As the ends of the spindle may be blocked by the first and second end stop it is not possible to screw a usual nut on the spindle. Thus, the travelling nut is preferably designed such that the nut can be opened and/or closed by means of the two segments of the travelling nut. Even if the end stops are already fixed to the spindle, the travelling nut is mountable to the spindle. Preferably the travelling nut is formed as a split nut.
[0012] Preferably the shading device is a roller blind. Particularly the shade is a sheet of flexible material. The shade may be attached upon the outer surface of a winding core such as a shade tube or roller. The travelling nut may interact with a driven portion of the shading device, such as aforementioned winding core, and the spindle may be stationary such that when the shading device is driven the travelling nut rotates and is displaced in an axial direction along the spindle. The spindle is preferably a threaded rod. When the travelling nut reaches the first or second end stop the nut can no longer be displaced along the spindle. Since the driven portion of the shading device is coupled with the nut, rotation of the driven portion will be stopped too.
[0013] According to a further embodiment of the present invention the travelling nut has two segments which are hinged with each other for arranging the travelling nut onto the spindle. For the opening of the travelling nut the ring-like shape of the nut can be resolved by moving the two segments of the nut away from each other. As a result the travelling nut has an aperture with a size appropriate to accommodate the spindle in a centre of the nut. The centre of the nut has a threaded inner side which mate with a threaded outer side of the spindle. Preferably the two segments are formed as a first half and a second half of the travelling nut connected with each other by a flexible hinge. The first half, the second half and the flexible hinge may be formed as one piece and/or as one integral part, particularly made of plastic.
[0014] Preferably the travelling nut is formed in one piece comprising a flexible hinge and a connection arrangement for detachably joining the two segments of the travelling nut. Thus, the travelling nut may be arranged on the spindle and/or removed from the spindle by the detachable connection as desired. The two segments of the travelling nut may comprise engaging means for securing the segments to one another. Particularly the connection is designed as a snap connection. A snap connection does not need any further mounting elements for connecting or disconnecting the segments of the nut.
[0015] The connection arrangement may have a first joint element and a second joint element, which have complementary formations for an engagement with each other. Preferably the first joint element having a snap-on catch is assigned to a first half of the travelling nut. The second joint element may have a recess complementary formed to the snap-on catch. The second joint element may be assigned to a second half of the travelling nut.
[0016] A further embodiment of the present invention provides the travelling nut comprising at least one engaging element on the outer circumference of the travelling nut for engagement with a complementary element on the inner surface of the winding core. Preferably the engaging element of the travelling nut interacts at least during normal operation of the shading device with the complementary element such that when the winding core is rotated around its longitudinal axis the travelling nut rotates and is displaced in an axial direction along the stationary spindle.
[0017] The travelling nut may comprise several engaging elements which are equidistantly distributed over the circumference of the travelling nut. Preferably the travelling nut has at least two, three or four engaging elements. With only one single engaging element the winding core may be rotated 360° around its longitudinal axis for arranging the end stop assembly with the travelling nut arranged on the spindle within the inner cavity of the winding core. Providing several engaging elements spaced over the circumference of the nut allows inserting of the end stop assembly with the travelling nut in the inner cavity of the winding core by rotating the winding core around its axis with only a fraction of 360°. Preferably the end stop assembly with the travelling nut can be inserted into the inner cavity in rotation steps and/or angle steps of 180°, 120° or 90° of the winding core around its longitudinal axis. As a result the adjusting of the lower and/or upper end position of the shade is simplified and more precise.
[0018] Preferably when the travelling nut interacts with and/or abuts the first end stop to set the upper end position of the shade, the upper end position of the shade is adjustable by removing the end stop assembly with the at least one travelling nut from the winding core while maintaining the orientation of the end stop assembly, rotating the winding core so as to unwind or wind up the shade as desired while still maintaining the orientation of the end stop assembly, preferably the orientation of the travelling nut relative to the spindle, and re-inserting the end stop assembly with the at least one travelling nut into the inner cavity of the winding core.
[0019] The engaging element of the travelling nut may be formed as a groove. Preferably the groove is aligned parallel to the longitudinal axis of the winding core. The complementary element on the inner surface of the winding core may be formed as a bar extending parallel to the longitudinal axis of the winding core. In an alternative embodiment the travelling nut may be formed as a bar and the complementary element on the inner surface of the winding core may be formed as a groove. The bar and the groove extend parallel to the longitudinal axis of the winding core.
[0020] According to a further embodiment of the present invention a first travelling nut and a second travelling nut are moveably arranged on the spindle between the first and second end stop. By using a first and second travelling nut the adjustment possibilities for setting the lower and upper end position of the shade are increased. Preferably the first travelling nut sets an upper end position of the shade by interacting with the first end stop. The second travelling nut sets a lower end position of the shade by interacting with the second end stop. The distance between the first and the second travelling nut on the spindle defines the amount and/or the length of the shade which can be unwind from or wind up on the winding core.
[0021] According to a further embodiment the spindle length between the first end stop and the second end stop is predetermined and unalterable. As an advantageous result the spindle and the first and second end stop may form an end stop assembly as one single unit. Thus, the necessity of providing the end stops as separate parts besides the spindle can be avoided. As the first and second end stops may be already inseparably connected with the spindle any further assembling and/or adjusting of the first and second end stops can be omitted. This allows a simplified assembling and/or adjusting of the shading device, particularly the end stop assembly.
[0022] Preferably the first end stop and the second end stop are inseparably connected with the spindle. The first end stop, the second end stop and the spindle may be formed in one piece or made as one integral part. Such an end stop assembly can be produced with reasonable costs. The end stop assembly consisting of the first end stop, the second end stop and the spindle may be made of plastic. The result is a single part or component including the spindle and the first and second end stop which is compact and space-saving. Preferably the first end stop and the second end stop are formed as opposing ends of the spindle. The length of the spindle between the first and second end stop is fixed and unchangeable. The first and/or second end stop may have a greater diameter than the spindle. The circumference of the first and/or second end stop may protrude over the circumference of the spindle. Thus, the inner sides of the first and/or second end stop oriented towards the spindle may serve as contact surfaces for the travelling nut or may have an abutment shoulder for interacting with a complementary abutment projection of the travelling nut.
[0023] The first end stop, the second end stop and the spindle may form an end stop assembly. The end stop assembly in regard to the first end stop, the second end stop and the spindle may be produced as one piece and/or one integral component. Preferably at least one travelling nut is part of or arranged on the end stop assembly. Particularly a first travelling nut and a second travelling nut are parts of or arranged on the end stop assembly. The end stop assembly may be arranged to a fixed rod or shaft. During normal operation of the shading device the rod or shaft is stationary. As the end stop assembly is non-rotatable mounted to the stationary rod or shaft, the end stop assembly itself is stationary. Preferably the winding core is rotatable mounted around the end stop assembly. By rotating the winding core in a first direction a flexible cord or shade material can be unwound from the winding core. Rotating the winding core in a second direction and directed opposite the first direction winds the cord or shade up around the winding core.
[0024] The end stop assembly may be formed as module. This module can be a component of a modular system for combining with components of the modular system. Preferably the components of the modular system which are combinable with the end stop assembly are stationary. A component of the modular system may be a rod, a counterbalance unit and/or a drive means. The modular system may allow for arranging all drive means for driving the winding core located at one end of the shading device. Preferably the components of the modular system, particularly at the end with the drive means, are designed such that they are stationary during normal operation of the shading device. The components may have a stationary point and/or a stationary central axis.
[0025] Preferably the first end stop and/or the second end stop each have an end stop connector for connecting the first end stop and/or the second end stop with a separate component. Because of the end stop connectors the end stop assembly is usable as a module which can be combined with other components of a modular system. The end stop connector may be formed as an opening. Preferably the first end stop, the second end stop and the spindle have a channel extending from an end stop opening of the first end stop to an end stop opening of the second end stop. Particularly the end stop openings and/or the channel have inner formations which mate with outer formations of a rod for non-rotatable fixing to the rod. Caused by the mating formations the end stop assembly is non-rotatable fixed relative to the rod. Furthermore, the end stop assembly may be also fixed by the mating formations in regard to prevent an axial movement.
[0026] According to a further embodiment of the present invention an end piece is arranged at an end of the winding core for mounting the winding core to a holding element. The end piece may be at least partly inserted into the inner cavity of the winding core. Preferably the holding element is mountable to a building structure. A building structure may be a wall, a ceiling and/or a reveal. The building structure may surround or define the architectural opening. Preferably the architectural opening is a window. The holding element may comprise a bracket.
[0027] Preferably the end piece and the holding element have correspondingly designed fixing elements for realizing a non-rotating connection of the end piece with the holding element. The end piece may be stationary attached to the stationary holding element. Preferably by realizing the connection of the end piece with the holding element the spindle is non-rotatable mounted to the holding element. As the end piece is non-rotatable mounted to the end stop assembly, the first and second end stop as well as the spindle of the end stop assembly are also stationary. The fixing elements may be designed as snap-on fittings allowing quick engagement and disengagement of the correspondingly designed fixing elements. A first fixing element may be formed as a protrusion and a second fixing element may be formed as a recess for accommodating a protrusion and realizing a form-fitting connection. A first fixing element may be assigned to the end piece and a second fixing element may be assigned to the holding element or vice versa.
[0028] According to a further aspect of the invention a bearing is assigned to the end piece. The bearing allows rotational movement of the winding core around the non-rotating end piece and the non-rotating spindle. Preferably the bearing is mounted to the outer surface of the end piece which interacts with the inner surface of the winding core. The end piece may be mounted to the winding core exclusively via the bearing.
[0029] Advantageously the end piece is connectable to the holding element in either one of several different orientations of the end piece relative to the holding element. By providing the possibility of several different orientations in which the end piece is connectable with the holding element an adjusting of the lower and/or upper end stop position of the shade is simplified and more precise. Preferably the end piece and the holding element have several correspondingly designed fixing elements or fixing means equidistantly and coaxially distributed around the longitudinal centre axis of the winding core defining several discrete and equally distanced holding positions of the end piece in interaction with the holding element. Thus, the winding core with the end piece and the end stop assembly may be rotated around the longitudinal centre axis of the winding core with discrete rotation steps and/or angle steps.
[0030] Preferably the end piece and the holding element provide at least four, six, eight, ten or twelve correspondingly designed fixing elements or fixing means which are equidistantly and coaxially distributed around the longitudinal axis of the winding core for defining accordingly discrete and equally distanced holding positions. Thus, the different holding positions may be distanced from each other according a rotation of the end piece and/or winding core around the longitudinal axis of the winding core in angle increments of 90°, 60°, 45°, 36° or 30°.
[0031] The first fixing element of the end piece may have a stick with grooves as fixing means on its outer surface aligned parallel the longitudinal axis of the stick. The second fixing element of the holding element may have a recess with bars as fixing means formed complementary to the grooves of the first fixing element.
[0032] According to a further embodiment of the present invention the first end stop and/or the second end stop are arranged on a stationary rod of a counterbalance unit. Preferably the first end stop or the second end stop interacts with the counterbalance unit for providing a preload for the counterbalance unit, particularly in an upper end position of the shade. The first or second end stop may interact with a pre-tensioned spring element of the counterbalance unit to hold the preload or pre-tensioning. The counterbalance unit may be generally similar to a counterbalance unit described in the applicant's published international applications WO 2010/089118 or WO 2013/129915.
[0033] Another aspect of the invention is related to a method for arranging a travelling nut according to present invention around and/or onto a spindle. According to this method the outer circumference of the travelling nut is opened in a first step by separating two segments of the travelling nut. This may be achieved by opening the ring-like shape of travelling nut by displacing the two segments. In a next step the travelling nut and/or the two segments are arranged around the spindle. In a further step the two segments are connected with each other for closing the ring-like shape and/or the outer circumference of the travelling nut.
[0034] The invention is also related to a method for adjusting the lower end stop position and/or upper end stop position of a shade providing a shade device according to the present invention with at least one travelling nut moveably arranged on the spindle between the first and second end stop, whereby the first end stop, the second end stop and the spindle form an end stop assembly. The method comprises the step of arranging the winding core having an end piece to a holding element mounted to a building structure. The winding core may be rotatable connected to the end piece by a bearing. Furthermore, the end piece may be non-rotatable connected to the spindle and/or end stop assembly. By arranging the end piece to the stationary mounted holding element, the end piece and the spindle, particularly the end stop assembly, is stationary.
[0035] The method further comprises the step of rotating the winding core to the lower end stop position of the shade at which the travelling nut interacts with the second end stop of the spindle. The travelling nut is connected with the inner surface of the hollow winding core such that rotating the winding core rotates the travelling nut around the spindle, which leads to a movement of the travelling nut along the longitudinal direction of the spindle axis. In a next step the end piece is disengaged from the holding element. Preferably the whole winding core is removed from any holding elements. According to a further step the winding core is rotated together with the end stop assembly around its longitudinally axis for rolling up or rolling off the shade from the winding core to set the desired shade length. In a following step the connection between the end piece and the holding element is re-established. This method allows a quick and easy way to adjust at least one end stop position of the shade.
[0036] Preferably the travelling nut during rotating of the winding core together with the end stop assembly remains its position in relation to the spindle and the second end stop. To set the desired shade length and/or an end stop position of the shade, the winding core including the end stop assembly is rotated around the longitudinal axis of the winding core. For the adjusting step there is no movement of the winding core relative to the spindle, particularly the end stop assembly. Thus, the travelling nut does not move relative to the spindle and remains abutting the second end stop.
[0037] According to a further embodiment of the method and before arranging the winding core with the end piece to the holding element, the end stop assembly is inserted into the inner cavity of the winding core with the shade in its upper end position. Preferably at least one travelling nut interacts with and or abuts the first end stop.
[0038] Preferably a first travelling nut and a second travelling nut are moveably arranged on the spindle between the first and second end stop. The distance between the first and second travelling nut sets the total length of the shade which may be wind onto or unwind from the winding core. The first travelling nut may be assigned to the first end stop for setting the upper end position of the shade. The second travelling nut may be assigned to the second end stop for setting the lower end position of the shade.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The following detailed description, given by way of example and not intended to limit the present invention solely thereto, will best be appreciated in conjunction with the accompanying figures, wherein like reference numerals denote like elements and parts, in which:
[0040] FIG. 1 is a schematic perspective view with partial removed elements of a shading device according to the present invention,
[0041] FIG. 2 presents a schematic perspective view of a section with partial removed elements of the shading device according to FIG. 1 ,
[0042] FIG. 3 is a further schematic perspective view of a section with partial removed elements of the shading device according to the invention,
[0043] FIG. 4 presents a schematic perspective view with partial removed elements of a shading device according to the present invention disengaged from holding elements,
[0044] FIG. 5 is a further schematic perspective view of a section with partial removed elements of the shading device according to the invention with two travelling nuts,
[0045] FIG. 6 is an exploded view of a shading device according to the present invention.
[0046] FIG. 7 is an exploded view of a holding element with an end piece for a shading device according to the invention.
[0047] FIG. 8 is a first perspective view of an assembled holding element and an end piece according to FIG. 7 ,
[0048] FIG. 9 is a second perspective view of an assembled holding element and an end piece according to FIG. 8 ,
[0049] FIG. 10 is a schematic perspective view of an end stop assembly for a shading device according to the present invention with a travelling nut in an opened position,
[0050] FIG. 11 is a schematic cross section of the end stop assembly with the travelling nut in the opened position according to FIG. 10 ,
[0051] FIG. 12 is a further schematic perspective view of an end stop assembly for a shading device according to the present invention with a travelling nut in a closed position, and
[0052] FIG. 13 is a schematic cross section of the end stop assembly with the travelling nut in the closed position according to FIG. 12 .
DETAILED DESCRIPTION
[0053] The present invention will now be described more fully hereinafter with reference to the accompanying figures 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 illustrated embodiments set forth herein. Rather, these illustrated 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.
[0054] FIG. 1 is a schematic perspective view with partial removed elements of a shading device 10 according to the present invention and shows the shading device 10 assembled for normal operation. According to this embodiment the shading device 10 is a roller blind. The shading device 10 comprises a winding core, more particularly a shade tube 11 . The shade tube 11 is designed as a roller. On an outer surface 12 of the shade tube 11 a shade 13 is attached. The shade 13 is made of a flexible material that can be rolled up and rolled down the shade tube 11 . A free end of the shade 13 has a bottom rail 14 for stabilizing the shade 13 and/or operating the shade 13 by hand.
[0055] The shade tube 11 is hollow and has an inner surface 15 defining an inner cavity 16 . Within the inner cavity an end stop assembly 17 is arranged. The end stop assembly 17 comprises a spindle 18 , a first end stop 19 and a second end stop 20 . In this embodiment the first and second end stop 19 , 20 are formed integrally with the spindle 18 .
[0056] The end stop assembly 17 is mounted to an end piece 21 . Here the first end stop 19 is arranged adjacent to the end piece 21 . The shade tube has a first tube end 22 and a second tube end 23 . The end piece 21 is inserted in the inner cavity 16 of the shade tube 11 at the first tube end 22 . The end piece 21 and the end stop assembly 17 are non-rotatable mounted to each other. A bearing 24 is arranged at the end piece 21 connecting the end piece 21 with the inner surface 15 of the shade tube 11 . Thus, the shade tube 11 is rotatable relative to the end piece 21 and the end stop assembly 17 .
[0057] A travelling nut 25 is moveably arranged on the spindle 18 between the first and second end stop 19 , 20 . With an engaging element on the outer surface the travelling nut 25 interacts with a complementary element 26 on the inner surface 15 of the shade tube 11 . In this embodiment the complementary element 26 is designed as a bar extending parallel to the longitudinal axis of the shade tube 11 .
[0058] The first and second tube ends 22 , 23 are respectively coupled to first and second holding elements 27 , 28 . Each of the holding elements 27 , 28 comprises a bracket 29 for mounting to a building structure. Furthermore, holding element 27 assigned to the end piece 21 of the first tube end 22 has a mounting disc 30 . In this embodiment the mounting disc 30 comprises a drive means for driving the shade tube 11 . The mounting disc 30 has a stationary recess which is non-rotatable fixed to the bracket 29 while the drive means of the mounting disc 30 is rotatable relative to the recess. The end piece 21 has a stick which is also non-rotatable connected to the mounting disc 30 , namely to the recess of the mounting disc 30 . Thus, the end stop assembly 17 is mounted via the end piece 21 to the holding element 27 .
[0059] The second tube end 23 has a stationary axle stub 31 extending out of the inner cavity 16 of the shade tube 11 . The axle stub 31 and the end piece 21 forms a rotation axis of the shade tube 11 around the longitudinal centre axis of the shade tube 11 . The axle stub 31 is non-rotatable coupled to the bracket 28 by an appropriate complementary mating formation 32 . The axle stub 31 is coupled by a further bearing 33 to the inner surface 15 of the shade tube 11 . The further bearing 33 is inserted in the inner cavity 16 of the shade tube 11 at the second tube end 23 . The bearing 33 allows rotation of the shade tube 11 relative to the stationary axle stub 31 .
[0060] FIG. 2 presents a schematic perspective view of a section with partial removed elements of the shading device 10 according to FIG. 1 . The spindle 18 is a threaded shaft. In this embodiment the spindle 18 is hollow to accommodate an end of a stationary rod (not shown). This rod may be an extension of axle stub 31 according to FIG. 1 or a rod of a counterbalancing unit. The external thread of spindle 18 mates with the internal thread of travelling nut 25 .
[0061] The first and second end stops 19 , 20 are forming end parts of the spindle 18 . Furthermore, the first and second end stops 19 , 20 have a greater diameter than the spindle 18 . Inner sides 34 of the first and second end stops 19 , 20 have an abutment shoulder for contacting and stopping the travelling nut 25 which has a complementary abutment shoulder.
[0062] The first and second end stops 19 , 29 each have a mounting part 35 for mounting the end stop assembly 17 to a rod (not shown). In this embodiment the mounting part 35 is designed as a bore for receiving a fixing means like a screw, pin, bolt, etc. The mounting part 35 and/or fixing means may interact with a rod (not shown) which is inserted in the hollow end stop assembly 17 through one of the end stop openings 36 . Accordingly, each end stop opening 36 can serve as connector for connecting the end stop assembly 17 to a stationary component of the shading device 10 .
[0063] According to FIG. 2 the travelling nut 25 is arranged in a mid region of the spindle between the first and second end stop 19 , 20 . Thus, the shade tube 11 may be driven to roll up or unroll the shade 13 .
[0064] FIG. 3 is a further schematic perspective view of a section with partial removed elements of the shading device 10 according to the invention. The travelling nut 25 interacts with the second end stop 20 . More particularly, an abutment shoulder of the travelling nut 25 abuts a complementary abutment shoulder at the inner side 34 of the second end stop 20 . Thus, the travelling nut 25 cannot be moved any further away from the first end stop 19 . This position of the travelling nut 25 corresponds to the lower end stop position of the shade 13 . In the lower end stop position of the shade 13 , the shade 13 cannot be unrolled any further of the shade tube 11 . Only a rotation of the shade tube 11 in an opposite direction to roll up the shade 13 is possible. Such a rotation of the shade tube 11 will move the travelling nut 25 along the spindle 18 towards the first end stop 19 .
[0065] FIG. 4 presents a schematic perspective view with partial removed elements of a shading device 10 according to the present invention disengaged from holding elements 27 , 28 . As in FIG. 3 the travelling nut 25 is contacting the second end stop 20 and the shade 13 is in its lower end stop position. The arrangement according to FIG. 4 shows the shading device 10 in a setting position for setting or adjusting the lower end stop position of the shade 13 . The disengagement from the holding elements 27 , 28 allows to roll up or unroll the shade while rotating the shade tube 11 together with the end stop assembly 17 without any relative movement of the spindle 18 or the travelling nut 25 in regard to the shade tube 11 . As a result the lower end stop position of the shade 13 is adjustable.
[0066] The holding element 27 has a fixing element 37 . In this embodiment the mounting disc 30 comprises the fixing element 37 which is stationary coupled to the bracket 29 . The fixing element 37 of the mounting disc 30 has as a recess for receiving and interacting with a correspondingly designed fixing element (not shown) of the end piece 21 for realizing a stationary connection of the end piece 21 with the holding element 27 .
[0067] The fixing element 37 of the holding element 27 and the respective complementary fixing element of the end piece 21 have equidistantly and coaxially distributed fixing means (not shown) to allow several different orientations of the stationary end piece 21 relative to the stationary holding element 27 . When disengaged from the holding element 27 the end piece 21 is rotatable to several discrete and equally distanced holding positions around a centre axis of the mounting disc 30 in which the end piece 21 is connectable to the holding element 27 .
[0068] Furthermore, the mounting disc 30 includes a drive unit in the form of a drive wheel 59 . The drive wheel 59 is rotatable mounted relative to the fixing element 37 of the mounting disc 30 . For normal operation the drive wheel 59 is fixed to the shade tube 11 according to FIGS. 1 to 3 . A cord or chain (not shown) may be arranged to the drive wheel 59 . By driving the drive wheel 59 via a cord or chain the shade tube 11 can be driven around the centre axis of the shade tube 11 and the stationary end stop assembly 17 .
[0069] FIG. 5 is a further schematic perspective view of a section with partial removed elements of the shading device 10 according to the invention with two travelling nuts 25 , 38 . First travelling nut 38 is assigned to the first end stop 19 for setting the upper end stop position of the shade 13 . The second travelling nut 25 is assigned to the second end stop 20 for setting the lower end stop position of the shade 13 . Both travelling nuts 25 and 38 are identically designed. The distance between the first and second travelling nut 25 , 38 defines the length of the shade 13 which can be rolled on or up rolled from the shade tube 11 . The smaller the distance between the first and second travelling nut 25 , 38 , the greater the windable length of the shade 13 is.
[0070] The second travelling nut 25 abuts according to FIG. 5 the second end stop 20 like in FIG. 3 . Thus, the travelling nut 25 cannot be moved any further away from the first end stop 19 . This position of the second travelling nut 25 corresponds to the lower end stop position of the shade 13 . For reaching the upper end stop position of the shade 13 , the shade tube 11 has to be rotated such that both travelling nuts 25 , 38 are moving towards the first end stop 19 . The upper end stop position of the shade 13 is reached when the first travelling nut 38 abuts the first end stop 19 .
[0071] Additionally FIG. 5 shows a rod 39 , which has not been shown in FIGS. 1 to 4 for clarity reasons, but which is also part of the embodiment of the present invention according to FIGS. 1 to 4 as well. The rod 39 is inserted through end stop openings 36 into the hollow end stop assembly 17 and through the hollow spindle 18 . The end stop assembly 17 may be additionally fixed to the rod 30 by the mounting parts 35 . The rod 39 is stationary coupled to the holding elements 27 , 28 . The rod 39 forms a stationary central axis of the shading device 10 around which the shade tube 11 is rotatable in normal operation of the shading device 10 . In this embodiment the rod 39 is part of a counterbalance unit.
[0072] FIG. 6 is an exploded view of a shading device 10 according to the present invention. In this embodiment the end stop assembly 17 has two travelling nuts 25 , 38 . In an alternative embodiment the end stop assembly 17 may have only a single travelling nut 25 .
[0073] The shading device 10 comprises a counterbalance unit 40 . The counterbalance unit 40 serves for balancing the shade 13 in every desired position of the shade 13 .
[0074] The end piece 21 may be replaced by an alternative end piece 41 . The end pieces 21 , 41 comprise a break device for slowing down or braking the rotation of the shade tube 11 . According to a further alternative end piece 21 may be replaced by an adapter, particularly in the form of end piece 41 , but without a break device. End pieces 21 and 41 both have a stationary fixing element and a bearing 24 .
[0075] Mounting unit 42 or 43 may be used as an alternative to mounting disc 30 . The mounting units 42 , 43 are designed to be mounted on the inner face of the brackets 29 like the mounting disc 30 . In this embodiment the mounting units 42 , 43 are drive units configured to drive the shade tube 11 . For this purpose the mounting unit 43 has a cord 44 . Pulling the cord 44 activates a drive means coupled with the shade tube 11 . The mounting unit 42 needs an additional chain (not shown) to drive a drive means to rotate the shade tube 11 . The drive means of the mounting units 42 , 43 are rotatable to a stationary fixing element 37 of the mounting units 42 , 43 which may be similar to the fixing element 37 of the mounting disc 30 .
[0076] FIG. 7 is an exploded view of the holding element 27 with the end piece 21 for a shading device 10 according to the invention. In detail the mounting disc 30 of the holding element 27 is shown in an exploded view. The mounting disc 30 comprises the drive wheel 59 , a bearing ring 60 , the fixing element 37 and a mounting cover 61 .
[0077] A ball chain 62 is provided for arrangement around the drive wheel 59 . The fixing element 37 has a mounting plate 63 . The mounting plate 63 has a tube like projection 64 . The projection 64 provides a recess 65 . The inner side of the recess 65 has several fixing means 66 . For clarity not all fixing means 66 have a reference numeral. In this embodiment the fixing means 66 of the fixing element 37 are formed as bars extending longitudinal to the projection 64 .
[0078] For assembling the mounting disc 30 to the bracket 29 the mounting cover 61 is arranged at the outer side of bracket 29 . Then the fixing element 37 is coupled with its mounting plate 63 to the inner side of the bracket 29 and coupled with the mounting cover 61 . Thus, the fixing element 37 is stationary mounted to the bracket 29 . The drive wheel 59 , ball chain 62 and bearing ring 60 form a drive unit which is attachable to the bracket 29 and the fixing element 37 . The drive wheel 59 is rotatable to the bearing ring 60 and the fixing element 37 .
[0079] FIG. 8 is a first perspective view of an assembled holding element 27 and the end piece 21 according to FIG. 7 . By pulling at one side of ball chain 62 the ball chain 62 and the drive wheel 59 which is coupled with the ball chain 62 rotates around the fixing element 37 . The drive wheel 59 has several coupling members 67 for coupling the drive wheel 59 to the inner side of the bearing 24 of end piece 21 .
[0080] FIG. 9 is a second perspective view of the assembled holding element 27 and the end piece 21 according to FIG. 8 . The end piece 21 has a fixing element 68 . The fixing element 68 of end piece 21 is stationary. In this embodiment the fixing element 68 is formed as a stick. The fixing element 68 is surrounded by the bearing 24 which is rotatable around the fixing element 68 . At the outer circumference of the fixing element 68 are several fixing means 69 . For clarity not all fixing means 69 have a reference numeral. According to this embodiment the fixing means 69 are designed as grooves.
[0081] The fixing means 69 of the end piece 21 are complementary formed to the fixing means 66 of the fixing element 37 of the holding element 27 . Fixing means 66 and 69 are equidistantly distributed around the centre axis of the fixing element 37 and 68 respectively. Fixing element 68 of end piece 21 can be inserted into the recess 65 of the fixing element 37 to establish a stationary coupling between end piece 21 and the holding element 27 . Because of the several fixing means 66 and 69 several different holding positions of the end piece 21 , namely the fixing element 68 , relative to the holding element 21 , namely the fixing element 37 , are realizable. Dependent of the amount of fixing means 66 , 69 the fixing element 68 is connectable with the fixing element 37 in predetermined angle increments around the centre axis of the end piece 21 . This allows a precise adjustment of the lower and/or upper end stop position of the shade 13 .
[0082] The inner side of the bearing 24 has several coupling members 70 which are complementary to the coupling members 67 of the drive wheel 59 . By establishing the connection between both fixing elements 37 and 68 the coupling members 67 , 70 are also coupled with each other.
[0083] FIG. 10 is a schematic perspective view of an end stop assembly 17 for a shading device 10 according to the present invention with a travelling nut 25 in an opened position. Travelling nuts 25 and 38 may (but need not) be identical. The following description of travelling nut 25 applies also to travelling nut 38 .
[0084] The travelling nut 25 is has articulated segments. More particularly, it comprises two segments 45 , 46 which are hingedly connected by a flexible hinge 47 . In this embodiment, the segments 45 , 46 are designed as a first half 45 and a second half 46 respectively of the travelling nut 25 . The flexible hinge 47 allows to flip open the travelling nut 25 for arranging the travelling nut 25 around the spindle 18 . The flexible hinge 47 is according to this embodiment substantially made as a flexible plastic strip which is flexibly connected with the two halves 45 , 46 .
[0085] For engaging the travelling nut 25 around the spindle 18 the travelling nut 25 is in its open position and half 45 is arranged to the spindle 18 such that the external thread 48 of the spindle 18 mates with the internal thread 49 of the half 45 .
[0086] The first half 45 of the travelling nut 25 has a first joint element 50 and the second half 46 of the travelling nut 25 has a second joint element 51 . The joint elements 50 , 51 are formed complementary to each other for realizing an engagement with each other. By engaging both joint elements 50 , 51 with each other the two halves 45 , 46 are connected to realize a closed position of the travelling nut 25 .
[0087] FIG. 11 is a schematic cross section of the end stop assembly 17 with the travelling nut 25 in the opened position according to FIG. 10 . According to this embodiment the first joint element 50 is designed as a snap-on catch and the second joint element 51 is designed as a recess complementary formed to the snap-on catch.
[0088] As the flexible hinge 47 is made as a flexible strip the two halves 45 , 46 are displaced from each other in the opened position of the travelling nut 25 . The flexible hinge 47 has several formations 52 , 53 which mate with complementary formed formations 54 , 55 on the halves 45 , 46 in a closed position of the travelling nut 25 .
[0089] The end stop openings 36 and the hollow spindle 18 have several grooves 56 at the inner side of a tube section of the end stop assembly 17 . These grooves 56 mate with complementary formed bars of a rod 39 for avoiding any rotation of the end stop assembly 17 relative to the rod 39 .
[0090] FIG. 12 is a further schematic perspective view of the end stop assembly 17 for the shading device 10 according to the present invention with the travelling nut 25 in a closed position. In comparison to FIG. 11 the travelling nut half 46 has been swung with the flexible hinge 47 around the spindle 18 for coupling the nut halves 45 , 46 with each other. In the closed position of the travelling nut 25 the two halves 45 , 46 form a ring shaped travelling nut 25 . The travelling nut 25 is moveably guided on the spindle 18 .
[0091] FIG. 13 is a schematic cross section of the end stop assembly 17 with the travelling nut 25 in the closed position according to FIG. 2 . The snap-on catch 50 is snapped on the correspondingly formed recess 51 . Thus, the halves 45 , 46 of the travelling nut 25 are detachable joined with each other.
[0092] The flexible hinge 47 is aligned to the travelling nut 25 , whereby the formations 52 and 53 engage the formations 54 and 55 respectively. An outer surface 57 of the travelling nut 25 contacts the inner surface 15 of the inner cavity 16 when the end stop assembly 17 with the closed travelling nut 25 is inserted into the shade tube 11 . In this case the connection between the two halves 45 , 46 cannot be unintentionally opened. The contact of the outer surface 57 of the travelling nut 25 with the inner surface 15 of the inner cavity 16 prevents a unintended opening of the travelling nut 25 .
[0093] The outer surface 57 of the travelling nut 25 has engaging elements 58 . In this embodiment the travelling nut 25 has two engaging elements 58 which are formed as grooves. The engaging elements 58 are assigned to the first half 45 and the second half 46 respectively. When the end stop assembly 17 with the travelling nut 25 is inserted into the inner cavity 16 of the shade tube 11 , the engaging elements 58 engage a complementary element in the inner surface 15 of the shade tube. In this embodiment this complementary element is formed as a bar 25 as shown in FIGS. 1 to 5 .
[0094] Although preferred embodiments of the present invention and modifications thereof have been described in detail herein, it is to be understood that this invention is not limited to these precise embodiments and variations and may be effected by one skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
[0095] The use of expressions like: “particularly”, “preferably” or “especially preferred” etc. is not intended to limit the invention. Features which are not specifically or explicitly described or claimed may be additionally included in the structure or method according to the present invention without deviating from its scope. | The invention relates to a shading device for an architectural opening comprising a shade, a drive unit for extending and retracting the shade between a first and second end position, a spindle, a first end stop, stationary connected to the spindle near a first end of the spindle and at least one travelling nut, movably arranged on the spindle and operatively connected to the drive unit so as to move towards, respectively away from the first end stop as the shade is extended, respectively retracted. The travelling nut is articulated in circumferential direction into segments, with at least two segments being detachably connectable to each other at one of their ends. |
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CROSS-REFERENCE TO RELATED APPLICATION
This is a Continuation of application Ser. No. 08/489,531, filed Jun. 12, 1995, now abandoned, which is a continuation-in-part of application Ser. No. 08/353,407, filed Sep. 12, 1994, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to translucent block assemblies for use in, for example, decorative wall constructions and windows in buildings.
2. Description of the Related Art
In our prior U.S. Pat. No. 4,891,925, issued Jan. 9, 1990, the disclosure of which is incorporated herein by reference, there is described a translucent construction block, made of plastic material, which can be connected together with a plurality of similar blocks by means of connecting members which have T-shaped ends engaged in T-shaped recesses formed at the corners of the blocks. The recesses are formed in enlarged portions at each corner of the block, the enlarged portions being spaced apart from one another in pairs for receiving therebetween an alignment strip attached to, for example, an existing wall by an adhesive backing. In this way, the block is positively located on the alignment strip, and the blocks can be quickly and easily positioned, using the alignment strip as a starting guide. In practice, the translucent blocks disclosed in the above-identified prior patent are frequently sold in an assembled condition, in a frame, and the blocks are manufactured in various widths, measured transversely of the major faces of the blocks, depending on the intended final use of the assemblies.
There are also available at the present time window frames which are formed with recesses of predetermined width for receiving windows of standard width. However, these standard window widths are substantially smaller than the widths of the translucent blocks manufactured in accordance with the teachings of the above-identified prior patent.
BRIEF SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a translucent block assembly which includes a novel and advantageous means for connecting translucent blocks into a frame recess having a width less than that of the blocks.
According to the present invention, there is provided a translucent block assembly which has a plurality of translucent blocks juxtaposed relative to one another in an opening defined by a frame, with an elongate connector extending around the opening between the frame and the translucent blocks for securing the translucent blocks in position in the opening. The frame defines a recess extending around the opening, and the translucent blocks have locating portions thereof spaced apart from one another at the peripheries of the blocks to form gaps. The connector includes a first portion abutting the translucent blocks and a second portion abutting the frame. The first portion comprises a longitudinally extending alignment projection which fits snugly into the gaps in the blocks for aligning the blocks, and the second portion includes faces spaced apart laterally of the connector by the width of the recess and engaging snugly in the recess for locating the connector relative to the frame.
With this arrangement, the first portion of the connector can be made as wide as may be required, depending on the width of the blocks, while the second portion can be made to fit into a standard recess width.
In the preferred embodiment of the invention, the connector is in the form of an extrusion, which is shaped, and which is formed with a thermal barrier, so as to counteract heat conduction through the connector.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features, objects and advantages of the present invention will be more readily apparent to those skilled in the art from the following description of a preferred embodiment thereof illustrated, by way of example, in the accompanying drawings, in which:
FIG. 1 shows a view in front elevation of a translucent block assembly embodying the present invention;
FIG. 2 shows a broken-away view, in perspective, of a part of the assembly of FIG. 1;
FIG. 3 shows an exploded, broken-away view of parts of the assembly of FIG. 1; and
FIGS. 4 and 5 show broken-away views taken in cross-section along the lines 4--4 and 5--5, respectively, of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 there is shown a translucent block assembly indicated generally by reference numeral 10, which is made up of a conventional rectangular window frame 12, a plurality of translucent blocks 14, which are juxtaposed relative to one another within an opening formed by the window frame 12, and an elongate connector in the form of an extrusion 16, which interposed between the blocks 14 and the window frame 12 and which serves, as described in greater detail below, to align and locate the blocks 14 relative to one another and, also, relative to the window frame 12.
In FIG. 2, a single one of the blocks 14, which are formed in accordance with the teachings of the above-identified prior patent, is shown in position in a comer of the window frame 12.
As can be seen in FIG. 2, the window frame 12 is formed as an extrusion, the shape of which is more clearly apparent from FIGS. 3, 4 and 5, and which is formed of three hollow portions 18, 20 and 22. The hollow portion 18 is at the innermost side of the window frame and the hollow portion 22 forms, at the bottom of the window flame, a window ledge. The hollow portion 18 is higher than the hollow portion 20 so as to form a step shaped recess 32, having a side wall 24 and a bottom wall 26. Between the hollow portions 20 and 22, there is formed a recess 28, which extends around the window opening and receives and retains a retainer strip 30 of plastic material. The retainer strip 30 has longitudinal edge thereof engaged in the recess 28 and, at its other longitudinal edge, abuts the extrusion 16 so as to fixedly secure the extrusion 16 and the blocks 14 relative to the window frame 16. The arrangement is such that the recess 32, is open inwardly of the window frame opening defined by the window frame 12 and also at lateral one side of the recess 32, which is the left-hand side of the recess 32 as viewed in FIGS. 4 and 5.
The connector 16 is in the form of an extrusion having a first portion generally by reference numeral 34 and a second portion indicated by general reference numeral 36. The first portion 34 comprises a pair of webs 38 and 40, at opposite sides of the connector 16, and an alignment projection in the form of a flat web 42.
The periphery of the block 14 is formed, at each corner of the block 14, with a pair of enlarged locating portions 44 which, in known manner, are formed with T-shaped recesses 46 for receiving connectors (not shown) for connecting the blocks to one another.
The locating portions 44 are spaced apart from one another to form a gap 48 therebetween, and the connector web 42 fits snugly into the gap 48 for aligning and locating the block 14 relative to the window frame 12 and, also, relative to the other blocks 14 of the assembly.
The webs 38 and 40, which extend from opposite sides of the second portion 36 of the connector extrusion 16, are spaced laterally from the web 42 and have abutment faces 50 in abutting engagement with the periphery of the block 14 at opposite lateral extremities of the periphery of the block 14. As is readily apparent from FIGS. 4 and 5, the periphery of the translucent block 14 has a width greater than that of the window frame recess 32. The web 38 includes a web portion 39 in face-to-face contact with a flat innermost wall 19 of the hollow portion 18.
The first portion 34 of the connector extrusion also has gaps 52 extending longitudinally of the connector extrusion between the web 42 and the webs 38 and 40, and also extending from the second portion 36 to the abutment faces 50, so as to prevent heat conduction between the webs 38 and 40 across the width of the connector 16.
The second portion 36 of the connector 16 has a pair of flat, parallel, laterally spaced webs 54 and 56, which have outer side faces 58 and 60 spaced, laterally of the connector 16, by the width of the window frame recess 32 and engaging snugly in the recess 32. The face 58 abuts the side wall 24 of the hollow portion 18. The edges of the webs 54 and 56 abut the bottom wall 26 of the recess 32.
The second portion 36 of the connector 16 also includes a portion 62 of low thermal conductivity which forms a thermal break between the opposite lateral sides of the connector 16.
The block 14 is formed with inclined outer edge faces 64 (FIG. 5), and the webs 38 and 40 are formed with inclined outer faces 66, the faces 64 and 66 converging with one another to form outwardly-open V-shaped recesses 68 where the translucent block 14 meets the webs 38 and 40. In this way, by painting the faces 66 a suitable colour, the assembly can be given the appearance of a grout between the connector 16 and the block 14.
The connector 16 is formed of four extrusion strips which are connected to one another, at the corners of the window frame opening, by fasteners in the form of screws 70 (FIG. 3) driven into circular recesses 72 (FIG. 5) in the second portion 34 of the connector 16.
As will be apparent to those skilled in the art, various modifications may be made in the above-described embodiment of the invention within the scope and spirit of the appended claims. | A translucent block assembly, for use in a decorative wall, window or the like in a building, has a connector extrusion for connecting juxtaposed translucent blocks in an opening of a frame having a recess extending around the opening. The connector extrusion has an alignment projection fitting snugly into gaps in the peripheries of the blocks for aligning the blocks and abutment faces for abutment with the blocks, and also has outwardly facing side faces engaging snugly in the recess. |
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Pat. application Ser. No. 540,841 filed Jan. 14, 1975 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to anti-pollution devices and, more particularly, to a portable toilet apparatus for receiving canine waste products for disposal in sealed plastic bags.
2. Description of the Prior Art
There are many devices used to scoop up solid animal wastes. These devices are difficult to use and are never completely effective as they require the prior violation and soiling of curbs and streets by dogs.
SUMMARY OF THE INVENTION
This invention provides a compact, hand-held canine, feline or other animal or pet toilet apparatus which holds a bag of plastic, paper, or other suitable material in an open position at the end of a handle. Once this apparatus is thrust under a pet while it is in the act of defecating, the pet soon becomes accustomed to the use of the invention. It is then a simple matter to catch solid animal wastes as they are expelled. It can, of course, be used to catch all waste matter or droppings discharged from the body such a vomit, urine or feces.
A first embodiment of this invention provides a handle with a mechanism to spread and close two articulated arms hinged to the end of the handle. The bases of the articulated arms form solid jaws and the ends of the arms are of flexible or spring material. A plastic bag having an open top with tubular edges is placed with the arms extending through the tubular edges. The inner upper bag edge may have an integrally molded plastic interlocking zipper formed on it, or a pressure sensitive tape or other fastening means may be applied to the inner edge of the bag opening. The arms are spread to hold the bag open when it is thrust under an animal to receive droppings. When the bag is removed, the mechanism is manipulated to close the arms so that the jaws at least partially seal the bag by crushing the fastening means together between them. The bag is then slipped from the arms, the seal is completed, and the bag and its contents are discarded. A practical and sanitary waste receiver for dogs is thus provided.
Another and preferred embodiment of this invention has permanently open spring arms that are fixed to the end of a handle and curve together and touch at their free ends to exert a resilient pressure. The arms are forced apart and the tubular edges of a bag are slipped over the arms to hold the bag open thereon. If a pressure sensitive fastening means is used, a covering strip may be removed from the bag after it is fixed on the arms. After use, the bag is pulled off the arms and the resilient pressure at the arm tips forces the edges of the bag opening together to seal it. The arms may be of spring steel, plastic, or wire. A plastic container for used bags may be snapped to the handle.
This invention provides a sanitary, easily used, and practical device which will allow dog owners to enjoy their pets despite new and threatened sanitary ordinances.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the waste receiver for dogs according to my invention with a dog shown in phantom lines;
FIG. 2 is a top view of the apparatus of FIG. 1 shown in the open bag position after use;
FIG. 3 is a top view of the apparatus of FIG. 1 shown in the closed bag position after use;
FIG. 4 is a side view of a broken away portion of the apparatus taken on line 4--4 of FIG. 3;
FIG. 5 is a section taken on line 5--5 of FIG. 4;
FIG. 6 is a plan view of a bag blank having an integrally formed interlocking closure;
FIG. 6A is a longitudinal section taken through a fragment of the end of a bag blank showing the attachment of a modified tubular element;
FIG. 7 is a section taken on line 7--7 of FIG. 6;
FIG. 8 is a perspective view of a complete bag formed from the blank of FIG. 6;
FIG. 9 is a perspective view of a preferred embodiment of this invention with the handle broken away;
FIG. 10 is a section taken on line 10--10 of FIG. 9 with the handle and lower portion of the bag broken away;
FIG. 11 is a side view taken on line 11--11 of FIG. 9 with the handle and lower portion of the bag broken away;
FIG. 12 is a plan view of a bag blank having a pressure sensitive closure means;
FIG. 13 is a section taken on line 13--13 of FIG. 12;
FIG. 14 is a perspective view of a bag holder according to a first embodiment of the preferred embodiment of this invention;
FIG. 15 is a perspective view of a bag holder according to a second modification of the preferred embodiment of this invention with a container for used bags shown clipped to the handle thereof; and
FIG. 16 is a perspective view of the container for used bags shown in FIG. 15.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-5, a first embodiment of my invention has a handle 20 with a hand held upper end 21. Handle 20 may be of wood of sufficient diameter to form a comfortable hand hold. It may also be of any other suitable material. The lower end 22 of handle 20 is fixed in socket 23 which is welded to the back of bracket 24 at a suitable angle so that bracket 24 is substantially vertical. Bracket 24 has upper and lower forwardly bent flanges 25 and 26 which receive the pins 27 and 28 to pivotally mount the plates 29 and 30. A coil spring 31 urges each plate 29 and 30 to swing outward. Tapered bosses 33 and 34 are pressed to extend outward from the sides of the plates 29 and 30 to a greater extent toward their free ends.
As may be particularly seen in FIGS. 2 and 4, rigid solid jaws 35 and 36, which may be substantially square in section, are attached to be cantilevered forward above plates 29 and 30 forming the slots 37 and 38 thereunder. An actuator 39 slides on handle 20 and has a rod 40 connected to it. Referring additionally to FIG. 3, side flanges 41 and 42 are bent forward from bracket 24. Member 43 is vertically pivoted from the flanges 41 and 42 by the arms 45 and 46 which terminate in the outward turned ends 47 and 48 which enter the flanges 41 and 42. The central portion 44 of member 43 is pivotally connected to rod 40. Arms 45 and 46 have tapered rollers 49 and 50 mounted on them. Pushing the actuator 39 toward bracket 24 causes the tapered rollers 49 and 50 as shown in FIG. 2 to roll forward and down over bosses 33 and 34 to close jaws 35 and 36. When the jaws 35 and 36 are closed as shown in FIGS. 3, 4 and 5, pulling the actuator 39 toward end 21 of handle 20 will allow the springs 31 to open jaws 35 and 36 to the position shown in FIGS. 1 and 2. The ends of the jaws 35 and 36 have the flexible ends 51 and 52 fixed to extend therefrom so that the jaws 35 and 36 and the flexible ends 51 and 52 form a pair of arms.
As shown in FIGS. 6, 7 and 8, a bag 55 has a top opening 56. The sides 57 and 58 of opening 56 have integrally formed interlocking male and female fastening means 59 and 60 formed thereon. Fastening means 59 and 60 may be a rib interference zipper. Outside and adjacent to the fastening means 59 and 60, the sides 57 and 58 of opening 56 have the tubular edge portions 61 and 62 fixed thereto to extend at least partially along the sides of opening 56. Bag 55 is formed from a substantially rectangular blank 63 as shown in FIGS. 6 and 7. Tubular edge portions 61 and 62 are fixed at the ends of blank 63 by folding lengths 65 and 66 into loops and heat sealing them in place. The blank 63 is then folded about its center 64 and its side edges 67 and 68 are heat sealed or otherwise joined. Alternatively, the lengths 65 and 66 may be formed integrally with blank 63 and folded back on blank 63 to form the tubular portions 61 and 62 by heat sealing.
As shown in FIG. 6A, a bag blank 63' may have a tubular portion 61' fixed thereto. Tubular portion 61' is formed from a length of bag material 65' which is heat sealed above and below the fastening means 59'.
As may be seen in FIGS. 1 and 2, bag 55 has its tubular edge portions 61 and 62 pulled over the flexible extensions 51 and 52 and jaws 35 and 26 which form a pair of arms. The jaws 35 and 36 are opened to support bag 55 at the ends of handle 20 in an open position. As a dog 69 defecates, an open bag 55 is thrust below it as shown to catch droppings 70. Upon catching droppings 70, actuator 39 is pushed forward to snap jaws 35 and 36 together closing bag 55 and locking the fastening means 59 and 60 at least partially along the top of opening 56 where it extends between jaws 35 and 36. The partially sealed bag 55 is then pulled from jaws 35 and 36 and the sealing is completed by hand before discharging bag 55 and its contents.
The device of this invention is sanitary and easy to use. Dogs rapidly get used to it and have been known to run happily to the door to go out when the device is produced. It is also suitable for indoor training as in an apartment house.
Referring now to FIGS. 9, 10 and 11, a preferred embodiment of my invention has a handle 75 which enters socket 76 on the shank 77 of bag holder 78. Bag holder 78 terminates in the spread-apart arms 79 and 80 that curve together to touch and maintain a resilient pressure between their outward flaring ends 81 and 82. The holder 78 is best molded of plastic to have resilient arms 79 and 80. It may also be forged and tempered from a suitable spring metal such as steel or brass.
As may be seen in FIGS. 9, 12 and 13, a bag 83 is formed from a generally rectangular blank 84 which is substantially rectangular. Two side panels 85 and 86 of blank 84 have end extensions 87 and 88 that are folded back to be heat sealed or otherwise fixed to form tubular edges 89 and 90. Contact cement strips 91 and 92, covered by tapes 93 and 94 until exposed to be used, are formed along the outer edges of the side panels 85 and 86. Bag 83 is formed by folding blank 84 on its center 95 and heat sealing or otherwise joining the side edges 96 and 97. It is to be noted that the tubular edges 89 and 90 of the completed bag 83 extend from side edge 96 and terminate a distance 98 from side edge 97, distance 98 being at least equal to one-half the maximum distance the curved arms 79 and 80 extend apart.
As shown in FIG. 9, the arms 79 and 80 are inserted in the tubular edges 89 and 90 from side edge 97. The arm ends 81 and 82 may be sprung slightly apart during this insertion. The distance 98 of the tubular edges 89 and 90 from edge 97 enables the bag 83 to have the arms 79 and 89 forced through the tubular edges 89 and 90 without tearing the bag as the distances 98 open to span the maximum spread of the arms 79 and 80. The holder 78 suspends bag 83 in an open position. The tape strips 93 and 94 are removed and the bag 83 is thrust below a pet to receive animal droppings. Bag 83 is withdrawn from the pet and bag 83 is drawn or pulled off the arms 79 and 80 and, while being so removed. the tips or ends 81 and 82 push the contact cement strips 91 and 92 together to completely seal bag 83 and its contents so that bag 83 may be discarded. With this embodiment of the invention, the bag 83 may be sealed and withdrawn from its holder 78 in one motion. It should be noted that the strips of contact cement 91 and 92 are formed to extend along the inner portions of the tubular edges 89 and 90. If desired, the tape strips 93 and 94 may be removed after a pet has used bag 83.
As shown in FIGS. 9 and 11, an inwardly and downwardly extending finger 125 may be formed between the arms 79 and 80 to engage inner and rearward edge 91a of bag 83. The purpose of this finger is to prevent the edge 91a which is unsupported between the arms 79 and 80 from moving upward when the bag is partially collapsed when in the position shown in FIG. 1 and the bottom of the bag is somewhat compressed against the ground. It has been found that with some bags the edge 91a is moved upward and forward due to inherent stability of the material of which the bag is formed. The finger 125 retains the bag in the fully opened position.
It should be understood that strips of contact cement 91 and 92 may be replaced by any pressure sensitive fastening means that are closed by pressure, such as adhesive, Velcro hooks, rib interference zippers, and the like. It should also be noted that the art of using pressure sensitive adhesives has now reached the point where tapes such as covering tapes 93 and 94 may be omitted.
FIG. 14 shows a first modification of the second and preferred embodiment of my invention. A handle 100 terminates in a socket 101 formed by a loop of spring steel band material. A shank 102 is formed from two runs of the spring steel that extend from socket 101 and are joined together by welding if required. The shank 102 diverges to form the two curved arms 103 and 104 that terminate in the touching tips 105 and 106. The spring steel bag holder 107 is used in the same manner as has been described for the holder 78 with a bag 83.
FIG. 15 shows a second modification of my preferred second embodiment of this invention. A handle 110 has its lower end fixed in a loop 111 forming a socket of a spring wire bag holder 112. A twisted wire shank 113 extends from socket or loop 111 to diverge and form the curved arms 114 and 115 which terminate in the touching ends 116 and 117 which may have plastic or metal large diameter tips fixed on them. The spring wire bag holder 112 is used in the manner which has been described with bag 83.
FIGS. 15 and 16 show a used bag or a bag supply container 120 which has an open top 119. Container 120 has a flat back wall 121 and a curved front wall 122. Clips 123 and 124 fix the container 120 to handle 110.
The second embodiment of my invention is inexpensive to fabricate, easy to use, sanitary, and efficient. The handle should extend up at an obtuse angle from the shank to make it easy to position the arms and a bag supported thereby horizontally below a pet. Bags may be of paper and other material as well as plastic film such as polyethylene. While the second and preferred embodiment of this invention has been shown as having pressure sensitive contact cement strips 91 and 92 as a sealing means, interlocks such as shown with the first embodiment of the invention may be used, as well as any other sealing means that only needs to be pressed together. | A waste receiver for canine toilet use has a handle and two spread-apart arms at the end of the handle. A plastic bag with an open top has two upper tubular edge portions which are slipped over the arms and support the bag in an open position. By means of the handle, the bag is placed below a pet to receive droppings therein. The upper inner edges of the bag incorporate closure means which are used to seal the bag closed after use. In one form, a mechanism on the handle closes the arms to at least partially seal a bag before its removal from the arms. In another form, spring arms meet at their tips to apply pressure and seal a bag as it is being removed from the arms. |
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FIELD
[0001] Various exemplary embodiments relate to storing cable, for example fiber optic cable and fiber optic drop wire along an aerial transmission route.
BACKGROUND
[0002] Modern telecommunication systems utilize a number of materials and mediums to transmit information. Recently, cables, such as fiber optic cables, have become more popular in the communication industry and have begun to replace electrical wires. Fiber optic cables include transparent optical fibers made of glass or plastic and are capable of transmitting voice, video, and data. Compared to electrical wires, fiber optic cables permit signals to travel longer distances with less loss and less electromagnetic interference.
[0003] One type of fiber optic cable used to transmit data across aerial transmission lines is all-dielectric self-supporting (ADSS) cables. Such cables typically have a strong non-metallic sheath that supports the optical fibers making up the cable. ADSS cables may also have a reinforcing strand at its core. All-dielectric cable has the advantage that it can be used in close proximity to electrical power lines, whereas conventional communication cables are required to be run in a separate zone, usually at least forty inches below the power cables and above ground neutral. Other types of fiber optic cable lines include, encased with ground wire, encased within phase conductor, and wrapped around phase conductor or ground wire cables.
[0004] Fiber optic cable is typically installed on aerial transmission routes in long lengths so as to minimize the number of splices, each of which degrades optical signals and is expensive. Because of certain problems related with splicing, such as increased noise, it is generally more desirable to overbuild for the amount of cable and store the cable as opposed to splicing cable in the future. To allow for rerouting, due to pole movement and for repairs, slack is provided in the form of surplus lengths of cable at intervals along the route. With increased storage intervals, it is less probable that lengths of cable must be rehung if rerouting is necessary. Storing surplus cable poses problems as optical cable has a minimum bend radius and is vulnerable to damage (fiber breakage) from bending and twisting, if the minimum radius is exceed.
SUMMARY
[0005] According to an exemplary embodiment, a cable supporting device includes a channel member. The channel member has a curved section bounding an interior. A top flange, a bottom flange, and an outer wall define a channel. The channel has an opening facing the interior.
[0006] According to another exemplary embodiment, a cable supporting device includes a channel member. The channel member has a top flange, a bottom flange, and an outer wall defining an inward facing channel. The inward facing channel extends around a curved back section, a first side section, and a second side section.
[0007] According to another exemplary embodiment, a cable distribution system includes a plurality of poles and a cable extending along the plurality of poles. A cable supporting device includes a channel member having a top flange, a bottom flange, and an outer wall defining a channel. The channel extends around a curved back section, a first side section, and a second side section defining an interior of the cable support. The channel has an opening facing the interior. A surplus portion of the cable is positioned in the channel of the cable supporting device.
[0008] A further exemplary embodiment is directed to a method of supporting cable. A cable supporting device is attached to an overhead line extending along a plurality poles. The cable supporting device has a channel member with an inward facing channel and a curved back section. A loop of a cable is formed and at least a portion of the loop is positioned in the channel member.
BRIEF DESCRIPTION OF DRAWINGS
[0009] The aspects and features of various exemplary embodiments will be more apparent from the description of those exemplary embodiments taken with reference to the accompanying drawings, in which:
[0010] FIG. 1 is a perspective view of a transmission line according to an exemplary embodiment;
[0011] FIG. 2 is a perspective view of a transmission line and cable loop according to an exemplary embodiment;
[0012] FIG. 3 is a perspective view of transmission line and cable loop with a cable support according to an exemplary embodiment;
[0013] FIG. 4 is a top perspective view of a cable support according to an exemplary embodiment;
[0014] FIG. 5 is a bottom perspective view of the cable support of FIG. 4 ;
[0015] FIG. 6 is a top view of the cable support of FIG. 4 ;
[0016] FIG. 7 is a bottom view of the cable support of FIG. 4 ;
[0017] FIG. 8 is a top perspective, sectional view of the cable support taken along line A-A in FIG. 6 ; and
[0018] FIG. 9 is a bottom perspective, sectional view of the cable support taken along line A-A in FIG. 6 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0019] FIG. 1 depicts an illustrative embodiment of an overhead transmission line 10 including a series of poles 12 inserted into the ground supporting standard power transmission lines and a fiber optic cable line 14 . The poles 12 utilize different clamps and connectors for the power and fiber optic cable lines 14 . One or more poles 12 include a surplus length or loop 16 of cable as depicted in FIG. 2 . A cable guide 18 having one or more slots is attached to the pole 12 to assist in guiding and supporting the cable loop 16 .
[0020] Storage of surplus cable should include measures to prevent the cable from exceeding the manufacture's minimum bending limits under variable conditions. According to an exemplary embodiment, one or more cable supports 20 attach to the cable line 14 to support the ends of the loop 16 and prevent the ends from bending beyond the minimum limit. According to the illustrative embodiment shown in FIG. 3 , two portions of the loop 16 are inserted into the cable guide 18 to separate the loop 16 into a first section and a second section. A first cable support 20 receives the first section of the loop 16 and is positioned on the line 14 so that the cable is taut or otherwise stretched to a required distance. A second cable support (not shown) receives the second section of the loop 16 and is positioned on the line 14 on the opposite side of the pole 12 so that the cable is taut or otherwise stretched to a required distance. The cable supports 20 may be attached to the line 14 by various mounting hardware, such as sleeves, clamps, and fasteners. The portions of the cable between the cable support 20 and the cable guide 18 can be secured to the line 14 using bands or tie wraps as needed.
[0021] FIGS. 4-9 depict an exemplary embodiment of a cable support 20 . The cable support 20 includes channel member 22 having a curved portion that retains a section of the cable approximately at or above a minimum bend radius associated with the cable. In the exemplary embodiment, the cable support 20 has a substantially horseshoe-shaped channel member 22 having an open front, an angled first side section 24 , an angled second side section 26 , and a curved back section 28 . First and second transitions 30 connect the first and second side sections 24 , 26 , respectively, to the back section 28 . The channel member 22 includes an outer wall 32 , a top flange 34 , a bottom flange 36 , a first open end 38 , and a second open end 40 . The top and bottom flanges 34 , 36 extend from the outer wall towards the interior of the cable support 20 to create an inward facing channel.
[0022] The inward facing channel provides at least one advantage over a cable support having an outward or upward facing channel. For example, cables stored in the cable support will have a tendency to bow outward or upward, potentially displacing the cables from the channel and the support. An inwardly facing channel resists this movement and helps to retain the cables.
[0023] According to an exemplary embodiment, the channel member 22 has one or more slots 42 positioned in the top and bottom flanges 34 , 36 . The exemplary embodiment includes three slots 42 with one positioned on the first side section 24 , one positioned on the second side section 26 , and one positioned on the back section 28 . A pair of ribs 44 extends from the outer wall 32 opposite each slot 42 . The slots 42 and ribs 44 can be used to retain bands or tie wraps wrapped around the channel member 22 as needed.
[0024] According to a further exemplary embodiment, a first cross brace 50 extends outward from the top flange 34 and at least partially across the back section 28 of the cable support 20 . The first cross brace 50 includes a top surface 52 , a depression 54 , a first end 56 , a second end 58 , a first sidewall 60 , and a second sidewall 62 . First and second angled shoulders 64 A, 64 B extend from the top flange 34 to the top surface 52 at the first end 56 and the second end 58 . The first and second ends 56 , 58 are curved to match the profile of the curved back section 28 , although other shapes and configurations may be used. The depression 54 is spaced below the top surface 52 and includes first and second outer sections 66 , 68 connected by a narrowed middle section 70 . The top surface 52 includes a first tab 72 and a second tab 74 extending towards the center of the first cross brace 50 that bounds the narrow middle section 70 . The depression 54 includes one or more openings 76 . The openings 76 and the depression 54 are configured to receive mounting components (not shown), for example mounting brackets and fasteners, to connect the cable support 20 to the cable line 14 .
[0025] According to an exemplary embodiment, a second cross brace 80 extends outward from the top flange 34 from the first side section 24 to the second side section 26 . The second cross brace 80 includes a top surface 82 , a depression 84 , first and second ends 86 , 88 , and first and second side walls 90 , 92 . First and second angled shoulders 94 A, 94 B extend from the top flange 34 to the top surface 84 at the first end 86 and the second end 88 . The first and second ends 86 , 88 are angled to match the profile of the first and second side sections 24 , 26 , although other shapes and configurations may be used. The depression 84 is spaced below the top surface 82 and includes first and second outer sections 96 , 98 connected by a narrowed middle section 100 . The top surface 82 includes a first tab 102 and a second tab 104 extending towards the center of the second cross brace 80 to narrow the middle section 100 . The depression 84 includes one or more openings 106 . The openings 106 and the depression 84 are configured to receive mounting components (not shown), for example mounting brackets and fasteners, to connect the cable support 20 to the cable line 14 .
[0026] In various alternative embodiments, the size, shape, and configuration of the cable support 20 varies. For example, the cable support 20 may have a closed configuration with a curved front and back. Other alternative embodiments can utilize fewer, or more than, two cross braces 50 , 80 and the position of the cross braces 50 , 80 may be varied from what is shown in the exemplary embodiments of FIGS. 4-9 .
[0027] The cable support 20 can be made from a plastic, metal, ceramic, or composite material, or any combination thereof. In various exemplary embodiments, the cable support 20 is made from an injection molded plastic, or any other stiff, lightweight material.
[0028] The cable support 20 can be a unitary structure or it can be formed from separate connected pieces. For example, the first and second cross braces 50 , 80 may be formed separately and welded to the channel member 22 .
[0029] Certain applications and additional components that can be used according to the described embodiments although not shown would be understood by one of ordinary skill in the art when viewing this disclosure. For example, U.S. Pat. No. 7,085,468, which is hereby incorporated by reference in its entirety to show additional exemplary components, but is not meant to affect or limit the scope of the claims of this application. The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining various principles and practical applications, thereby enabling others skilled in the art to understand that other various embodiments and modifications are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the invention to the exemplary embodiments disclosed. Any of the embodiments and/or elements disclosed herein may be combined with one another to form various additional embodiments not specifically disclosed. Accordingly, additional embodiments are possible and are intended to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way.
[0030] As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upward,” “downward,” “outward,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present invention, and are not intended to limit the structure of the exemplary embodiments of the present invention to any particular position or orientation. Terms of degree, such as “substantially” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments. | A cable supporting device includes a channel member. The channel member has a curved section bounding an interior. A top flange, a bottom flange, and an outer wall define a channel. The channel has an opening facing the interior. |
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BACKGROUND OF THE INVENTION
The invention relates to a pile repair jacket form being useful in repairing bridge, pier or walkway supports that are submerged in a body of water. Walkways such as piers or boardwalks are supported over a body of water by way of piles that have been driven into the bottom of the body of water below the mud line. Such piles can consist of concrete, timber and steel. It is obvious that the concrete, timber and steel piles are subject to corrosion or deterioration because of being permanently located in a water environment. Concrete piles are subject to corrosion, especially if the steel re-bars located therein are subject to rusting if they are located too close to the outer surface of the concrete pile or are exposed altogether. The timber piles are always pressure treated against corrosion or deterioration but the time span of their useful life is substantially shortened when the timber piles are located in a body of water. Steel piles are water proofed prior to their installation but over a period of time the water proofing is not durable or protective enough to protect the steel from corroding.
Most of the damage in all of the above supporting piles occurs at the water line because of the wave action. This wave action is further aggravated by the tides which are prevalent at most installations. In many installations, the high tide covers a greater height of the pile, while at a low tide, a greater length of the pile is exposed to the environment. Therefore, the piles undergo drying and wetting cycles which tend to eat away at the pilings, especially the wooden piles, thus weakening the piles mostly at their mid sections of their total length. Also, water insects like marine borers tend to accelerate the above noted deterioration and are the leading cause of timber pile deterioration.
Many devices have been used to repair the above noted damages short of replacing the pilings altogether. This tends to substantially increase the cost of such an installation.
The DENSO™ North America Corp. teaches the use of fiber form jackets that are placed over the whole length of the pile to be repaired or over the damage at the tidal zone. The jacket is made of fiber glass and therefore has some flexure in the material, especially over greater lengths. Because of its ability to flex, the jackets can be installed at the desired location without having to disassemble the superstructure above the piles. Once in place, the jackets at their longitudinal open edges have a tongue and groove arrangement to close and seal the longitudinal edges. Bandings are placed around the jacket at about every 12″. Also standoffs between the pile and the interior surface of the jacket should be used to increase its stability. The use of fiberglass material is very expensive.
Another suggested use is demonstrated by the above noted corporation and that is the use of a fabric form jackets. The fabric form jacket is made of 100% continuous multifilament NYLON fibers and is placed around the damaged area of the pile and the top and the bottom is then closed against the pile by banding. A longitudinal zipper is then closed to complete a cylindrical enclosure. A disadvantage with this kind of an arrangement is that the cylindrical fabric form does not have a form stability in that when the concrete fill is inserted therein, it has a tendency to collect more concrete in the bottom of the cylinder and less at the top, whereby a pear-shaped form is assumed. Therefore, more concrete has to be used than is necessary. Hydraulic concrete is quite expensive. Also, the fabric form pile jacket itself is quite expensive.
A similar jacket system is disclosed by the ROCKWATER Corp. in Farmingdale, N.Y. They disclose fiberglass reinforced pile jackets under the name of ROCKFORM™ F and a nylon Pile Jacket under the name of ROCKFORM™ N. As a matter of fact, there is an illustration in their brochure showing the nylon jacket installed on a pile after having been filled with concrete. This illustration clearly demonstrates the disadvantage of this type of a repair wherein more of the concrete is located in the bottom of the bag instead of being equally distributed throughout the length of the bag, as was enumerated above already
Another form jacket is disclosed by the DESLAURIERS, Inc. company. The disclosed jacket consists of two halves that have to be bolted together at their respective flanges and therefore can be installed around existing piles without having to disturb the decking which is supported by the same. However, the assembly underwater is quite cumbersome, expensive and time consuming.
OBJECTS OF THE INVENTION
According to the invention, applicant is using a high density polyethylene HDPE pipe, which pipe has a smooth interior wall and an annular corrugated exterior for strength. This pipe is manufactured by the Advanced Drainage Systems, Inc. of Columbus, Ohio. High Density Polyethylene is an extremely tough material that can easily withstand the normal impacts involved in shipping and installation. The proposed applications for this pipe have been specified for culverts, cross drains, storm sewers, land fills and other public and private constructions. There is no proposal to use these pipes for repairing pile supports above water or below.
The pipe, as is, could be used for that purpose but only after the decking, which is supported by the pile, has been removed, and then the pipe could be slipped over and along the pile. However, this pipe cannot be used as a jacket in sections above and below water without first removing the decking or superstructure. In the inventive concept, the pipe has been modified for this purpose by cutting through the pipe longitudinally first. This cutting alone will not suffice because the annular corrugations prevent the pipe at its longitudinal cut to be opened to such an extent and size so that the jacket can easily be slipped around a damaged pile. The corrugations are of such a size and strength so as to not allow any such movement. To accommodate a proper opening, the casing or jacket has been cut in a V-shape and only through the corrugations and opposite the longitudinal cut but not into the wall itself that supports the corrugations and forms the interior smooth surface, thereby creating a live hinge. The HDPE material is flexible enough to allow repeated openings and closings of the jacket along its live hinge without breaking or separating. The corrugated pipe is readily available in diameters from 4 inches to 48 inches and therefore lends itself to many applications including in square concrete pile applications. The pipe also is available in various lengths which enhances the installation possibilities under water. If various lengths have to be assembled, the various sections can be supplied with bell- and spigot ends that fit well within each other including various seals between the sections.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the pile repair jacket;
FIG. 2 is a perspective view of the jacket installed on a pile to be repaired;
FIG. 2A is a perspective view of an alternative seal;
FIG. 2B is a perspective view of still another alternative seal;
FIG. 3 is a somewhat different embodiment of FIG. 2;
FIG. 3A shows a different seal for the edges of the jacket;
FIG. 4 illustrates a construction of closing the edges of the jacket;
FIG. 5 shows a bell and spigot arrangement of connecting two units;
FIG. 6 illustrates an installation of the jacket within a tidal zone;
FIG. 7 is a top view of a modified jacket form of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates the invention of the pile repair jacket as it has been modified from what is known in the prior art. The jacket is being identified as 1 . The jacket 1 normally has a solid but somewhat resilient and circumferential wall forming a cylinder. Around the cylindrical wall a multiple of corrugations 3 are formed or molded to give the jacket a strong rigidity. The cylinder is being cut in a longitudinal direction to expose longitudinal edges 4 . Opposite from the longitudinal edge 4 a V-shaped cut is made into the corrugations but only onto the straight cylindrical to maintain its integrity. This is shown at 6 . The jacket 1 has a smooth interior wall 7 and an upper edge 2 . This way a live hinge 8 is created by virtue of the wall being somewhat flexible because of the loss of the corrugations 3 at that particular point 8 . It is now apparent that the former rigid cylinder may now be opened up so that it can be draped around a timber pile that is in need of a repair. If any larger diameter piles or supports within a body of water needs to be repaired, it is quite possible to cut at least three V-shaped cuts into the corrugations 3 down to the smooth wall so as not to over stress any individual live hinge in case that the jacket has to be opened rather wide to surround a large pile support such as could happen with square concrete piles. Once the jacket has been installed around a pile, the edges 4 have to be brought together again and sealed against each other. Therefore, a self-adhesive seal 5 has been provided between the edges 4 which will seal against water leaking into the jacket or concrete leaking out at a later time when the jacket is filled with concrete. The adhesive seal may consist of a soft foam rubber or some other flexible rubber. The seal is adhesive at least on one side so that it will firmly adhere to at least one of the edges 4 and cannot be dislodged.
FIG. 2 illustrates the jacket 1 after it is installed around a damaged area of the pile P. Like reference characters have been applied to like elements as explained in FIG. 1 . In order to stabilize the interior wall against the pile P, standoffs 9 have been provided which are merely nailed into the pile P. The standoffs have been shown as U-shaped but can take many other forms. It is also noted that the standoffs should be made of a plastic material or other non-corrosive material, because if it is too close to the surface, once the concrete is cast and is cured, the standoff if it is made of metal, could be a cause for corrosion and/or rusting. In order to bring the outer circumference of the jacket 1 back into its original circular shape, the edges 4 are pulled together by banding 10 which will settle in annular grooves between the annular corrugations 3 . The banding 10 shown in FIG. 2 is of the conventional ratchet type otherwise known as hose clamps in automobile engines, for example. The banding 10 is tightened within the groove by ratchet screw 10 a which is well known. The seal 5 is shown as self-adhering to one of the edges 4 . When the banding 10 is applied to the jacket 1 , the seal 5 may have to applied with a notch 5 a so that the banding 10 will not disturb the shape of the rectangular seal 5 .
FIG. 2A illustrates another seal 11 which is not self-adhering but instead is supplied with plugs 11 a which are formed in such a shape so that will snugly fit within the interior openings of the corrugations 3 . This type of an arrangement will assure a longer lasting fit and could be reusable, while a self-adhering seal 5 will have a one time use only.
FIG. 2B illustrates still another seal 26 which has plugs 26 a and 26 b on both sides of the rectangular seal 26 . Additionally, the rectangular is somewhat enlarged so that it will extend into the interior of the jacket form 1 . The extension into the interior of the jacket form has lateral holes 26 c therein. When the jacket form 1 is being filled with concrete, the concrete will migrate into these holes to completely fill the same. Of course, the soft rubber seal of FIG. 2A would not be practical in this type of installation. It is preferred that the same material by used in this instance as was used to manufacture the jacket form 1 such as HDPE. All other seals disclosed above could have the same interior extensions as shown in FIG. 2 B. This type of installation makes a very rigid fastening system.
Turning now to FIG. 3, there is shown a similar jacket 1 of FIG. 2 but with some preferred modifications. It is clear that when installing a jacket 1 around a pile P that there always should be at least two bandings 10 . Another type of banding is shown 13 . This banding is also well known. It is made of a plastic material and has a non-reversing or one-way buckle 14 . FIG. 3 also illustrates the use of form-fitting plugs 12 which are pressed into the interior of each of the corrugations of one of the edges and are received in the same manner in the other interiors of the other corrugations of the other edge. This will assure a rigid fit between the longitudinal edges 4 of the jacket 1 . These plugs also help in locating the edges 4 relative to each other in a self-aligning manner when the jacket is installed. After all, the assembly takes place in an underwater environment and the visibility might be hampered.
FIG. 3A shows a different seal 15 to be used between the edges 4 when they are closed. This seal 15 is a rectangular seal but having openings 15 a therein to accommodate the plugs 12 there through when the plugs 12 enter the openings in the corrugations.
Turning now to FIG. 4 which shows a different fastening system for closing the jacket onto its edges 4 . This fastening system consists of a buckle system 16 of the over center type. To this end, the buckle 16 includes two plates 17 and 19 which are riveted by rivets 17 a and 19 a , respectively, to the top or outside surfaces of the respective corrugations 3 . Plate 17 has a longitudinal hasp 18 mounted thereon which is pivotal around pivot 18 a . The other plate 19 has a pivotal handle 20 mounted thereon which is pivotal around pivot 20 a . The handle 20 also carries a hook 21 thereon. When it is desired to lock the two edges 4 of the jacket together including the seal 5 , the hasp 18 is placed within the hook 21 on handle 20 and the handle 20 is then moved to a closed position, as shown in FIG. 4, whereby the hook 21 pulls the hasp 18 and thereby the edges 4 together until the hook 21 is pulled past the pivot 20 a which position is over the center of the buckle system 16 . This assures a secure lock. Of course, two such buckle systems need to be used, one at the top of the jacket and a second one at the bottom. The advantage is this type fastening system is that it can be used repeatedly in many different installations. Another advantage resides in the fact that no tools are required to lock the edges 4 together which greatly enhances the use in an underwater assembly. Another advantage lies in the fact that this installation can be a one man operation. All of the above lessens the cost of the installation and the assembly is quicker to perform.
FIG. 5 illustrates how two jackets are connected together through the use of a bell and spigot system. Lines and arrow I denote the lower section of the upper jacket, while lines and arrow II denote the upper section of the lower jacket. The lower section of the upper jacket has an extension or bell S which overlaps the first two annular corrugations, 3 a and 3 b , of the upper section of the lower jacket. For this purpose, the two annular corrugations 3 a and 3 b are somewhat reduced in circumferential size so that the extension S can slip over the same. The corrugation 3 a also has the seal 25 embedded in its outer surface to assure a tight seal between the two jackets.
FIG. 6 illustrates a complete installation of the jacket on a limited extent of the underwater pile P. In the previously described jackets, above, it was assumed that the jacket would completely cover the pile P all the way to and below the mud line of the body of the water. FIG. 6 only repairs or rehabilitates only part of the pole P. It is a well known fact that most of the damage to a timber pile occurs at the wave line W and within the tidal zone T. The corrosion has been indicated by C. To this end, a jacket 1 is installed over the deteriorated section C and is stabilized laterally by standoffs 9 . The bottom of the jacket is stabilized relative to the height of the pile P by spikes 23 driven into the pile or otherwise fastened to the pile. In order to completely close the bottom of the jacket 1 against the loss of concrete, a Nylon fabric bag 24 is installed. The bag 24 is banded within a valley of the last corrugations 3 of the jacket 1 through the use of banding 24 a and the lower end of the bag is banded against the pole P itself through the use of banding 24 b . The numeral 22 indicates a port for the entry of concrete. It is a known fact that concrete should be introduced into the interior of the jacket at a bottom thereof. This will force the water therein upwardly and furthermore avoid air bubbles from forming within the concrete.
Finally, turning to FIG. 7, there is shown repair jacket form having at least three V-shaped cuts 6 , 6 a and 6 b made through the corrugations 3 . In some repair undertakings larger piles in circumference are encountered including square concrete piles that require the repair jacket form to be opening rather wide. This might overstress the material tolerance of just a single live hinge. Therefore the presence of three live hinges 6 , 6 a and 6 a will considerably elleviate this overstressing.
SUMMARY OF THE INVENTION
From all of the above, it can now be seen that the repair or rehabilitation of an underwater pile has greatly been simplified with a lower cost realization. The jacket forms disclosed herein can be reused many times over or the jacket forms can be left in situ which may prolong the life of the installation indefinitely. The installation has been simplified and speeded up to thereby save cost in labor. These were the objects of the invention. | The invention relates to a plastic jacket that is used for repairing underwater piles that have been corroded by the wave action at the waterline or by a tidal zone. The jacket consists of a cylindrical wall having annular corrugations on its exterior surface. The cylindrical wall has a longitudinal cut along its length to exhibit two opposing edges. A seal is placed between the opposing edges. Opposite from the longitudinal cut there is a V-shaped cut through the corrugations to the cylindrical wall to create a living hinge in the plastic material of the wall. Banding is provided to pull the opposing edges into a tight relationship and trapping the seal there between. The V-shaped cuts enable the jacket to be opened and placed around a damaged pile in spite of the corrugations which would prevent such an opening. |
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BACKGROUND OF THE INVENTION
The present invention relates to a door stop, in particular for a door of a motor vehicle, which enables an unhindered movement of a door in a first door opening angular region and for stepless stopping and retaining the door in an arbitrary selected opening position in a second opening angular region.
A known door stop of the above-described type includes a hydraulic cylinder connectable to a door assembly part, a door or a door frame, a stop piston longitudinally displaceable in the hydraulic cylinder and separating two pressure chambers formed in a cavity of the hydraulic cylinder, a piston rod fixedly secured to the stop piston for connecting the stop piston with another part of the door assembly, two separate conduits formed in the stop piston for communicating the two pressure chambers of the cylinder, two closing pistons located in the two separate conduits and displaceable therein in opposite directions between an open position, in which they permit flow of a pressure medium through the conduits from one of the pressure chambers to another of the pressure chambers, and a closing position, in which they block the fluid flow through the conduits, and spring means for biasing the two closing pistons to their closing positions.
In the closing position, the closing pistons keep the door in its selected position until an actuation force is generated in one or the other of the cylinder pressure chambers which exceeds the retaining force of the respective biasing spring. Under the action of such actuation force, one of the closing pistons then moves to its open position, in which it permits flow through the conduit associated therewith, and the door becomes freely pivotable as long as an appropriate actuation force acts on the door.
Such a door stop is disclosed in a German patent No. 1,459,182. The drawback of this known door stop consists in that the beginning of the adjustable door movement must be jerky to bring the closing piston into its open position. This, of course, makes a comfortable door handling, which is required in modern motor vehicles, impossible. Moreover, the known door stop does not permit to achieve a reliable stop of the door immediately after the actuation forces ceases to act on the door, because the biasing force acting on the closing piston cannot be made too large, in view of the requirements to the operation of the door, to overcome the residual pressure medium pressure existing in the flow conduits after the actuation force ceases to act on the door. As a result, the door, after the actuation force ceases to act thereon, still undergoes a creeping movement, which is especially the case with respect to motor vehicle doors, especially when the vehicle stays on an uneven surface, and gravity forces may cause a self-induced movement of the door.
Another door stop is disclosed in a German patent No. 4,239,172. This door stop has a single flow passage controlled by a closing piston, which is spring-biased in its closing direction and is associated with a control conduit with a pressure relief valve for each of the two opposite flow directions. In this door stop, the medium pressure, which is generated in one of the two pressure chambers of the cylinder upon the action of the actuation force on the door, opens a respective pressure relief valve and the closing piston is subjected to the medium pressure and moves against the spring-biasing force into its open position, in which fluid is able to flow through the flow conduit. As soon as the closing piston is moved to its open position, the pressure relief valve of the corresponding control conduit closes, and fluid flows only through the flow conduit.
When the actuation force acting on the door ceases, the same pressure is established in both pressure chambers of the cylinder. As a result, even a weak biasing force moves the closing piston to its closed position. However, this does not insure a reliable fixation of the door in the open position desired by the user. In addition, the manufacturing of such a door stop, because of a need in two pressure relief valves, is rather expensive.
In addition, none of the two above-described door stops provides for a free movement of the door in a sense that first, the door stop provides for movement of the door through a predetermined opening angular region.
Accordingly, an object of the invention is a door stop of the above-described type which would insure application of high retaining forces at the reduced dimensions of the door stop, which would be inexpensive to produce, and which would insure a large as possible comfortable operational handling of the door, with the possibility of a reliable retaining of the door in the selected-by-the-user position.
Another object of the invention is a door stop which would insure the smooth door movement with small actuation forces.
SUMMARY OF THE INVENTION
These and other objects of the invention, which will become apparent hereinafter, are achieved by providing a door stop of the above-described type, with two separate conduits and two closing pistons, in which each closing piston is formed of several parts and has at least one axial pressure relief bore extending between the two parts, and in which a limited length conduit is formed in the hydraulic cylinder, by-passing the stop piston and directly communicates the two pressure chambers with each other.
Providing a limited length conduit in the hydraulic cylinder, preferably defined by a plurality of axial grooves formed in the cylinder wall and bridging over the stop piston, insures the free movement of the stop piston over a predetermined limited angle of the door opening particular in a sense that the door is movable over a predetermined initial opening angle without any resistance, i.e., it can be open or closed without the operation of the stop. It is of a particular advantage, that such free movement can be achieved without using additional parts.
The other important feature of the present invention, namely, providing in each of the closing pistons an axially extending relief bore, is likewise can be implemented without additional costs and insurers, among others, an exact fixation of the door in a selected position, that is, the closing pistons, upon stoppage of the door, are immediately spring-biased to their closing positions and, thus, prevent any further movement of the door.
In the preferred embodiment of the invention, there is provided that the closing pistons, in their closing position, closed both region of the flow conduits formed in the stop piston. At that, the closing elements of the closing pistons are so formed that the closing pistons are adjustable, under the pressure prevailed in the cylinder, only in one direction. The closing pistons are displaceable in widening portion of the flow conduits and, in their closing positions, close, at one side, the inlet and, at the other side, the outlet of the widening portion of respective flow conduits. To provide for the adjustment of the closing piston only in one direction, it is contemplated by the invention that a flow conduit portion, which forms a widening portion inlet, extends axially, in particular centrally, relative to the end face of the widening portion, and a flow conduit portion, which forms the outlet of the widening portion, extends radially with respect to the widening portion.
In connection with such form of flow conduits, which are located in the stop piston, it is contemplated by the invention to provide, on the outer circumference of the cylindrically shaped closing piston body, over a first body portion, axially extending grooves, which form the flow paths, and to form the second body portion as a closing element. The axially extending grooves form outlets for respective radial bores formed in the circumferential wall of the stop piston. The radial bores are so arranged that they communicate with axial nuts formed in the closing pistons only in the open positions of the closing pistons. This insures not only a simplified manufacture of the closing pistons but also their smooth displacement in the widening portions of the respective flow conduits. The closing piston has, at an end thereof adjacent to the inlet-forming portion of the respective flow conduit, a loose blocking element which, preferably, is formed as a ball having a diameter greater than the diameter of the mouth opening of the inlet-forming portion of the flow conduit.
Advantageously, the closing piston has, at its end adjacent to the inlet-forming portion of the flow conduit, an axially extending collar offset inwardly with respect to the outer circumference of the closing piston and is joined with the relief bore.
The collar forms a ball cage for the ball-shaped blocking element, with the ball having a smaller diameter than the cage. This provides for free movement of the ball in the cage in a direction transverse to the cage axis so that the ball, upon movement of the closing piston to its closing position, can be exactly aligned with the mouth opening of the inlet-forming portion of the flow conduit. The exact alignment of the ball with the mouth opening insures a reliable blocking of the flow conduit even in the case when relatively weak spring-biasing forces act on the closing piston to move it to its closing position, and at the same time, a sensitive response of the stop. Therefore, for further movement of the door, only a small actuation force need be applied to the door.
According to the invention, the inlet-forming flow conduit portion consists of a plurality, in particular, three, arranged in a form of a star, radial bores formed in the circumferential wall of the closing piston and communicating with respective axial grooves provided in the circumferential wall. Thereby an unhindered flow of the pressure medium in the flow conduit is insured, together with an exact displacement of the closing piston in the cylinder. Preferably, the radially-extending bores are inclined to the closing piston axis.
In order, on one hand, to provide for a predetermined medium pressure in the system and, on the other side, to compensate the unavoidable pressure medium losses, it is further contemplated, according to the invention, to provide inside the cylinder, at the end thereof opposite to the end through which the piston rod extends, a refill reservoir which is separated from an adjacent pressure chamber of the cylinder by a separation wall and which is associated with an accumulator. The refill reservoir is connected to the adjacent pressure chamber by a pressure relief valve.
The accumulator advantageously is subjected to an action of an insulating air cushion having a predetermined pressure. The accumulator is connected to the adjacent pressure chamber by a check valve, adjusted to a predetermined pressure, and a throttle opening. The check valve serves for compensating temperature-dependent changes of the pressure medium volume.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and objects of the present invention will become more apparent, and the invention itself will be best understood from the following detailed description of the preferred embodiments when read with reference to the accompanying drawings, wherein:
FIG. 1 shows a schematic perspective view of a door stop according to the present invention;
FIG. 2 shows a longitudinal cross-sectional view of the door stop shown in FIG. 1 at an increased scale;
FIG. 3 shows a side view of a closing piston;
FIG. 4 shows an end view of the closing piston shown in FIG. 3; and
FIG. 5 shows a cross-sectional view of the door stop shown in FIGS. 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The door stop according to the present invention is formed by a hydraulic cylinder including a hollow cylinder 1 and a stop piston 2, which divides the cavity of the hollow cylinder 1 into two pressure chambers 3 and 4. The hollow cylinder 1 is connected in a manner, not shown in the drawings, to a part of a door assembly, a door, or a door frame, and the stop piston 2 is connected by a connection piston rod 5 in a manner, likewise not shown in the drawings, to another part of the door assembly. In order to achieve the same pressure medium displacement during the adjusting movement of the stop piston 2 in both pressure chambers 3 and 4 of the hollow cylinder, the piston rod 5 is provided with an extension 6 projecting beyond the stop piston 2. Inside the stop piston 2, there are provided two through passages 7 and 8 for connecting the pressure chambers 3 and 4 and which are arranged one beneath the other. Each of the through passages 7 and 8 has a widening portion 9 in which a closing piston 10, which either permits the pressure medium flow therepast or blocks the pressure medium flow, is arranged for axial displacement against a biasing force of a loading spring 11. The through passages 7 and 8 have each three radial, inclined toward the axis of the stop piston 2, passage portions 12 which connect, on one hand, axially extending grooves 13, formed in the circumference of stop piston 2, with a respective one of pressure chambers 3 and 4 and which, on the other hand, have mouth portions 14 opening into a respective widening portion 9. The widening portions 9 of the through passages 7 and are in the shown embodiment, formed cylindrical for receiving the likewise cylindrically formed closing piston 10. The closing pistons 10 have on their circumference axial grooves 15, which extend along a portion of the length of the closing pistons 10 and with which a cylindrical portion of the closing piston 10, which forms a closing part 16, is associated. Radial bores 17, which are formed in the circumference of the stop piston 2 and which open into the axial grooves 13 of the stop piston 2, are associated with the axial grooves 15 of the closing piston 10. The radial bores 17 are so arranged relative to the length of the widening portion 9 that, in the closed position of the closing piston 10, they are closed by the closing part 16 of the closing piston 10 and, in the open position of the closing piston 10, they overlap the axial grooves 15 of the closing piston 10. Thereby, only in the open position of the closing piston 10, the pressure medium flows through the through passages is possible. The closing piston 10 has, at an end face thereof which is opposite to the closing part 16, a central axial blind bore 18 and an axial collar 19 extending inwardly of the closing piston outer circumference, The blind bore 18 and the collar 19 form a cage for a loosely arranged therein ball 20 which forms a closing element for the mouth portion 14 of the respective through passage 7 or 8o The diameter of the ball 20 is larger than the diameter of the mouth portion 14 of the through passage 7 or 8 but smaller than the inner diameter of the blind bore 18 and the collar 19, so that the ball 20 easily aligns itself with the mouth portion 14 of the respective through passage 7 or 8 and completely closes the mouth portion 14 when the closing piston 10 moves to its closed position.
To relieve the closing piston 10 from the medium pressure developed or retained in the widening portion 9 during movement of the closing piston 10 to its closing position, relief bores 21 having a small diameter are formed in the closing piston 10. This insures that when the actuation forces ceases to act on the door, the closing piston 10 immediately and completely moves into its closing position, and the door is kept in an exactly open position selected by the user. To insure unhindered passage of the door over a selected position, there is provided, in the inner circumference wall of the hollow cylinder 1, a radial by-pass which is formed, in the embodiment shown, by at least one groove 22 and which bridges over the central, sealed with respect to the inner circumference wall of the hollow cylinder 1, region of the stop piston 2. The by-pass provides for flow of unpressurized pressure medium between the pressure chambers 3 and 4.
To maintain a predetermined selected medium pressure in the system and, at the same time, to automatically compensate unavoidable losses of the pressure medium, there is provided, in the hollow cylinder 1 in an end portion thereof opposite to the end through which the piston rod 5 projects out of the hollow cylinder 1, a refill reservoir 25, which is separated from the pressure chamber 3 by a separation wall 23 and which borders an accumulator 24.
A check valve 28 connects the refill reservoir 25 with the pressure chamber 3 and acts in a return direction. The accumulator 24 is subjected to action of an insulating air cushion and is connected with the pressure chamber 3 by a relief pressure valve 26, which is adjusted to a predetermined pressure, and a throttle opening 27. The accumulator 24 serves for compensation of the temperature-dependent changes of the pressure medium volume.
Though the present invention was shown and described with reference to the preferred embodiments, various modifications thereof will be apparent to those skilled in the art and, therefore, it is not intended that the invention be limited to the disclosed embodiments or details thereof, and departure can be made therefrom within the spirit and scope of the appended claims. | A door stop including an hydraulic cylinder connectable to one of a door assembly part, a stop piston longitudinally displaceable in the hydraulic cylinder and connected with another part of the door assembly by a piston rod, and two spring-biased closing pistons located in two separate conduits formed in the stop piston for communicating two, spaced by the stop piston, pressure chambers formed in the cylinder, with a limited length conduit being formed in the hydraulic cylinder and by-passing the stop piston for directly communicating the pressure chambers. |
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[0001] This application is based on the foreign priority of Canadian Application No. 2,923,280, filed Mar. 10, 2016.
BACKGROUND OF THE INVENTION
[0002] Safety pool ladders for above-ground swimming pools are known in the prior art. One well known type of safety pool ladder for above-ground swimming pools is described in patent documents U.S. Pat. No. 3,908,795, to Gannon (Sep. 30, 1975) and US20130025042A1, to Lin et Al. (Jan. 31, 2013). This type of safety pool ladder is generally represented by a substantially A-shaped ladder disposed in a saddle-like manner over the pool wall of a conventional above-ground swimming pool. The safety pool ladder typically has a relatively small horizontal platform at the top, and a set of ladder steps or rungs on each side of its A-shaped configuration, for climbing over the pool wall from either side thereof.
[0003] Furthermore, the set of ladder steps or rungs on the outside of the pool are mounted to a pair of parallel ladder side members having their upper ends pivotably attached to an upper portion of the A-shaped ladder. Thus, a user may selectively pivot this assembly upwardly when the pool must not be accessed unattended by an adult.
[0004] This type of safety pool ladder of the prior art, with its ladder steps and side members assembly thus pivoted upwardly, has the disadvantage of being relatively unstable during strong wind conditions, to a point of sometimes rolling over and tumbling out of the pool if not well anchored. This type of safety ladder further requires sufficient space near the pivotable assembly outside the pool, for allowing the relatively long pair of ladder side members to freely pivot upwardly. Finally, this type of safety ladder, with its ladder steps and side members assembly pivoted upwardly does not always particularly blend well aesthetically with pool side design furniture.
[0005] Another known type of safety pool ladder for above-ground swimming pools is described in patent documents U.S. Pat. No. 8,191,682B2, to Lipniarski (Jun. 5, 2012), U.S. Pat. No. 8,430,205B2, to Leung (Apr. 30, 2013), and FR2986032, to Bouillet (Jan. 23, 2012). This type of safety ladder also has a substantially A-shaped configuration, with a relatively small horizontal platform at the top and sets of ladder steps or rungs on each side thereof. This type of safety ladder further has a deployable or otherwise removably attachable cover that a user may selectively use to hide or at least block access to the set of ladder steps on the outer side of the pool wall, in order to prevent access to the pool.
[0006] This type of safety pool ladder solve some of the disadvantages of the previously described type of safety pool ladder by being more stable during strong wind conditions, requiring only limited space to be functional, and being more aesthetically appealing. On the other hand, this type of safety pool ladder may be less secure since it may allow some determined 7-8 year old kids to have unattended access to the pool by slightly jumping up to grab a lower part of the handrails typically positioned on each side of the platform, and using the step cover as a climbing ramp means that provides sufficient support adherence under their running shoes for relatively easily climbing the ladder.
[0007] Thus, there is a need for an improved automatic safety pool ladder for above-ground swimming pools. In a broad aspect, the present invention provides such an improved automatic safety pool ladder that avoids the aforementioned disadvantages.
SUMMARY OF THE INVENTION
[0008] In a broad aspect, the present invention provides an improved automatic safety pool ladder for an above-ground swimming pool. The swimming pool defines a pool wall extending upwardly above ground, a pool bottom and a pool peripheral ground extending substantially adjacently around the pool wall.
[0009] According to an embodiment of the present invention, the automatic safety pool ladder generally comprises a stationary ladder assembly and a rotative ladder assembly.
[0010] The stationary ladder assembly includes a pair of ladder side members. Each one in the pair of ladder side members has substantially an open trapezoidal configuration defined by a substantially vertically extending ladder side in-pool leg portion and a substantially vertically extending ladder side ground engaging leg portion, that are joined through the upper ends thereof by a ladder side apex portion extending therebetween.
[0011] Each one in the pair of ladder side members is disposed in a parallelly spaced apart relationship relative to the other one, with a ladder platform extending between the ladder side apex portions thereof, and a set of stationary ladder step members extending horizontally between the pair of ladder side in-pool leg portion, and disposed in an equidistantly spaced apart relationship therealong.
[0012] The rotative ladder assembly includes a set of rotative rungs fixed in guide holes inside the pair of ladder side members. A spring is placed on the bottom of one of the ladder side to hold the mechanism in secure position.
[0013] When in closed position, rungs forms a flat surface, preventing climbing.
[0014] Each ladder assembly step member is joined in a parallelly spaced apart relationship relative to the other ones through a rod extending parallelly between each adjacent ends thereof, this rod fixed to a lever permitting controlled rotation. The lever end is placed along the platform, out of the reach of children.
[0015] Hence, when the lever is pulled down in the ladder deployed position, a user standing on the pool peripheral ground can climb the safety pool ladder.
[0016] The weight of users is enough to let the rungs stay in open position, permitting to climb to the top platform without being preoccupied with the lever.
[0017] Then, without weight on any rung, the spring let the lever to be automatically released in normal position, letting reset all rungs in flat position.
[0018] When the lever is released in the ladder retracted position, a user standing on the pool peripheral ground is prevented from climbing the safety pool ladder.
[0019] Thus, the automatic safety pool ladder for above-ground swimming pools of the present invention is relatively stable during strong winds, requires only limited space to be functional, is more likely to be aesthetically appealing among pool side design furniture and, most importantly, may discourage very determined young kids from accessing an unattended above-ground swimming pool.
[0020] Other advantages, novel features and alternate embodiments of the present invention will be more apparent from the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 , in a perspective view, illustrates an embodiment of an automatic safety pool ladder, according to the present invention;
[0022] FIG. 2 , in a perspective view, illustrates an automatic safety pool ladder, here shown in a retracted position;
[0023] FIG. 3 , in a partial, side cross-sectional view, illustrates an embodiment of a rotative ladder assembly, here shown with the rotative ladder assembly (rungs) moved in its retracted position;
[0024] FIG. 4 , in a partial, side cross-sectional view, illustrates another embodiment of a retractable ladder assembly, here shown with the rotative ladder assembly (rungs) moved to its open position;
[0025] FIG. 5 , in a partial, front elevational view, illustrates the rotative ladder assembly in FIG. 3 ;
[0026] FIG. 6 , in a partial side cross-sectional view, illustrates the rotative ladder assembly in FIG. 3 , here shown provided with a lock means for locking the rotative ladder assembly in a retracted position.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 illustrates various aspects of an embodiment, according to the present invention, of a safety pool ladder 10 for an above-ground swimming pool 12 .
[0028] The swimming pool 12 defines a pool wall 14 extending upwardly above ground 16 , a pool bottom 18 and a pool peripheral ground 20 extending substantially adjacently around the pool wall 14 .
[0029] Now referring more particularly to FIGS. 1 and 2 respectively, the safety pool ladder 10 generally comprises a stationary ladder assembly 22 and a rotative ladder steps assembly 24 .
[0030] The stationary ladder assembly 22 has substantially an open trapezoidal configuration defined by a substantially vertically extending ladder side in-pool leg portion 28 and a substantially vertically extending ladder side ground engaging leg portion 30 , that are joined through the upper ends thereof by a ladder side apex portion 32 extending therebetween.
[0031] Each one in the pair of ladder side members 22 is disposed in a parallelly spaced apart relationship relative to the other one.
[0032] The stationary ladder assembly 22 further includes a ladder platform 34 extending horizontally between the ladder side members and substantially adjacently the ladder side apex portions 32 thereof.
[0033] The stationary ladder assembly 22 further includes a set of stationary ladder step members 36 extending horizontally between the pair of ladder side in-pool leg portions 28 , and disposed in an equidistantly spaced apart relationship therealong.
[0034] Furthermore, the stationary ladder assembly 22 defines an underside trapezoidal outline 38 substantially circumscribed by the parallelly extending ladder side in-pool leg portions 28 , the platform 34 , and the parallelly extending ladder side ground engaging leg portions 30 .
[0035] The rotative step ladder 24 has substantially a parallelepiped shape.
[0036] In addition, a protrusive rotation axis 40 is placed on each side of the steps 24 and fits into the lateral leg portions 30 .
[0037] Another control axis 41 is placed on one of the sides of the steps 24 and is inserted into the guide rod 42 , this one is placed inside one of the leg portion 30 .
[0038] The guide rod 42 is pierced at equal distance to allow the insertion of control axis 41 of each step 24 , allowing steps to be fixed by their control axis 41 equidistantly and leave no opening between each of the steps when in retracted position. It also allows maneuvering all the steps in unison.
[0039] Furthermore, this guide rod 42 is connected by a pivot 44 to the lever 43 . This lever 43 protrudes on the top side of the ladder side apex portion 32 .
[0040] This lever 43 stands normally in a vertical position when in retracted position. When the user lowers a few degrees the lever 43 , its drag along the guide rod 42 by moving the series of steps in their open position, which allows the user to ascend or descend.
[0041] Furthermore, control axis 41 are retained in good place in their displacement by lunar-shaped slots 31 in the lateral leg portion 30 who receive the mechanism.
[0042] Also, this guide rod 42 is connected to a compression spring 45 which allows to retain the steps in their retracted position. This spring is strong enough to hold up steps closed, but enough relaxed to not cause too much tension on the lever 43 .
[0043] Hence, when the rotative ladder assembly 10 is in the ladder deployed position as illustrated in FIG. 1 , a user standing on the pool peripheral ground 20 can climb the safety pool ladder 10 . And when the rotative ladder assembly 60 is in the ladder retracted position as illustrated in FIG. 2 , a user standing on the pool peripheral ground 20 is prevented from climbing the safety pool ladder 10 .
[0044] As illustrated in FIG. 1 , the safety pool ladder 10 is sufficiently sized and shaped for substantially stably standing over the pool wall 14 in a saddle-like configuration, with a lower end of the ladder side in-pool leg portions 28 resting on the pool bottom 18 , and a lower end of the ladder side ground engaging leg portions 30 resting on the pool peripheral ground 20 .
[0045] In some embodiments, as illustrated in FIG. 6 , the safety pool ladder 10 further includes a lock means 120 along the lever 43 , for locking the rotative ladder assembly 10 substantially in the retracted position.
[0046] For example, the lock means 120 may define a padlock aperture 66 configured and sized for engaging a locking member 121 of a padlock. The padlock aperture 66 may fit exactly through a side portion of a second padlock aperture that is suitably fixed on the platform 34 so as to block the movement of the lever 43 , consequently to the rotative ladder assembly.
[0047] As would be obvious to someone familiar with locking means for slidable assemblies, such as doors and the like, other known types and arrangements for a locking means 120 are also possible.
[0048] In some embodiments, as illustrated in FIG. 1 , the ladder side apex portion 32 of each one in the pair of ladder side members 30 is extending relatively higher than the platform 34 so as to define a pair of substantially rigid pool ladder side guardrails for safely helping users move across the platform 34 .
[0049] In some embodiments, as best illustrated in FIGS. 1 and 2 , the set of stationary ladder step members 36 has a substantially equivalent number of step members relative to the set of ladder assembly step members 24 .
[0050] Although the above description contains many specificities, these should not be construed as limitations on the scope of the invention but is merely representative of the presently preferred embodiments of this invention. | The present invention relates to an automatic safety pool ladder for an above-ground swimming pool composed of a set of rotative self-closing steps where the retracted position prevents access to water and where access to open steps is easily controlled by user through a lever arm and positioned so that the arm is not accessible to children. |
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FIELD OF THE INVENTION
This invention relates to a vehicle barrier system and relates particularly, though not exclusively, to a vehicle barrier system to prevent intrusion through a barrier by an unauthorised vehicle.
BACKGROUND OF THE INVENTION
Threats from car bombs have become prevalent amongst terrorists throughout the world. Terrorists will ram a gate of an embassy or other selected building with a vehicle. Once entry is gained they detonate their bomb as close to the building as possible to maximise the death and injuries caused by their actions. Gates and doors are necessary to gain access to the building or perimeter fence and provide a weak link for such terrorist attacks. Most gates rely on the weight of the gate and its mounting to a foundation to decelerate such vehicles. These gates do not attempt to absorb the shock and the vehicle may still penetrate a significant distance. The resulting damage is usually significant and will require costly and timely replacement.
SUMMARY OF INVENTION
It is an object of the present invention to provide a vehicle barrier system that will absorb the impact energy from the moving vehicle and reduce the penetration distance when the vehicle has been stopped.
A further object of the invention is to provide a vehicle barrier system that can be readily repaired or replaced once vehicle impact has occurred.
In one aspect of the present invention there is provided a vehicle barrier system including a barrier movable between an open position to allow vehicle access therethrough and a closed position which prevents vehicle access therethrough, said barrier being attached to barrier supports at either end of said barrier, said barrier supports being secured to a slide plate which will slide after a predetermined force is applied thereto by vehicle impact with said barrier to absorb the impact energy of said vehicle.
Preferably said slide plate is sufficiently long to have a part of said vehicle sitting thereon at impact. Preferably said movement of said slide plate is controllable. Preferably said movement is controllable by one or more of a group selected from a ballast attached directly or indirectly to said slide plate, at least one further slide plate attached to said slide plate, the extension of attachment means attached to said at least one further slide plate and/or said ballast, the extension of attachment means attached to said slide plate and a surface over which said slide plate moves, and the shearing of at least one rivet securing said slide plate to a surface on which said slide plate slides.
In a practical embodiment a plurality of rivets protrudes through said at least one slot in said slide plate. Preferably a pair of slots are provided and said slide plate rests on a sliding surface formed by a pair of ground engaging beams aligned with respective slots. Preferably a pair of upright beams are secured to the ground in front of respective barrier supports, said upright beams being secured to said pair of ground engaging beams at one end and pivotally and/or slidably linked to said barrier supports at the other end.
In a further aspect of the invention there is provided a vehicle barrier system including a barrier movable between an open position to allow vehicle access therethrough and a closed position which prevents vehicle access therethrough, said barrier being attached to barrier supports at either end of said barrier, said barrier supports being secured to the ground on a ground engaging plate(s), a pair of bridging slide plates on one side of each of said barrier supports attached at one end to a respective said barrier support and at the other end to said ground engaging plate(s), said slide plates joined by at least one rivet, said slide plates movable with respect to one another when said at least one rivet is sheared after a predetermined force is applied from vehicular impact with said barrier to absorb the impact energy of said vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more readily understood and put into practical effect, reference will now be made to the accompanying drawings, in which:
FIG. 1 is a perspective view of a first embodiment of a vehicle barrier system made in accordance with the invention showing the barrier in the closed position;
FIG. 2 is the same view as FIG. 1 in the open position;
FIG. 3 is an underneath view of FIG. 1 ;
FIG. 4 is a plan view of FIG. 1 ;
FIG. 5 is a cross-sectional view along and in the direction of arrows 5 - 5 shown in FIG. 4 ;
FIG. 6 a is similar view to that of FIG. 5 which includes a part plan view made in accordance with a second embodiment of the invention showing a vehicle moving towards the barrier;
FIG. 6 b is a similar view to that of FIG. 6 a showing the vehicle impacting the barrier;
FIG. 6 c is a similar view to that of FIG. 6 b showing the shearing of the first set of rivets;
FIG. 6 d is a similar view to that of FIG. 6 c showing the shearing of the second set of rivets;
FIG. 6 e is a similar view to that of FIG. 6 d showing the shearing of the third set of rivets;
FIG. 7 is a plan view similar to that of the FIG. 6 e of a third embodiment made in accordance with the invention;
FIG. 8 is a similar view to that of FIG. 6 e of a fourth embodiment made in accordance with the invention;
FIG. 9 a is a similar view to that of FIG. 6 a of a fifth embodiment made in accordance with the invention with the barrier closed;
FIG. 9 b is a plan view of the vehicle barrier system shown in FIG. 9 a with the barrier open;
FIG. 10 is a perspective view of a sixth embodiment made in accordance with the invention;
FIG. 11 is a perspective view of a seventh embodiment made in accordance with the invention;
FIG. 12 is a perspective view of an eighth embodiment made in accordance with the invention showing the barrier lowered;
FIG. 13 is a perspective view of the embodiment shown in FIG. 12 with the barrier raised;
FIG. 14 is an end view in the direction of arrows 14 - 14 shown in FIG. 12 ;
FIG. 15 is a side view in the direction of arrows 15 - 15 shown in FIG. 12 ;
FIG. 16 is an exploded partial cross-sectional perspective view of the vehicle barrier system shown in FIG. 13 ;
FIG. 17 a is a longitudinal cross-sectional view of the vehicle barrier system shown in FIG. 13 before vehicular impact;
FIG. 17 b is a longitudinal cross-sectional view of the vehicle barrier system shown in FIG. 13 during vehicular impact;
FIG. 18 a is a perspective view of a ninth embodiment made in accordance with the invention showing the barrier lowered;
FIG. 18 b is a perspective rear view of the embodiment shown in FIG. 18 a with the barrier raised;
FIG. 19 is a perspective front view of the embodiment shown in FIG. 18 b with the barrier raised;
FIG. 20 is a longitudinal cross-sectional view of the vehicle barrier system shown in FIG. 19 with the barrier being manually raised;
FIG. 21 is a longitudinal cross-sectional view of the vehicle barrier system shown in FIG. 19 with the barrier being automatically raised;
FIG. 22 is a plan view of a tenth embodiment made in accordance with the invention showing the barrier closed;
FIG. 23 is a perspective view of one end of the vehicle barrier systems shown in FIG. 22 ; and
FIG. 24 is a cross-sectional view of the embodiment shown in FIG. 22 during vehicular impact.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Throughout this specification the same reference numerals have been used to identify similar integers in the various embodiments to reduce repetition of description. In FIGS. 1 to 5 there is shown a vehicle barrier system 10 which will protect an opening (not shown) in a perimeter fence or building opening. The vehicle barrier system 10 includes a pair of I-beams 12 , 14 mounted parallel with each other. Although I-beams have been described it is clear from embodiments to be discussed later that the I-beams could be replaced by an anchor plate on the ground. I-beams 12 , 14 are typically secured to the ground by concrete supports 15 . I-beams 12 , 14 have respective top flanges 16 , 18 and lower flanges 20 , 22 . A pair of hollow beams 24 , 26 are welded to respective support plates 28 , 30 . Apertures 31 in support plates 28 , 30 allow support plates 28 , 30 to be bolted to concrete supports 15 . A cross- beam 32 bridges hollow beams 24 , 26 . An electric motor 34 is secured to beam 26 and allows barrier 46 to be raised or lowered.
Counterweights 36 balance the weight of barrier 46 and are located within hollow beams 24 , 26 .
Pulleys 38 guide a cable 40 on either side of barrier 46 with motor 34 providing movement of cables 40 . Barrier guides 42 , 44 are secured to the sides of hollow beams 24 , 26 and allow sliders 41 coupled to barrier 46 to slide up and down.
A pair of barrier supports 48 , 50 are mounted parallel to hollow beams 24 , 26 . The top of barrier supports 48 , 50 are pivotally and slidably linked to beam plates 51 on either side of hollow beams 24 , 26 . Pins 51 c , 51 d project through slots respectively to allow movement of barrier supports 48 , 50 . At the other end of barrier supports 48 , 50 there is attached a slide plate 52 .
Slide plate 52 rests on the top flanges 16 , 18 of I-beams 12 , 14 . Slots 54 , 56 are provided in slide plate 52 and three pairs of rivets 58 , 60 ; 62 , 64 ; 66 , 68 are secured to the top flanges 16 , 18 of I-beams 12 , 14 . Attachment beams 70 , 72 , 74 , 76 are welded to the underside of slide plate 52 . The attachment beams 70 - 76 have attachment points 78 for attachment thereto of links 79 . Links 79 allow pull rods or tension bars 80 , 82 to be connected to ballast 84 by attachment points 86 on ballast 84 . Pull rods or tension bars 80 , 82 have a Z- shaped configuration and can be straightened when tensioned. Pull rods or tension bars 80 , 82 can have a plurality of bends in them to suit requirements and are not limited to the shape shown in this embodiment. Ballast 84 can be any form of weight, for example, a block of concrete, or a plurality of logs located in a framework as shown in FIGS. 1 to 5 . Ballast 84 is located in a trough 88 with the base of the trough 90 being inclined.
In the preferred embodiment barrier 46 includes horizontal ram plates 92 which at each end are slidingly located on barrier supports 48 , 50 through guide holes 94 . A plurality of vertical spacers 96 are welded between—respective horizontal ram plates 92 to provide a strong anti-penetration gate.
The number and position of vertical spacers 96 can be varied to suit requirements. It is preferred that the spacing between horizontal ram plates 92 is closer at a position where vehicle impact would occur. Vertical slats are welded to horizontal ram plates 92 .
In the embodiment shown in FIGS. 6 a to 6 e the ballast 84 has been replaced by a second slide plate 100 which is supported by 12 , 14 .
The second slide plate 100 is similarly affixed to top flange 18 via rivets 60 a , 64 a , 66 a through slot 56 a and corresponding rivets (not shown) and slot (not shown) on I-beam 12 . FIGS. 6 a to 6 e provide a sequential illustration of a vehicle 102 attempting to crash through vehicle barrier system 10 . The operation of the barrier system 10 is also applicable to the embodiment shown in Figs. to 5 .
In FIG. 6 a , vehicle 102 is moving with a velocity as indicated by arrows 106 and front wheels 104 will roll over second slide plate 100 . Barrier 46 will be in the closed position as shown in FIG. 1 . Vehicle 102 will continue to move forward and front wheels 104 will roll over slide plate 52 as shown in phantom lines 108 in FIG. 5 to make contact with barrier 46 . FIG. 6 b shows vehicle 102 having contacted barrier 46 with consequent damage to the vehicle and to vertical slats 98 . The slats 98 will crumple and absorb an amount of impact force. The horizontal ram plates 92 and vertical spacers 96 will also assist in reducing the velocity of vehicle 102 .
Slide plate 52 will be held fast at this time by rivets 58 - 68 , which will be assisted by the weight of vehicle 102 upon slide plate 52 to increase the frictional forces needed to move slide plate 52 .
FIG. 6 c shows that rivets 66 , 68 have been sheared at a predetermined force applied thereto. The force is applied to slide plate 52 through the impact load applied to barrier supports 48 , 50 passed from horizontal ram plates 92 . Slide plate 52 will thus move to the left as indicated by the increasing width of gap 110 between slide plate 52 , the straightening of pull rods 80 , 82 and the bowing of barrier supports 48 , 50 as shown by phantom lines 112 in FIG. 5 . Slide plate 52 will slide along I-beams 12 , 14 to move barrier supports 48 , 50 with it and pivot and move about pins However, hollow beams 24 , 26 will not move as they are fastened to 24 , 26 . The second slide plate 100 will provide resistance to assist in the straightening of pull rods 80 , 82 .
Further dissipation of the vehicle impact will occur when rivets 62 , 64 are sheared at a further predetermined force applied thereto as shown in FIG. 6 d . Gap 110 will widen further and pull rods 80 , 82 will be further straightened. FIG. 6 e shows rivets 60 being sheared to further increase the width of gap 110 . Pull rods 80 , 82 have been fully straightened. The weight and speed of vehicle 102 will determine whether all rivets 58 - 68 will be sheared or whether the impact force is dissipated prior to that occurrence. If vehicle 102 is still not stationary, then the same sequence of shearing of rivets 60 a , 64 a , 68 a , etc will occur for second slide plate 100 . This sequence will not be described, as it will be obvious to the man skilled in the art based on the previous operational discussion.
In the embodiment shown in FIGS. 1 to 5 the second slide plate 100 is replaced by ballast 84 . The operational sequences will be very similar with the resistance of the ballast 84 engaging when rivets 66 , 68 are sheared. In tests the vehicle barrier system 10 has been effective to prevent a 4000-kg (8800lb.) load from entering barrier 46 at 30 The damaged barrier 46 can be readily replaced as hollow beams 24 , 26 are not damaged and the barrier lifting mechanism is on the hollow beams 24 , 26 . It is a relatively simple procedure to replace barrier 46 as barrier supports 48 , 50 can be re-used. The downtime for an attempted intrusion is substantially reduced without compromising safety.
FIG. 7 shows a very similar embodiment to that shown in FIGS. 6 a to 6 e with the addition of a third slide plate 114 . Again third slide plate 114 is coupled to second slide plate 100 by pull rods 80 a and is fastened to I-beams 12 , 14 by rivets 60 b , 64 b , 68 b.
FIG. 8 shows a very similar embodiment to that shown in FIG. 7 with the addition of ballast 84 from the embodiment of FIGS. 1 to 5 . Ballast 84 is coupled to third slide plate by pull rods 80 b.
FIGS. 9 a and 9 b illustrate a further embodiment where barrier 46 is replaced by a pivotal ramp 116 which is attached to slide plate 52 through pivot plates 118 .
Ramp 116 can pivot between a closed or vertical position as shown in FIG. 9 a and a horizontal or open position as shown by phantom lines 120 . The ramp 116 is held in either position by a latching mechanism (s) (not shown) and is biased towards the closed position by springs 122 . There are slide plates 52 , 100 , which are constructed and operate in a similar way to those shown in FIGS. 6 a to 6 e.
Vehicle 102 can drive over ramp 116 when in the open position as indicated in FIG. 9 a but cannot pass when ramp 116 is raised. Ramp 116 can be of any suitable construction to withstand the initial impact by vehicle 102 . This embodiment does not have the hollow beams 24 , 26 . The impact force will be applied to slide plate 52 through the impact load applied to pivot plates 118 rather than barrier supports 48 , 50 passed from ramp 116 . The movement of slide plates 52 , 100 will be the same as that described in FIGS. 6 a to 6 e.
The embodiment shown in FIG. 10 shows barrier 46 being replaced by a pair of swinging gates 124 , 126 . Slide plate 52 will again operate in a similar manner to that previously described in relation to FIGS. 9 a and 9 b.
The embodiment shown in FIG. 11 is similar to the embodiment shown in FIG. 10 with swinging gates 124 , 126 replaced by a sliding gate 128 . Slide plate 52 will again operate in a similar manner to that previously described in relation to FIGS. 9 a and 9 b.
The embodiment shown in FIGS. 12 to 17 b is similar to the embodiment shown in FIGS. 9 a and 9 b . In this embodiment the I-beams are replaced by an anchor plate 130 which is affixed to the ground. A plurality of holes 132 are formed in the ground and are preferably strengthened using concrete. Locking cylinders 134 are pushed through respective apertures 136 in slide plate 52 and locked in place by pins 138 . The locking cylinders 134 are tamperproof as they are located underneath covers 140 and the end of ramp 116 . A pair of tension bars 82 are secured at respective ends to slide plate 52 and anchor plate 130 .
Ramp 116 is pivotally mounted to slide plate 52 through bracing elements 142 .
Bracing elements 142 are notched to grip the vehicle at impact and provide deformation of the vehicle to reduce the speed of the vehicle. A back plate 144 is also pivotally mounted to slide plate 52 and provides additional support to ramp 116 under impact. Again bracing elements 146 are provided to strengthen the back plate 144 . Bracing elements 146 protrude slots 148 in ramp 116 and are coupled to pin 150 which is guided within track 152 on bracing elements 142 . When non-operational, the vehicle barrier system in FIGS. 12 to 17 b is folded into the position shown in FIG. 12 . A vehicle may be easily driven over the vehicle barrier system and it will act basically as a speed hump. The operational position is shown in FIGS. 13 and 17 a with ramp 116 in the raised position. Any unauthorised vehicle will travel in the direction of the arrow shown in FIG. 17 a and ride over covers 140 and hit ram ramp 116 . The impacting of the vehicle is shown in FIG. 17 b and is similar in operation to that of FIGS. 9 a and 9 b with slide plate 52 moving along anchor plate 130 and severing in turn the rivets 60 , 64 , 66 and straightening of tension bars 80 , 82 . The embodiment shown in FIGS. 18 a to 21 is very similar to the embodiment shown in FIGS. 12 to 17 b . In this embodiment a handle 154 is locatable in a tube 156 and has one end located in boss 158 on slide plate 52 . The handle 154 will allow a manual movement of ramp 116 into its raised position as shown in FIG. 20 . By locating the handle in tube 156 , additional strength will be provided to the ramp 116 on impact. Gas struts 160 will also assist in the raising of ramp 116 . An example of a remote activated raising of ramp 116 is also shown in this embodiment. A pair of springs 162 are held in a tensioned condition as shown in FIGS. 19 and 20 . The springs 162 are held by pin 164 coupled to an explosive device 166 . When explosive device is detonated electronically by switch 168 , pin 164 will be released and the tensioned force contained within springs 162 will immediately raise ramp 116 as shown in FIG. 21 . The explosive device 166 can be substituted by any other suitable activation means, for example, solenoid, etc. The impact operation of this embodiment will be the same as the embodiment of FIGS. 12 to 17 b.
The embodiment shown in FIGS. 22 to 24 differs from the previous embodiments by the different positions of the slide plate and tension bars. This embodiment shows a boom gate 170 which is pivotally mounted to support 172 .
Boom gate 170 can be raised manually by handle 174 or electrically through a gear 176 coupled to a gear driven motor means (not shown). A latch 178 is attached at the other end of boom gate 170 and can be locked in position by solenoid 180 . A further support 182 is provided and both supports 172 , 182 are attached to ground anchor plates 184 , 186 which are secured to the ground.
Tension bar 80 is secured to ground anchor plate 184 by brackets 188 and pin 190 whilst tension bar 82 is similarly secured by brackets 192 and pin 194 . The other ends of tension bars 80 , 82 are again secured to supports 172 , 182 by brackets 196 , 200 and pins 198 , 202 . The method of attachment can be varied to suit requirements, for example, direct welding or other means. A pair of fixed plates 204 are also welded to anchor plates 184 , 186 at an angle thereto. Slide plates 206 are attached to both supports 172 , 182 . Respective slots 208 in fixed plates 204 allow slide plates 206 to be held thereagainst by rivets
FIG. 24 shows the operation of the vehicle barrier system of FIGS. 22 to 24 .
When the vehicle 102 impacts with boom gate 170 the supports 172 , 182 will be bent backwards which will cause extension of tension bars 80 , 82 . Further bending of supports 172 , 182 will cause the sequential shearing of rivets 210 in a similar manner to the previously described embodiments.
From the above description of the various embodiments it is evident to the man skilled in the art may make changes to the construction of the vehicle barrier system 10 . Depending on construction constraints slide plate 52 need not be coupled to a further slide plate or ballast. The construction of barrier 46 can be of any suitable type that can withstand a heavy impact. The number and types of slide plates can vary. Similarly, the numbers of rivets can be varied from 1 to any number deemed applicable. The shearing strength of the rivets can be varied or be the same. The preferred embodiments have been described with reference to their use as a gate but the construction is also applicable to doors of buildings.
The invention will be understood to embrace many further modifications as will be readily apparent to persons skilled in the art and which will be deemed to reside within the broad scope and ambit of the invention, there having been set forth herein only the broad nature of the invention and certain specific embodiments by way of example. | The invention discloses a vehicle barrier system ( 10 ) including a barrier ( 46 ) movable between an open position to allow vehicle access therethrough and a closed position which prevents vehicle access therethrough. Barrier ( 46 ) is attached to barrier supports ( 48, 50 ) at either end of barrier ( 46 ) with barrier supports ( 48, 50 ) being secured to a ground engaging slide plate ( 52 ). The ground engaging slide plate ( 52 ) will slide after a predetermined force is applied thereto by vehicle ( 102 ) impact with barrier ( 46 ) to absorb the impact energy of vehicle ( 102 ). |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to provisional application 60/765,900 filed Feb. 6, 2006, the entire contents of which are incorporated herein by reference.
BACKGROUND
In the hydrocarbon exploration and recovery art there is often a need to install control lines of one sort or another on strings being run in the well. Such control lines are generally desired to be connected in some way to the string to avoid damage thereto. While there have been different attempts to by hand or mechanically insert the lines there is much to be desired in efficient and competent installation of the control lines. To this end the art is always in need of alternate means that improve efficiency and reliability.
SUMMARY
Disclosed herein is a system for inserting control lines to a control line receptacle at an alternate path structure. The system includes an upper guide having a path structure engagement roller, a control line insertion wheel and a control line bypass space and further includes a lower guide separate from the upper guide and having a path structure engagement roller and a control line insertion wheel, the path structure engagement roller and control line insertion wheel being resiliently biased to a position calculated to cause control line insertion to said alternate flow path structure when in an engaged position.
Further disclosed herein is a control line insertion tool for inserting control line to a control line receptacle at an alternate flow path structure. The tool includes a frame, a path structure engagement roller in operable communication with the frame, and a handle in operable communication with the frame. The tool further includes a control line insertion wheel in operable communication with the handle and a retention arrangement that in a disengaged position allows movement of the handle relative to said frame and in an engaged position, restricts movement of the handle relative to the frame.
Yet further disclosed herein is a spring biased control line insertion tool for inserting a control line to a control line receptacle at an alternate flow path structure. The tool includes a control line insertion wheel, an alternate path structure engagement roller, a biasing arrangement in operable communication with the wheel and the roller, and the biasing arrangement, and a biasing arrangement in operable communication with the wheel and the roller toward one another.
Also disclosed herein is a method for inserting a plurality of control lines to a control line receptacle at an alternate flow path structure. The method includes separating a plurality of control lines supplied from a remote source, engaging one of the plurality of control lines with a control line insertion wheel of an upper control line guide and urging the engaged control line to the control line receptacle, bypassing at least one other control line of the plurality of control lines with the insertion wheel of the upper control line guide, and engaging one control line of the at least one other control line with a control line insertion wheel of a lower control line guide and urging the one control line of the at least one other control line to the control line receptacle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevation view of a section of tubular having an alternate flow path and a set of guides in an engaged position;
FIG. 2 is the view of FIG. 1 with the set of guides in an unengaged position;
FIG. 3 is a cross-sectional view of the upper guide taken along section line 3 - 3 in FIG. 1 ;
FIG. 4 is a perspective view of the lower guide; and
FIG. 5 is a section view of the lower guide taken along section line 5 - 5 in FIG. 4 .
DETAILED DESCRIPTION
Referring to FIG. 1 , a system for inserting control lines to a control line receptacle at an alternate flow path structure is generally illustrated at 10 . Numeral 12 denotes a tubular upon which an alternate flow path structure 14 is mounted. Tubular 12 may be any type of tubular or even other arrangement but commonly an alternate flow path structure is utilized with respect to a gravel packing apparatus and the tubular therefore is commonly a screen. For the embodiments discussed herein the alternate flow path structure 14 includes a passage 16 , which might be used for a flow of material and at least one control line receptacle 18 (illustrated herein as two receptacles 18 ). The type of alternate flow path structure contemplated herein is similar to that described within U.S. Publication No. 2006/0219404 A1 filed on Jan. 12, 2006, which is incorporated herein by reference. Also visible within FIG. 1 are two control lines 20 and 22 being deposited within the control line receptacle 18 by upper guide (or tool) 24 and lower guide (or tool) 26 . In one embodiment of the system, an upper guide 24 (“upper” is used only for distinctive purposes) inserts a first control line while bypassing a second control line. The second control line is then inserted by a lower guide 26 (“lower” is used only for distinctive purposes). In one embodiment, the upper guide 24 is tethered via tether 28 to a fixed distance structure such as the control line sheave (not shown). Tether 28 maintains upper guide 24 in a longitudinally fixed position but allows for it to move laterally relatively easily. Upper guide 24 is tethered to lower guide 26 by tether 30 to maintain a convenient distance between upper guide 24 and lower guide 26 . In one embodiment it has been determined that less than eighteen inches is a convenient distance for appropriate operability. It should be further noted at this juncture the tether 30 connects to lower guide 26 at a pivot pin 32 . This is important to be noted because if tether 30 is connected at pin 32 the normal frictional drag seen by lower guide 26 along the control line and the alternate flow path structure 14 is effectively translated to additional clamping force of lower guide 26 onto alternate flow path structure 14 . The clamping force and the structure of lower guide 26 will be made more clear subsequently herein when the lower guide 26 is discussed in detail. One further point to be made with respect to FIG. 1 is that upper guide 24 includes a separation pin 34 whose purpose it is to prevent the control lines from crossing over one another prior to insertion. If such crossover should happen, it is possible that the control lines would become crushed during insertion.
Referring to FIG. 2 , tubular 12 will be familiar as will be alternate flow path structure 14 . These have not changed in configuration or location. It will be appreciated that upper guide 24 is illustrated in an alternate position from that of FIG. 1 . It will also be appreciated that lower guide 26 is illustrated in an alternate position from that of FIG. 1 . The positions illustrated for upper guide 24 and lower guide 26 in FIG. 2 are in the open position, which position allows the placement of the guides 24 and 26 over alternate flow path structure 14 prior to engagement therewith. It should be appreciated that control line insertion wheel 36 of upper guide 24 and alternate flow path structure engagement roller 38 are not positioned in engagement with the alternate flow path structure 14 or in contact with control lines 22 or 20 . It should further be recognized that a first control line insertion wheel 40 of lower guide 26 and a second control line insertion wheel 42 of lower guide 26 are not in contact with control lines 20 or 22 in the illustration of FIG. 2 . In order to insert lower guide 26 onto alternate flow path structure 14 , the lack of contact allows the guide 26 to be placed over alternative flow path structure 14 prior to being engaged therewith. It will further be appreciated that the upper guide 24 and lower guide 26 engage the alternate flow path structure 14 differently from each other. Whereas wheel 36 and roller 28 of upper guide 24 are both out of engagement with alternate flow path structure 14 when being installed, lower guide 26 is illustrated with a pair of rollers 44 and 46 already engaged with alternate flow path structure 14 . Only the control line insertion wheels 40 and 42 are disengaged in lower guide 26 . This is because the lower guide 26 operates on a spring principle, which will be discussed hereinafter, when lower guide 26 is discussed in detail.
Turning now to a detailed description of upper guide 26 and referring to FIGS. 1 , 2 and 3 simultaneously, it will be appreciated that upper guide 26 includes a frame 48 upon which are articulated two handles 50 and 52 . Each handle is attached to frame 48 via a pin 54 such as a cap screw and each handle 52 and 50 includes an opening 56 alignable with a through hole 58 in frame 48 through which a release pin 60 may be selectively inserted and retained. In one embodiment, the handles 50 and 52 include an undercut 61 to receive a retention arrangement 62 of release pin 60 . As noted above in the FIG. 2 embodiment, the upper guide 24 is illustrated in the open position whereas in FIG. 1 it is illustrated in the closed position with release pins 60 in place. Upon each handle 50 and 52 and between a location of pin 54 and opening 56 is a wheel retention arrangement 64 . The arrangement 64 , in one embodiment, utilizes a socket head shoulder screw 66 and bearing 68 to pivotally retain control line insertion wheel 36 which comprises a cylindrical portion 70 and a flange portion 72 with a concavity 74 , which concavity is complimentary to a control line such as control line 20 or control line 22 intended to be inserted to control line receptacle 18 by upper guide 24 . It should be pointed out that FIG. 3 illustrates the control line insertion side of upper guide 24 and does not illustrate the engagement roller side of upper guide 24 . The view however would be nearly identical except that concavity 74 would be substituted by a perimeter of flange 72 having no concavity. Cylinder 70 both locates flange 74 to proper location relative to the rest of the guide 24 and provides room for control line bypass in control line bypass area 76 .
As was alluded to above, the upper guide 24 is intended to insert one of the plurality of control lines being mated with alternate flow path structure 14 . In the illustrations herein two control lines are shown however it should be understood that more control lines could be utilized if control line receptacle were sized sufficiently to accept more than two.
Because upper guide 24 inserts only the first control line, there is a significant amount of excess room within receptacle 18 . Therefore, there is no need for upper guide 24 to have any resilience. The pin structure therefore is desirable.
Once the upper guide 24 is closed and the pins 60 put in place upper guide 24 will very effectively insert one of the control lines while allowing a second control line to bypass upper guide 24 in bypass area 76 . The control line that is bypassed by upper guide 24 remains outside of receptacle 18 until encountering lower guide 26 at which time it is inserted into receptacle 18 adjacent the control line that was inserted therein by upper guide 24 .
Turning to lower guide 26 reference is made to FIGS. 1 , 2 , 4 and 5 , simultaneously. Lower guide 26 operates on a spring principle to allow for tolerances in the control lines and the alternate flow path structure. Guide 26 utilizes a bow spring 80 , in one embodiment, that is connected at each end thereof to a lower guide arm 82 and 84 . Spring 80 is connected to the lower guide arms 82 and 84 via bow spring retainer pins 86 which are threadedly received in lower guide arms 82 and 84 . In one embodiment a snap ring which is not visible is placed between the bow spring 80 and the lower guide arms 82 and 84 on the retainer pins 86 to maintain the bow spring and retainer pins as an assembly when the retainer pins are unscrewed from the lower guide arms 82 and 84 , which capability is utilized when control lines 20 and 22 are to be inserted in the opposite side receptacle 18 of path structure 14 from that which is illustrated in the drawings herein. In such case, the lower guide arms 82 and 84 are swapped so that the same function of inserting a control line can be done on the opposite receptacle 18 of structure 14 .
Also mounted upon retainer pins 86 is a lower guide locking arm 88 (there may be one locking arm 88 or two locking arms 88 , as illustrated herein) and a lower guide handle arm 90 . These arms are articulated on the retainer pins 86 and are articulated to each other at pin 32 . The function of the locking arm 88 and handle arm 90 are to urge the bow spring outwardly when it is required to either engage or disengage the lower guide 26 from alternate flow path structure 14 . It will be apparent from FIG. 4 that the locking arm 88 and handle arm 90 are disposed at an angle to one another at pin 32 . If the handle on 90 is urged in a direction to longitudinally align locking arm 88 and handle arm 90 , the distance between retainer pins 86 will grow forcing bow spring 80 to yield and forcing the control line insertion wheels 40 and 42 to grow more distant from engagement rollers 44 and 46 , respectively. In one embodiment, and as illustrated, the angle of handle arm 90 is such that pin 32 will “over-center” when the handle 90 is urged toward pin 86 so that the lower guide 26 will be locked in an open position. The bow spring 80 when in the engaged position provides a resilient clamping force on the remaining uninstalled control line to urge the same into control line receptacle 18 . The distinction between upper guide 24 and lower guide 26 is directly related to the number of control line versus the size of the receptacle 18 . As noted above, upper guide 24 inserts a single control line into a receptacle 18 that is sized to receive more than one control line. Therefore, there is plenty of room for the control line to move in without concern for tolerance stack-up. In the illustrated embodiments herein, however, the receptacle 18 is intended to hold two control lines. Since the lower guide inserts the second control line into control line receptacle 18 tolerance stack-up is indeed an issue and must be considered. In order to avoid potential problems due to tolerance stack-up the lower guide 26 has been rendered resilient so that it can be deflected outwardly should the tolerances grow larger than expected.
Finally and importantly with respect to lower guide 26 , the lower guide arms 82 and 84 are configured to provide specific axis angles for the mounting of the two control line insertion wheels 40 and 42 and the two alternate flow path structure engagement rollers 44 and 46 to ensure that the flanges of each will be positioned appropriately relative to a tangent line 90° to the axis of the wheels and rollers. In order to understand the foregoing, it is useful to identify access pin 92 , roller bearing 94 and wheel 40 , which comprises cylindrical portion 96 , flange portion 98 and concavity 100 . The wheel 40 has a base surface 102 . The angle of this base surface 102 is important relative to the angle of force supplied to the control line being inserted into control line receptacle 18 . In order to optimize the insertion process, it is desirable to provide forced direction vectors both inwardly to the control line receptacle 18 and in a direction toward the tubular upon which the alternate flow path structure is mounted. Utilizing a tangent line as a starting point, which line is defined perpendicular to the axis 92 of wheel 40 , the desired off tangent angle for wheel 40 is between 0 degrees and about 20 degrees inclined toward the base tubular 12 and in one embodiment is about 10° under the tangent. The same is true for engagement roller 44 .
In FIG. 5 it will be easily noticed that the angles of wheel 42 and engagement roller 46 appear to be different from the angles of wheel 40 and engagement roller 44 . This is an optical illusion due to the fact that the alternate flow path structure is helical on the base tubular and therefore the lower guide 26 is essentially helical in configuration which makes for the angle appearance difference. The wheel 42 and roller 46 are positioned within the same range of angles as wheel 40 and roller 44 .
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 system for inserting control lines to a control line receptacle at an alternate path structure including an upper guide having a path structure engagement roller, a control line insertion wheel and a control line bypass space. The system further includes a lower guide separate from the upper guide and having a path structure engagement roller and a control line insertion wheel. The path structure engagement roller and control line insertion wheel are resiliently biased to a position to cause control line insertion to the alternate flow path structure when in an engaged position. A method for inserting control lines is included. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
Provisional Patent Application Ser. No. 60/439,955 Filed: Jan. 13, 2003 Entitled: “DOWNHOLE RESETTABLE JAR TOOL WITH AXIAL PASSAGEWAY AND MULTIPLE BIASING MEANS” For Inventor: RAYMOND DALE MADDEN ODESSA, TEXAS 79761
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
A novel resettable jar tool for use downhole in a borehole for enhancing the retrieval of stuck objects. The stuck object may be part of a tool string that includes the jar tool of this invention. The jar tool can withstand high temperature and other deleterious downhole conditions without significantly reducing the magnitude of the stored energy employed for actuating the jar tool.
The jar tool is resettable as many times as required to dislodge a stuck object by manipulating the operating wireline that allows electronic communication between apparatus connected to the bottom of the tool and the surface by an electrical conductor that extends through the entire jar tool. The jar includes a hammer, anvil and releasable latch device cooperatively interconnected to increase the safety of the tool and to deliver a powerful uphole thrust responsive to wireline tension.
BRIEF SUMMARY OF THE INVENTION
In the art of producing fluid from a borehole, sometime a borehole is drilled fairly straight, sometime it is crooked, or is deliberately slanted. Most boreholes are crooked, thereby tremendously increasing the probability of a string of tools becoming stuck downhole in a borehole. This invention is directed to a wireline actuated jar tool for use in retrieving a stuck downhole tool from a borehole. Hence, it is apparent that the stuck tool string must somehow be unstuck without resorting to placing undue tension on the supporting wireline.
A parted wireline is considered a catastrophe in the oil patch for a costly fishing job is then necessary, and such a delay will be disastrous for any delicate instrument package left downhole long enough to be fried by the bottom hole temperatures. The jar tool of this invention overcomes the necessity of ever applying excessive tension in the wireline that supports the tool string. This is achieved in accordance with the present invention by a resettable, stored energy jar tool system capable of multiplying the tension of the E-line as much as ten fold, as will be more fully appreciated as this disclosure is further digested.
The preferred embodiment of the jar tool of this invention discloses a downhole tool string which includes the downhole jar tool. The jar tool includes an upper member opposed to a lower member with the two members being coupled together by means of a lost motion coupling in a manner to provide axial slidable movement therebetween, whereby the opposed members provide opposed masses that are selectively moved towards and away from one another a distance determined by the lost motion coupling which is attached therebetween.
The lower member of the jar tool is attached to most any desired downhole tool, apparatus, or device, including an instrument package, for example, that might also be insulated from the high temperature formations, while the upper jar tool member is provided with a unique plurality of spaced stored energy chambers therein, whereby a plurality of forces are advantageously added together and made available for creating a powerful upthrust when one member is released from the other and is accelerated responsive the magnitude of the stored energy.
Means are provided for releasing the energy of said stored energy chambers upon demand to effect rapidly accelerating movement of one member respective the other member and thereby propel one said member away from the other member. At a selected length of stroke, an internal part of the tool acts as a hammer with the hammer being positioned to strike another internal part of the tool which acts as an anvil, thereby providing sudden deceleration of a magnitude and direction to accelerate the entire tool string uphole with sufficient thrust to un-stick the tool string when it is stuck down-hole. This action incrementally drives the entire downhole tool string in an uphole direction with a thrust which un-sticks the stuck tool string.
An outstanding feature of this invention is the provision of a longitudinally extending passageway disposed along the central axis of the jar tool and extends from the up-hole tool end, through each of the jar tool members, including the lost motion coupling, where the passageway terminates within the lowermost member of the jar tool and thereby allows for the employment of an insulated conductor within the passageway that continues through the remainder of the jar tool to an instrument package therebelow enabling transmission of important data along the conductor from and to the surface of the earth. Provision is made to eliminate problems associated with change in length of the insulated conductor as the jar tool components are extended in length and then retracted as the jar tool moves from the extended configuration following a jarring action into the retracted standby configuration.
Furthermore, safe protection of the insulated conductor that extends through the jar tool is provided by a through tubing positioned within the recited axial passageway which encloses the insulated conductor so that the conductor is protected, whereby one terminal end of the insulated conductor ultimately is placed into electrical communication with the downhole instrument package, for example, or other tool package, with the opposed terminal end of the conductor being electrically connected to the wireline or other means for data transmission uphole to a surface receiver. Accordingly, the downhole instrument can conduct or electronically transfer various vital information between the instrument package, through the axial conductor within the jar tool, and finally to an above ground facility.
Some instrument packages are extremely valuable, and contain confidential information and design secrets which must be protected from damage as well as from evil plagiarists. Therefore, it is essential that in such a situation, the electronic package must not remain downhole for extended lengths of time because the apparatus must be kept out of harms way. The present invention provides a unique safe guard for such valuable apparatus.
This disclosure further provides means for resetting the jar tool a multiplicity of times to thereby again store energy within spaced energy storing chambers thereof so that the jar tool of this invention can provide a multiplicity of sequential jarring actions that sooner or later result of the jar tool being translocated axially away from the stuck location, dragging along any attached apparatus therewith.
Another outstanding feature of this invention is the provision of a jar tool having multiple sources of energy available to strike the recited anvil with a powerful blow of the hammer, which jointly provide unexpected improvements in jar tools. These forces are realized by the joint action of the E-line tension, and the force derived from the multiplicity of energy storage devices. Further, adjustment means related to the magnitude and timing of the effect obtained from the use of the several stored energy devices is taught herein. Variation in the length of stroke of the two interconnected coacting jar tool parts, the cumulative force available from the stored energy chambers, and the tension required in the E-line to trigger the hammer blow is considered to be within the comprehension of this invention. Equally important is the novel concept and method of extending an electrical conductor through the axis of the jar tool, as well as the unique safety features presented and claimed herein. Other objects and advantages of this invention will be evident from the following description.
Accordingly, a primary object of this invention is the provision of a down-hole jar tool for use in a bore-hole for enhancing the retrieval of stuck objects. The stuck object may be part of a tool string that includes the jar tool. The jar tool is made of suitable alloys which can withstand high temperature and other deleterious down-hole conditions without significantly or unduly reducing the operating efficiency of the jar tool.
Another object of this invention is the provision of a preferred embodiment of the jar tool, having an upper member and a lower member coupled together by a lost motion coupling in the form of opposed members arranged for limited axially slidable movement thereof, whereby the opposed members provide opposed masses that are selectively moved towards and away from one another as determined by the characteristics of the lost motion coupling located therebetween; thereby providing means by which a hammer and an anvil of the jar tool are manipulated to impact one said member against the other member with sufficient force which results in uphole thrust of the members. This action drives the entire downhole tool string in an uphole direction with a powerful upthrust which invariably un-sticks the stuck tool.
A further object of this invention is provision of the above downhole jar tool wherein one said member thereof can be attached within most any desired downhole tool string, including an instrument package, for example, that often will be insulated from high temperature formations while the other said member of the jar tool is provided with a unique plurality of spaced stored energy chambers therein whereby a plurality of forces are advantageously added together and made available for creating upthrust when one impacts against the other, thereby unsticking a stuck downhole tool or tool string in a new and unobvious manner.
A still further object of this invention is the above recited jar tool wherein means are provided for releasing the energy of said stored energy chambers upon demand to effect rapid accelerating movement of one jar tool member respective the other jar tool member and thereby propel one said member away from the other said member in a manner to move both members uphole. At a selected length of stroke, a part of the tool acts as a hammer positioned to strike a part of the tool which acts as an anvil, and thereby provides sudden deceleration having an impact of a magnitude to accelerate the entire tool string uphole with sufficient thrust to un-stick the tool when the tool is stuck down-hole.
Another and still further object of the invention is a jar tool having the provision of a central passageway that lays along the longitudinal central axis of the tool extending from the up-hole tool end to the lowermost tool end and thereby allows for safe protection of an insulated conductor to be placed into communication with a downhole instrument or other package, whereby the downhole instrumentation can conduct and transfer electronically various vital information between the instrument package and an above ground facility.
An additional object of the invention is the provision of means for resetting the tool set forth in the above objects, by manipulation of the wireline tension to thereby again store energy within the spaced energy storing chambers so that the jar tool of this invention can provide a multiplicity of sequential jarring actions.
Still another and further object of this invention is the provision of adjustment means related to the magnitude and timing of the stored energy devices. In particular, the length of stroke of the two coacting tool parts, the force available from selected stored energy chambers, and the tension required in the E-line to trigger the hammer blow is considered to be within the comprehension of this invention.
These and other objects and advantages of this invention will become readily apparent to those skilled in the art upon digesting the following detailed description and claims and by referring to the accompanying drawings.
The above objects are attained in accordance with the present invention by provision of a combination of elements which are fabricated in a manner substantially as described herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a part schematical, part diagrammatical, part cross-sectional representation of a wellbore that produces fluid from a fluid producing strata and discloses the present invention associated therewith in the standby configuration ready to jar;
FIG. 2 is an enlarged, broken or composite view of the tool disclosed in FIGS. 1 and 4 illustrating the proper arrangement of the tool of FIGS. 2A , 2 B, 2 C, 2 D, 2 E, and 2 F;
FIGS. 2A , 2 B, 2 C, 2 D, 2 E, and 2 F, when taken together, set forth an enlarged, detailed, part schematical, part diagrammatical, part cross sectional representation of the invention disclosed in FIGS. 1 , 2 , and 3 ;
FIG. 3 is a part schematical, part diagrammatical, part cross-sectional, side view showing the assembled tool of this invention in the alternate extended configuration;
FIG. 4 is a hypothetical plot illustrating the dissipation of the stored energy of the tool of the previous figures of the drawings during impact of a jar action.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 of the drawings disclose an oil well or borehole 10 within which there is supported a tubing string 12 telescopingly received within a casing 14 . Casing 14 is located within the formed borehole 10 that extends from wellhead 18 at the surface 11 of the earth, through a formation or payzone F, and continues on downhole at 14 , or might instead curve at 14 ′ into another payzone as noted at F 2 , such as is achieved with directional drilling. Casing 14 is perforated in the usual manner at P or P 2 .
A wire line tool string 15 has been run into tubing string 12 contained within casing 14 of borehole 10 on an E-line 17 , a slick line or wire rope having an electrical conductor therein. Sometime the tool may be run into the borehole on the end of any suitable elongate member, such as a suitable conduit or elongate tendon such as a pipe, a sucker rod string, or most any logical support member suitable for the occasion.
Usually, a wire rope 17 having a suitable insulated electrical conductor therewithin, is used for supporting a tool string 15 . A lifting rig 215 can take on any number of different forms and should include a weight indicator connected to determine tension of the wire rope or E-line 17 which is spooled onto a drum 20 with the downhole end of E-line 17 terminating in a rope socket at the up-hole end 21 of a sinker bar 22 of tool string 15 . The insulated conductor is electrically connected to continue through a passageway formed in sinker bar 22 , through a jar tool 16 , made in accordance with the present invention, and to the lowermost apparatus 24 which is supported by the lower end 31 of jar tool 16 , thereby providing transfer of electronic data signals downhole and uphole along E-line 17 that supports tool string 15 .
Sometime borehole 10 is relatively straight, as seen in FIG. 2 . Sometime a borehole is crooked, or is deliberately slanted as illustrated in FIG. 1 . Most boreholes are crooked and this increases the probability of a string of tools becoming stuck downhole in the borehole, as seen illustrated in FIG. 1 at 118 , for example.
The uphole end of the jar tool 16 as seen in FIG. 2A , preferably terminates in a closure that takes on the form of a sub 30 presenting a box end 30 ′ opposed to the downhole end 31 , where various different apparatus, including instrument packages and the like, can be supported. The opposed ends 30 , 31 are easily interfaced with other tools by standard subs in a manner that is known in this art.
FIG. 3 discloses additional details of tool string 15 of FIG. 1 , comprising, commencing at the upper end of FIG. 2 , a wire line or E-line 17 , a rope socket attached at 21 , to a sinker bar 22 , the jar tool 16 of this invention, and an adaptor sub 31 which terminates in attached relation respective any desired tool or instrument package 24 that reasonably can be supported from the lower end 31 thereof.
Still looking at FIG. 3 , sinker bar 22 can be of any desired length, so long as its mass enables resetting jar tool 16 after a jarring action of the jar tool has taken place, thereby enabling multiple sequential jarring actions to be carried out, as will be more fully appreciated later on herein. At the top 30 of jar tool 16 and in underlying relationship respective sinker bar 22 , it will be seen that the diagrammatical representation of the jar tool 16 of FIGS. 2 and 3 has been subdivided into the indicated FIGS. 2A through 2F , thereby enabling the details of each of these assembled Figures to be more fully disclosed on six different sheets of drawing, submitted herewith and forming part of this non-provisional patent application. It should be appreciated that an E-line 17 or equivalent, is connected to a conductor extending axially through sinker bar 22 into communication respective the uppermost end 30 of jar tool 16 , and thereafter the electrical conductor extends axially through jar tool 16 into electrical contact respective the instrument package 24 .
FIG. 2A illustrates the preferred embodiment of the uphole marginal length of jar tool 16 in greater detail. An upwardly opening box end 30 forms the upper end of jar tool 16 and threadedly engages the lower end of the before mentioned sinker bar 22 by using a suitable interfacing sub as may be necessary. An axial passageway 32 extends longitudinally through the entire jar tool 16 , as well as through the sinker bar 22 . Hence numeral 32 indicates the initial part of the annular passageway formed between connector 35 and the connector 42 .
The upper terminal end of a hollow protective tubing 33 is anchored or removably received in close tolerance relationship within connector 142 in order to sealingly accommodate the electrically insulated conductor 34 suitably protected therewithin for providing a source of power to any desired instrument package 24 attached at the lowermost end 31 of jar tool 16 for data transmission from below jar tool 16 uphole to the surface 11 , as previously noted.
Cylindrical insulator 35 provides for attachment of the conductor 34 at terminal end 36 of through conductor 34 . Connectors 37 , 39 are male and female connectors that are telescopingly fitted together and mounted within the enlarged portion 38 of passageway 32 to facilitate assembly of the various threadedly connected tool components of this invention. Seal means (not shown) are suitably seated within the seal grooves 40 and preferably are high temperature o-rings. Chamber 141 formed within the bell shaped member 41 isolates connector 39 therewithin to enable access to connector 39 and to continue through chamber 241 into the next adjacent chamber 51 of FIG. 2C .
In FIG. 2B , axial passageway 32 that accommodates tube 33 continues down through the central axis of jar tool 16 where it is concentrically arranged respective to a larger annular chamber formed between the outside diameter of protective tubing 33 and the inside diameter of the main housing 49 .
Main housing 49 includes a marginal length of the hollow main shaft member 43 reciprocatingly received therein. Looking again now to FIG. 2A together with FIG. 2B , the sealed connection device 142 in chamber 141 seals the working chamber or annulus 146 respective the hollow main shaft 43 . Any number of different seal devices can be used, this example being for teaching purposes in order to enable full comprehension of the disclosure.
In FIGS. 2B and 2C , conductor 34 , tube 33 and axial passageway 32 continue axially through jar tool 16 in order to protect insulated electrical conductor 34 which is coextensive therewith. The illustrated through conductor 34 is protected by suitable insulation which further is protected by the before mentioned through tubing 33 .
The before mentioned hollow main shaft member 43 is threadedly engaged by adjustment nut 44 which is locked thereto by adjustable fastener means as indicated by numeral 45 . The lower end of adjustment nut 44 abuttingly engages the uphole end of the illustrated annular Bellville washer stack 46 having a strong spring or biasing action. Bellville washer stack 46 terminates with the downhole end thereof abuttingly engaging the uphole end of a powerful, fully compressible spring device 47 , with there being a spacer or separator 48 , such as a washer, placed therebetween and separating annulus 149 into stored energy chambers 146 , 147 .
Main housing 49 of FIGS. 2A , 2 B, and 2 C is seen to be sectioned into multiple lengths to facilitate assembly, and are connected together by means of a sub 50 ( FIG. 2C ) through which the before mentioned main shaft member 43 ( FIGS. 2B and 2C ) reciprocatingly extends. Main shaft 43 continues into threaded engagement with respect to an internal shaft connector 51 , which also serves as a guide that is slidably received within main housing 149 , which is considered a continuation of housing 49 .
The tube 33 , positioned within axial passageway 32 , continues through hollow main shaft member 43 and includes insulated conductor 34 therein, all of which continues through main housing 49 , 149 as shown in FIGS. 2A , 2 B, 2 C and 2 D. Note that the upper housing 49 , 149 are positioned above the lost motion coupling 68 of FIG. 2D while the lower housing 249 of FIG. 2E is therebelow, as will be more fully discussed later on herein. The housing 49 as seen in FIG. 2C , is connected to housing 149 by means of a sub halving opposed faces 150 , 250 through which internal threaded bores are formed for threadedly receiving the before mentioned hollow shaft member 43 into threaded engagement with respect to internal slidable connector 51 .
As shown in FIG. 2C , axial passageway 32 continues on through main housing 49 , 149 , sub 50 , internal connector 51 , and axially through the lower spring chamber 154 where it is connected to the releasable latch apparatus 56 , 57 , 156 disclosed in FIG. 2C .
Adjustment nut 52 , as best seen in FIG. 2C , threadedly engages the marginal threaded end 43 ′ of the lower end 43 ″ of hollow main shaft part 43 , while the lower end thereof also threadedly engages internal connector 51 as noted at 151 in FIG. 2C . Internal main shaft connector 51 threadedly engages the uphole end 243 ′ of releasing member 53 ′ and is a continuation of the before mentioned main shaft part 43 . It can be seen that sub 51 is slidably received in a reciprocating manner within the interior of main housing 149 .
In FIGS. 2C and 2D , the upper end of power spring 54 abuttingly engages the lower end of sub 51 as noted by numeral 151 in FIG. 2C , and is contained within the illustrated annular spring chamber 55 . As seen in FIGS. 2C and 2D , the lower end of spring 54 abuttingly engages the upper enlarged end of sleeve 56 , while the opposed circumferentially extending end 356 of sleeve 56 bears against internal shoulder 59 of the main housing. Sleeve 56 can be moved axially within its chamber 154 between spring 54 and shoulder 59 responsive to movement of main shaft 43 . The sleeve has a counterbore forming an interior shoulder at 156 which abuttingly engages a complimentary shoulder 157 formed on enlargement 57 of latch member 60 that is formed at the lower end of main shaft 43 . Hence, lower terminal end 356 of sleeve 56 abuttingly engages shoulder 59 formed internally at 149 on main housing 49 . Enlargement 60 , which is part of latch apparatus 60 , 61 is a continuation of main shaft 43 and forms the male latch part 143 , 156 , 57 , the skirt 356 , and the enlargement 60 at the lower terminal end thereof. Male latch part 60 , when forced into the interior of female latch member 61 of the latch device 60 , 61 , occurs responsive to downhole movement of the main housing which concurrently compresses the before mentioned three spaced biasing or spring members seen in stored energy chambers 149 , 147 and 154 when the tool is reset into the standby configuration, ready to deliver a jarring action. At terminal end 63 of enlargement 60 is a passageway 132 that is a continuation of passageway 32 that slidably receives through tube 32 therewithin, remembering that the tube is anchored to the before mentioned seal 142 , and thereby enables relative movement between main shaft 43 and the through tube 32 while the tube 32 forms a protective housing for conductor 34 . It should be noted at this time that the conductor 34 does not significantly telescope respective to the telescoping tube 32 .
As further seen in FIGS. 2D and 2E , releasable latch apparatus 60 , 61 includes female member 61 made of a multiplicity of radially arranged, circumferentially extending, longitudinally disposed resilient fingers 62 which enlarge at 64 to threadedly engage elongated lower main shaft member 65 while the lower end of main housing 149 threadedly engages a bottom closure member in the form of a sub 66 (see FIG. 2D ). Sub 66 includes guide pin 168 ′ received within a keyway or spline 168 formed on lost motion coupling 68 to maintain closure member or sub 66 of lower housing 249 and sub 66 of upper housing 149 aligned respective to one another as the confronting faces 70 , 71 of the spaced jar tool subs 66 , 69 are moved towards and away from one another, but always remain spaced apart from one another a slight amount after the tool is scoped together for reset, and assumes the illustrated configuration of FIGS. 2D , 2 E following a jarring action and prior to reset. The spaced distance between subs 66 , 69 is the measure of one stroke.
In FIGS. 2E and 2F , sub 69 is seen to include a radially formed longitudinal counterbore that forms blind passageway 73 within which a guide member 72 is reciprocatingly received such that upper terminal end 74 thereof is always spaced from the blind end of the counterbore that forms radial passageway 73 .
As particularly illustrated in FIG. 2E , one end of guide member 73 is affixed to a pressure differential traveling piston 174 . The piston has seal grooves 75 suitably formed thereon, thereby isolating chambers 76 , 77 from one another as fluid enters and leaves through the ports 78 , thereby isolating chamber 77 from well fluids while subjecting chamber 76 , to the hydrostatic head of the well fluids.
Chamber 77 is filled with a non-compressible, non-conducting mineral oil to reduce the likelihood of well fluids contaminating the electronic components of the jar tool.
Accordingly, piston 74 moves in low friction relationship respective the interior of main housing 249 and the exterior surface of through tube 32 through which conductor 34 extends, thereby avoiding contamination of the interior of tube 32 .
Conductor 34 , as shown in FIG. 2E , is formed into a looped or serpentine configuration as indicated at numeral 80 , allowing the feed through wire tube 32 to move along the central axis of the jar tool while always having slack at 80 in order to accommodate undue wire tension during reciprocation of tube 32 within main shaft member 43 , noting that tube 32 reciprocates concurrently respective sub 49 seen at the anchor seal at the upper end of the jar tool. Enlargement 81 forms a stop member on the interior of main housing 249 for limiting travel of piston 74 in the unlikely event of leakage of well fluid thereinto.
In FIG. 2F , the lowermost end of conductor 34 is received by electrical connector 82 and continues through lowermost sub 83 that forms the lower terminal end of jar tool 16 and thereby enables jar tool 16 to be connected to any desired apparatus at threaded end 283 . As further seen in FIG. 2F , a connector 84 is received within enlarged axial counterbore 85 for conducting current flow at 86 to and from the illustrated instrument package 24 . Seals 87 and 88 prevent entry of fluid into the lower end of jar tool 16 .
FIG. 4 illustrates a hypothetical analyses of the action of jar tool 16 during one jar action. Curve 4 is a plot of he wire line tension commencing with the tool static, hanging free within the in borehole. Curves 1 - 3 illustrate the upthrust realized from each of the three spring or stored energy chambers. The remaining curve that reaches 1,000 pounds is the sum of curves 1 - 4 .
Characteristics of curves 1 - 3 can be modified by various changes to the tool as set forth herein, and this, of course, results in a modification of the 1,000 pound curve. In actual practice, it is possible to develop approximately 3,000 pounds upthrust with this embodiment of the invention.
IN OPERATION
In operation, the assembled jar tool 16 is adjusted or set to be actuated at a predetermined fraction of the maximum tensile strength of the E-line. For example, if the E-line breaking strength is 1,000 pounds, the operator may elect to adjust the release tension of the tool latch 61 to be triggered by an uphole force of 200-300 pounds, as read on a weight indicator. This is the force required for the E-line to trigger or pull the male end 60 from the female end 62 of the releasable latch member 60 , 61 . Resetting the tool for subsequent jar actions requires a downhole force applied to the upper end of the jar tool, similar to the releasing force, depending on the design of releasable latch member 60 , 61 . Hence, sinker bar 22 must be of a weight greater than the releasing value of latch 61 in order to be on the safe side. Those skilled in the art know to consider the entire weight of the E-line and tool string when viewing the weight indicator at the surface.
Adjusting nut 52 should be set by the shop technician who should make certain that latch means 61 is also adjusted into proper position respective sleeve 56 , and reduced diameter passageway at 349 , at this time by properly spacing out the component parts of the jar tool. Adjusting nut 44 , located immediately adjacent the upper stored energy or spring chamber 146 , is rotated or set for minor adjustments in the field. This action gains the desired releasing value of latch assembly 61 and is realized through trial and error while studying the situation using a suitable weight indicator for accuracy.
The adjustments of nut 44 pre-loads the three spring chambers of the upper spaced spring chambers which in turn places a continuous uphole force on male member 60 of releasable latch assembly 60 , 61 . Accordingly, this action commences a releasing action which is somewhat analogous to the action of the E-line as the release tension force is applied.
The complex action of the jar tool is easily comprehended when it is appreciated that the operating mandrel or main shaft 43 extends from enlargement 43 ′ located at the upper extremity thereof and extends through first spring chamber 146 , through second spring chamber 147 , through sub 50 , adjustment nut 52 , and operating chamber 152 , where it is joined to the threaded internal connector 51 , continues through the third and lowermost spring or energy storage chamber 154 , and terminates as the illustrated male part 60 of releasable latch device 61 . The main shaft 43 therefore can be forced to slide axially between the limits provided by opposed confronting faces 151 , 252 and 250 , 152 within chamber 350 .
In FIG. 2D , hammer 166 and anvil 165 are illustrated in the impact position.
Male release member 60 together with female latch member 61 are unique in that it cooperates with the third spring chamber 55 in several different manners. Note sleeve 56 is slidably received within the third spring chamber 154 and has an enlargement 156 thereon that abuttingly engages power spring 54 as well as the enlarged diameter part 349 that forms shoulders 59 , 59 ′ formed on an inner limited length of main upper housing 149 . Also note enlarged member 57 on latch member 60 that is also part of the main shaft 43 and engages member 156 at shoulder 157 . Further, sleeve 56 has a downhole end 58 that abuttingly engages shoulder 59 of outermost housing 249 . The third spring 54 biases sleeve 56 downhole while abutting internal slidable connector 51 to thereby provide part of the stored energy for contributing to the upthrust of main body 49 together with the other biasing means or stored energy devices of this disclosure. Hence, sleeve 56 is always biased or urged downhole against shoulder 59 by adjacent spring 54 as shown, except when main upper housing 149 moves downhole towards lower main housing 249 during reset. In order for connected or engaged latch assembly 61 to telescope into smaller diameter chamber 260 , the latch parts 60 , 61 must be fully engaged while they are within the large diameter latch chamber 261 , because the latch assembly 61 cannot be reset nor released once it is positioned within small diameter chamber 169 , due to the relative diameters of the coacting members.
The latch 60 telescopes into chamber large diameter bore that forms chamber 261 where latch parts 60 , 61 have ample room to expand into latched engagement, while they are within the large part 349 of the latch chamber. Hence the latch cannot be set nor released once it is positioned within small diameter bore 349 of chamber 260 .
Those skilled in the art having digested this disclosure will appreciate that the lower main housing of the jar tool, when stuck or otherwise held stationary, while the upper box end 30 is forced downward respective thereto, the lost motion coupling 68 telescopes into closure member or sub 66 , while the anvil 65 is repositioned further towards the upper tool end as the main housing descends, thus moving the latch means and anvil uphole away from hammer 166 concurrently with the separation of faces 70 , 71 , respectively, of the confronting subs 66 , 69 while at the same time moving enlargement or anvil 65 along with the female latch part 61 into the latched position, which occurs only in the large diameter latch chamber. Accordingly, confronting faces 70 , 71 of the main chamber members are brought into proximity of one another, but preferably, they always remain slightly spaced apart.
At this time, main housing 49 connector sub 50 contacts nut 52 , thereby forcing main shaft 43 downhole which compresses each spring associated with the three spring chambers 146 , 147 , 155 and latches members 60 , 62 together.
During this movement, the male latch part 60 is telescopingly received within the resilient fingers 62 of the female member of the latch device 61 as the female part 62 encapsulates the downwardly moving male part 60 of the latch device 61 , 61 . Simultaneously with this action, energy is stored within the three spring chambers.
In addition to the ability to preload the various springs by addition of spacers and the like, the adjustment means 44 near the upper end of the main shaft as well as the other adjustment means 52 located within chamber 53 between sub 50 and internal slidable connector 51 are adjusted to control the required tension in the E-line for triggering the release of latch 60 , 61 . It should be noted that the uphole enlarged terminal end of main shaft 43 is always spaced from anchor and seal means 42 as shown to prevent impact therebetween. Further, nut 44 , when torqued one turn 360 degrees against spring device 46 , preloads both the first and second spring devices with the equivalent of 50 pounds wireline tension, and consequently places an uphole force on male member 60 of the releasable latch device, thereby providing a means by which the tension in the E-line for releasing the latch device can be selected in the field.
When adjusting nut 52 is moved along threaded surface 53 ′, the length of the jarring stroke is changed, while at the same time should the adjusting nut 52 be torqued against the downhole face of sub 50 , this action will force male part 60 further into female part 61 of the latch device while pre-compressing the springs in all three stored energy chambers. Further, it should be noted that latch device 60 , 61 can always be set into the latched position so long as the parts are properly spaced out to provide for the before mentioned adjustment.
In one embodiment of the invention, for example, the adjusting nut 44 increased the line tension 50 # for each full rotation of the nut. | A wireline jar tool delivers instrument packages into wellbores and retrieves tools when they get stuck. The jar has several stored spring chambers connected to accelerate an upper spring chamber away from a stuck lower carrier chamber that supports instrument packages. Wireline tension actuates the jarring action and then lowers a sinker bar for reset as many times as required to incrementally jar the un-stick fish uphole. The wire line connects to a conductor that extends inside the tool through a main operating shaft, release coupling, hammer and anvil, lost motion coupling, into the lower chamber where the end connects to the instruments for communication to the surface. A small wireline tension provides unexpected large impact forces. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] This invention relates building insulation products generally, and more particularly to a thermal insulation material for use in combination with spray foam thermal insulation for insulating wall spaces in residential and commercial buildings.
BACKGROUND OF THE INVENTION
[0002] Insulation products, such as fiberglass insulation, are widely accepted for residential and light commercial construction. The insulation products are made in a variety of configurations tailored to facilitate installation in specific locations. For example, in the United States, insulation batts or rolls are often installed in wall cavities between 2×4 or ×6 studs. In many applications, this insulation technique does not reach its optimal thermal performance due to air infiltration through the cladding, sheathing and into the insulation material.
[0003] One option to correct this problem is the use of a vapor-permeable water-resistant barrier, commonly referred to as “housewrap,” such as Tyvek® brand housewrap. While this material can help prevent air infiltration and control moisture, it can also be very costly.
[0004] Alternatively, a thin coating of a spray-on polyurethane coating can be applied to the inside surface of the exterior sheathing. This coating results in a spray-foam of from about ½-inch to 1½-inch thick. Using a closed-cell polyurethane foam effectively seals the exterior sheathing against all air infiltration. The foam also has a perm value of from about 0.5 to about 1.0, which almost eliminates the movement of water vapor through the wall. In addition to sealing, the closed-cell foam provides an increased R-value on the order of R-6.0 to R-6.5 per inch, as compared to the R-3.7 per inch typical of low-density fiberglass batts. After application of this thin foam coating, the remainder of the cavity is filled with a standard R-11/R-13/R-15 batt (for 2×4 studs) or an R-19/R-21 batt (for 2×6 studs).
[0005] The problem with this technique is that the presence of a foam layer within the wall space reduces the total space available for fitting the insulation blanket or batt. Insulation blankets and batts are normally manufactured so that their thickness is exactly the same as the distance between the exterior and interior wall sheathings, so as to maximize the thermal insulating potential of the space and to prevent bulging of the inner sheathing (e.g. wall board such as Sheetrock® brand wallboard) which could occur if the blanket/batt were thicker than the wall space. For insulation materials that are compressed for packaging and transport, the manufacture of the insulation rolls and batts is tightly controlled to ensure that their thickness recovers to exactly the design thickness on site. As a result, when a layer of spray-on foam is added to the inside surface of the exterior sheathing, the insulation blanket or batt must be forced into a space that is smaller than the space it was designed to fill. This can lead to a decrease in overall R-value of the insulation blanket or batt, and can also cause the interior walls to bulge between the studs, since the blanket/batt must be compressed in order to fit it completely within the wall space. Additionally, for homes in which the inner sheathing is glued onto the studs, this compression can cause the sheathing to separate from the studs, which can lead to bulging, cracking, etc. of the inner wall sheathing or of the joints between sheathing panels.
[0006] Accordingly, there is a need for insulation system that provides the combined benefits of spray-on foam and standard insulation blankets or batts, and which fully exploits the insulating properties of the blanket/batt, while preventing bulging or non-union of inner wall sheathing that can occur with current designs.
SUMMARY OF THE INVENTION
[0007] An insulation system for insulating a wall space is disclosed. The system can comprise a foam layer having a first thickness, and an insulation mat overlying the foam layer. The insulation mat can have a second thickness corresponding to an uncompressed condition of the insulation mat. The insulation mat and foam layer can be configured for installation within a space defined by a plurality of structure members, where the distance between first and second of the plurality of structure members is substantially equal to the sum of the first and second thicknesses.
[0008] A reduced size insulation product is disclosed comprising an insulation mat having a width and a thickness. The mat can be configured for installation between a plurality of structure members, where first and second of the plurality of structure members are separated by a space width, and third and fourth of the plurality of structure members are separated by a space thickness. The insulation mat thickness can be smaller than the space thickness by a first predetermined amount, the first predetermined amount corresponding to a thickness of foam insulation material disposed adjacent at least one of the plurality of structure members such that when the insulation mat is completely disposed between the plurality of structure members the insulation mat is substantially non-compressed.
[0009] A method of insulating a building space is disclosed. The method can comprise providing a first structural surface; applying a first insulation material to the first structural surface; applying a second insulation material over the first insulation material; and applying a second structural surface over the second insulation material to enclose the first and second insulation materials between the first and second structural surfaces without compressing the first or second insulation materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings illustrate preferred embodiments of the invention so far devised for the practical application of the principles thereof, and in which:
[0011] FIG. 1 is a partial perspective view of the insulation system of the present invention;
[0012] FIG. 2 is a top section view of the insulation system of FIG. 1 ;
[0013] FIG. 3 is a side view of the insulation system of FIG. 1 ;
[0014] FIG. 4 is a cross section view of an exemplary insulation mat for use in the insulation system of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0015] This invention is directed to insulation materials for use in insulating wall spaces of residential and commercial buildings. Insulation systems for use within the walls of buildings typically comprises a blanket or batt of thermal insulation material disposed between adjacent wall studs and between the inner and outer wall sheathing. Often, to improve insulative properties of the wall, a “house wrap” such as Tyvek® housewrap is installed on the outer surfaces of the outer wall sheathing to provide a barrier to wind entering the house through joints, seams or gaps in the house structure, as well as through permeable building materials used to construct the walls. Similar wind-resistance can be provided by a spray-on foam applied internal to the inner surface of the outer wall sheathing, and to the adjacent studs. This foam can provide multiple benefits, including increased insulative properties (inherent in the foam itself), decreased air permeability, and increased wall racking strength. One problem with using such foam with normally dimensioned thermal insulation rolls or batts is that the combined thickness of the foam and insulation material will inevitably be greater than the space between the inner and outer wall sheathing. Thus, the interior walls can be caused to bulge, impacting the aesthetics of the affected room.
[0016] In accordance with the Figures, and particularly FIGS. 1-3 , there is shown an insulation system 10 for insulating a wall space in a typical residential or commercial building. The system 10 can comprise an insulation mat portion 20 and a spray-applied foam portion 30 . The mat portion 20 and foam portion 30 are disposed between a pair of adjacent wall studs 40 a, b and between the inner and outer wall sheathings 50 , 52 to insulate the wall space. The insulation mat and foam portions 20 , 30 may have respective thicknesses “MT,” “FT” and the mat portion may also have a width “MW.”
[0017] In one embodiment, the foam portion 30 is a spray-applied foam, and is sprayed onto the exterior wall sheathing 52 to a desired thickness. The foam 30 is also applied to fill the seam between the wall studs 40 a, b and the exterior sheathing 52 to eliminate potential pathways for air infiltration. In an alternative embodiment, the foam portion 30 is applied to cover the inner surfaces of the wall studs 40 a, b to provide a U-shaped layer of foam within the wall cavity. Covering the wall studs with foam will provide increased structural stability to the wall (i.e. racking strength), as previously noted.
[0018] The insulation mat 20 may comprise a high or low density insulation material, formed from organic fibers such as polymeric fibers or inorganic fibers such as rotary glass fibers, textile glass fibers, stonewool (also known as rockwool) or a combination thereof. The insulation mat can comprise insulation boards, such as duct boards, insulation rolls or batts and acoustic insulation. Mineral fibers, such as glass, are preferred. Referring to FIG. 4 , the insulation mat 20 can include first and second major surfaces 22 , 24 and longitudinal side portions 23 , 25 . In some embodiments, a facing layer 27 , which may be a cellulosic paper, typically formed from Kraft paper, coated with a bituminous adhesive material, such as asphalt, polymeric resin, or polymeric film, such as LDPE (low density polyethylene), or a combination of these materials, is provided on one major surface 22 of the mat portion 20 . Other examples of facing layer 27 materials which can be bonded to the mat include (1) thin polymer films (PE (polyethylene), PA (polyamide)) and (2) FSK (foil-scrim-kraft). FSK is used mainly in commercial applications with more stringent fire safety requirements.
[0019] The insulation blanket or batt component 20 may include a pair of optional side tabs 28 and 29 that can be fastened to the wall studs 40 a, b , for example. Various known configurations for side tabs or flaps 28 and 29 are known. Alternatively, there may be no tabs on the Kraft facing. Further, the facing layer 27 may be water vapor impermeable or permeable, depending on the intended use.
[0020] In an exemplary embodiment, the mat portion 20 is a low density mat or batt formed from glass fibers bound together with a thermoplastic or thermosetting binder, such as nylon fibers, or heat cured binder, such as known resinous phenolic materials, like phenolformaldehyde resins or phenol urea formaldehyde (PUFA). Melamine formaldehyde, acrylic, polyester, urethane and furan binder may also be utilized in some embodiments. The insulation is typically compressed after manufacture and packaged, so as to minimize the volume of the product during storage and shipping and to make handling and installation of the insulation product easier. After the packaging is removed, the batt insulation product 20 tends to quickly recover to its prescribed thickness for insulation.
[0021] The foam component 30 can comprise any of a variety of spray-applied foam materials having either open and closed cell structures, and preferably, a spray-applied foam. Closed cell foams are preferred to open cell foams because they typically have a higher R value, they can provide a better barrier to air and moisture infiltration, and they are more resistant to absorbing moisture compared to open cell foams. Closed cell foams also are of higher density than open cell foams, and they can provide greater increases in the racking strength (described in more detail below) of the wall as compared to open cell foams. Furthermore, closed-cell foams provide good toughness, and the thickness at which they are applied is well controllable (i.e. they don't undergo extreme expansion when they are applied, and they can be applied to a specified thickness ±¼-inch).
[0022] Positioning the foam layer 30 between the exterior wall sheathing and the insulation mat 20 also prevents moisture from accumulating in the mat 20 .
[0023] As noted, an additional benefit to providing a foam layer as described is that it can increase the “racking strength” of the wall structure, which is a measure of the strength of a wall when subjected to shear loading. The use of closed cell foam material in particular may improve racking strength of the wall sufficiently to allow the builder to utilize thinner stiffening materials in other areas of the wall structure, thus reducing overall material costs for the structure. For example, where current regulations require the use of thick plywood sheeting at the corners of the structure, using closed cell foam as previously described may enable the use of thinner plywood or other lower cost materials, such as foamboard, on the corners, reducing building costs.
[0024] Additionally, using closed cell foam can also allow the builder to forego installing expensive house wrap materials, such as Tyvek®, and may instead using standard building paper (e.g. kraft paper) for wrapping the house, or may forego wrapping the house entirely.
[0025] One preferred foam material is a closed-cell spray applied polyurethane foam insulation material manufactured and sold by ComfortFoam®, which is a division of Foam Enterprises, Inc., 13620-A Watertower Circle, Minneapolis, Minn. 55441-3787. This polyurethane foam can be supplied in a two-component form which is mixed at the work site and applied using a spray gun.
[0026] Although closed-cell foams are preferred, open-cell foams can also be used as appropriate. Open-cell foams are less resistant to air or wind infiltration and they generally have lower R values than closed-cell foams. As such, they may be appropriate for use in temperate climates, where lower R values are acceptable, and where a high degree of resistance to air and moisture infiltration is not required.
[0027] Foam materials other than polyurethanes can also be used, as appropriate. For example, thermoset foams such as polyisocyanurate, and phenolic can be applied in the wall cavity. Thermoset foams, requiring a resin and catalyst can be mixed onsite via spray mixing or liquid mixing and pouring. Thermoplastic foams such as polystyrene, polyethylene, and polypropylene can also be used. Thermoplastic foams, while generally impractical to foam in place, may be applied in either monolithic form or in particulate form bonded together by an adhesive. Furthermore, although the foam material has been disclosed as being a spray-applied material, pour-applied foam materials could also be used for the foam portion 30 of the invention. Additionally, foam layers or films, with, or without, adhesive backing layers, could be employed.
[0028] In one embodiment, the insulation mat portion 20 is a mineral wool insulation, and the foam portion 30 is a closed-cell polyurethane spray-applied material. In this embodiment, the thickness of the wall space may be about 3½ inches. Thus, the thickness of the foam portion 30 may be about ⅛-inch to about 2½-inches, preferably about 1-inch, and the thickness of the insulation mat portion 20 may be 3½ inches to about 1 inch, preferably about 2½ inches. Likewise, the width of the wall cavity may be about 14½ inches, such that the thickness of the foam portion 30 may be about ⅛-inch to about 1-inch, preferably about ½-inch on either side, and the width of the insulation mat portion 20 may be about 13½ inches. Thus, a 2½-inch insulation mat 20 may be rated at R-10, and the 1-inch foam portion 30 may be rated at R-6, resulting in a system insulation rating of about R-16. This is substantially greater than the insulation rating obtainable where a 3½ inch thickness of insulation material alone is used to fill the space. It is noted that the actual insulation rating of the system will be slightly greater than R-16 if the studs are coated with a ½-inch layer of foam 30 because this ½-inch thickness will run the entire thickness of the wall space, providing ½-inch thick slices of R-6 material running along each side of the mat 20 .
[0029] It is noted that the foam and insulation materials can be provided in any desired width and thickness FT, MT, MW, as long as the combination of the respective dimensions is substantially equal to the width and thickness of the wall cavity to be insulated. The proportional thickness between foam and insulation batt/roll can also be varied, depending on the desired thermal performance and installed cost targets for the system. In practical application, the insulation mat portion 20 will be provided with external markings on the facing layer 17 that indicate the appropriate thickness of foam 30 to be applied to the wall cavity, and whether the foam should be applied to both the external sheathing 52 and studs 40 a, b , or to the external sheathing 52 alone. The indicated thicknesses will correspond to the reduced thickness (and optionally width) of the insulation mat 20 to which the markings are applied. Thus, the foam thickness FT can be from about ½-inch to about 1½-inch, depending on the associated mat thickness MT and the dimensions of the wall space.
[0030] In addition to the above mentioned advantages, using the disclosed arrangement provides the additional benefit of preventing waste by optimizing the insulative properties of each component in the system 10 . With prior techniques, a 1-inch thick layer of foam insulation would typically be applied within a wall space having a 3½ inch clearance between the interior and exterior sheathing 50 , 52 . A 3 1 / 2 inch thick insulation mat would then be forced into the wall space, compressing the mat by about 1-inch in thickness to conform it to the available space. As a result, a portion of the R-value of the insulation mat would be wasted (e.g. under a 1-inch compression an R-13 mat would be reduced to about R-11). This waste would also occur where foam material is applied to the studs, thus requiring a typically sized batt to be compressed laterally in order to fit it into the wall space. As previously noted, compressing the mat also results in an increased likelihood for bulging of the interior wall sheathing or non-union of the sheathing with the wall studs (where the sheathing is glued to the studs). With the inventive system, such waste, bulging and non-union is eliminated.
[0031] It is expected that the insulation system 10 will be sold as a multi-component system having an insulation mat portion 20 and a spray-applied foam portion 30 . The insulation mat portion 20 will be labeled with the R-value of the ultimate mat/foam combination, and will also specify the appropriate type and thickness of foam 30 to be applied to the wall space. This, in combination with the reduced thickness (and optionally the reduced width) of the mat 20 is expected to minimize the chance that the installer could use the mat 20 in an unintended manner (i.e. without the foam).
[0032] In use, the installer can unpack the insulation mat 20 component from its package and allow it to decompress or “recover” to its design thickness. The wall space, comprising the exposed surfaces of the exterior wall sheathing 52 and wall studs 40 a, b can be prepared by removing construction debris or loose dirt (note that this preparation step may not be required, since spray foam is expected to adhere well to the wall space even if debris or dirt are present), etc., followed by the spray application of a layer of closed-cell polyurethane foam 30 to the inner surfaces of the wall sheathing 52 , and depending on the dimensions of the insulation mat 20 , to the inner surfaces of the wall studs 40 a, b . The foam 30 should be allowed to cure thoroughly, whereupon the mat 20 may be cut to length and fit within the wall space, snugging it up against the foam layer 30 .
[0033] Although it is preferred that the foam be allowed to cure prior to the application of the insulation mat, it is also possible to engage the mat 20 with the foam layer 30 while the foam is still wet. This may be advantageous because it adheres the mat to the foam, thus ensuring that there will be no gaps between the two. Such adherence may not be necessary with the present invention, however, because the close and careful dimensioning of the foam layer 30 and the mat 20 will ensure continued long term contact between the two without substantial air gaps. Furthermore, allowing the foam to dry thoroughly prior to application of the mat 20 is preferable to a “wet foam” fit-up method because it ensures proper curing of the foam.
[0034] As previously noted, closed cell foams can be applied to fairly close tolerances due to the fact that they do not undergo substantial expansion upon application. However, if too great a thickness of foam is applied, the foam can be shaved to reduce the thickness to the appropriate amount. This can be done rather easily if the shaving or trimming is performed within about an hour after spraying. Greater difficulty in shaping the foam will be encountered, however, if the foam is allowed to cure for several hours first, due to substantial hardening of the foam as it cures.
[0035] Accordingly, it should be understood that the embodiments disclosed herein are merely illustrative of the principles of the invention. Various other modifications may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit and the scope thereof. | A reduced thickness and/or reduced width insulation product is provided for use in combination with spray-on foam insulation. The insulation product is configured to be inserted into standard-size spaces between adjacent wall studs to which a spray-on foam insulation has been applied. The reduced size of the insulation product is specifically designed so that the combined width and thickness of the insulation product and the spray-on foam insulation fill the entirety of the building space, but do not overfill the space. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The invention relates to a home appliance door, for example a home chiller appliance door, and to a method for assembly of a home appliance door.
From the prior art a home appliance door is already known. The home appliance door comprises a door unit having an inner wall and an outer wall. A decor panel is located on the inner wall, in an assembled state. The main function of the decor panel is to improve the design of the inner wall of the door unit.
SUMMARY OF THE INVENTION
An objective of the invention is, in particular, to provide a home appliance device with improved characteristics regarding a user convenience. This objective is achieved, according to the invention, while further implementations and further developments of the invention may be gathered from the dependent claims.
A home appliance door, for example a home chiller appliance door, is proposed, comprising: at least one door unit having an outer wall and an inner wall which in particular encompass at least one interior space which is at least partly and preferably at least mostly filled with insulation material; and at least one covering element which at least partly or at least mostly or by considering tolerances completely covers at least one feature of the inner wall.
By a “home appliance door” is in particular to be understood a door of a home appliance device and/or of a home appliance. By a “home appliance device” is in particular to be understood at least a portion, preferably a sub-assembly group, of a home appliance. The home appliance is in particular provided for storing and preferably tempering victuals such as beverages, meat, fish, vegetables, fruits, milk and/or dairy products in at least one operating state, advantageously for the purpose of enhancing a keepability of the stored victuals. For example, the home appliance is embodied as a home chiller appliance, which is in at least one operating state configured for cooling victuals. The home chiller appliance could in particular be embodied as a climate cabinet, an ice-box, a refrigerator, a freezer, a refrigerator-freezer combination and/or a wine cooler. However, the home appliance could also be embodied as a home appliance for warming and in particular for cooking victuals, e.g. an oven and/or a steamer and/or a microwave. Alternatively, the home appliance could also be embodied as a home appliance for cleaning, e.g. a washing machine and/or a dryer and/or a dishwasher. The home appliance may in particular comprise at least two, in particular at least three and preferably at least four home appliance devices.
A “door unit” is in particular to be understood as a unit which is, in at least one assembled state, connected to an appliance body in a movable and in particular swiveling fashion and which at least partly defines, in at least one operating state, at least one storage space. In at least one operating state the door unit in particular defines the storage space together with the appliance body. The door unit in particular comprises at least one seal, which is in particular provided for sealing at least one gap between the inner wall and the appliance body in at least one operating state. The door unit itself, in particular without the covering element, is in particular sufficient for closing at least one storage space and/or for sealing at least one gap between the inner wall and the appliance body. The door unit can, for example, at least partly comprise at least one stamped part and/or at least one stamped portion. Alternatively and/or additionally, the door unit can for example comprise at least partly one thermoforming part and/or at least one thermoforming portion.
The appliance body is in particular part of a home appliance device, which in particular also comprises the home appliance door. An “appliance body” is in particular to be understood as a unit at least partly defining at least one storage space and in particular defining the storage space at least substantially together with at least one home appliance door. In particular, the home appliance device comprises, in at least one operating state, the home appliance door. The appliance body and the home appliance in particular define the storage space in at least one operating state at least substantially and preferably by considering tolerances completely. The appliance body in particular comprises at least two, in particular at least four and preferably at least five walls. The walls in particular delimit the storage space. The walls may in particular be embodied as a lateral wall and/or as a rear wall and/or as a bottom wall and/or as a top wall. The appliance body in particular has two lateral walls, preferably opposite each other, one rear wall, one bottom wall and one top wall, which is preferably situated opposite the bottom wall.
In at least one operating state, the inner wall of the door unit is in particular located facing the storage space and/or the appliance body, in particular the rear wall of the appliance body. In at least one operating state, the outer wall is in particular located facing a user. In at least one assembled state, the inner wall and the outer wall are connected and/or fixed to one another, thereby in particular defining at least one interior space. The interior space is, in at least one assembled state, in particular at least partly and preferably at least mostly filled with insulation material. The inner wall and/or the outer wall can for example be in particular at least partly thermoforming parts/a thermoforming part.
The term “at least mostly” with reference to an object is in particular to mean by more than 50% or more than 65% or by more than 80% or by more than 95% of that object, in particular of a surface area and/or of a volume and/or of a mass of the object. An “operating state” is in particular to be understood as a state in which the storage space is closed and an access to the storage space is prevented, in particular by the door unit. In the operating state, the door unit and the appliance body are in particular located with respect to one another in a manner with a maximum contact area.
A “covering element” is in particular to be understood as an element having the main function of covering at least one feature of the inner wall. For example, the covering element can in particular have at least one further function which is of less priority than the main function. The main function of the covering element is in particular the reason for using the covering element. An element covering at least one feature of the inner wall and having a main function that differs from covering at least one feature of the inner wall is in particular not to be understood as a covering element. The covering element can for example be in particular at least partly a stamped part. In particular, the covering element differs from at least one door bin and/or shelf.
The term that the covering element “at least partly” covers at least one feature of the inner wall is in particular to mean that the covering element covers more than 50% or by more than 65% or by more than 75% or by more than 85% of the feature of the inner wall.
In this context, “configured” is in particular to mean specifically programmed, designed and/or equipped. By an object being configured for a certain function is in particular to be understood that the object implements and/or fulfills said certain function in at least one application state and/or operating state.
By means of the invention, in particular a high level of convenience for a user can be provided. Features of the inner wall and/or located on the inner wall can in particular be covered in an easy and/or cost-saving manner. The home appliance door and in particular the covering element can in particular be used for several and preferably for any brands. It is in particular possible to change the design of the covering element in an easy manner, in particular just using different types of material and/or coloring, thereby in particular creating different designs for different brands and/or types of home appliance doors.
Further, it is proposed that the covering element is embodied as a covering plate. The covering element has in particular at least one longitudinal extension and at least one transverse extension, which are at least 5 times or at least 10 times or at least 20 times or at least 50 times larger than at least one thickness of the covering element. In this context, a “longitudinal extension” of an object is in particular to be understood as an extension of the longest side of an imaginary smallest rectangular cuboid just still entirely encompassing the object. In this context, a “transverse extension” of an object is in particular to be understood as an extension of the second-longest side of an imaginary smallest rectangular cuboid just still entirely encompassing the object. In this context, a “thickness” of an object is in particular to be understood as an extension of the shortest side of an imaginary smallest rectangular cuboid just still entirely encompassing the object. In particular, the longitudinal extension and the transverse extension and the thickness are perpendicular to one another, respectively. On account of this, the covering element can in particular be produced and/or manufactured in an easy and/or fast manner.
Further, it is proposed that the covering element is fixed to the inner wall. As a result of this, a high stability can in particular be provided.
The covering element can in particular be fixed to the inner wall by means of a friction-fit connection and/or by means of a form-fit connection. Preferably the covering element is fixed to the inner wall by means of an adhesive bond. For example, the covering element can be fixed to the inner wall by means of a tape and/or double-sided tape. In this way, in particular a stable and/or cost-saving implementation can be provided. A usage of screws can in particular be avoided, thus in particular reducing the number of parts used.
The feature of the inner wall and/or located on the inner wall which may be covered by the cover element can in particular comprise quality problems, such as in particular a usage of too many parts and/or at least one gap located on the inner wall and/or at least one scratch located on the inner wall. Additionally and/or alternatively, the feature can in particular comprise mechanical parts, such as in particular at least one rail and/or at least one screw and/or at least one air duct and/or at least one elbow and/or mechanical details. Preferably, the feature comprises at least one re-enforcing element and/or at least one air duct and/or at least one rail of the inner wall. The re-enforcing element strengthens and/or reinforces in particular the inner wall and/or the door unit. In at least one assembled state, the rail is in particular provided for mounting of at least one door bin in particular of the home appliance door. As a result of this, a high-grade convenience for a user can in particular be provided.
In an exemplary implementation of the invention it is proposed that the home appliance door further comprises at least one rail. For example, the rail and the covering element can in particular be connected to each other, wherein the rail can in particular be connected to a surface of the covering element. Alternatively, the rail and the covering element can in particular be made of one piece. The rail can in particular be embodied as a projection of the covering element. Preferably the rail and the door unit are in particular connected to each other, wherein the rail is in particular connected to the inner wall of the door unit. For example, the covering element can comprise at least one recess through which the rail projects. The rail and the recess of the covering element can in particular be adapted to one another, in particular in size and/or form and/or location. In particular, the rail and the recess can be located correspondingly to one another. It is also proposed that the rail may be located at least completely behind the covering element. The covering element defines at least one plane behind which the rail is located. For example, the rail can be covered by the covering element. The covering element may comprise at least one recess through which the rail can be seen in a front view. This allows, in particular, providing a compact implementation.
Further, it is proposed that the home appliance door may further comprise at least one door bin and that the covering element comprises at least one recess through which the door bin may be fixed to the rail. In particular, the door bin may be provided for storing victuals to be cooled and/or tempered, for example bottles and/or milk and/or juice and/or butter and/or food and/or groceries. The door bin can for example be fixed to the rail in a permanent fashion. Alternatively, the door bin may be fixed to the rail in a releasable fashion. As a result of this, a high convenience for a user can in particular be provided.
Additionally, it is proposed that the inner wall comprises at least one groove, in which the rail is located. In particular, the inner wall comprises at least one delimiting element which in particular delimits and/or defines the groove. In this context, a “delimiting element” is in particular to be understood as a portion of the inner wall, defining and/or bordering the groove. The groove can in particular be a ridge of the inner wall. In particular, the groove is opened towards the covering element. This allows, in particular, providing a compact implementation.
Additionally, it is proposed that the home appliance door further comprises at least one support element located between the inner wall and the outer wall and attached to a rear side of at least one delimiting element of the inner wall, which delimits the groove. In this context, a “support element” is in particular to be understood as an element, being separate from the inner wall and supporting and/or reinforcing the groove and/or the delimiting element and/or the inner wall. In at least one mounted state, the support element is in particular located within the interior space in particular defined by the outer wall and the inner wall. In particular, the rail is fixed to the support element in at least one mounted state, in particular by means of at least one fixing element. The door unit in particular comprises at least one fixing element, which in particular fixes the rail to the support element in at least one mounted state. For example, the fixing element can be a latching element. The fixing element may also be a screw. The support element in particular is embodied at least mostly of metal. The support element may have at least one at least essentially U-shaped region which is in particular attached to the rear side of the delimiting element. The support element may have at least one further region contacting a rear side of the inner wall beside the groove. Alternatively and/or additionally, the support element may have at least one further region extending into the interior space without contacting the inner wall and the outer wall. As a result of this, an improved fixation of the support element by at least one solidified insulation material, located within the interior space, can in particular be provided. For example, the home appliance door can comprise several support elements, being arranged along a height direction of the door unit. Alternatively, the home appliance door can comprise exactly one support element for each delimiting element of the inner wall, e.g. two support elements in total. The support element can for example be an extruded part. In this way, the rail is in particular fixed to the inner wall and/or to the solidified insulation material and/or to the support element. The rail may not be fixed to the covering element. As a result of this, no forces acting on the rail are transmitted onto the covering element.
In addition, it is proposed that the covering element comprises at least one air recess, which is located correspondingly to at least one air duct of the inner wall. The home appliance door can in particular comprise at least one ventilation which in particular leads to the air duct of the inner wall. On account of this, a storage time of victuals to be cooled and/or tempered which are stored in the storage space can in particular be prolonged.
For example, the covering element can in particular be mounted to an in particular flat surface of the inner wall. For example, the inner wall may comprise at least one flange on which the covering element is mounted. As a result of this, a high stability can in particular be provided.
Furthermore, it is proposed that the covering element and at least one portion of the inner wall may be arranged flush with each other. The term that the covering element and at least one portion of the inner wall are arranged “flush” with each other is in particular to mean that a small offset and/or tolerances are admissible and/or allowed. On account of this, a compact implementation can in particular be provided. In particular, requirements of a flat door concept can be fulfilled. The at least one portion of the inner wall may surround one, two or all edges of the covering element.
It is also proposed that the covering element is at least mostly made of metal, e.g. sheet metal. For example, the covering element can in particular be at least mostly made of aluminum and/or stainless steel and/or galvanized steel. The covering element can in particular be painted and/or varnished. As a result of this, a high stability can in particular be provided.
A convenience for a user can in particular be enhanced by a home appliance device, in particular a home chiller appliance device, comprising at least one home appliance door according to the invention.
A convenience for a user can in particular be further improved by a home appliance, in particular a home chiller appliance, comprising at least one home appliance device, in particular at least one home chiller appliance device, according to the invention.
A comfortable and/or convenient solution can in particular be provided by a method for assembly of a home appliance door, in particular a home chiller appliance door, according to the invention; the home appliance door comprising: at least one door unit having an outer wall and an inner wall; at least one feature of the inner wall being at least partly covered.
Herein the home appliance door and/or the home appliance device is not to be limited to the application and implementation described above. In particular, for the purpose of fulfilling a functionality herein described, the home appliance door and/or the home appliance device may comprise a number of respective elements, structural components and units that differs from the number mentioned herein. Furthermore, regarding the value ranges mentioned in this disclosure, values within the limits mentioned are to be understood to be also disclosed and to be used as applicable.
Further advantages may become apparent from the following description of the drawing. In the drawing an exemplary embodiment of the invention is shown. The drawing, the description and the claims contain a plurality of features in combination. The person having ordinary skill in the art will purposefully also consider the features separately and will find further expedient combinations.
If there is more than one specimen of a certain object, only one of these is given a reference numeral in the figures and in the description. The description of this specimen may be correspondingly transferred to the other specimens of the object.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 a home appliance comprising a home appliance device which comprises a home appliance door in an operating state, in a schematic front view,
FIG. 2 a home appliance comprising a home appliance device, which comprises a home appliance door in an opened state, in a schematic front view,
FIG. 3 a door unit, a rail and a covering element of the home appliance door, in a schematic exploded view,
FIG. 4 a portion of the door unit, the rail and the covering element in an assembled state, in a schematic view,
FIG. 5 a portion of an inner wall of the door unit and the covering element in an assembled state, in a schematic sectional view and
FIG. 6 a cross-section along line VI-VI in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a home appliance 34 comprising a home appliance device 10 , in a schematic perspective view. The home appliance 34 is embodied as a home chiller appliance. The home appliance device 10 is embodied as a home chiller appliance device.
In the present embodiment the home appliance 34 is embodied as a refrigerator. The home appliance 34 could further be embodied in particular as a wine cooler, a climate cabinet, an ice-box, a freezer and/or a refrigerator-freezer combination.
In FIG. 1 the home appliance device 10 is shown in an installation position. The home appliance device 10 is installed on a base 38 . The base 38 defines a substantially horizontal plane.
The home appliance device 10 comprises an appliance body 40 . The appliance body 40 partly defines an appliance housing. The appliance body 40 is installed on the base 38 substantially upright.
The appliance body 40 partly defines a storage space 42 . The appliance body 40 comprises walls 44 , 46 , 48 , 50 . The walls 44 , 46 , 48 , 50 delimit the storage space 42 . The appliance body 40 comprises two lateral walls 44 , preferably opposite each other. The appliance body 40 comprises a rear wall 46 . The appliance body 40 comprises a bottom wall 48 . The appliance body 40 comprises a top wall 50 , preferably opposite the bottom wall 48 .
The home appliance device 10 comprises at least one insert 52 . In the present case the home appliance device 10 comprises six inserts 52 . It is conceivable that the home appliance device 10 may comprise a differing number of inserts 52 as is deemed advantageous by someone skilled in the art. The home appliance device 10 may preferably comprise a combination of different embodiments of inserts 52 , for example at least one insert 52 embodied as a shelf and at least one further insert 52 embodied as a bottle holder. For the sake of clarity, in the following only one insert 52 is given a reference numeral and is described in detail. The following description may be transferred to further inserts 52 accordingly.
The home appliance device 10 comprises a home appliance door 12 . The home appliance door 12 is connected to the appliance body 40 . In a mounted state, the home appliance door 12 is rotatably connected to the appliance body 40 .
The home appliance door 12 comprises a door unit 14 . The door unit 14 has an outer wall 16 and an inner wall 18 . In an assembled state, the inner wall 18 and the outer wall 16 are connected to one another. The inner wall 18 and the outer wall 16 define an interior space 58 (compare FIGS. 5 and 6 ). The interior space 58 is, in an assembled state, mostly filled with insulation material.
The home appliance door 12 comprises a covering element 20 . In an assembled state, the covering element 20 covers several features 22 of the inner wall 18 . The covering element 20 is, in the present embodiment, mostly made of metal. The covering element 20 is embodied as a covering plate.
The home appliance door 12 comprises at least one re-enforcing element 24 . In the present embodiment, the home appliance door 12 comprises eight re-enforcing elements 24 . For the sake of clarity, in the following only one re-enforcing element 24 is given a reference numeral and is described in detail. The following description may be transferred to further re-enforcing elements 24 accordingly.
The re-enforcing element 24 is located on the inner wall 18 . In an assembled state, the re-enforcing element 24 is connected to the inner wall 18 . For example, the re-enforcing element 24 and the inner wall 18 can be made in one piece. The feature 22 comprises the re-enforcing element 24 .
The home appliance door 12 comprises an air duct 26 . In an alternate embodiment, the home appliance door 12 may comprise more than one air duct 26 .
The air duct 26 comprises an air duct inlet 62 . The air duct inlet 62 is located in a bottom part of the home appliance door 12 . The air duct 26 comprises an air duct outlet 64 . The air duct outlet 64 is located in a top part of the appliance door 12 .
The air duct 26 is located on the inner wall 18 . In an assembled state, the air duct 26 and the inner wall 18 are made in one piece. The feature 22 comprises the air duct 26 .
The home appliance door 12 comprises at least one rail 28 . In the present embodiment, the home appliance door 12 comprises two rails 28 . For the sake of clarity, in the following only one rail 28 is given a reference numeral and is described in detail. The following description may be transferred to the further rail 28 accordingly.
The rail 28 is located on the inner wall 18 . In an assembled state, the rail 28 is connected to the inner wall 18 . For example, the rail 28 and the inner wall 18 can be made in one piece. The feature 22 partly comprises the rail 28 , which means that in particular only a portion of the rail 28 is part of the feature 22 .
The inner wall 18 comprises a groove 66 . In an assembled state, the rail 28 is located in the groove 66 . The inner wall 18 comprises a delimiting element 70 . The delimiting element 70 delimits the groove 66 .
The home appliance door 12 comprises a support element 68 . In an assembled state, the support element 68 is located between the inner wall 18 and the outer wall 16 . The support element 68 is located in the interior space 58 , in an assembled state. In an assembled state, the support element 68 is attached to a rear side of the delimiting element 70 by means of a fixing element 72 . In the present embodiment the fixing element 72 is a screw.
In an assembled state, the covering element 20 is fixed to the inner wall 18 . In the present embodiment, the covering element 20 is fixed to the inner wall 18 by means of adhesive bonding.
The inner wall 18 comprises a flange 54 . In an alternative embodiment, the inner wall 18 can comprise a greater number of flanges 54 , for example at least one flange 54 per side of the inner wall 18 . The covering element 20 is, in an assembled state, mounted on the flange 54 .
The flange 54 is in the present embodiment curved in a direction towards the outer wall 16 . In an assembled state, the covering element 20 and a portion 56 of the inner wall 18 are arranged flush with each other. The portion 56 of the inner wall 18 is part of a frame 60 of the inner wall 18 .
The home appliance door 12 comprises at least one frame 60 . The frame 60 is located on the inner wall 18 . In an assembled state, the frame 60 is connected to the inner wall 18 . For example, the frame 60 and the inner wall 18 can be made in one piece. The frame 60 projects over a surface of a base body of the inner wall 18 .
The covering element 20 is, in an assembled state, located in front of the rail 28 . In an assembled state, the rail 28 is located completely behind the covering element 20 .
In the present embodiment, the home appliance door 12 comprises four door bins 32 . For the sake of clarity, in the following only one door bin 32 is given a reference numeral and is described in detail. The following description may be transferred to the further door bin 32 accordingly.
In the present embodiment, the covering element 20 comprises two recesses 30 . For the sake of clarity, in the following only one recess 30 is given a reference numeral and is described in detail. The following description may be transferred to the further recess 30 accordingly.
In an assembled state, the recess 30 is located correspondingly to the rail 28 . In an assembled state, the door bin 32 is fixed to the rail 28 through the recess 30 .
In an assembled state, the covering element 20 is located between a base body of the inner wall 18 and the door bin 32 . In an operating state, the door bin 32 is located inside the storage space 42 .
In the present embodiment, the covering element 20 comprises two air recesses 36 . For the sake of clarity, in the following only one air recess 36 is given a reference numeral and is described in detail. The following description may be transferred to the further air recess 36 accordingly. In an assembled state, the air recess 36 is located correspondingly to the air duct 26 .
In a method for assembly of the home appliance door 12 several features 22 of the inner wall 18 are partly covered.
The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:
10 Home appliance device 12 Home appliance door 14 Door unit 16 Outer wall 18 Inner wall 20 Covering element 22 Feature 24 Re-enforcing element 26 Air duct 28 Rail 30 Recess 32 Door bin 34 Home appliance 36 Air recess 38 Base 40 Appliance body 42 Storage space 44 Wall 46 Wall 48 Wall 50 Wall 52 Insert 54 Flange 56 Portion 58 Interior space 60 Frame 62 Air duct inlet 64 Air duct outlet 66 Groove 68 Support element 70 Delimiting element 72 Fixing element | For the purpose of providing a home appliance device with improved characteristics regarding a user convenience, a home appliance door, in particular a home chiller appliance door, is proposed: The home appliance door has at least one door unit with an outer wall and an inner wall; and at least one covering element which at least partly covers at least one feature of the inner wall. |
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FIELD OF THE INVENTION
Present invention relates to devices and methods for positioning, setting, and releasing a downhole tool, and more particularly, to setting tools of the type which prevent premature or unintentional release of a liner hanger or similar mechanically set tool in a subterranean wellbore.
BACKGROUND OF THE INVENTION
A liner is a length of tubular suspended in a wellbore, and which normally does not extend to the surface. In exemplary applications, liners are used to repair damaged casing strings, or to test questionable production zones. A liner hanger secures the liner within the well bore, and typically includes radially movably slips with teeth for biting engagement with the outer casing or sides of the "open hole" bore. The liner may be mechanically "set" in the well by axially moving the drill string with respect to the slips, thereby forcing the teeth radially outward into biting engagement with the casing.
A liner setting tool is conventionally placed on the drill string axially above the liner hanger, and assists in setting the liner hanger. Once the liner hanger has been set, the liner setting tool can be released from the liner hanger by rotating the drill string. Most importantly, the setting tool should allow for the quick yet reliable disengagement of the liner hanger, so that the setting tool and drill string can be retrieved to the surface, leaving the hanger and liner fixedly positioned in the well bore. In certain applications, e.g., when cementing a liner in place, it is preferable that the liner hanger be set and the setting tool structurally be disengaged from the liner hanger, while thereafter still employing the setting tool for rotating the drill string.
A significant problem with many prior art liner setting tools is that the liner hanger may be prematurely or inadvertently released from the setting tool during the process of positioning the equipment at its desired depth in the wellbore. A liner may, for example, be 100 feet or more in length and have a diameter only slightly less than the downhole casing through which it passes. If the wellbore is vertical and the liner diameter is substantially less than the downhole casing diameter, the entire drill string may remain in tension while lowering the equipment in place due to the weight of the drill string and liner, in which case premature release of the liner hanger may not be a problem. If, however, the well bore is highly deviated or perhaps has substantially horizontal portions, or if the liner or liner hanger gets "stuck" in a casing only slightly larger in diameter than the liner hanger, the drill string is frequently used to "push" the setting tool, liner hanger, and the liner through the well bore. In this case, axial movement of the drill string with respect to the liner hanger is possible, so that premature unlocking of the setting tool may occur. Moreover, the accidental unlocking of the setting tool may not be known to operators at the surface, who may then attempt rotate the drill string to free the presumed "hang-up". This action, in turn, may cause the inadvertent release of a liner hanger from the setting tool, thereby necessitating a more costly retrieval operation.
One type of prior art liner assembly, hereinafter referred to as the TIW RRP liner assembly, includes an elongate setting collar with an upper spline receiving section and a lower spline receiving section. The drill string above and below the setting tool includes an upper spline and a lower spline, with the connecting nut of the setting tool being axially spaced between the splines. The lower spline may be engaged to rotate the liner prior to setting of the liner hanger. The upper spline may be engaged to rotate the liner subsequent to releasing the hanger from the setting tool nut.
Engagement of one of the splines in the TIW RRP assembly would also prevent inadvertent separation of the setting tool and liner hanger while the assembly was being positioned in the wellbore. This equipment has, however, significant drawbacks over other liner hanger setting equipment. The spline arrangement and setting collar are expensive to manufacture. To rotate the liner after setting the liner hanger, the upper spline must be properly aligned to mate with the upper spline receiving section of the setting collar. If a liner is to be reset in a well,the tubing string must be carefully manipulated so that the lower and upper splines pass through their respective sections of the setting collar. The splines may become damaged or their ends deformed by the "blind" attempt to align these components, so that the desired liner rotation or resetting operation can thereafter not be successfully accomplished. Lastly, rotation of the setting tool and drill string subsequent to the setting of the liner hanger requires that the lower spline be pulled upward through the lower spline receiving section of the setting collar in order to retrieve the setting tool. Dogs on the lower spline may be spring biased to quickly pass by the lower spline receiving section, but the dogs can become locked or jammed in a fully or partially extended position. In this case, the drill string must be rotated so that the dogs are in alignment with the spline receiving portion, so that the lower spline can pass upwards for retrieval. This latter operation, which takes time and patience, conflicts wih the operator's desire to quickly retrieve the setting tool after cementing is complete to insure that the setting tool and drill string do not become stuck in a cemented wellbore.
The disadvantages of the prior art are overcome by the present invention, and an improved setting tool and method of setting a liner or other downhole tool are hereinafter disclosed.
SUMMARY OF THE INVENTION
The improved setting tool includes a cylindrical mandrel having a plurality of upper recesses and a plurality of lower recesses, each with cam or ramp surfaces. A torque control ring assembly and a liner hanger connection nut are each positioned about and are axially movable with respect to the mandrel for reciprocating motion during the liner hanger setting operation. The torque control ring assembly includes a plurality of downwardly projecting fingers, each biased downward for engagement with corresponding slots in the hanger. The fingers are forced upward with respect to torque control ring by the axial separation of sleeves, which in turn is caused by radial movement of interference rollers as they ride out of the recesses along the cam surfaces.
During "run-in" of the tool to position the liner hanger in the well, the fingers are locked for engagement with the slots in the liner hanger while interference rollers are within one of the upper or lower recesses in the mandrel. The recesses are axially positioned such that the upper recesses lock the fingers in engagement with the liner hanger when the drill string is in compression, and the lower recesses rotatably lock the setting tool and liner hanger while the drill string is in tension. Inadvertent separation of the liner hanger and setting tool are thus avoided, since the drill string is generally either in tension or in compression if a tool becomes stuck in a well.
To release the setting tool from a set liner hanger, the drill stem is reciprocated so that the interference rollers are axially positioned between the upper and lower recesses, thereby raising the fingers to the release position. The drill string is then rotated, unthreading the setting tool liner hanger connection nut beneath the fingers from the liner hanger. Thereafter, the fingers may still be brought into engagement with the respective slots in the liner hanger to allow rotation of the liner during the cementing operation. In order to thereafter retrieve the setting tool and the drill string, the operator need only "pickup" on the drill string.
It is an object of the present invention to provide a reliable setting tool for assisting in the mechanical setting of a downhole tool by reciprocating the tubular string, wherein the setting tool is adapted for rotation of the tubular string to release the setting tool from the downhole tool.
It is another object of the invention to provide a setting tool which will be automatically locked to the downhole tool while the tubular string is either in tension or compression, and which includes all retrievable locking member components axially spaced above a lowermost position of the threaded nut of the setting tool, which interconnects the setting tool and the downhole tool.
The features of the present invention may be utilized in a liner setting tool which includes downwardly projecting fingers adapted for engagement within slots in a liner hanger to enable rotation of the setting tool to rotate the liner either prior or subsequent to setting of the liner hanger. The fingers are preferably biased for engagement toward the slots, such that rotation of the setting tool axially coupled to the liner hanger automatically engages the fingers within the slots to allow rotation of the liner with the setting tool.
An advantage of the present invention is that a downhole liner hanger adapted for mechanical setting in a wellbore may be reliably locked to its setting tool while the tool string is either in tension or compression. After the liner hanger is set in the well and the setting tool is rotated to become mechanically released from the liner hanger, the setting tool and drill string may thereafter be picked up for retrieval to the surface without risking the re-engagement of the components which previously locked the setting tool and liner hanger together.
These and further objects, features, and advantages of the present invention become from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified vertical half-sectional view of a portion of the drill string which includes a setting tool according to the present invention and portions of a suitable liner hanger and liner.
FIG. 2 is a half-sectional view of a setting tool generally shown in FIG. 1 in locked engagement with a portion of the liner hanger.
FIG. 3 is a half-sectional view along the line as as shown in FIG. 5 of the setting tool shown in FIG. 2 in a position rotatably released from and interconnected with the liner hanger.
FIG. 4 is a half-sectional view along the line as shown in FIG. 5 of the setting tool shown in FIG. 2 in a liner hanger released position.
FIGS. 5, 6 and 7 are cross-sectional views of the liner setting tool shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the setting tool of the present invention is generally depicted in a suitable environment for setting a liner hanger in a subterranean well bore. The well bore 6 shown in FIG. 1 is defined by a conventional casing 8, although it should be understood that the concepts of the present invention are applicable for setting liner hangers in both cased and uncased or "open hole" wells.
A tubular setting mandrel 10 is threadably connected to a conventional drill pipe 12 at threads 14. Cylindrical interior diameter 24 of the mandrel 10 defines a central passageway through the mandrel. A setting ring assembly 30 which includes a spring retainer 32, spring 68, torque finger retainer 64, torque control ring 34, sleeves 72, 74, and torque fingers 36 is axially movable along mandrel 10, but is fixed against rotation (as explained subsequently) by keyways 26. A nut 78 is also axially movable and rotatably fixed to mandrel 10. The nut 78 is positioned axially below assembly 30, and threadably interconnects the mandrel 10 to liner hanger sleeve 40. The nut 78 as shown in FIG. 1 in its lower most position, with key cover ring 80 in engagement with lower connection 84.
A liner setting sleeve extension 46 is threadably connected to liner hanger setting sleeve 40, and projects upwardly therefrom. A liner hanger 48 may be connected to the lower end of sleeve 40, and supports a plurality of slips 50 for biting engagement with the casing 8, a centralizer 56, a J-slot arrangement 54, and a plurality of drag springs 52. If desired, a section of liner (not shown) may be connected to the hanger 48 beneath the centralizers 56 in conventional fashion. Mandrel 10 is connected at its lower end to a packoff member 49, a setting tool swivel 51, and a wiper plug 53. The liner, liner hanger, slips, centralizer, J-slot arrangement, drag springs, packoff member, setting tool swivel, and wiper plug are each conventional in the industry, and are generally illustrated to show a suitable environment and to assist in describing the method of the present invention.
Referring now to FIG. 2, mandrel 10 is shown connected to drill pipe 12 at threads 14. The intermediate portion of the elongate mandrel has been deleted from FIG. 2, and it should be understood that the mandrel 10 typically is approximately 3 feet or more in length. Four elongate keyways or slots 26 are circumferentially spaced at 90° intervals about the mandrel, and extend from an upper portion to a lower portion of the mandrel, as shown. Two upper recesses 16 are circumferentially spaced at 180° apart about the upper portion of the mandrel are provided for cooperating with the setting ring assembly, as described subsequently, and two similar lower recesses 16' are also depicted. (FIG. 2 should thus be understood as being schematic, in that the cross-sectional half shows both a slot and an upper and lower recess, although these components are circumferentially spaced, as shown in FIG. 5.) Each recess 16 or 16 ' has a substantially planar base surface 18, a cam or ramp surface 20 interconnecting the base surface 18 with the outer cylindrical surface 22 of the mandrel 10, and a pair of substantially parallel side surfaces 19. As explained subsequently, rollers move radially inward or outward as they travel axially along each of the ramp surfaces 20, and thereby move the fingers 36 axially into and out of position for engagement with the liner hanger setting sleeve 40. FIG. 5 illustrates the circumferential spacing of the keyways 26 in the mandrel 10, and also illustrates the upper two circumferentially spaced recesses 16. It should be understood that although at least two keyways 26 and two recesses 16 are preferably provided in the mandrel 10, any number of keyways and upper and lower recesses may be provided.
Torque control ring 34 has three circumferentially spaced fingers 36 slidably positioned in slots 38 therein, so that each finger 36 may move axially with respect to ring 34. The fingers 36, in turn, are each fixed to finger retainer 64 by bolts 66. Finger retainer 64 is biased downwardly by spring 68, which is then held in place by spring retainer 32 threadably connected to 34 at 62. Slots 38 in ring 34 and ports 60 in retainer 32 allow for fluid communication between the spring 68 and the sleeve 46 (see FIG. 1). Sleeve 72 is shown in engagement with both finger retainer 64 and sleeve 74, so that the fingers 36 are in their downward position for engagement with upwardly opening slots or stop surfaces on the top of liner hanger sleeve 40. In this position, each of the rollers 70 is within a corresponding one of the lower recesses 16', and is positioned between the base 18 of its recess and a pair of angled surfaces 92, formed by the ends of the members 64, 72, and 74.
The nut 78 is positioned axially below the setting ring assembly 30, and is axially below the lower plurality of recesses 16 when the nut 78 is in its lowermost position with cover 80 in engagement with bottom connection 84, which in turn is secured to the mandrel by threads and bolts 86. Keys 81 and sleeve 82 cooperate with keyways 26 to allow the nut 78 and the setting ring assembly 30 to move axially with respect to the mandrel 10, but prohibit the nut 78 and assembly 30 from rotation in either direction with respect to the mandrel 10. Nut 78 has left-hand threads 90 intended for mating engagement with threads on the liner setting sleeve 40, and thus interconnects the mandrel and the liner hanger.
When the setting assembly is in the position as shown in FIG. 2, the tool string is in tension, and the torque control ring and liner hanger are rotatably locked together by fingers 36. The mandrel 10 and the liner hanger setting sleeve 40 are interconnected by nut 78, so that rotation of the drill stem rotates the nut and the assembly 30, which rotates the liner hanger setting sleeve 40 simultaneously with the nut 78. Accordingly, rotation of the drill string in either direction will not unthread the liner hanger setting sleeve 40 from the nut 78 as long as the fingers 36 are locked to the liner hanger setting sleeve, as shown in FIG. 2.
Lowering of the drill string with respect to the slips 50 (as explained subsequently), allows the liner setting assembly to move into position as shown in FIG. 3. The rollers 70 have ridden up the ramp surfaces 20 of each lower recess 16', and are in engagement with the outer cylindrical surface 22 of the mandrel. The taper of the ramp surfaces 20 may be altered to obtain the desired radial force in response to a selected or presumed axial force, and preferably will be approximately 10° from the central axis of the mandrel 10. This radial force, in turn, causes axial separation between sleeves 72 and 74, and between the sleeve 74 and the finger retainer 64, thereby compressing spring 68. Accordingly, each of the plurality of fingers 36 is moved axially upward approximately one-inch with respect to the torque control ring 34, so that the fingers 36 no longer engage the side surfaces 39 of the slots 41. This same lowering action of the mandrel causes axial separation between the key cover ring 80 and the bottom connector 84, as shown.
With the setting assembly in position as shown in FIG. 3 and with the liner hanger axially secured to the casing, the drill string may be rotated to unthread the nut 78 from the liner hanger sleeve 40, thereby moving the nut to the position as shown in FIG. 4. (The liner hanger may include a bearing assembly which allows the liner to be rotated after the liner hanger is set in the well bore, although the torque required to rotate the set liner is substantially less than that necessary to unthread the nut 78 from the sleeve 40.) In this position, mandrel 10 is structurally disconnected from the liner hanger 40, and accordingly the setting assembly may be retrieved to the surface by simply raising the drill string 10.
A typical liner setting operation will now be described. A liner, liner hanger, and setting assembly will be lowered from the drill string into the well, with the tool string generally in tension due to the weight of these components, and the rollers 70 thus positioned within the corresponding lower recesses 16' of the mandrel. If the liner hanger should, however, get stuck while in the well bore, the tool string can be pushed into compression without concern for unthreading the liner hanger from the setting tool, since the mandrel 10 will move axially so that the rollers 70 move from the lower recesses 16' to the corresponding upper recesses 16 in the upper portion of the mandrel. Thus, when the tool string is in compression, retainer ring 32 is closely adjacent the shoulder surface 11 of the mandrel 10, and the fingers 36 are again in their downward position, engaging slots 41 of mandrel setting sleeve 40. When the tool string is thus either in tension or compression, the rollers 70 are disposed within one of the recesses 16 or 16', the fingers 36 rotatably lock the mandrel 10, and thus the nut 78 to the liner hanger setting sleeve 40, and the nut 78 cannot be unthreaded from the liner hanger setting sleeve 40.
When the liner is at its desired position within the well bore, the tool may be picked up and rotated in conventional fashion to disengage the J-slot arrangement 54. Thereafter, the operator can "set down" on the tool string, thereby moving the mandrel 10 downward to force the slips 50 radially outward into biting engagement with the casing 8. During this setting operation, centralizer 56 keeps the tool string generally centered within the casing, and the drag springs 52 provide sufficient resistence to allow the desired stroke between these components to set the liner hanger in the well bore.
This setdown operation will both bring the slips 50 into biting engagement with the casing 8, and will move the rollers 70 from the position as shown in FIG. 2 to a position wherein the rollers are in engagement with the outer cylindrical surface of the mandrel 10, as shown in FIG. 3. In other words, the liner hanger setting operation will automatically move the rollers 70 to an axial position between the upper recesses 16 and the lower recesses 16' , and the fingers 36 will then automatically be in the raised position relative to slots 41 in liner hanger setting sleeve 40 as shown in FIG. 3. While, in this position, as explained above, the drill string 12 may be rotated to allow the nut 78 to unthread from the liner setting apparatus.
Once the mandrel 10 and the liner hanger 40 have been unthreaded and thus structurally disconnected, the tool string may be set down until the rollers 70 are in the upper recesses 16 (see FIG. 4), in which case the fingers 36 will be in their downward position with respect to the locking ring 34. With the fingers in this position, the drill string and thus the assembly 30 may be lowered so that the fingers 36 re-engage the slots 41 in the liner setting sleeve 40, thereby enabling rotation of the drill string to cause simultaneous rotation of the liner setting hanger sleeve 40 after the nut 78 has been disconnected from the liner hanger. The biasing force of springs 78 enables the setting assembly 30 to be axially lowered so that the fingers 36 would be positioned within the slots 41, but would be moved upwardly to compress the spring if the fingers are not rotatably aligned with the slots 41. The drill string may then be rotated so that the fingers snap into place when rotationally aligned with the slots. Again, the liner setting apparatus may be easily and quickly retrieved to the surface by simply raising up on the drill pipe 12.
Various modifications to the liner setting tool will be suggested by the above description. Rollers are preferred for engagement with the ramp surfaces to provide a large area of engagement, although hardened balls or other radially shiftable actuating members could be used instead of rollers. The term "drill string" as used herein should be understood to include various tubular members used in petroleum recovery operations, including drill pipe, tubing and casing.
The setting tool of the present invention may also be employed to assist in setting a downhole tool other than a liner hanger using the axial movement of the mandrel with respect to the tool to set the tool in the well bore, then unthreading the setting tool from the downhole tool. The setting tool may, for example, be used to fix a mechanically set packer in a well bore, and then the drill string rotated to unthread the setting tool from the packer, as described above.
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 improved setting tool is provided for positioning, setting, and releasing a liner in a subterranean wellbore. The setting tool includes a plurality of fingers, each biased for locking engagement with axially spaced recesses provided in the wall of the tool mandrel axially above a lowermost position of the liner hanger connecting nut. The fingers are automatically forced upward into a release position when interference rollers move radially out of their respective recesses and separate a plurality of axially movable sleeves. Premature release of the liner is avoided by positioning the recesses in the mandrel such that the fingers are in a lock position when the tool string is either in tension or compression. The liner can be rotated after setting the liner hanger, so that the setting tool and drill string can thereafter be reliably retrieved by simple axial pick-up. |
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TECHNICAL FIELD
[0001] The present invention generally relates to asphalt paving machines, and more particularly to a control for a tamping mechanism on an asphalt paving machine.
BACKGROUND
[0002] Asphalt paving machines are used to spread asphalt relatively evenly over a desired surface. These machines are regularly used in the construction of roads, parking lots and other areas where a smooth durable surface is required for cars, trucks and other vehicles to travel. An asphalt paving machine generally includes a hopper for receiving asphalt material from a truck and a conveyor system for transferring the asphalt from the hopper for discharge on the roadbed. Screw augers spread the asphalt transversely across the road bed in front of a floating screed, which is connected to the paving machine by pivoting tow arms or draft arms. The screed smoothes and somewhat compacts the asphalt material and ideally leaves a roadbed of uniform depth and smoothness. The screed is sometimes equipped with an eccentric bar that rotates and thereby causes the screed to vibrate, which assists with the compaction. Although the screed compacts the asphalt material to some degree, it is often desirable to exert greater compaction force on the asphalt. To do so, some screeds include a tamping mechanism which often includes a tamping bar, located in front of the screed, relative to the direction of travel of the paving machine, and transversely to the direction of travel. The tamping bar moves up and down, striking the asphalt on each downward stroke thereby imparting increased compaction force on the asphalt. The speed with which the tamping bar moves upward and downward is generally controlled by an operator input device such as a control knob.
[0003] It is desirable to have the asphalt on the roadbed compacted uniformly so that the density of the roadbed is consistent from one place to another. Prior art tamping systems control only the frequency of the up and down motion of the tamping bar thereby causing the screed to tamp at a fixed rate. If the asphalt paving machine is moving at a constant speed the tamping bar will strike the asphalt the same number of times per unit distance traveled. Because the tamping bar strikes the asphalt the same number of times for every foot traveled, it is more likely to produce a uniformly dense roadbed. However, if the operator changes the speed of the asphalt paving machine the number of times the tamping bar strikes the asphalt per foot traveled will change, thereby increasing the likelihood that the density of the roadbed will be inconsistent.
[0004] It would be preferable to have an automatic tamping control that would deliver a uniform number compaction strokes for each unit distance traveled, irrespective of the speed of the asphalt paving machine.
SUMMARY OF THE INVENTION
[0005] The present invention includes a control system for use with a tamping mechanism on an asphalt paver. The control system preferably includes an electronic control module that is connected with an operator input device for inputting a desired tamping frequency. The electronic control module is also connected to a speed sensor that produces a signal indicative of the speed of the asphalt paver. The electronic control module controls the speed of the tamping mechanism as a function of the operator input and the asphalt paver speed.
[0006] These and other advantages of the present invention will be apparent upon reading the detailed description in connection with the drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The drawings are provided to assist in the understanding of the present invention and represent a preferred embodiment of practicing the invention. Other embodiments could be created that will fall within the scope of the present invention as defined by the appended claims.
[0008] [0008]FIG. 1 is a side view of an asphalt paving machine;
[0009] [0009]FIG. 2 is a side view of a screed including a tamping mechanism associated with the asphalt paving machine of FIG. 1;
[0010] [0010]FIG. 3 is a block diagram of a control system of preferred embodiment of the present invention; and
[0011] [0011]FIG. 4 is a flowchart of preferred software control of the control system of the present invention.
DETAILED DESCRIPTION
[0012] A preferred embodiment of the best mode of practicing the present invention is described herein. Referring first to FIG. 1, a typical form of track-laying, floating screed asphalt paver 30 is shown. In accordance with well known practice, the paver is provided with push rollers 31 at the front, for engaging and pushing forwardly on the wheels of a truck loaded with asphalt paving material. The paving material is arranged to be discharged progressively from the truck into a hopper 32 at the front of the paver. Conveyor means (not shown) controllably transport the paving material to the rear of the paver and deposit it in a mass 33 on the prepared paving bed 34 . Screw augers 35 distribute the paving material laterally in front of a screed, generally designated by the numeral 36 . The screed is towed behind the paver and connected thereto by a pair of elongated, forwardly extending tow bars 37 connected at their front ends to the chassis of the paver. In accordance with known practice, by controlling the elevation of the tow points 38 and the angle of attack of the bottom surface of the screed 36 , a level, uniform paving mat 39 is laid behind the paver as it advances forwardly.
[0013] Referring now to FIG. 2, a screed 36 of the type used in connection with the asphalt paver 30 is shown. The screed 36 comprises a baseplate 100 which is configured to float on paving material 33 laid upon a prepared paving bed 34 and to “smooth” or level and compact the paving material on the base surface, such as for example a roadway or roadbed. The base plate 100 is connected, preferably by means of a carrier 105 , to a vibrating shaft 110 coupled to a vibratory drive (not depicted). As is known to those skilled in the art, the vibratory shaft 110 generally includes weights placed eccentrically so that when the vibratory drive rotates the vibrating shaft 110 , the shaft 110 causes the screed 36 to vibrate. The vibrating screed 36 to some degree improves compaction and quality of the asphalt mat being laid on the prepared paving bed 34 .
[0014] The screed also includes a tamping mechanism 111 which includes a tamping bar 115 arranged in front of the baseplate 100 and extending generally transversely to the paving direction over substantially the entire width of the baseplate 100 . The tamping bar 115 is configured to be driven so as to move alternately in upward and downward directions (i.e., generally toward and away from the base surface). Preferably, the tamping bar 115 is driven by an eccentric drive 120 and is configured to be adjustably displaceable by the amount of an adjustable stroke of the eccentric drive 120 . A speed sensor 290 is preferably located adjacent the eccentric drive and produces a speed signal on an electrical connector 300 that is an input to an electronic control module 210 , described in more detail below with reference to FIGS. 3 and 4. Further, the tamping bar 115 has a lead-in slope 125 located at the front edge of the bar 115 . The angle of the lead-in slope 125 is preferably between 30 degrees and 70 degrees, so as to ensure an optimum feed of the paving material.
[0015] The screed 36 has preferably includes a front wall 130 disposed proximal to the screw auger 35 (shown in FIG. 1), the screw auger 35 functioning to spread paving material falling off the end of a conveyor mounted on the paver 30 The front wall 130 includes a lower guide portion 135 which is preferably inclined relative to the tamping bar 115 and which terminates adjacent to the bar 115 , such that the guide portion 135 directs paving material from the auger 35 to the tamping bar 115 . The angle of inclination of the guide portion 135 preferably corresponds approximately to the angle of the lead-in slope 125 of the tamper bar 115 .
[0016] Referring now to FIG. 3, a block diagram of a preferred embodiment of an electronic control system 200 for use with the tamping mechanism 111 is shown. The electronic control system preferably includes an electronic control module (“ECM”) 210 connected with the various system components shown. A tamper bar mode selector 230 is connected with the ECM 210 . In the drawing, the tamper bar mode selector is shown as a three position toggle switch 240 . Those skilled in the art will recognize that other devices, including rotary switches, depressible button switches and the like could readily and easily be substituted for the three position switch. As described in more detail below with reference to FIG. 4, the mode selector 230 preferably includes three positions corresponding to an off mode, a manual mode and an automatic mode. The operator of the asphalt paving machine preferably places the mode selector 230 in a position corresponding to the desired mode. The mode selector then produces a mode signal on electrical connectors 250 indicative of the selected mode.
[0017] A tamper bar desired speed input 260 is connected with the ECM 210 by connector 270 . Although this input is described herein as a desired speed input, it also controls the desired number of tamps per unit distance when the system is in the automatic mode. As shown in the drawing, the tamper bar desired speed selector is shown as a rotary dial 280 . Preferably there are markings on the dial indicating to the operator a general desired tamping bar rotational velocity (when in manual mode) or a desired number of tamps per foot (when in automatic mode). The operator of the asphalt paving machine moves the dial to a position corresponding to the desired rotational speed of the tamping bar or number of tamps per foot and the rotary dial 280 produces a signal on connector 270 indicative of the desired tamping bar speed or tamps per foot.
[0018] A tamping bar speed sensor 290 is associated with the eccentric drive 120 of the tamping mechanism 111 and produces a tamping bar speed signal on connector 300 indicative of the rotational velocity of the eccentric drive 120 . Preferably, the tamping bar speed sensor is a passive sensor, such as a magneto restrictive type sensor. However, other types of speed sensors can be used without deviating from the scope of the present invention.
[0019] The ECM 210 produces a tamper bar control signal 310 to control the rotational speed of the shaft eccentric drive 120 . As shown in the drawing, the tamper bar control signal 310 is received by a solenoid 320 connected with a hydraulic pump 330 associated with the hydraulic motor 125 . The tamper bar control signal 310 controls the flow of hydraulic fluid through conduits 340 , 350 and thereby controls the rotational speed of the hydraulic motor 125 and eccentric drive 120 of the tamper bar. Although the preferred embodiment shows the use of a hydraulic pump 330 and motor 125 to control the rotational speed of the eccentric drive 120 , other power sources could readily and easily be substituted for the hydraulic motor without deviating from the scope of the present invention. For example, in some applications it might be preferable to replace the hydraulic motor with an electric motor and controllably power the motor with electric power through associated power circuitry.
[0020] Also connected with the ECM 210 is a asphalt paving machine speed sensor 360 that produces a signal on connector 370 indicative of the speed that the asphalt paving machine is travelling. The speed sensor is preferably associated with a driveline on the asphalt paving machine, which connects the engine to the tracks, or other ground engaging device. The speed sensor produces a signal indicative of the speed of the track, or other ground engaging device, which can be readily converted by the ECM 210 to ground speed. Any of a variety of well known speed sensors could be used in connection with the present invention.
[0021] Referring now to FIG. 4, a block diagram of a preferred embodiment of the software control associated with the ECM 210 of the present invention is shown. Software control begins in block 400 and passes to block 410 .
[0022] In block 410 the ECM 210 reads the signal on connectors 250 and determines whether the operator has placed the tamper bar mode selector 230 in the position corresponding to off mode. If the mode selected is the off mode then software control returns to block 400 . Otherwise, program control continues to block 420 .
[0023] In block 420 , software control determines whether the operator has placed the tamper bar mode selector 230 in the position corresponding to manual mode. If the mode selected is the manual mode then software control passes to block 430 . Otherwise, software control passes to block 440 .
[0024] In block 430 , the ECM 210 reads the desired tamping speed signal on connector 270 produced by the tamping bar desired speed input 260 . Program control then passes to block 470 . In block 470 , the ECM produces a tamper bar control signal as a function of the desired connector 270 . In a preferred embodiment of the invention the speed of the tamper bar shaft 122 is controlled open loop. However, as will be apparent to those skilled in the art, the ECM 210 could readily and easily use the electrical connector 300 as feedback to implement a closed loop tamper bar speed control. From block 470 program control returns to block 400 .
[0025] Returning to block 420 , as described above if the position of the mode selector 230 does not correspond to the manual position, then software control passes to block 440 and the control system is in automatic mode.
[0026] Software control passes from block 440 to block 450 .
[0027] In block 450 , the ECM 210 reads the signal on connector 270 , which in the automatic mode corresponds to a desired number of tamps per foot (or other unit distance) that the asphalt paving machine travels. Program control then passes to block 460 where the ECM determines a corresponding desired tamping speed. To do this, the ECM preferably reads the asphalt paving machine speed signal on connector 370 and calculates the desired tamping bar speed. In a preferred embodiment, the control system of the present invention uses two asphalt paving speed sensors 360 and averages the signals of those two sensors. Program control then passes to 470 .
[0028] As described above, in block 470 , the ECM produces a tamper bar control signal as a function of the desired connector 270 . In a preferred embodiment of the invention the speed of the tamper bar shaft 122 is controlled open loop. However, as will be apparent to those skilled in the art, the control could readily and easily use the electrical connector 300 as feedback to implement a closed loop tamper bar speed control. From block 470 program control returns to block 400 .
INDUSTRIAL APPLICABILITY
[0029] The control described in the present application permits the operator of the asphalt paving machine to select between three modes of tamping: an off mode; a manual mode; and an automatic mode. In the off mode, the screed will not tamp the asphalt material. In the manual mode the operator can select a desired tamping speed which produces a desired tamping rate (i.e., a desired number of tamps per unit time). In the automatic mode the operator can select a desired number of tamps per unit distance. In the automatic mode the control will automatically adjust the tamping speed as a function of the speed that the asphalt paving machine is moving. This will allow the operator to better achieve consistent compaction from the tamper bar with minimum operator action. | A control system for use with an asphalt paving machine receives inputs from an operator interface for inputting a desired tamping frequency or a desired tamping rate (tamps/ft) and a speed sensor that produces a signal indicative of the speed of the asphalt paver. The control system includes an automatic mode and when in automatic mode the system modifies the tamping frequency to better achieve a desired number of tamps per foot traveled irrespective of speed. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based in part upon a U.S. Provisional Patent Application, Serial No. 60/250,544, filed Dec. 1, 2000.
TECHNICAL FIELD
The present invention relates generally to kitchen utensils, and is particularly directed to a kitchen utensil of the type which both contains liquid (such as soap) and pushes refuse into a kitchen sink garbage disposal. The invention is specifically disclosed as a garbage disposal “plunger” that is placed into the opening of a garbage disposal up to a predetermined distance, but is prevented from being inserted past that predetermined distance by a stopper member, and which exhibits a removable lid to dispense a liquid contained therewithin.
BACKGROUND OF THE INVENTION
Kitchen utensils, used to push refuse into a kitchen sink garbage disposal, are fairly well known in the art as disclosed by way of example in U.S. Pat. No. 3,427,636 to Seifert, U.S. Pat. No. 3,765,275 to Johnson, U.S. Pat. No. 4,268,080 to Lindley, and U.S. Pat. No. 4,745,642 to Shands. For instance, the Shands device merely provides a spherical knob for the user to grip while using the device, which does not, however, allow a user's hand to be in a position to employ a substantial gripping posture. Similarly, the Seifert device provides a handle only for the user to hold, and does not provide a knob portion to prevent the user's hand from slipping off the device. The Lindley device does not include a structure which specifically prevents the fingers of the user from entering the garbage disposal.
The conventional devices that push refuse into a kitchen sink garbage disposal could easily be improved to eliminate some of their disadvantages. It would, therefore, be advantageous to provide a garbage disposal plunger that manifests improved gripping characteristics and is convenient and safe to use around working garbage disposals.
SUMMARY OF THE INVENTION
Accordingly, it is an advantage of the present invention to provide a garbage disposal waste removing apparatus having a handle portion in conjunction with a knob portion which allows the user to employ a tactile posture that provides better gripping capabilities for convenience of use and added safety.
It is another advantage of the present invention to provide a garbage disposal waste removing apparatus having a stopper portion that is large enough to prevent a user's hand from entering a sink garbage disposal unit to add a further safety feature to a handle portion and a knob portion which allow the user to employ a tactile posture that provides better gripping capabilities.
It is a further advantage of the present invention to provide a garbage disposal waste removing apparatus having a handle portion in conjunction with a knob portion which allows the user to employ a tactile posture that provides better gripping capabilities for convenience of use and added safety, and further includes a plunger portion with a cylindrical shape exhibiting a substantially constant diameter that is long enough to push refuse into the sink garbage disposal, yet is mated to a stopper portion that limits the effective length of the plunger portion so as to not contact the blades of the garbage disposal unit.
It is yet a further advantage of the present invention to provide a garbage disposal waste removing apparatus having a handle portion in conjunction with a knob portion which allows the user to employ a tactile posture that provides better gripping capabilities for convenience of use and added safety, and in which the knob portion also contains a lid that provides access to an interior chamber containing a liquid, which thereby allows the user to dispense the liquid (e.g., a dishwasher detergent) from the interior chamber.
It is still another advantage of the present invention to provide a garbage disposal waste removing apparatus having a stopper portion that is large enough to prevent a user's hand from entering a sink garbage disposal unit to add a further safety feature to a handle portion and a knob portion which allow the user to employ a tactile posture that provides better gripping capabilities, and in which the knob portion also contains a lid that provides access to an interior chamber containing a liquid, which thereby allows the user to dispense the liquid (e.g., a dishwasher detergent) from the interior chamber.
It is still a further advantage of the present invention to provide a garbage disposal waste removing apparatus having a handle portion in conjunction with a knob portion that also contains a lid that provides access to an interior chamber containing a liquid, which thereby allows the user to dispense the liquid (e.g., a dishwasher detergent) from the interior chamber, and further includes a plunger portion with a cylindrical shape exhibiting a substantially constant diameter that is long enough to push refuse into the sink garbage disposal, yet is mated to a stopper portion that limits the effective length of the plunger portion so as to not contact the blades of the garbage disposal unit.
Additional advantages and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention.
To achieve the foregoing and other advantages, and in accordance with one aspect of the present invention, an improved garbage disposal plunger device is provided that, in a preferred embodiment, is constructed of molded plastic so as to be lightweight yet of sturdy construction. The plunger device is designed to push refuse into a standard kitchen sink garbage disposal unit that grinds waste and sends it down the drain pipe. The device includes four major sections: a knob portion or member, a handle portion or member, a stopper portion or member, and a plunger portion or member.
The knob portion/member has an overall rounded appearance and is used to prevent the human hand of a human user from slipping while gripping the plunger device. The handle portion/member acts as a shank between the gripable knob and the plunger, and has an outline that exhibits a mildly curved convex shape. The gradually shaped convex surface of the handle, in conjunction with the knob portion, is designed to enhance the gripping capabilities of the human user while also providing a surface shape that aids comfort when gripped by the user's hand.
The knob portion exhibits an outer contour shape that exhibits a maximum cross-section near the end of the plunger apparatus that is proximal to the human user (and distal from the garbage disposal unit), yet smoothly changes to a minimum cross-section at the very proximal end portion of the plunger apparatus. In addition, the knob's maximum cross-section smoothly changes to a smaller cross-section at a location where it meets said handle member in their adjacent relationship. This smaller cross-section of the knob as it meets the handle portion provides a contoured surface area that is easily gripped by the fingers of a human hand. Moreover, the maximum cross-section in combination with the smoothly changing minimum cross-section at the very end of the knob provide a different contoured surface area that mates well to the palm of a human hand. This shape enhances the “gripability” of the plunger apparatus by the user's hand.
The stopper portion/member is located approximately at the mid-portion of the plunger device. The stopper portion manifests a larger diameter as compared to both the handle portion and the plunger portion, and is used as a “stopper” to prevent the plunger portion of the device from contacting the blades of the garbage disposal. Also, the stopper portion prevents the human hand of the user from entering the garbage disposal.
The plunger portion/member is used to push the refuse into the garbage disposal unit. The plunger portion is mainly cylindrical in shape, having a substantially constant diameter. In the preferred embodiment, the main diameter of the plunger portion is sized to fit into the standard kitchen garbage disposal unit opening, with a small amount of clearance for an easy insertion fit.
In an alternative preferred embodiment, the garbage disposal plunger device has a lid at its top portion (i.e., at the handle's knob) that can be removed to allow access to an interior volume which contains a liquid. This interior volume can run essentially throughout the entire inner surfaces that make up the molded walls of the device, and the liquid contained therewithin could be a dishwasher detergent, for example, or some other liquid that is useful in the kitchen. Other useful liquids could include hand soap or a sink cleanser, for example. The lid could be a snap-on/snap-off cap that is hinged, or that literally snaps completely off, or it could be a threaded design that twists on and off, which is the embodiment illustrated below.
Still other advantages of the present invention will become apparent to those skilled in this art from the following description and drawings wherein there is described and shown a preferred embodiment of this invention in one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description and claims serve to explain the principles of the invention. In the drawings:
FIG. 1 is a perspective view from the front and the side of a garbage disposal plunger built according to the principles of the present invention.
FIG. 2 is a perspective view of the garbage disposal plunger of FIG. 1 showing the apparatus from a view that is further along its side.
FIG. 3 is a front elevational view of the garbage disposal plunger of FIG. 1 .
FIG. 4 is a rear elevational view of the garbage disposal plunger of FIG. 1 .
FIG. 5 is a side elevational view of the garbage disposal plunger of FIG. 1 from its right side (as viewed in FIG. 1 ).
FIG. 6 is a side elevational view of the garbage disposal plunger of FIG. 1 from its left side (as viewed in FIG. 1 ).
FIG. 7 is a top plan view of the garbage disposal plunger of FIG. 1 .
FIG. 8 is a bottom plan view of the garbage disposal plunger of FIG. 1 .
FIG. 9 is a perspective view from the front and the side of a second preferred embodiment of a garbage disposal plunger built according to the principles of the present invention.
FIG. 10 is a perspective view of the garbage disposal plunger of FIG. 9 showing the apparatus from a view that is further along its side.
FIG. 11 is a front elevational view of the garbage disposal plunger of FIG. 9 .
FIG. 12 is a rear elevational view of the garbage disposal plunger of FIG. 9 .
FIG. 13 is a side elevational view of the garbage disposal plunger of FIG. 9 from its right side (as viewed in FIG. 9 ).
FIG. 14 is a side elevational view of the garbage disposal plunger of FIG. 9 from its left side (as viewed in FIG. 9 ).
FIG. 15 is a top plan view of the garbage disposal plunger of FIG. 9 .
FIG. 16 is a bottom plan view of the garbage disposal plunger of FIG. 9 .
FIG. 17 is front elevational view in partial cross-section of the garbage disposal plunger of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings, wherein like numerals indicate the same elements throughout the views.
Referring now to the drawings, FIG. 1 shows a garbage disposal plunger device generally designated by the reference numeral 10 that is constructed in accordance with the principles of the present invention. The device could be made of any durable material including plastics, metal or wood. In a preferred embodiment, the device 10 would be made of molded plastic, but any suitable material could be used without departing from the principles of the present invention. The plunger device 10 includes four major sections: a handle portion 40 , a knob portion 50 , a stopper portion 20 and a plunger portion 30 .
The handle portion 40 preferably exhibits a contoured surface having a gradual convex shape, as seen at 42 , with a maximum outer diameter 44 at a distance that is approximately halfway between a top minimum outer diameter at 46 and a bottom minimum outer diameter at 48 . This configuration gives the handle portion 40 an overall curved shape. The gradually shaped convex surface 42 is designed to aid a human user of the device 10 for maximum gripping capabilities and comfort.
The handle portion 40 also includes a through hole 60 located in an area near the boundary between the handle portion 40 and the knob portion 50 . A string (not shown in FIG. 1) can be inserted through the through hole 60 to enable the device 10 to be hung on a hook in a household pantry or any other convenient location as desired by the human user. Such a through hole 60 could be located at other locations of the device 10 without departing from the principles of the present invention, or optionally the through hole could be omitted entirely.
The knob portion 50 tends to prevent the human hand from slipping while gripping the handle portion 40 . The knob portion 50 preferably exhibits a rounded contour surface at 56 , having a maximum outer diameter seen at 54 . This configuration also gives the knob portion 50 an overall rounded appearance.
The plunger portion 30 preferably exhibits a cylindrical surface 36 of substantially constant diameter, having a planar surface 32 , at the distal end of the device 10 . A rounded edge at 34 changes the diameter between the planar surface 32 at the distal end of the device 10 and the cylindrical surface 36 of the plunger portion 30 . It will be understood that the overall outer dimensions of plunger portion 30 are not constrained to be an exact cylinder with a perfectly straight contour, but instead could exhibit a mildly curved or tapered shape without departing from the principles of the present invention.
The stopper portion 20 is used to protect the hand of the human user from accidentally entering the garbage disposal, and to prevent the distal end surface at 32 from contacting the moving blades of a garbage disposal in use while the device 10 is being placed into the bottom area of a sink. The stopper portion exhibits a maximum outer diameter at 22 which is also the maximum outer diameter of the entire device 10 . FIG. 1 shows a portion at 26 along the bottom area of the stopper portion 20 , which exhibits a change in diameter 26 between the maximum diameter at 22 of the stopper portion 20 and the cylindrical surface 36 of the plunger portion 30 . A substantially symmetrical change in diameter is also exhibited along the top area at 24 of the stopper portion 20 , which is not shown in FIG. 1 . Thus the stopper portion exhibits rounded, substantially smoothly outer edges due to its outer contoured shape at 22 , 24 , and 26 (see FIG. 3 ).
FIG. 2 shows a second perspective view from further along the side of the plunger device 10 . FIG. 2 shows a string 62 or similar flexible object which is placed through the hole 60 . String 62 is used for hanging the device 10 , as noted above. As can be seen in this view, the plunger device 10 is substantially of the same shape as viewed in FIG. 1 .
FIG. 3 shows a front elevational view of the plunger device 10 . In FIG. 3, the proximal end surface at 52 of the device 10 can be viewed, as well as the most proximal point or peak of the knob at 58 . Additionally, the rounded top surface 24 of the stopper portion 20 can be seen in this view. FIG. 3 more clearly shows the planar shape of the distal surface 32 of the device 10 , and the rounded change in diameter at 34 of the plunger portion 30 .
The knob portion 50 exhibits an outer contour shape that exhibits a maximum cross-section at 54 near the end of the plunger apparatus, and smoothly changes to a minimum cross-section at 58 that form the very proximal end portion of the plunger apparatus (at the point or peak 58 ). This smoothly changing cross-sectional area is due to the rapidly decreasing diameter of the knob portion, as viewed at 52 , between the peak 58 and the maximum diameter at 54 .
In addition, the knob's maximum cross-section at 54 smoothly changes to a smaller cross-section at a location where it meets said handle member (i.e., at 46 ) in their adjacent relationship. This smaller cross-section of the knob at 46 as it meets the handle portion provides a contoured surface area at 56 that is easily gripped by the fingers of a human hand. Moreover, the maximum cross-section at 54 in combination with the smoothly changing minimum cross-section at the very end of the knob (i.e., and the peak 58 ) provide a different contoured surface area that mates well to the palm of a human hand. This shape enhances the “gripability” of the plunger apparatus by the user's hand.
FIG. 4 shows a rear elevational view of the plunger device 10 . FIG. 4 indicates a constant diameter “D” of the plunger portion 30 . In the preferred embodiment, the diameter D is sized to easily fit into a standard kitchen sink drain hole. Additionally, the plunger portion 30 has a length, “L”, which in the preferred embodiment is short enough not to touch the blades of the garbage disposal yet long enough to effectively push all the garbage into the disposal.
FIG. 5 and FIG. 6 are a right side elevational view and a left side elevational view of the plunger device 10 , respectively. FIGS. 5 and 6 show the same general features as seen in FIG. 4 .
FIG. 7 is a top planar view of the plunger device IC. FIG. 7 shows the rounded outer shape of the stopper portion 20 with its maximum outer diameter at 22 , the knob portion 50 with its maximum outer diameter 54 , and a peak or most proximal point 58 in the knob portion 50 .
FIG. 8 is a bottom planar view of the plunger device 10 . FIG. 8 shows the rounded outer shape of the stopper portion 20 with its maximum outer diameter 22 . FIG. 8 also shows the rounded outer shape of the cylindrical plunger portion 30 having a distal end surface 32 which is preferably planar, and which has its circular outer diameter (in this view) at 36 .
Referring now to FIG. 9, an alternative embodiment of a garbage disposal plunger device is generally designated by the reference numeral 110 , and is constructed in accordance with the principles of the present invention. The plunger device 110 is generally designed to be constructed of plastic, preferably using a plastic blow molding process. This plunger device 110 could be made of an alternative material, however, this alternative embodiment preferably includes an interior chamber to hold a liquid material, and is therefore essentially hollow in construction. Plunger device 110 includes four major sections: a handle portion 140 , a knob portion 150 , a stopper portion 120 and a plunger portion 130 .
The knob portion 150 includes a removable lid 170 , and a lid gap at 190 is illustrated as the separation line between the upper and lower members of the knob portion 150 . The upper member of the knob portion 150 includes the surfaces 152 and 154 , which are described below in greater detail. The lower member of the knob portion 150 includes the surfaces 146 and 156 , which are described below in greater detail. Finally, the details of the lid 170 construction are discussed below with regard to the discussion of FIG. 17 .
The handle portion 140 preferably exhibits a contoured surface having a gradual convex shape, as seen at 142 , with a maximum outer diameter 144 at a distance that is approximately halfway between a top minimum outer diameter at 146 and a bottom minimum outer diameter at 148 . This configuration gives the handle portion 140 an overall curved shape. The gradually shaped convex surface 142 is designed to aid a human user of the device 110 for maximum gripping capabilities and comfort.
The handle portion 140 also includes a through hole 160 located in an area near the boundary between the handle portion 140 and the knob portion 150 . A string (not shown in FIG. 9) can be inserted through the through hole 160 to enable the plunger device 110 to be hung on a hook in a household pantry or any other convenient location as desired by the human user. Such a through hole 160 could be located at other locations of the device 110 without departing from the principles of the present invention, or optionally the through hole could be omitted entirely.
The knob portion 150 tends to prevent the human hand from slipping while gripping the handle portion 140 . The knob portion 150 preferably exhibits a rounded contour surface at 156 , having a maximum outer diameter seen at 154 . This configuration also gives the knob portion 150 an overall rounded appearance.
The plunger portion 130 preferably exhibits a cylindrical surface 136 of substantially constant diameter, having a planar surface 132 , at the distal end of the device 110 . A rounded edge at 134 changes the diameter between the planar surface 132 at the distal end of the device 110 and the cylindrical surface 136 of the plunger portion 130 . It will be understood that the overall outer dimensions of plunger portion 130 are not constrained to be an exact cylinder with a perfectly straight contour, but instead could exhibit a mildly curved or tapered shape without departing from the principles of the present invention.
The stopper portion 120 is used to protect the hand of the human user from accidentally entering the garbage disposal, and to prevent the distal end surface at 132 from contacting the moving blades of a garbage disposal in use while the device 110 is being placed into the bottom area of a sink. The stopper portion exhibits a maximum outer diameter at 122 which is also the maximum outer diameter of the entire device 110 . FIG. 9 shows a portion at 126 along the bottom area of the stopper portion 120 , which exhibits a change in diameter 126 between the maximum diameter at 122 of the stopper portion 120 and the cylindrical surface 136 of the plunger portion 130 . A substantially symmetrical change in diameter is also exhibited along the top area at 124 of the stopper portion 120 , which is not shown in FIG. 9 . Thus the stopper portion exhibits rounded, substantially smoothly outer edges due to its outer contoured shape at 122 , 124 , and 126 (see FIG. 11 ).
FIG. 10 shows a second perspective view from further along the side of the plunger device 110 . FIG. 10 shows a string 162 or similar flexible object which is placed through the hole 160 . String 162 is used for hanging the device 110 , as noted above. As can be seen in this view, the plunger device 110 is substantially of the same shape as viewed in FIG. 9 .
FIG. 11 shows a front elevational view of the plunger device 110 . In FIG. 11, the proximal end surface at 152 of the device 110 can be viewed, as well as the most proximal point or peak of the knob at 158 . Additionally, the rounded top surface 124 of the stopper portion 120 can be seen in this view. FIG. 11 more clearly shows the planar shape of the distal surface 132 of the device 110 , and the rounded change in diameter at 134 of the plunger portion 130 .
The knob portion 150 exhibits an outer contour shape that exhibits a maximum cross-section at 154 near the end of the plunger apparatus, and smoothly changes to a minimum cross-section at 158 that form the very proximal end portion of the plunger apparatus (at the point or peak 158 ). This smoothly changing cross-sectional area is due to the rapidly decreasing diameter of the knob portion, as viewed at 152 , between the peak 158 and the maximum diameter at 154 .
In addition, the knob's maximum cross-section at 154 smoothly changes to a smaller cross-section at a location where it meets said handle member (i.e., at 146 ) in their adjacent relationship. This smaller cross-section of the knob at 146 as it meets the handle portion provides a contoured surface area at 156 that is easily gripped by the fingers of a human hand. Moreover, the maximum cross-section at 154 in combination with the smoothly changing minimum cross-section at the very end of the knob (i.e., and the peak 158 ) provide a different contoured surface area that mates well to the palm of a human hand. This shape enhances the “gripability” of the plunger apparatus by the user's hand.
FIG. 12 shows a rear elevational view of the plunger device 110 . FIG. 12 indicates a constant diameter “D” of the plunger portion 130 . In the preferred embodiment, the diameter D is sized to easily fit into a standard kitchen sink drain hole. Additionally, the plunger portion 130 has a length, “L”, which in the preferred embodiment is short enough not to touch the blades of the garbage disposal yet long enough to effectively push all the garbage into the disposal.
FIG. 13 and FIG. 14 are a right side elevational view and a left side elevational view of the plunger device 110 , respectively. FIGS. 13 and 14 show the same general features as seen in FIG. 12 .
FIG. 15 is a top planar view of the plunger device 110 . FIG. 15 shows the rounded outer shape of the stopper portion 120 with its maximum outer diameter at 122 , the knob portion 150 with its maximum outer diameter 154 , and a peak or most proximal point 158 in the knob portion 150 .
FIG. 16 is a bottom planar view of the plunger device 110 . FIG. 16 shows the rounded outer shape of the stopper portion 120 with its maximum outer diameter 122 . FIG. 16 also shows the rounded outer shape of the cylindrical plunger portion 130 having a distal end surface 132 which is preferably planar, and which has its circular outer diameter (in this view) at 136 .
FIG. 17 shows some of the interior details of the knob portion 150 , especially of the construction of the lid 170 . The end surface 152 , with its uppermost point at 158 , and the maximum outer diameter 154 of the rounded contour surface make up the outer surface of the lid 170 , while an interior threaded wall 172 comprises the member of lid 170 that mates to the remaining members of the plunger device 110 .
The “bottom” member (as seen in FIG. 17) includes areas of the knob portions 150 , including the rounded contour surface 156 and the top minimum outer diameter at 146 , which make up the external surfaces of this area of the knob portion, as well as the through hole 160 . The interior of the bottom member of knob portion 150 includes a threaded spout 180 , and a planar upper surface at 184 . The spout 180 essentially comprises a hollow cylinder that is threaded along the outer surface of its vertical (as seen in FIG. 17) wall 182 . These external threads are designed to mate with the internal threads of the wall 172 of the lid 170 . It is preferred that the threaded walls 172 and 182 , when engaged, provide a largely liquid-tight seal, while at the same time it is preferred that the threaded engagement can be broken by a simple twisting motion of the lid by a human hand.
The interior volume or “chamber” of plunger device 110 will preferably include all interior spaces that are not needed to maintain structural integrity of the entire device, so that a maximum quantity of liquid can be placed therewithin. Some of the interior volume is visible on FIG. 17, including a space 192 that is nearest the lid gap 190 and above (as seen in FIG. 17) the through hole 160 , and including a space 194 that is below (as seen in FIG. 17) the through hole 160 .
By making the plunger device 110 into a liquid-containing “bottle,” the present invention can thereby readily perform two functions: (1) that of holding and dispensing a liquid (such as a hand soap or a dish washing detergent) through the spout 180 , and (2) acting as a garbage disposal plunger that is placed into the opening of a garbage disposal up to a predetermined distance, but is prevented from being inserted past that predetermined distance by the stopper member 22 .
It will be understood that the precise construction of the plunger device 110 (or 10 ) can be modified to various degrees without departing from the principles of the present invention. For example, the threaded lid 170 could be eliminated by using a hinged lid structure, so that the lid would be “snapped” closed and “unsnapped” open by the human user. Certainly other forms of lid structures are envisioned by the inventors, including a lid that slides “up” to be in an “open” position, and then slides “down” to be in a “closed” position. Moreover, the lid could exhibit child-proof characteristics.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto. | A garbage disposal plunger is provided that is designed to push refuse into a standard kitchen sink garbage disposal unit. The plunger apparatus includes four major sections: a knob portion, handle portion, stopper portion, and plunger portion. The knob portion is used to prevent the human hand of the user from slipping while gripping the device; the handle portion acts as a shank between the gripable knob and the plunger and, in conjunction with the knob portion, is designed to aid the human user of the device for maximum gripping capabilities and comfort. The stopper portion manifests a larger diameter which prevents the plunger portion of the device from contacting the blades of the garbage disposal, and prevents the human hand of the user from entering the garbage disposal. The plunger apparatus contains a liquid which can be dispensed through a spout which has a lid. |
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BACKGROUND OF THE INVENTION
1. Technical Field
This device relates to post anchoring systems that are used to mount a post in the ground by use of separate anchored structures.
2. Description of the Prior Art
Prior art devices of this type have relied on a number of different structural configurations to mount posts in the ground--see for example U.S. Pat. Nos. 427,815; 4,156,332; 844,726; 870,752; 4,271,646; and applicant's U.S. Pat. No. 4,644,713.
In U.S. Pat. No. 427,815 a bottom for fence posts is disclosed having a U-shaped channel upper portion and a cross sectionally T-shaped lower portion that is driven into the ground. A post is bolted within the channel portion with the post resting on the lower portion.
In U.S. Pat. No. 4,156,332 a post assembly is disclosed having a stake portion and a post support platfrom with an upstanding angular member thereon. An alternate form of the invention discloses a pair of oppositely disposed apertured plates with intrically formed downturned extending ground engaging angles.
U.S. Pat. No. 844,726 discloses a fence post setting tool having a hollow pointed stake portion with a post receiving socket formed on the opposite end.
In U.S. Pat. No. 870,752 a clothes line prop is disclosed wherein a cylindrical socket having a back plate and side flanges as shown.
U.S. Pat. No. 4,271,646 discloses a post support means having a stake formed of crossed angular members and a post receiving socket on one end thereof.
In applicant's own U.S. Pat. No. 4,644,713 a post anchor device is disclosed which utilizes a hollow stake configuration with an upstanding bracket into which the bottom of the post is positioned and then secured.
SUMMARY OF THE INVENTION
A post and anchor device to rapidly position and support a post in the ground. the post and anchor device is comprised of an anchor stake having an elongated angle configuration with a ground support element and a post engaging element positioned in spaced relation thereon. The anchor stake is driven into the ground and is then wedgeably engaged in an axial bore of a post positioned over the anchor stake providing a secure upright mounting of the post.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prospective view of the post and anchor stake device with portions broken away.
FIG. 2 is a sectional view on lines 2--2 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A post and anchoring device 10 can be seen in FIG. 1 of the drawings comprising a post assembly 11 and an anchor stake 12.
The post assembly is comprised of a main vertically aligned solid wood post 13 having a top end portion 14 and an oppositely disposed free end portion 15 thereon.
A centrally aligned bore extends inwardly from said free end portion 15 at 16.
A horizontally disposed cross member 17 is secured on and extends from said top end portion 14 of the main post 13. The cross member 17 is notched transversally in spaced relation to its free end at 18 for receiving engagement with said top end portion 14 of the main post 13 as will be understood by those skilled in the art.
A cross sectionally triangular shaped corner support 19 is secured by fasteners (not shown) at the intersection of the herein before described main post 13 and the cross member 17 for additional support thereto.
Referring now to FIGS. 1 and 2 of the drawings the anchor stake 12 can be seen comprising an elongated angle bar 20 having spaced parallel angular edges 21. A ground engaging anchor plate 22 is secured across the edges 21 midway along said angle bar 20.
The ground anchor plate 22 extends beyond said edges 21 providing an increased ground engagement characterized by such well known structures within the art. A post anchor plate 23 is secured to the angle bar 20 across and beyond the edges 21 in longitudinally spaced relation to said ground anchor plate 22.
The post anchor plate 23 has tapered oppositely disposed sides 23A and 23B angled outwardly from said angle bar 20 towards said ground anchor plate 22.
In use the post and anchor device can be seen with the anchor stake 12 driven into the ground G to a depth that falls just midway between said post and ground anchor plates 22 and 23 respectively. The mounting post 13 with its central bore at 16 is driven down over said upstanding portion of said anchor stake 12, achieving a friction fit between said post 13, anchor stake 12, and anchor plate 23. The post anchor plate 23 with its tapered sides 23A and 23B is driven into wedging engagement within said bore at 16 impinging into the main post 13 beyond the confines of the bore at 16. The wedging action of said post anchor plate 23 securely fastens the post assembly 11 on to the anchor stake in a vertical upstanding position.
Referring to FIG. 1 of the drawings a depth indicator coating is shown at 24 in which a colored coating is applied to the anchor stake 12 including the ground anchor plate 22. This depth coating indicator 24 is used to guide the user to the proper depth that the stake 12 should be driven in the ground.
It will thus be seen that a new and novel post and anchor device has been illustrated and described and that various changes and modifications may be made therein without departing from the spirit of the invention, | A post and anchoring device that rapidly secures a wooden post to the ground. An anchor stake is driven into the ground to a predetermined depth onto which a wooden post having an appeal bore is insertively engaged and locked to the anchor stake. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to downhole oil well tools namely run on a pipe string, impact or jarring type downhole oil well tools, and more particularly, to a fluid operated jarring tool for use in well bores that jars upwardly and downwardly and wherein the tool has a bit or working end that rotates when the bit is not subject to weight of the pipe string in order to prevent imprinting on the drilling surface.
2. General Background
In downhole well operation, there is a need for jarring or impact devices. For example, in workover operations using a pipe string such as coil tubing or snubbing equipment, it is necessary to provide downward jarring impact at the bottom of the string to enable the string to pass obstructions or otherwise enter the well. During fishing operations or other operations, such as paraffin scraping, it is sometimes necessary to apply upward jarring or impact forces at the bottom of the string if the fishing tool or the like becomes stuck.
In prior U.S. Pat. No. 3,946,819, naming the applicant herein as patentee, there is disclosed a fluid operated well tool adapted to deliver downward jarring forces when the tool encounters obstructions. The tool of my prior U.S. Pat. No. 3,946,819, generally includes a housing with a tubular stem member telescopically received in the housing for relative reciprocal movement between a first terminal position and a second terminal position in response to fluid pressure in the housing. The lower portion of the housing is formed to define a downwardly facing hammer and the stem member includes an upwardly facing anvil which is positioned to be struck by the hammer. The tool includes a valve assembly that is responsive to predetermined movement of the stem member toward the second terminal position to relieve fluid pressure and permit the stem member to return to the first terminal position. When the valve assembly relieves fluid pressure, the hammer moves into abrupt striking contact with the anvil. The tool of prior U.S. Pat. No. 3,946,819, is effective in providing downward repetitive blows. The tool of the '819 patent will not produce upwardly directed blows.
In prior U.S. Pat. No. 4,462,471, naming the applicant herein as patentee, there is provided a bidirectional fluid operated jarring apparatus that produces jarring forces in either the upward or downward direction. The jarring apparatus was used to provide upward or downward impact forces as desired downhole without removing the tool from the well bore for modification. The device provides downward jarring forces when the tool is in compression, as when pipe weight is being applied downwardly on the tool, and produces strong upward forces when is in tension, as when the tool is being pulled upwardly.
In U.S. Pat. No. 4,462,471, there is disclosed a jarring or drilling mechanism that may be adapted to provide upward and downward blows. The mechanism of the '471 patent includes a housing having opposed axially spaced apart hammer surfaces slidingly mounted within the housing between the anvil surfaces. A spring is provided for urging the hammer upwardly. When it is desired to use the mechanism of the '471 patent for jarring, a valve including a closure and a compression spring is dropped down the string to the mechanism.
In general, the mechanism of the '471 patent operates by fluid pressure acting on the valve and hammer to urge the valve and hammer axially downwardly until the downward movement of the valve is stopped, preferably by the full compression of the valve spring. When the downward movement of the valve stops, the seal between the valve and the hammer is broken and the valve moves axially upwarly.
The direction jarring of the mechanism of the '471 patent is determined by the relationship between the fluid pressure and the strength of the spring that urges the hammer upwardly. Normally, the mechanism is adapted for upward jarring. When the valve opens, the hammer moves upwardly to strike the downwardly facing anvil surface of the housing. The mechanism can be made to deliver a downward and upward blow by increasing the fluid pressure and decreasing the strength of the spring that urges the hammer upwardly. When the mechanism is so arranged, the downward momentum of the hammer is increased such that the hammer strikes the upwardly facing anvil of the housing prior to being urged upwardly to strike the downwardly facing anvil surface. The mechanism of the '471 patent can be adapted to produce only downward forces by either shortening the length of the valve spring or by lengthening the valve such that the valve recloses prior to the hammers reaching the downwardly facing anvil surface on the upstroke.
One of the problems with these prior art devices is the fact that during impact drilling, imprinting on the drilling surface can occur reducing or preventing penetration. The present invention rotates the working end, eg. a drill bit, during impact drilling. With the present invention, by rotating the bit when it is not subject to weight of the pipe string, very little energy is required. As compared to rotating the bit when it is weighted, this "unweighted" rotation slows bit wear. Thus, impact drilling can proceed with a constant movement or rotation of the bit to prevent imprinting on the drilling surface.
SUMMARY OF THE PRESENT INVENTION
The present invention provides an improved well tool for use with an elongated pipe string that can load the tool transmitting impact thereto. The tool includes a housing connectable to and in fluid communication with the lower end of a pipe string, and defining at least one fluid chamber therein. A tubular stem having a flow channel therethrough is telescopically received by the housing for relative reciprocal movement and sealing engagement therewith between a first "pressured up" unloaded and a second "impact" loaded position.
An impact receptive working member is attached to one end of the stem for relative movement therewith between the first and second positions, wherein impact is transmitted to the working member in the second impact position.
A valve carried by the housing is operable by fluid pressure transmitted by the pipe string, and responsive to a predetermined movement of the stem with respect to the housing relieves fluid pressure in the tool housing permitting return of the stem and the housing to the first "pressure up" position.
Biasing springs disposed in the chamber bias the stem member and the housing toward the first position and bias the valve means into a closed position when the stem member and the housing are in the first "pressure up" position. An interface between the housing and the stem rotate the working member during relative movement of the housing and the stem.
In the preferred embodiment, the interface includes a clutch assembly for rotating the working member in one rotational direction and for preventing rotation of the working member in the opposite rotational direction.
In the preferred embodiment, the interface comprises a clutch assembly with a sleeve positioned concentrically between the housing and the stem for rotating the working member when the housing and stem move relative to one another.
In the preferred embodiment, the clutch assembly includes a tubular member having one or more spiralling and longitudinally extending slots and the slots define a track, and a corresponding number of pins connects the housing and tubular stem together.
In the preferred embodiment, the interface rotates the working member at least partially when the working member is unloaded.
In the preferred embodiment, the working member is rotated prior to loading of the working member with the pipe string.
In the preferred embodiment, the tubular stem is contained within the housing and the interface sleeve is positioned concentrically between the housing and the stem.
In the preferred embodiment, the interface includes a tubular member having an enlarged lower end that engages the housing upon impact transmitted to the bit.
In the preferred embodiment, the valving means includes a tubular valve element having a fluid port therethrough, one end portion communicating with the fluid chamber and the other end portion positioned to form a fluid seal with the tubular stem for stopping fluid flow therethrough to the working member.
In the preferred embodiment, the tubular stem is an elongated generally cylindrical stem with a central stem flow bore or channel therethrough and the flow bore or channel is in fluid communication with the working member.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:
FIG. 1 is a sectional elevational view of the preferred embodiment of the apparatus of the present invention during impact;
FIG. 2 is a sectional elevational view of the preferred embodiment of the apparatus of the present invention illustrating the tool in an unloaded position and with the valve closed;
FIG. 3 is a sectional elevational view of the preferred embodiment of the apparatus of the present invention illustrating the tool in an unloaded position with the valve opened;
FIG. 4 is a sectional elevational view of the preferred embodiment of the apparatus of the present invention in the impact position with the valve opened;
FIG. 5 is a sectional view taken along lines 5--5 of FIG. 4;
FIGS. 5A--5B are fragmentary views illustrating the locking cam portion of the clutch member;
FIG. 6 is a sectional view taken along lines 6--6 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-4 illustrate the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10. In FIGS. 1-4, there can be seen sequential sectional elevational views showing operation of the tool beginning with the post impact position (immediately prior to pressuring up) that is shown in FIG. 1 and ending with the tool impact position shown in FIG. 4.
Otherwise, the component parts and construction of the apparatus 10 can be seen by viewing the FIGS. 1-4 at one time.
The apparatus 10 includes a housing 11 having upper 11A and lower 11B end portions. The housing provides at upper end portion 11A, a longitudinally extending port 12. The upper end portion 11A of the tool body 11 can be attached for example to a running and pulling sub (not shown) which is then attached to a pipe string such as, for example, a coil tubing unit. The connection of the tool 10 to a coil tubing unit using a running an pulling sub is described generally in my prior U.S. Pat. Nos. 3,946,819 and 4,462,471 which are incorporated herein by reference.
The lower end portion 11B of the tool body 11 carries a working member such as drill bit 14. A central tubular section 13 of housing 11 with an annular wall 15 defines an internal fluid chamber 16. Chamber 16 communicates with port 12 at 17 so that fluid transmitted to the tool 11 through the pipe string of the coil tubing unit can be used to "pressure up" the tool by conveying pressurized fluid to the tool chamber 16 via port 12.
Fluid chamber 16 carries valving member 20, a longitudinally extending valve member having a generally X-shaped cross section such as the valving member shown in FIG. 6 of my prior U.S. Pat. No. 3,946,819.
Valve member 20 includes an upper 21 and lower 22 end portions. Lower end portion 22 can form a fluid tight seal at seat 23 with the upper end portion 26 of tubular stem 25. Coil spring 24 biases valving member 20 upwardly when the seal at seat 23 between lower end portion 22 of valve 20 and the upper end portion 26 of stem 25 is broken. Thus, 23 defines a valve seat for sealing the longitudinal flow bore 27 of stem 25.
The lower most end portion 28 of stem 25 carries working member 14, such as a drill bit. The central longitudinal stem flow bore 27 thus extends the full length of stem 25 communicating with the bore 29 of working member 14. When fluid flows downwardly in the tool 10 and more particularly through chamber 16 and into bore 27 of stem 25, flow can also communicate with and flow through bore 29 of working member 14, exiting the bit or working member 14, carrying away cuttings generated during drilling or like operations. The position of the tool 10 in FIG. 1 illustrates the impact position in that the housing 11 rests upon the bit 14 with the annular shoulder 11C of housing 11 resting upon the annular shoulder 32 of clutch 35.
The lowermost end portion of clutch member 35 is enlarged below shoulder 32. Clutch 35 allows only clockwise rotation of bit 14 during operation as viewed from the top view. This rotation also tightens all threaded connections of the tool apparatus 10..
In FIG. 2, a "pressured up" position is shown. Fluid under pressure is entering chamber 16 via port 12 (see arrows 40, FIG. 2) and forces housing 11 to rise with respect to stem 25 and bit 14. When member 11 starts its upward movement, the weight of the pipe string is supported by body 11, through stem 25, through bit 14 to the drilling surface. During this upward travel, member 35 is unloaded and the clutch allows the member 35 to rotate counter-clockwise around stem member 25, by means of the helix slots 50 and the pins 60.
The lowermost shoulder 11C of housing 11 is now spaced from the upper annular shoulder 32 of clutch 35. In the position of FIG. 2, coil spring 24 has been fully compressed, and the valve member 20 can move no further in the direction of arrow 41 with respect to housing 11 because the coil spring 24 is fully compressed above by shoulder 42 of valving member 20, and below by the annular shoulder 43 of tubular section 13. Because of the presence of pressurized fluid within fluid chamber 16, housing 11 continues to rise, carrying valving member 20 with it, and away from stem 25 until the seal at seat 23 is broken. Valve 20 travels with sleeve 11, the lower end 22 of valving member 20 lifts from the upper end 26 of stem 25 breaking the seal at 23 so that fluid contained within the chamber 16 is now free to discharge via the stem longitudinal flow bore 27 (FIG. 3).
Diagonal or helical slot 50 of clutch sleeve 35A has rotated upon pin 60 which is connected to the tubular section 13 of housing 11 and more particularly extends from the annular wall 15 portion thereof. The pressurized fluid contained in chamber 16 exits the tool 10 via stem longitudinal bore 27 and the bore 29 of working member 14. This exiting of pressurized fluid helps clean cuttings away from the drilling area.
When pressure within the tool chamber 16 equalizes with external pressure, nothing is preventing the full weight of the pipe string from thrusting the housing 11 downwardly. As the housing 11 moves downwardly as shown by the arrows 44 in FIG. 3, the pin 60 travels in spiralling slot 50 of sleeve 35A causing bit or working member 14 to rotate.
Clutch 35 is a single rotation directional clutch which only allows clockwise rotation of the bit 14. Clutch 35 (FIG. 5) uses a a plurality of small closely spaced cam members C. Such unidirectional clutch cam members C are commercially available. The cams C have flat upper and lower surfaces, and fit within recess 35A. Each cam C has a radially extending vertical surface 71 that is larger than its opposed vertical radial surface 70. Each cam has a smaller inner curved vertical surface 72 and a larger outer curved vertical surface 73. The outer curved surface thus has a locking tip 74 which binds against surface recess 35A when rotation is in one direction. However when rotation is in the opposite direction, the locking tip 74 rotates toward stem 25 so that binding is stopped and rotation permitted.
A feature of the present invention is that rotation of the bit thus takes place prior to loading of the bit with the housing and the pipe string. Notice in FIG. 3 that as the pin 60 moves downwardly through spiralling slot 50, rotation of the bit takes place. It is not until the lower annular shoulder 11C of housing 11 strikes the upper annular shoulder 32 of clutch 35 that the impact is transmitted from the housing 11 and the pipe string directly to the working member 14 (see FIG. 4).
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. | A downhole oil well tool uses impact, reciprocal drilling and an improved rotating bit or like working member, receiving both fluid pressure and weight from an elongated pipe string with a flow bore in order to drive the tool. A valve within tool housing controls fluid pressure to the working end so that the tool pressures up, then releases pressure through the working member allowing the pipe string to load the bit, creating impact. A clutch rotates the working member during drilling to prevent imprint upon the formation. |
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FIELD OF THE INVENTION
The present invention relates generally to the art of window coverings and more particularly to mini blind head rails.
BACKGROUND OF THE INVENTION
Mini blinds have been known and used for many years for the selective admission of light into a room and for privacy. Typically, mini blinds are installed at a window opening and include a plurality of slats that can be pivoted between an open horizontal position and a closed nearly vertical position.
A conventional mini blind includes a head rail mounted to head rail supports positioned near the top of the window opening. The head rail generally has a U-shaped cross-section with an open interior for receiving the various components that control the pivotable slats. The head rail also includes a number of apertures for access to the various control components, e.g. flexible ladders, basket assemblies, and drawcord assemblies.
The flexible ladders which support the pivotable slats are usually connected to the basket assemblies through appropriate apertures in the bottom of the head rail. Additionally, access holes are provided for the pullcord which raises and lowers the bottom rail and the slats, and for the rotating wand used to control the tilter bar which with the basket assemblies. The basket assemblies, in turn, facilitate control of the flexible ladders which allow the slats to pivot between the open and closed positions.
The basket assemblies generally include a framework which rests within the open interior of the head rail and a rotator element to which the flexible ladders are attached. The ladders each have two flexible strings which are suspended from this rotating element with the strings being connected over opposed sides of the rotating element. Thus, when the rotator element is rotated in one direction., one string will be lowered while the other string is raised, and the opposite result is achieved when the element is rotated in the opposite direction. Each ladder also includes a plurality of cross links connected between the two strings. The slats are positioned over these cross links along the length of the ladders. When the rotator elements are rotated, the slats are pivoted as one end of each cross link is pulled upwards while the other end of each cross link is lowered.
To ensure that each ladder and its respective cross links are pivoted the same amount, a tilter bar extends through each rotator element. The tilter bar is connected to a gearbox at one end of the head rail which, in turn, is connected through an appropriate aperture in the head rail to the rotating wand. Thus, a person may rotate the tilter bar by rotating the wand and pivot the slats to a position that allows total privacy or the desired amount of light to pass through the mini blind.
Usually, a pullcord is also employed with a mini blind so the user may raise or lower the slats in the window opening. Generally, the pullcord enters the head rail through an opening equipped with a locking mechanism, extends along the interior of the head rail, and includes a cord that passes out of the head rail at each socket. Each cord passes through axially aligned apertures in the slats and is connected to a bottom rail below the slats. By pulling on the pullcord, the bottom rail will be raised, thereby raising the slats. The locking mechanism is positioned in the pullcord aperture so the pullcord may be locked and the bottom rail suspended at any point between a fully raised position and a fully lowered position.
In current mini blind systems, problems exist with both the head rail and the baskets. Current head rails have a flat bottom wall. The open design does not resist bending, especially when the head rail extends over a long span. Additionally, during manufacture of a mini blind with this type of head rail, it is difficult to determine when the baskets are accurately located over the cord and ladder apertures. Consequently, the basket installer must often make time consuming adjustments to basket position after the baskets are initially installed into the open portion of the head rail. Also, the flat bottom wall can interfere with the pivotal movement of the uppermost slat towards a fully closed position (i.e., vertical). For instance, the top edge of the uppermost slat may contact the bottom wall of the head rail restricting further pivotal motion of the slats and leaving small spaces between the lower slats through which excess light may filter. It would be advantageous to have a head rail designed to alleviate these problems.
Additionally, full closure of the slats is also inhibited by the design of the ladder apertures and cord apertures in both the bottom wall of the head rail and the basket assemblies. Typically, the lower wall of the head rail includes three openings beneath each basket assembly. Ladder strings are threaded through the outermost apertures, while the drawcord extends through the center aperture. The basket has matching apertures which are aligned with the three head rail apertures when the basket is installed. Since the support strings of the ladder go through apertures separated by a central drawcord aperture, the strings cannot move close enough to one another in the fully closed position to fully pivot the cross links and pivotable slats to a vertical position. It would be advantageous to design both the basket and the head rail so the ladder strings could move sufficiently close to one another that full closure is accomplished.
SUMMARY OF THE INVENTION
The present invention features a mini blind system including a stronger head rail which promotes ease of assembly and more complete closure. The head rail includes a pair of generally parallel side walls and a bottom wall, thus providing the head rail with a generally U-shaped cross section. The bottom wall includes flat portions on either side of a recessed channel extending along the length of the head rail. The bottom wall also includes at least one aperture through which both a ladder and drawcord extend.
The apertures are formed in the bottom wall so that a section of the channel portion and sections of the flat portions are removed. Each basket can thus be located by nesting it within the apertures so that it rests against and is supported by the flat portions of the bottom wall. In this manner, each basket can be precisely located in one rapid step during the assembly process. Additionally, the bottom wall aperture is formed as a single aperture through which both the ladder and the drawcord extend.
Similarly, the basket includes an aperture that is generally aligned with the bottom wall aperture. The basket aperture is a single opening through which both the ladder and drawcord extend. Thus, the side support strings of each ladder are free to move closely towards and away from each other, permitting full closure of the mini blind.
How these features of the invention are accomplished will be described in the following detailed description of the preferred embodiment of the invention taken in conjunction with the drawings. Other ways in which they could be accomplished will appear to those skilled in the art after reading the present specification. Such other ways are deemed to fall within the scope of the present invention if they fall within the scope of the claims which follow.
DESCRIPTION OF THE DRAWINGS
The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a perspective view of a mini blind system according to a preferred form of the present invention showing the overall layout of the components;
FIG. 2 is a perspective view generally showing the bottom wall of a prior art head rail;
FIG. 3 is a perspective view generally showing the bottom wall of a head rail according to the present invention;
FIG. 4 is a cross-sectional view of the head rail taken generally/along the line 4--4 of FIG. 3;
FIG. 4A is a cross-sectional view of an alternate head rail;
FIG. 4B is a cross-sectional view of an alternate head rail;
FIG. 4C is a cross-sectional view of an alternate head rail;
FIG. 4D is a cross-sectional view of an alternate head rail;
FIG. 5 is a cross-sectional view of the mini blind system including the head rail according to the present invention taken generally along the line 5--5 of
FIG. 5 is a cross-sectional view of the mini blind system showing the slats in a vertical position; and
FIG. 6 is a perspective exploded view showing the basket assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring generally to FIG. 1, a mini blind system 10 according to the present invention, includes a head rail 12 which is usually mounted near the top of a window opening between a pair of head rail supports 14. As will be appreciated by those skilled in the art, other support structures, including supports intermediate the ends, could be employed. The head rail has a generally U-shaped cross-section and at least one basket assembly 16 and preferably two or more basket assemblies depending on the length of head rail 12. Each basket assembly 16 includes a rotator element 18 mounted within a basket frame 20. These latter elements will be described in greater detail with reference to FIG. 5.
A flexible ladder 22 is suspended from each rotator element. Each flexible ladder includes a pair of side support strings 24 and 24A connected to each other by a plurality of cross links 26. (See also FIG. 5) Pivotable slats 28 are spaced apart from one another and are supported by the cross links 26 as is well known in the art. The uppermost cross link is typically a rigid slat clip 29 which is attached to the uppermost slat 28. Thus, slats 28 rest on the cross links while support string 24A of each flexible ladder 22 is disposed on the front side of the slats and the other support string 24 is disposed on the back side of the slats. The support strings 24 and 24A are similarly connected to the front and back side of each rotator element (See FIG. 5) so that when rotator elements 18 are rotated a first direction, the front support string 24A will move downwardly while the rear support string 24 moves upwardly to pivot the cross links 26 and the slats 28. When the rotator elements 18 are rotated in a second direction, the back support string 24 will move downwardly while the front support string 24A moves upwardly to pivot slats 28 in the opposite direction. In this manner, slats 28 may be pivoted between a fully opened (horizontal) and a fully closed (vertical) position.
A tilter bar 30 extends through each rotator element 18 so they are all rotated simultaneously and by the same amount. Tilter bar 30 is connected to a small gearbox 32 which, in turn, is connected to a control wand 34 through a wand opening 36 formed in head rail 12.
Additionally, the plurality of slats 28 may be raised or lowered in the window opening by a drawcord 38. Drawcord 38 includes one or more draw strings 40 secured to a bottom rail 42 disposed beneath the lowermost of slats 28. From the bottom rail 42, draw strings 40 extend up through axially aligned holes 44 in slats 28, through basket assemblies 16, over rollers 45 (See FIG. 5), and along the interior of head rail 12 to a draw string opening 46. Rollers 45 facilitate the movement of the drawstrings and are each supported by a pair of tabs 47. A locking mechanism 48 (which itself may be of conventional design) is disposed within the drawstring opening 46 to selectively lock the drawstring 40. By pulling on drawcord 38, bottom rail 42 may be raised and lowered to any position the user desires and locked into the desired location using mechanism 48.
As shown in FIG. 2, a conventional head rail 54 according to the prior art includes a pair of side walls 56 spanned by a bottom wall 58. The bottom wall 58 is substantially planar and includes various apertures such as drawcord opening 60 and a wand opening 62. Additionally, basket assemblies are disposed between side walls 56 and over a triple aperture area 64. The triple apertures include narrow outer apertures 65 through which the ladder support strings extend and a center aperture 66. The outer apertures are separated from the center apertures by divider elements 67. The drawstrings extend through openings 66. As discussed previously, aligning the basket assemblies over these apertures 65-66 is often difficult and adds time to the assembly process.
As illustrated generally in FIGS. 3-6, a head rail 12, according to the present invention, includes a pair of generally parallel sidewalls designated as 70 and 72. Sidewalls 70, 72 include top edges 74 and 76 respectively as well as bottom edges 78 and 80 respectively. A bottom wall 82 extends between edges 78 and 80 of side walls 70 and 72. Bottom wall 82 is preferably integral to the other walls and edges, as head rail 12 is typically an extruded element (e.g., extruded aluminum or vinyl or other materials known to the mini blind art). A pair of flanges 84 extend inwardly from the top edges 74 and 76. As shown most clearly in FIG. 4, head rail 12 has a generally U-shaped cross-section enclosing an elongate longitudinal cavity 85. Alternate embodiments of head rail 12 are illustrated in FIGS. 4A-4D and denoted as head rails 12'-12"", respectively.
Bottom wall 82 includes a pair of flat portions 86 adjacent edges 78 and 80 and an intermediate, elongate channel portion 88 which extends inwardly along head rail 12. The preferred configuration for channel portion 88 is a V-shape, with the base of the V being truncated. In this configuration, channel portion 88 forms a channel 90 along the outside surface of bottom wall 82. The channel portion 88 provides head rail 12 with greater structural rigidity to resist bending, particularly in the downward direction.
Although channel portion 88 is preferably formed as shown in FIG. 4, having angled side segments 92 and a short top segment 94, various other cross-sectional configurations can also be used, e.g. a circular, arcuate, or U-shaped channel portion 88' (see FIG. 4A), a V-shaped channel portion 88" (see FIG. 4B), a rectangular channel portion 88'". (see FIG. 4C), or multiple recessed portions forming multiple channels of any of the various cross-sectional configurations (see for example FIG. 4D showing two channel portions 88"" having truncated V cross-sections).
At least one basket assembly aperture 96 and preferably two or more such apertures extend through bottom wall 82. As illustrated generally in FIG. 3, each aperture 96 extends through portions 86 of the bottom wall 82 as well as through channel portion 88. Preferably, each aperture 96 is shaped like a cross including a longitudinal cut-out 98 and a transverse cut-out 100. The longitudinal cut-out 98 is disposed generally through channel portion 88, while the transverse cut-out 100 is disposed perpendicular to longitudinal cut-out 98 and extends into the flat portions 86 of bottom wall 82. This configuration leaves a plurality of corner tabs 102, preferably four, on which each basket assembly 16 may rest when inserted into longitudinal cavity 85.
The longitudinal cut-out 98 of each aperture 96 is appropriately sized so that the basket assembly frame 20 will nest between aperture ends 103 of the channel portion 88 adjacent each aperture 96. The corner tabs 102, formed at each point of intersection between aperture cut-outs 98 and 100, provide a base on which each basket assembly 16 is supported. This feature also assists in the easy location of the basket assemblies 16 since an installer can slide them along channel 85 until they settle between the aperture ends 103 and come to rest on corner tabs 102.
Transverse cut-out 100 provides ample room through which flexible ladder 22 and drawcord 38 may extend. Additionally, cut-outs 98 and 100 are not divided, as was the case with the head rail apertures of the prior art. This is particularly important with respect to transverse cut-out 100 since it allows the vertical support strings 24 and 24A of each ladder 22 to freely move between the outer edges of aperture 96 and the center of aperture 96. As shown in FIG. 5A, support strings 24 and 24A are thus able to move into closer proximity with one another when slats 28 are pivoted to a closed position. This will narrow the gap between the slats 28, so that a greater percentage of the light is blocked by slats 28. Preferably, the uppermost slat is disposed close enough to bottom wall 82 to allow a portion of the slat to be pivoted into channel 90 as shown in FIG. 5A. This blocks a greater percentage of light. Without channel 90, slats 28 could not be moved to their fully closed (vertical) position since the top slat would contact bottom wall 82 before reaching the fully closed position.
Basket frame 20 (See FIG. 6) also includes a similar unobstructed opening 104 which allows support strings 24 free movement between a fully opened position and a fully closed position without contacting any separator elements. Preferably, basket frame 20 has a bottom wall 106 which includes the single unobstructed opening 104. A pair of support walls 108 extend from bottom wall 106 and support rotator element 18. Framework 20 is reinforced by a pair of reinforcement walls or members 110 connected between the outside edges of support walls 108. Opening 104 extends between the reinforcement members and preferably spans more than one half the entire width of bottom wall 106. Of course, framework 20 may have various other configurations that also permit the use of a single unobstructed opening in the lower portion of the basket assembly.
It will be understood that the foregoing description is of a preferred exemplary embodiment of this invention, and that the invention is not limited to the specific forms shown. For example, the ladder apertures may be of various configurations depending on the overall design of the basket assemblies and the generally U-shaped cross-section of the head rail may be changed. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims. | A head rail for a mini blind system is disclosed. The mini blind system includes a plurality of pivotable slats supported on flexible ladders that are connected to basket assemblies mounted in the head rail. The head rail includes a pair of sidewalls and a bottom wall. The bottom wall includes flat wall portions and a recessed channel which strengthens the head rail and allows for full pivotable movement of the uppermost mini blind slats. The head rail further includes cross-shaped apertures extending through the recessed channel and configured for locating and receiving the basket assemblies of the present invention. The head rail apertures, as well as the bottom openings on the basket assemblies, include unobstructed cut-out portions which facilitate pivoting of the slats to a position which is very close to a vertical position. |
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TECHNICAL FIELD
[0001] The present disclosure relates to tips in rock or mining bits for use in a rock excavation apparatus.
[0002] The disclosure particularly relates to tips with hollow bases.
BACKGROUND
[0003] There are several different methods used for drilling in earth formations. Some use rotary movement and some use a combination of rotary and percussive movement. One common aspect of these methods is that a drill bit rotates at an end of a drill string.
[0004] Rotary drilling is conducted by rotating a rigid string of tubular rods to which a rock-cutting bit is attached. The rotary drill imparts two basic actions through the drill rod and bit into the rock, i.e. axial thrust and rotational torque. Percussive drills break rock predominantly by crushing and chipping rock with the repeated application of high-frequency, high-energy blows through a drill bit. The impact energy is developed by a piston that strikes the bit (down-the-hole drill) or drill steel (surface-mounted drill).
[0005] To improve the wear resistance and increase the lifetime of such drill bits, cutting elements in the form of tips or inserts are attached to the drill bit body. These tips are often made of cemented carbide, most commonly tungsten carbide, due to its excellent combination of high hardness and high toughness. The tips can also be made of polycrystalline diamond (PCD). The purpose of the tips is mainly to apply pressure to and fracture rock. Sometimes tips are also positioned on the drill bit body as protection for the surrounding steel. The tips must therefore withstand high compressive and transverse loads.
[0006] The tungsten carbide tips are commonly mounted in cylindrical recesses in the outer surface of the drill bit body. The tips can be made a few hundredths of a mm larger than the recess and are pressed in to have a tight interference fit to prevent loosening during usage.
[0007] Tungsten carbide tips are also used for soft cutting conditions such as excavation of coal. The tips are, in this application, often named caps and are often adhesively bonded to a pick body by, for example, brazing or welding.
[0008] Several standard shapes are used for tungsten carbide tips, such as a part-spherical, conical, a double cone, a ballistic and a chisel crest. Common for these different shapes is that the base, also called mounting portion, of the tip is generally cylindrical.
[0009] In many applications it is advantageous to use tips having a diameter of about 2 cm or larger. The advantages being that fewer tips need to be used and also that the protrusion of the tip from the surface of the bit body can be greater while maintaining adequate strength to avoid transverse failure during the excavation operation. Having large tips concentrates the load to fewer tips and greater rock penetration can be obtained without engagement of the steel surface, resulting in improved excavation rate. Having large tips that extend a greater distance from the bit also increases the lifetime of the bit as the large tips can accommodate appreciable wear before they are worn out.
[0010] One problem with large diameter tips is that they are expensive. This is due to the high cost of the material required to manufacture a tip. The material quantity required increases with the square of the diameter of the tip. When using tungsten carbide tips it is more costly to use few tips with a diameter of about 2 cm than using a larger amount of small tips.
[0011] This problem is addressed in U.S. Pat. No. 4,150,728. Here tungsten carbide tips with hollow bases are shown. Such a tip has a cavity opening to the inner end of the tip with a volume in the range of from about 15 to 30% of the volume of the base portion of the tip.
[0012] The present inventor has surprisingly found that several prominent problems occur at tips with hollow bases. One is that the base of the tip tends to get oval in shape. Another problem is that the form of the tip tends to get conical, i.e. the diameter of the mounting portion decreases when approaching the very bottom of the tip. Ovality and conicity in the mounting portion decreases the force for pulling the tip from the drill bit body and therefore loosening of the tip is an unfavorable consequence.
[0013] Another problem is that the mounting portion may crack when a tip is press fitted into a recess in the drill bit body.
[0014] These and other aspects of, and advantages with the present invention will be apparent from the detailed description and the accompanying drawings.
SUMMARY
[0015] One object of the present invention is to provide a hollow tip concept, which has better strength than known hollow tips. Another object is to provide a hollow tip concept which can be produced at a lower cost compared to solid tips, thus solving the above mentioned problems.
[0016] According to a first aspect, there is provided a rock bit tip comprising: a mounting portion, an end portion converging from a top end of the mounting portion to form a work surface and at least one recess in a bottom of the mounting portion, the recess extending towards said end portion, wherein there are more than one recess.
[0017] In a second aspect, there is provided a rock bit comprising a tip with more than one recess.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the detailed description of the present invention reference will be made to the accompanying drawings, wherein,
[0019] FIG. 1 schematically illustrates a conventional tip or button, in a side view, suitable for excavation of rock,
[0020] FIG. 2 schematically illustrates a tool for rotary drilling, in a side view,
[0021] FIG. 3 schematically illustrates a tool for percussive drilling, in a perspective view from above,
[0022] FIG. 4 schematically illustrates a mining pick in a side view,
[0023] FIG. 5 a schematically illustrates a first embodiment of a tip according to the invention in a perspective view from below,
[0024] FIG. 5 b schematically illustrates a first embodiment of the tip according to the invention in an axial cross-sectional view through the tip centre axis A,
[0025] FIG. 6 schematically illustrates a second embodiment of a tip according to the invention in a perspective view from below,
[0026] FIG. 7 schematically illustrates a third embodiment of a tip according to the invention in a perspective view from below,
[0027] FIG. 8 schematically illustrates a fourth embodiment of a tip according to the invention in a perspective view from below,
[0028] FIG. 9 a schematically illustrates a fifth embodiment of a tip according to the invention in a perspective view from below,
[0029] FIG. 9 b schematically illustrates the tip according to FIG. 9 a in a side view,
[0030] FIG. 9 c schematically illustrates the tip according to the line IX C-IX C in FIG. 9 b , and
[0031] FIG. 9 d schematically illustrates the tip according to the line IX D-IX D in FIG. 9 b.
DESCRIPTION OF EMBODIMENTS
[0032] The features and advantages of the present invention are well understood by reading the following detailed description in conjunction with the drawings in which like numerals indicate similar elements and in which:
[0033] FIG. 1 illustrates a tip 10 suitable for rock excavation. The tip comprises an end portion 11 having a top 13 . The end portion is intended to project from a front surface of a bit to form a work surface that is in contact with the rock. The tip also comprises a mounting portion 12 extending from the end portion 11 towards a bottom end 14 . The mounting portion of the tip is intended to be positioned in a recess in a drill bit body and assures that the tip is securely fixed to the bit body. If the tip 10 is comprised in a mining pick, the bottom end 14 may be secured to the bit, for example, by means of brazing or welding.
[0034] FIG. 2 illustrates a rock bit for rotary drilling 20 . The bit comprises a thread 24 whereby the rotary bit 20 is to be connected to a drill string. The bit further comprises legs 25 with roller cones 21 attached at one end. Tips, of the type herein described, can be used as protective tips 23 on the legs 25 and/or as active tips 22 on the roller cones 21 . The term “protective” means that the main purpose of the tip 23 is to protect the steel in the drill bit from being too heavily worn. The term “active” means that the main purpose of the tip 22 is to apply pressure to and fracture rock. The technology is more closely described in U.S. Pat. No. 6,446,739.
[0035] FIG. 3 illustrates a percussive rock drill bit 30 that comprises a drill bit head 31 and a shank 32 . The drill bit head 31 may comprise tips, of the type described below, such as peripheral tips 33 and/or front tips 34 . The technology is more closely described in U.S. Pat. No. 7,296,641.
[0036] FIG. 4 illustrates a mining pick 40 used in operations such as cutting soft minerals such as, for example, coal. The mining pick 40 includes a body 41 having a head 42 and a shank 43 . The tip 44 is made according to the invention and is the part that actively cuts minerals. It is made of a hard material such as cemented carbide, diamond, SiC-D or combinations thereof. The technology is more closely described in U.S. Pat. No. 8,210,618.
[0037] FIGS. 5 a and 5 b illustrate a first embodiment of the invention. The tip 110 has a mounting portion 112 . Four identical open recesses 115 extend axially from the bottom end 114 of the mounting portion 112 . The open recesses 115 have cross sections at the bottom end 114 that can be substantially like circle sectors with rounded corners for avoiding stress concentrations. The recesses 115 are spaced apart by a support structure 116 . At least one open recess 115 has its geometric centre axis B separate from the longitudinal tip centre axis A.
[0038] FIG. 6 illustrates a second embodiment of the invention. The tip 120 has a mounting portion 122 . Three identical open recesses 125 extend axially from the bottom end 124 of the mounting portion 122 . The open recesses 125 may have cross sections at the bottom end 124 that are substantially like truncated circle rings. The recesses 125 are spaced apart by a support structure 126 . At least one open recess 125 has its geometric centre axis B separate from the longitudinal tip centre axis A.
[0039] FIG. 7 illustrates a third embodiment of the invention. The tip 130 has a mounting portion 132 . Seven identical open recesses 135 extend axially from the bottom end 134 of the mounting portion 132 . The open recesses 135 have cross sections at the bottom end 134 that are substantially hexagonal. The recesses 135 are spaced apart by a support structure 136 . At least one open recess 135 has its geometric centre axis B separate from the longitudinal tip centre axis A. A central open recess 135 has its geometric centre axis B substantially coinciding with the longitudinal tip centre axis A.
[0040] FIG. 8 illustrates a fourth embodiment of the invention. The tip 140 has a mounting portion 142 . Six open recesses 145 extend axially from the bottom end 144 of the mounting portion 142 . The open recesses 145 have cross sections at the bottom end 134 that are substantially circular. The recesses 145 are spaced apart by a support structure 146 . At least one open recess 145 has its geometric centre axis B separate from the longitudinal tip centre axis A.
[0041] FIGS. 9 a - 9 d illustrate a fifth embodiment of the invention. The tip 150 has a mounting portion 152 . One open recess 155 extends axially from the bottom end 154 of the mounting portion 152 . Between the bottom end 154 and the end portion, the open recess 155 is split into three identical separate recesses 157 . The recesses 157 are spaced apart by a support structure 156 . At least one of the recesses 157 has at least one cross section (IX D-IX D), parallel to the bottom of the mounting portion, between the bottom of the mounting portion and the end portion, which has its geometric centre axis B separate from the longitudinal tip centre axis A, FIG. 9 d.
[0042] The number of recesses, and their sizes, may be altered compared to the examples described in the above-captioned embodiments. It is also possible to combine recesses with different sizes and shapes into a new embodiment. The depth of the recesses can also be varied, but the recesses are always of the blind hole type.
[0043] The present invention is not limited to the above described embodiments. Different alternatives, modifications and equivalents might be used. The above mentioned embodiments should therefore, not be considered limiting to the scope of the invention, which is defined by the patent claims. | A rock bit tip includes a mounting portion, an end portion converging from a top end of the mounting portion to form a work surface and at least one recess in a bottom of the mounting portion, the recess extending towards the end portion. Particularly, there are more than one recess. The disclosure further relates to a rock bit. |
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RELATED APPLICATIONS
There are no current co-pending applications.
FIELD OF THE INVENTION
This disclosure relates to drywall installation accessories and, more particularly, to a system and method for aiding in drywall installation on vertical wall surfaces and horizontal ceiling surfaces.
BACKGROUND OF THE INVENTION
Drywall consists of a thin layer of gypsum sandwiched between two (2) layers of heavy paper. It is commonly used in residences and buildings to cover walls and ceilings, because it is both faster and cheaper to install than plaster. Drywall panels are manufactured in standard sizes, commonly of four-by-eight feet rectangular dimensions. Due to their size and weight, these panels are both wearying and cumbersome to fasten them to either vertical framing studs or horizontal ceiling joists.
Drywall installation is a tiresome job requiring a great deal of physical work. Drywall sheets are heavy and must usually be carried manually to their final position. This work is magnified if the drywall sheets are installed on ceilings. Such installations usually require three (3) workers to do; two (2) workers to place and hold the drywall at either end and the third worker to drive drywall screws or pound nails. This work requires multiple ladders as well and subjects the workers to off-balance positions, possible falls, and associated ergonomic injuries. Other solutions involve drywall jacks or holding “T's” that may reduce manpower, but are still difficult, costly, and cumbersome to use. Accordingly, there exists a need for a means by which drywall and similar materials can be installed on ceiling surfaces with a minimum of aggravation, reduced manpower and a reduction in physical exertion.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the prior art, it has been observed that there is need for a drywall installation system including a plurality of pivoting brackets removably attached to existing joists located at a horizontal ceiling surface within an existing structure, and a plurality of fixed brackets removably attached to existing joists located at a vertical wall surface within the existing structure. Advantageously, the pivoting brackets enable a user to install an existing first drywall section at the horizontal ceiling surface while the fixed brackets enable a user to install an existing second drywall section at the vertical wall surface. Preferably, each of the pivoting brackets has a single and unitary body and each of the fixed brackets has a single and unitary body.
In a non-limiting exemplary embodiment, each of the pivoting brackets includes a retaining leg and a support leg integral therewith. In this manner, during installation of the existing first drywall section, the retaining leg is positioned at a first orientation capable of retaining the existing first drywall section in a stable position flush against the horizontal ceiling surface. Furthermore, after installation of the existing first drywall section, each the pivoting brackets is rotated one hundred eighty degrees (180°) such that: (1) the retaining leg is positioned at a second orientation so that the support leg is located beneath the existing first drywall section in a flush manner, and (2) the retaining leg retains an adjacent section of the existing first drywall section flush against the horizontal ceiling surface.
In a non-limiting exemplary embodiment, each of the pivoting brackets includes a pivoting bracket aperture intermediately positioned relative to the retaining leg and the support leg. Such a pivoting bracket aperture passes through the retaining leg and the support leg. A pivoting bracket fastener is removably inserted into the pivoting bracket aperture in such a manner that the pivot bracket is rotated three hundred sixty degrees (360°) about the pivoting bracket fastener while affixed to the existing joist.
In a non-limiting exemplary embodiment, each of the pivoting brackets has a generally rectangular shape and a generally “Z”-shaped cross-section.
In a non-limiting exemplary embodiment, each of the fixed brackets includes a retaining section and a support section integral therewith. In this manner, during installation of the existing second drywall section, the fixed bracket is fastened to the vertical wall surface thereby enabling the retaining section to assist in retaining the existing second drywall second in a desired vertical mounting position. Furthermore, after installation of the existing second drywall section, the fixed brackets are removed and repositioned along the vertical wall surface to assist in mounting an adjacent section of the existing second drywall section.
In a non-limiting exemplary embodiment, each of the fixed brackets include a fixed bracket aperture located at an offset planar portion of the support section, and a fixed bracket removably inserted into the fixed bracket aperture in such a manner that the fixed bracket is maintained at a stationary position while affixed to the vertical wall surface. Advantageously, the retaining section is gradually indented relative to the offset planar portion of the support section thereby providing a resting portion for the existing second drywall section to set flush against the vertical wall surface.
In a non-limiting exemplary embodiment, each of the fixed brackets has a generally rectangular shape.
A method of installing drywall including the initial step of: providing and removably attaching a plurality of pivoting brackets to existing joists located at a horizontal ceiling surface within an existing structure in such a manner that the pivoting brackets enable a user to install an existing first drywall section at the horizontal ceiling surface. Each pivoting bracket has a single and unitary body. Next, providing and removably attaching a plurality of fixed brackets to existing joists located at a vertical wall surface within the existing structure in such a manner that the fixed brackets enable a user to install an existing second drywall section at the vertical wall surface. Each fixed brackets has a single and unitary body.
The method further includes the steps of: providing and engaging the existing first drywall section with the pivoting brackets; providing and engaging the existing second drywall section with the fixed brackets; fastening the existing first drywall section to the existing joists located at the horizontal ceiling surface; rotating one of the pivoting brackets so that a portion of the one (1) pivoting bracket is flush against the fastened existing first drywall section; removing and fastening the pivoting brackets to existing joists located at another section of the horizontal ceiling surface; fastening the existing second drywall section to the existing joists located at the vertical wall surface; and removing and fastening the fixed brackets to existing joists located at another section of the vertical wall surface.
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 system for installing drywall 10 , according to a preferred embodiment of the present invention;
FIG. 2 is a perspective view of a pivoting bracket 20 , according to a preferred embodiment of the present invention;
FIG. 3 is a side view of the pivoting bracket 20 , according to a preferred embodiment of the present invention;
FIG. 4 is a perspective view of a fixed bracket 30 , according to a preferred embodiment of the present invention;
FIG. 5 is a side view of the fixed bracket 30 , according to a preferred embodiment of the present invention; and,
FIG. 6 is another environmental view of the system for installing drywall 10 , according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10
system for installing drywall
12
ceiling joist
13
drywall
14
vertical surface
20
pivoting bracket
22
retaining leg
24
support leg
26
pivoting bracket aperture
28
pivoting bracket fastener
30
fixed bracket
32
retaining section
34
support section
36
fixed bracket aperture
38
fixed bracket fastener
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 FIG. 1 through 6 . 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 of the referenced items.
The present invention describes a system for installing drywall (herein described as the “system”) 10 , which provides a means for providing a pair of brackets 20 , 30 which assist in the installation of drywall 13 by a single installer.
Referring now to FIG. 1 , an environmental view of the system 10 , according to the preferred embodiment of the present invention, is disclosed. The system 10 comprises a pair of pivoting brackets 20 and a pair of fixed brackets 30 . The system 10 enables one (1) installer to mount drywall 13 on a ceiling or other similar vertical surface 14 such as depicted within FIG. 1 which further illustrates a sheet of drywall 13 being installed onto ceiling joists 12 . The system 10 utilizes the existing ceiling joists 12 to temporarily attach each pivoting bracket 20 and a vertical surface 14 to temporarily attach each fixed bracket 30 . It is known that the fixed brackets 30 may also be attached to the ceiling joists 12 and it is also known that the pivoting brackets 20 may be attached to the vertical surface 14 . The system 10 can be utilized with drywall 13 , sheet rock, or other similar panel-type coverings utilized to create interior walls and ceilings may be utilized without limiting the scope of the invention.
Referring now to FIG. 2 , a perspective view of the pivoting bracket 20 and FIG. 3 , a side view of the pivoting bracket 20 , according to the preferred embodiment of the present invention, are disclosed. The pivoting brackets 20 comprises a retaining leg 22 and a support leg 24 which are utilized for securing the drywall 13 to the ceiling joist 12 . The retaining leg 22 and support leg 24 are integral to the pivoting bracket 20 . The pivoting brackets 20 are preferably fabricated from a durable plastic material, yet it is known that other materials may be utilized without limiting the scope of the invention. The pivoting brackets 20 comprise a generally rectangular shape having a generally “Z”-shaped cross-section. The pivoting brackets 20 measure approximately nine inches (9 in.) length and one inch (1 in.) in height, yet it is known that other dimensions which accommodate the space requirements of installing drywall 13 may be utilized. Furthermore, it is understood that the retaining leg 22 and support leg 24 portions may be introduced having different thickness dimensions being suitable for positioning various building materials having corresponding thicknesses such as, but not limited to: one-quarter inch (¼ in.) sheetrock, three-eighths inch (⅜ in.) hardy, five-eighths inch (⅝ in.) siding, five-eighths inch (⅝ in.) plywood, and the like.
The pivoting brackets 20 comprise an intermediately positioned pivoting bracket aperture 26 which enables a counter-sinking insertion of a pivoting bracket fastener 28 . The pivoting bracket fastener 28 is preferably a standard wood screw such as a lag bolt or other similar fastener which fastens to the ceiling joist 12 or vertical surface 14 yet enables the pivoting brackets 20 to rotate three-hundred-sixty degrees (360°). It is also known that the installer may also unscrew the pivoting bracket fastener 28 slightly out of the ceiling joist 12 or vertical surface 14 which would also enable the pivoting bracket 20 to freely rotate.
Referring now to FIG. 4 , a perspective view of the fixed bracket 30 and FIG. 5 , a side view of the fixed bracket 30 , according to the preferred embodiment of the present invention, are disclosed. The fixed brackets 30 also assist the installer in mounting drywall 13 onto a desired surface. The fixed brackets 30 comprise a retaining section 32 and a support section 34 which are utilized to hold the drywall 13 upwardly against the ceiling joist 12 and may also be utilized similarly as the abovementioned pivoting bracket 20 . The fixed brackets 30 comprise a generally rectangular shape and similar to the pivoting bracket 20 are fabricated from a durable plastic, yet it is known that other materials may be utilized without limiting the scope of the invention. The fixed bracket 30 measure approximately seven inches (7 in.) in length and one inch (1 in.) in height.
The fixed brackets 30 comprise a retaining section 32 and a support section 34 which are integral portions of the fixed bracket 30 to assist in retaining the drywall 13 It is known that the fixed brackets 30 are to be utilized in conjunction with the pivoting brackets 20 . The retaining section 32 is slightly and gradually indented into the fixed bracket 30 , thereby providing a resting portion for the drywall 13 to set flush against the desired mounting surface when utilized in a supporting manner. The retaining section 32 is also utilized to provide a stable footing beneath the drywall 13 . The support section 32 is utilized to secure the fixed bracket 30 into the ceiling joist 12 or the vertical surface 14 . The retaining section 32 may also be utilized to support the drywall 13 against the ceiling joist 12 similar to the pivoting bracket 20 . A fixed bracket aperture 36 is located at a slightly offset portion of the support section 34 . The fixed bracket aperture 36 enables insertion of a fixed bracket fastener 38 which is preferably a common wood screw which can temporarily secure the fixed bracket 30 on the desired surface.
Referring now to FIG. 6 , another environmental view of the system 10 , according to the preferred embodiment of the present invention, is disclosed. FIG. 6 depicts drywall 13 installed upon the ceiling joist 12 . When drywall 13 is being installed, the retaining leg 22 of the pivoting brackets 20 retains said drywall 13 in a stable position flush against the ceiling joist 12 (or vertical surface 14 ). This position enables the installer to fasten the drywall 13 into position in a normal fashion. Once the drywall 13 has been fastened appropriately the pivoting brackets 20 are rotated one-hundred-eighty degrees (180°) (depicted herein) so that the support leg 24 is beneath the previously fastened drywall 13 in a flush manner and the retaining leg 22 is in position to retain an adjacent section of drywall 13 . The fixed bracket 30 is fastened against the vertical surface 14 (depicted herein), thereby enabling the retaining section 32 to assist in retaining the drywall 13 in the desired mounting position. It is known that once the drywall 13 is fastened into the desired position that the fixed brackets 30 are removed and replaced to assist in mounting adjacent section of drywall 13 .
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 preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the system 10 , it would be installed as indicated in FIG. 1 .
The method of installing and utilizing the system 10 may be achieved by performing the following steps: acquiring the system 10 ; attaching the fixed brackets 30 onto a desired mounting surface such as a vertical surface 14 or other similar surface via inserting a fixed bracket fastener 38 into the fixed bracket aperture 36 and furthermore into the desired mounting surface; attaching the pivoting bracket 20 onto the desired mounting surface such as ceiling joist 12 at appropriate distances to retain the drywall 13 ; placing the drywall 13 onto the retaining section 32 on the fixed brackets 30 and onto the retaining legs 22 on the pivoting brackets 20 ; fastening the drywall 13 in a normal manner upon the ceiling joist 12 or other mounting surface; rotating the pivoting bracket 30 so that the support leg 34 is flush against the fastened drywall 13 ; replacing the brackets 20 , 30 on another location for additional mounting of drywall 13 as desired; removing the brackets 20 , 30 as desired; and, utilizing the system 10 to install drywall 13 in a quick and easy manner.
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 system to aid in the installation of drywall or similar items on ceilings or vertical wall surfaces comprises a set of bracket structures. A first pair of brackets is fixed, and a second pair of brackets comprises a pivot screw that is swung in place after the drywall is lifted into place. Each bracket is provided with a mounting fastener adapted to be attached to the ceiling joists or wall studs. Once in place, the drywall is slid into the brackets and held securely in place. The drywall is then fastened into the joists and the brackets can then be removed. The brackets are spun around or reinstalled and the process repeated as needed. |
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TECHNICAL FIELD OF THE INVENTION
This invention relates in general to downhole telemetry and, in particular to, utilizing the subsea template of a platform to carry an electrical current for communicating electromagnetic signals carrying information between surface equipment and downhole equipment.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with communication between surface equipment and downhole devices during hydrocarbon production, as an example. It should be noted that the principles of the present invention are applicable not only during production, but throughout the life of a wellbore including, but not limited to, during drilling, logging, testing and completing the wellbore.
Heretofore, in this field, a variety of communication and transmission techniques have been attempted to provide real time communication between surface equipment and downhole devices. The utilization of real time data transmission provides substantial benefits during the production of hydrocarbons from a field. For example, monitoring of downhole conditions allows for an immediate response to potential well problems including production of water or sand.
One technique used to telemeter downhole data to the surface uses the generation and propagation of electromagnetic waves. These waves are produced by inducing an axial current into, for example, the production casing. This current produces the electromagnetic waves that include an electric field and a magnetic field, which are formed at right angles to each other. The axial current impressed on the casing is modulated with data causing the electric and magnetic fields to expand and collapse thereby allowing the data to propagate and be intercepted by a receiving system. The receiving system is typically connected to the ground or sea floor where the electromagnetic data is picked up and recorded.
As with any communication system, the intensity of the electromagnetic waves is directly related to the distance of transmission. As a result, the greater the distance of transmission, the greater the loss of power and hence the weaker the received signal at the surface. Additionally, downhole electromagnetic telemetry systems must transmit the electromagnetic waves through the earth's strata. In free air, the loss is fairly constant and predictable. When transmitting through the earth's strata, however, the amount of signal received is dependent upon the skin depth (δ) of the media through which the electromagnetic waves travel. Skin depth is defined as the distance at which the power from a downhole signal will attenuate by a factor of 8.69 db (approximately 7 times decrease from the initial power input), and is primarily dependent upon the frequency (f) of the transmission and the conductivity (σ) of the media through which the electromagnetic waves are propagating. For example, at a frequency of 10 hz, and a conductance of 1 mho/meter (1 ohm-meter), the skin depth would be 159 meters (522 feet). Therefore, for each 522 feet in a consistent 1 mho/meter media, an 8.69 db loss occurs. Skin depth may be calculated using the following equation.
Skin Depth=δ=1/√ (πfμσ) where:
π=3.1417;
f=frequency (hz);
μ=permeability (4π×10 6 ); and
σ=conductance (mhos/meter).
As should be apparent, the higher the conductance of the transmission media, the lower the frequency must be to achieve the same transmission distance. Likewise, the lower the frequency, the greater the distance of transmission with the same amount of power.
A typical electromagnetic telemetry system that transmits vertically through the earth's strata may successfully propagate through ten (10) skin depths. In the example above, for a skin depth of 522 feet, the total transmission and successful reception depth would only be 5,220 feet. It has been found, however, that in offshore applications, the boundary between the sea and the sea floor has a nonuniform and unexpected electrical discontinuity. Conventional electromagnetic systems are, therefore, unable to effectively transmit or receive the electromagnetic signals through the boundary between the sea and the sea floor. Additionally, it has been found that conventional electromagnetic systems are unable to effectively transmit the electromagnetic signals through sea water or through the boundary layer between the sea and air.
Therefore, a need has arisen for a system that is capable of telemetering real time data between the surface and downhole devices using electromagnetic waves to carry the information. A need has also arisen for an electromagnetic telemetry system that is capable of transmitting and receiving electromagnetic signals below the sea floor and relaying the information carried in the electromagnetic signals through the sea water to the surface. Further, a need has arisen for such an electromagnetic telemetry system that is capable communicating commands to specific downhole devices and receiving confirmation that the operation requested in the command has occurred.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises a subsea template electromagnetic telemetry system that is capable of telemetering real time data between the surface and downhole devices using electromagnetic waves to carry the information. The system transmits and receives electromagnetic signals below the sea floor and relays the information carried in the electromagnetic signals through the sea water to the surface. The system provides a method to communicate commands to specific downhole devices and receiving confirmation that the operation requested in the command has occurred.
The subsea template electromagnetic telemetry system comprises an electromagnetic downlink and pickup apparatus that includes a subsea conductor and a surface installation. The subsea conductor may be, for example, a subsea template of an offshore production platform. The subsea conductor and the surface installation are electrically connected using a pair of conduits. The conduits form a pair terminals on the subsea conductor between which a voltage potential may be established, thereby providing a path for current flow therebetween.
The surface installation includes a signal generator and a signal receiver. The signal generator injects a current carrying information into the subsea conductor that will generate electromagnetic waves carrying the information which are propagated downhole through the earth. The signal receiver interprets information carried in a current generated in the subsea conductor by electromagnetic waves received by the subsea conductor.
The conduits electrically connecting the subsea conductor to the surface installation may be electrical wires. Alternatively, one or both of the conduits electrically connecting the subsea conductor to the surface installation may be riser pipes including platform legs, conductor pipes of wells and the like.
The subsea conductor may have an electrical coupling extending outwardly therefrom and extending above the sea floor to provide a connection between an electric wire and the subsea conductor. The electrical coupling may be a post, a ring or the like.
The electromagnetic downlink and pickup apparatus may be used with the telemetry system for changing the operational state of a downhole device. In this case, the surface installation transmits a command signal to the subsea conductor. The subsea conductor retransmits the command signal using electromagnetic waves. The electromagnetic waves are received by an electromagnetic receiver disposed in a wellbore. An electronics package electrically connected to the electromagnetic receiver and operably connected to the downhole device, generates a driver signal in response to the command signal that prompts the downhole device to change operational states.
The downhole portion of the system may include an electromagnetic transmitter disposed in the wellbore. The electromagnetic transmitter may transmit a verification signal to indicate that the command signal has been received and that the command has been executed or both. The verification signal is received by the subsea conductor that forwards the signal to the surface installation.
The system is capable of operating numerous downhole devices disposed in multiple wells extending from one or more platforms. To achieve this result, the command signal generated by the surface installation are uniquely associated with specific downhole devices.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic illustration of an offshore oil and gas production platform operating a subsea template electromagnetic telemetry system of the present invention;
FIGS. 2A-2B are quarter-sectional views of a sonde of a subsea template electromagnetic telemetry system of the present invention;
FIG. 3 is a schematic illustration of a toroid having primary and secondary windings wrapped therearound for a sonde of a subsea template electromagnetic telemetry system of the present invention;
FIG. 4 is an exploded view of one embodiment of a toroid assembly for use as a receiver for a sonde of a subsea template electromagnetic telemetry system of the present invention;
FIG. 5 is an exploded view of one embodiment of a toroid assembly for use as a transmitter for a sonde of a subsea template electromagnetic telemetry system of the present invention;
FIG. 6 is a perspective view of an annular carrier of an electronics package for a sonde of a subsea template electromagnetic telemetry system of the present invention;
FIG. 7 is a perspective view of an electronics member having a plurality of electronic devices thereon for sonde of a subsea template electromagnetic telemetry system of the present invention;
FIG. 8 is a perspective view of a battery pack for a sonde of a subsea template electromagnetic telemetry system of
FIG. 9 is a block diagram of a signal processing method used by a sonde of a subsea template electromagnetic telemetry system of the present invention; and
FIGS. 10A-B are flow diagrams of a method for operating a subsea template electromagnetic telemetry system of the present invention.
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 invention.
Referring to FIG. 1, a subsea template electromagnetic telemetry system in use on an offshore oil and gas platform is schematically illustrated and generally designated 10. A production platform 12 is centered over submerged oil and gas formations 14, 15 located below sea floor 16. Wellheads 18, 20, 22 are located on deck 24 of platform 12. Wells 26, 28, 30 extend through the sea 32 and penetrate the various earth strata including formations 14, 15, forming, respectively, wellbores 34, 36, 38, each of which may be cased or uncased. Wellbore 36 includes a lateral or branch wellbore 37 that extends from the primary wellbore 36. The lateral wellbore 37 is completed in formation 15 which may be isolated for selective production independent of production from formation 14 into wellbore 36. Also extending from wellheads 18, 20, 22 are tubing 40, 42, 44 which are respectively, disposed in wellbores 34, 36, 38. Tubing 43 is disposed in lateral wellbore 37 and may join tubing 42 for production thererhrough.
Wells 26, 28, 30 along with legs 41, 45 extend through subsea template 47. Subsea template 47 helps to support platform 12 and allows for the accurate positioning of wells 26, 28, 30. Extending outwardly from subsea template 47 is coupling 49 which may be a ring, a post or the like. Coupling 49 is electrically connected to electrical wire 51 that extends through sea 32 and terminates at surface installation 58. An electrical wire 60 connects surface installation 58 to the conductor pipe of well 30. Thus, a complete electric circuit is formed that includes subsea template 47, coupling 49, electrical wire 51, surface installation 58, electrical wire 60 and the conductor pipe of well 30.
Surface installation 58 may be composed of a computer system that processes, stores and displays information relating to formations 14, 15 such as production parameters including temperature, pressure, flow rates and oil/water ratio. Surface installation 58 also maintains information relating to the operational states of the various downhole devices located in wellbores 34, 36, 37, 38. Surface installation 58 may include a peripheral computer or a work station with a processor, memory, and audio visual capabilities. Surface installation 58 includes a power source for producing the necessary energy to operate surface installation 58 as well as the power necessary to generate a current between electrical coupling 49 and well 30 through subsea template 47. This current will, in turn, generate electromagnetic wave fronts 65. As such, surface installation 58 is used to generate command signals that will operate various downhole devices. Electrical wires 51, 60 may be connected to surface installation 58 using an RS-232 interface.
As part of the final bottom hole assembly prior to production, a sonde 46 is disposed within wellbore 38. Likewise, sondes 48, 50, 53 are respectively disposed within wellbores 36, 34, 37. Sonde 46 includes an electromagnetic transmitter 52, an electronics package 54 and an electromagnetic receiver 56. Also disposed in wellbore 38 are sensors 67 which may obtain, for example, temperature, pressure, flowrate, or fluid composition data relating to production from formation 14. Thus, if the operator needs to obtain real time information from formation 14, surface installation 58 would generate a request for information by injecting a modulated current through subsea template 47 between coupling 49 and well 30. The current will produce the modulated electric and magnetic fields of electromagnetic wave fronts 65 to communicate the request to sonde 46. Electromagnetic wave fronts 65 are picked up by electromagnetic receiver 56 of sonde 46 and passed on to electronics package 54 for processing and amplification. Electronics package 54 interfaces with sensors 67 requesting the desired information.
Once sensors 67 obtain the information, the information is returned to electronics packages 54 for processing. Electronics package 54 then establishes the frequency, power and phase output of the information prior to forwarding the information to electromagnetic transmitter 52 of sonde 46 that radiates electromagnetic wave fronts 64 into the earth. The electric field of electromagnetic wave fronts 64 will generate a modulated current in subsea template 47 between coupling 49 and well 30 which serve as electrodes for sensing the voltage therebetween. The information then travels to surface installation 58 via electrical wave 51. The information may then be processed by surface installation 58 and placed in a useable format.
AlternativeLy, if the operator wanted to reduce the flow rate of production fluids in well 28, surface installation 58 would be used to generate a command signal to restrict the opening of bottom hole choke 62. The command signal would be injected into subsea template 47 via electrical wire 51. The command signal would then be radiated into the earth in the form of electromagnetic wave fronts 65. Electromagnetic wave fronts 54 are picked up by electromagnetic receiver 66 of sonde 48. The command signal is then forwarded to electronics package 68 of sonde 48 for processing and amplification. Electronics package 68 interfaces with bottom hole choke 62 and sends a driver signal to bottom hole choke 62 to restrict the flow rate therethrough.
Once the flow rate in well 28 has been restricted by bottom hole choke 62, bottom hole choke 62 interfaces with electronics package 68 of sonde 48 to provide verification that the command generated by surface installation 58 has been accomplished. Electronics package 68 then sends the verification signal to electromagnetic transmitter 70 of sonde 48 that radiates electromagnetic wave fronts 72 into the earth which are picked up by subsea template 47 and passed onto surface installation 58 via electrical wire 51 as describe above.
As another example, the operator may want to shut in production in lateral wellbore 37. As such, surface installation 58 would generate the shut in command signal and inject it into subsea template 47. Electromagnetic wave fronts 65 are then generated as described above. The shut in command would be packed up by electromagnetic receiver 55 of sonde 53 and processed in electronics package 57 of sonde 53. Electronics package 57 interfaces with valve 59 causing valve 59 to close. This change in the operational state of valve 59 would be verified to surface installation 58 as described above, by radiating electromagnetic wave fronts 61 from electromagnetic transmitter 63 which generate a current in subsea template 47 that relays the verification to surface installation 58 via electrical wire 51.
Similarly, the operator may want to actuate a sliding sleeve in a selective completion with sliding sleeves 74. A command signal would again be generated by surface installation 58 and injected into subsea template 47 via electrical wire 51. Electromagnetic wave fronts 65 would then be generated, thereby transmitting the command signal to electromagnetic receiver 76 of sonde 50. The command signal is forwarded to electronics package 78 for processing, amplification and generation of a driver signal. Electronics package 78 then interfaces with sliding sleeves 80, 82 and sends the driver signal to shut off production from the lower portion of formation 14 by closing sliding sleeve 82 and allow production from the upper portion of formation 14 by opening sliding sleeve 80. Sliding sleeves 80, 82 interface with electronics package 78 of sonde 50 to provide verification information regarding their respective changes in operational states. This information is processed and passed to electromagnetic transmitter 84 which generates electromagnetic wave fronts 86. Electromagnetic wave fronts 86 propagated through the earth and are picked up by subsea template 47. The verification information is then passed onto surface installation 58 via electrical wire 51 for analysis and storage.
Each of the command signals generated by surface installation 58 is uniquely associated with a particular downhole device such as bottom hole choke 62, valve 59, sensors 67 or sliding sleeves 80, 82. Thus, as will be further discussed with reference to FIGS. 9 and 10 below, electronics package 68 of sonde 46 will only process a command signal that is uniquely associated with a downhole device, such as bottom hole choke 62, located within wellbore 36. Similarly, electronics package 57 of sonde 46 will only process a command signal that is uniquely associated with a downhole device, such as valve 59, located within wellbore 37, while electronics package 54 of sonde 46 will only process a command signal that is uniquely associated with a downhole device, such as sensors 67, located within wellbore 38 and electronics package 78 of sonde 50 will only process a command signal uniquely associated with a downhole device, such as sliding sleeves 80, 82, located within wellbore 34. Thus, the subsea template electromagnetic telemetry system of the present invention allows for the monitoring of well data and the control of multiple downhole devices located in multiple wells from one central point.
Even though FIG. 1 depicts three wells 26, 28, 30 extending from a single platform 12, it should be apparent to those skilled in the art that the principles of the present invention are applicable to a single platform having any number of wells or to multiple platforms so long as the wells are within the transmission range of the electromagnetic wave such as electromagnetic wave fronts 65 from the master platform such as platform 12. It should be noted, that the transmission range of electromagnetic waves such as electromagnetic wave fronts 65 is significantly greater when transmitting horizontally through a single or limited number of strata as compared with transmitting vertically through numerous strata. For example, electromagnetic waves such as electromagnetic wave fronts 65 may travel between 3,000 and 6,000 feet vertically while traveling between 15,000 and 30,000 feet horizontally depending on factors such as the voltage, the frequency of transmission, the conductance of the transmission media, and the level of noise. The transmission range of electromagnetic waves such as electromagnetic wave fronts 65 may be extended, however, using electromagnetic repeaters that may extend either the vertical or horizontal transmission range or both.
Even though FIG. 1 depicts well 30 as completing the electrical circuit between surface installations 58 and subsea template 47, it should be understood by those skilled in the art that a variety of electrical connections could be used to complete the electrical circuit including, but not limited to, wells 26, 28, legs 41, 45 or other riser pipe in electrical contact with subsea template 47. Also, it should be understood by those skilled in the art that the current injected by surface installation 58 may travel either from well 30 to coupling 49 or from coupling 49 to well 30 for the generation of electromagnetic wave fronts 65. Similarly, it should be understood by those skilled in the art that the current generated between well 30 and coupling 49 by electromagnetic waves such as electromagnetic wave fronts 61, 64, 72, 86 may travel either from well 30 to coupling 49 and up electrical wire 51 to surface installation 58 or from coupling 49 to well 30 and up the conductor pipe of well 30 to surface installation 58.
Representatively illustrated in FIGS. 2A-2B is a sonde 77 of the present invention. For convenience of illustration, FIGS. 2A-2B depict sonde 77 in a quarter sectional view. Sonde 77 has a box end 79 and a pin end 81 such that sonde 77 is threadably adaptable to other tools in a final bottom hole assembly. Sonde 77 has an outer housing 83 and a mandrel 85 having a full bore so that when sonde 77 is disposed within a well, tubing may be inserted therethrough. Housing 83 and mandrel 85 protect the operable components of sonde 77 during installation and production.
Housing 83 of sonde 77 includes an axially extending and generally tubular upper connecter 87. An axially extending generally tubular intermediate housing member 89 is threadably and sealably connected to upper connecter 87. An axially extending generally tubular lower housing member 90 is threadably and sealably connected to intermediate housing member 89. Collectively, upper connecter 87, intermediate housing member 89 and lower housing member 90 form upper subassembly 92. Upper subassembly 92 is electrically connected to the section of the casing above sonde 77.
An axially extending generally tubular isolation subassembly 94 is securably and sealably coupled to lower housing member 90. Disposed between isolation subassembly 94 and lower housing member 90 is a dielectric layer 96 that provides electric isolation between lower housing member 90 and isolation subassembly 94. Dielectric layer 96 is composed of a dielectric material, such as teflon, chosen for its dielectric properties and capably of withstanding compression loads without extruding.
An axially extending generally tubular lower connecter 98 is securably and sealably coupled to isolation subassembly 94. Disposed between lower connecter 98 and isolation subassembly 94 is a dielectric layer 100 that electrically isolates lower connecter 98 from isolation subassembly 94. Lower connecter 98 is electrically connected to the portion of the casing below sonde 77.
It should be apparent to those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward, etc. are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. It is to be understood that the downhole component described herein, for example, sonde 77, may be operated in vertical, horizontal, inverted or inclined orientations without deviating from the principles of the present invention.
Mandrel 85 includes axially extending generally tubular upper mandrel section 102 and axially extending generally tubular lower mandrel section 104. Upper mandrel section 102 is partially disposed and sealing configured within upper connecter 87. A dielectric member 106 electrically isolates upper mandrel section 102 from upper connecter 87. The outer surface of upper mandrel section 102 has a dielectric layer disposed thereon. Dielectric layer 108 may be, for example, a teflon layer. Together, dielectric layer 108 and dielectric member 106 serve to electrically isolate upper connecter 87 from upper mandrel section 102.
Between upper mandrel section 102 and lower mandrel section 104 is a dielectric member 110 that, along with dielectric layer 108, serves to electrically isolate upper mandrel section 102 from lower mandrel section 104. Between lower mandrel section 104 and lower housing member 90 is a dielectric member 112. On the outer surface of lower mandrel section 104 is a dielectric layer 114 which, along with dielectric member 112, provides for electric isolation of lower mandrel section 104 from lower housing number 90. Dielectric layer 114 also provides for electric isolation between lower mandrel section 104 and isolation subassembly 94 as well as between lower mandrel section 104 and lower connecter 98. Lower end 116 of lower mandrel section 104 is disposed within lower connecter 98 and is in electrical communication with lower connecter 98. Intermediate housing member 89 of outer housing 83 and upper mandrel section 102 of mandrel 85 define annular area 118. A receiver 120, an electronics package 122 and a transmitter 124 are disposed within annular area 118.
In operation, sonde 77 receives a command signal in the form of electromagnetic wave fronts 65 generated by subsea template 47 of FIG. 1. Electromagnetic receiver 120 forwards the command signal to electronics package 122 via electrical conductor 126. Electronics package 122 processes the command signal as will be discussed with reference to FIGS. 9 and 10 and generates a driver signal. The driver signal is forwarded to the downhole device uniquely associated with the command signal to change the operational state of the downhole device. A verification signal is returned to electronics package 122 from the downhole device and is processed and forwarded to electromagnetic transmitter 124. Electromagnetic transmitter 124 transforms the verification signal into electromagnetic waves which are radiated into the earth and picked up by subsea template 47 and passed to surface installation 58 via electrical wire 51.
Referring now to FIG. 3, a schematic illustration of a toroid is depicted and generally designated 180. Toroid 180 includes magnetically permeable annular core 182, a plurality of electrical conductor windings 184 and a plurality of electrical conductor windings 186. Windings 184 and windings 186 are each wrapped around annular core 182. Collectively, annular core 182, windings 184 and windings 186 serve to approximate an electrical transformer wherein either windings 184 or windings 186 may serve as the primary or the secondary or the transformer.
In one embodiment, the ratio of primary windings to secondary windings is 2:1. For example, the primary windings may include 100 turns around annular core 182 while the secondary windings may include 50 turns around annular core 182. In another embodiment, the ratio of secondary windings to primary windings is 4:1. For example, primary windings may include 10 turns around annular core 182 while secondary windings may include 40 turns around annular core 182. It will be apparent to those skilled in the art that the ratio of primary windings to secondary windings as well as the specific number of turns around annular core 182 will vary based upon factors such as the diameter and height of annular core 182, the desired voltage, current and frequency characteristics associated with the primary windings and secondary windings and the desired magnetic flux density generated by the primary windings and secondary windings.
Toroid 180 of the present invention may serve, for example, as electromagnetic receiver 120 or electromagnetic transmitter 124 of FIG. 2. The following description of the orientation of windings 184 and windings 186 will therefore be applicable to each of the above.
With reference to FIGS. 2 and 3, windings 184 have a first end 188 and a second end 190. First end 188 of windings 184 is electrically connected to electronics package 122. When toroid 180 serves as electromagnetic receiver 120, windings 184 serve as the secondary wherein first end 188 of windings 184 feeds electronics package 122 with the command signal via electrical conductor 126. The command signal is processed by electronics package 122 as will be further described with reference to FIGS. 9, 10 below. When toroid 180 serves as electromagnetic transmitter 124, windings 184 serve as the primary wherein first end 188 of windings 184, receives the verification signal from electronics package 122 via electrical conductor 128. Second end 190 of windings 184 is electrically connected to upper subassembly 92 of outer housing 83 which serves as a ground.
Windings 186 of toroid 180 have a first end 192 and a second end 194. First end 192 of windings 186 is electrically connected to upper subassembly 92 of outer housing 83. Second end 194 of windings 186 is electrically connected to lower connecter 98 of outer housing 83. First end 192 of windings 186 is thereby separated from second end 192 of windings 186 by isolations subassembly 94 which prevents a short between first end 192 and second end 194 of windings 186.
When toroid 180 serves as electromagnetic receiver 120, electromagnetic wave fronts, such as electromagnetic wave fronts 65 induce a current in windings 186, which serve as the primary. The current induced in windings 186 induces a current in windings 184, the secondary, which feeds electronics package 122 as described above. When toroid 180 serves as electromagnetic transmitter 124, the current supplied from electronics package 122 feeds windings 184, the primary, such that a current is induced in windings 186, the secondary. The current in windings 186 induces an axial current on the casing, thereby producing electromagnetic waves.
Due to the ratio of primary windings to secondary windings, when toroid 180 serves as electromagnetic receiver 120, the signal carried by the current induced in the primary windings is increased in the secondary windings. Similarly, when toroid 180 serves as electromagnetic transmitter 124, the current in the primary windings is increased in the secondary windings.
Referring now to FIG. 4, an exploded view of a toroid assembly 226 is depicted. Toroid assembly 226 may be designed to serve, for example, as electromagnetic receiver 120 of FIG. 2. Toroid assembly 226 includes a magnetically permeable core 228, an upper winding cap 230, a lower winding cap 232, an upper protective plate 234 and a lower protective plate 236. Winding caps 230, 232 and protective plates 234, 236 are formed from a dielectric material such as fiberglass or phenolic. Windings 238 are wrapped around core 228 and winding caps 230, 232 by inserting windings 238 into a plurality of slots 240 which, along with the dielectric material, prevent electrical shorts between the turns of winding 238. For illustrative purposes, only one set of winding, windings 238, have been depicted. It will be apparent to those skilled in the art that, in operation, a primary and a secondary set of windings will be utilized by toroid assembly 226.
FIG. 5 depicts an exploded view of toroid assembly 242 which may serve, for example, as electromagnetic transmitter 124 of FIG. 2. Toroid assembly 242 includes four magnetically permeable cores 244, 246, 248 and 250 between an upper winding cap 252 and a lower winding cap 254. An upper protective plate 256 and a lower protective plate 258 are disposed respectively above and below upper winding cap 252 and lower winding cap 254. In operation, primary and secondary windings (not pictured) are wrapped around cores 244, 246, 248 and 250 as well as upper winding cap 252 and lower winding cap 254 through a plurality of slots 260.
As should be apparent from FIGS. 4 and 5, the number of magnetically permeable cores such as core 228 and cores 244, 246, 248 and 250 may be varied, dependent upon the required length for the toroid as well as whether the toroid serves as a receiver, such as toroid assembly 226, or a transmitter, such as toroid assembly 242. In addition, as will be known by those skilled in the art, the number of cores will be dependent upon the diameter of the cores as well as the desired voltage, current and frequency carried by the primary windings and the secondary windings, such as windings 238.
Turning next to FIGS. 6, 7 and 8 collectively, therein are depicted the components of an electronics package 195 of the present invention. Electronics package 195 may serve as the electronics package used in the sondes described above. Electronics package 195 includes an annular carrier 196, an electronics member 198 and one or more battery packs 200. Annular carrier 196 is disposed between outer housing 83 and mandrel 85. Annular carrier 196 includes a plurality of axial openings 202 for receiving either electronics member 198 or battery packs 200.
Even though FIG. 8 depicts four axial openings 202, it should be understood by one skilled in the art that the number of axial openings in annular carrier 196 may be varied. Specifically, the number of axial openings 202 will be dependent upon the number of battery packs 200 that are required.
Electronics member 198 is insertable into an axial opening 202 of annular carrier 196. Electronics member 198 receives a command signal from first end 188 of windings 184 when toroid 180 serves as, for example, electromagnetic receiver 120 of FIG. 2. Electronics member 198 includes a plurality of electronic devices such as limiter 204, preamplifier 206, notch filter 208, bandpass filters 210, phase lock loop 212, clock 214, shift registers 216, comparators 218, parity check 220, storage device 222, and amplifier 224. The operation of these electronic devices will be more full discussed with reference to FIGS. 9 and 10.
Battery packs 200 are insertable into axial openings 202 of axial carrier 196. Battery packs 200, which includes batteries such as nickel cadmium batteries or lithium batteries, are configured to provide the proper operating voltage and current to the electronic devices of electronics member 198 and to toroid 180.
Turning now to FIG. 9 and with reference to FIG. 1, one embodiment of the method for processing the command signal is described. The method 500 utilizes a plurality of electronic devices such as those described with reference to FIG. 7. Method 500 provides for digital processing of the command signal generated by surface installation 58 and transmitted via electromagnetic wave fronts 65. Limiter 502 receives the command signal from electromagnetic receiver 504. Limiter 502 may include a pair of diodes for attenuating the noise in the command signal to a predetermined range, such as between about 0.3 and 0.8 volts. The command signal is then passed to amplifier 508 which may amplify the command signal to a predetermined voltage suitable for circuit logic, such as 5 volts. The command signal is then passed through a notch filter 508 to shunt noise at a predetermined frequency, such as 60 hertz. The command signal then enters a bandpass filter 510 to attenuate high noise and low noise and to recreate the original waveform having the original frequency, for example, two hertz.
The command signal is then fed through a phase lock loop 512 that is controlled by a precision clock 513 to assure that the command signal which passes through bandpass filter 510 has the proper frequency and is not simply noise. As the command signal will include a certain amount of carrier frequency first, phase lock loop 512 will verify that the received signal is, in fact, a command signal. The command signal then enters a series of shift registers that perform a variety of error checking features.
Sync check 514 reads, for example, the first six bits of the information carried in the command signal. These first six bits are compared with the six bits stored in comparator 516 to determine whether the command signal is carrying the type of information intended for a sonde, such as sondes 46, 48, 50, 53. For example, the first 6 bits in the preamble of the command signal must carry the code stored in comparator 516 in order for the command signal to pass through sync check 514. Each of the sondes of the present invention, such as sonde 46, 48, 50, 53 may use the same code in comparator 516.
If the first six bits in the preamble correspond with that in comparator 516, the command signal passes to an identification check 518. Identification check 518 determines 14, whether the command signal is uniquely associated with a specific downhole device controlled by that sonde. For example, the comparator 520 of sonde 48 will require a specific binary code while comparator 520 of sonde 50 will require a different binary code. Specifically, if the command signal is uniquely associated with bottom hole choke 62, the command signal will include a binary code that will correspond with the binary code stored in comparator 520 of sonde 48.
After passing through identification check 515, the command signal is shifted into a data register 520 which is in communication with a parity check 522 to analyze the information carried in the command signal for errors and to assure that noise has not infiltrated and abrogated the data stream by checking the parity of the data stream. If no errors are detected, the command signal is shifted into storage registers 524, 526. For example, once the command signal has been shifted into storage register 524, a binary code carried in the command signal is compared with that stored in comparator 528. If the binary code of the command signal matches that in comparator 528, the command signal is passed onto output driver 530. Output driver 530 generates a driver signal that is passed to the proper downhole device such that the operational state of the downhole device is changed. For example, sonde 50 may generate a driver signal to change the operational state of sliding sleeve 82 from open to close.
Similarly, the binary code in the command signal stored in storage register 526 is compared with that in comparator 532. If the binary codes match, comparator 532 forwards the command signal to output driver 534. Output driver 534 generates a driver signal to operate another downhole device. For example, sonde 50 may generate a driver signal to change the operational state of sliding sleeve 80 from closed to open to allow formation fluids from the top of formation 14 to flow into well 26.
Once the operational state of the downhole device has been changed according to the command signal, a verification signal is generated and returned to sonde 50. The verification signal is processed by sonde 50 and passed on to electromagnetic transmitter 84 of sonde 50. Electromagnetic transmitter 84 transforms the verification signal into electromagnetic wave fronts 86, which are radiated into the earth to be picked up by subsea template 47. As explained above, the verification signal is then forwarded to surface installation 58 via electrical wire 51.
Even though FIG. 9 has described sync check 514, identifier check 518, data register 520 and storage registers 524, 526 as shift registers, it should be apparent to those skilled in the art that alternate electronic devices may be used for error checking and storage including, but not limited to, random access memory, read only memory, erasable programmable read only memory and a microprocessor.
In FIGS. 10A-B, a method for operating a subsea template electromagnetic telemetry system of the present invention is shown in a block diagram generally designated 600. The method begins with the generation of a command signal 602 by surface installation 58. When the command signal 602 is generated, a timer 604 is set. If the command signal 602 is a new message 606, surface installation 58 initiates the transmission of command signal 602 in step 608. if command signal 602 is not a new message, it must be acknowledged in step 607 prior to being transmitted in step 608.
Transmission 608 involves sending the command signal 602 to subsea template 47 via electrical wire 51 and generating electromagnetic wave fronts 65. The sondes listen for the command signal 602 in step 610. When a command message 602 is received by a sonde in step 612, the command signal 602 is verified in step 614 as described above with reference to FIG. 9. If the sonde is unable to verify the command signal 602, and the timer has not expired in step 616, the sonde will continue to listen for the command signal in step 610. If the timer has expired in step 616, and a second time out occurs in step 618, the command signal is flagged as a bad transmission in step 620.
If the command signal 602 is requesting a change in the operational state of a downhole device, a driver signal is generated in step 622 such that the operational state of the downhole device is changed in step 624. Once the operational state of the downhole device has been chanced, the sonde receives a verification signal from the downhole device in step 626. If the verification signal is not received, the sonde will again attempt to change the operational state of the downhole device in step 624. If a verification signal is not received after the second attempt to change the operational state of the downhole device, in step 628, a message is generated indicating that there has been a failure to change the operational state of the downhole device.
The status of the downhole device, whether operationally changed or not, is then transmitted by the sondre in step 630. The surface installation listens for the carrier in step 632 and receives the status signal in step 634, which is verified by the surface installation in step 636. If the surface installation does not receive the status message in step 634, the surface installation continues to listen for a carrier in step 632. If the timer has expired in step 638, and a second time out has occurred in step 640, the transmission is flagged as a bad transmission in step 642. Also, if the surface installation is unable to verify the status of the downhole device in step 636, the surface installation will continue to listen for a carrier in step 632. If the timers in steps 638, 640 have expired, however, the transmission will be flagged as a bad transmission in step 642.
In addition, the method of the present invention includes a check back before operate loop which may be used prior to the actuation of a downhole device. In this case, command message 602 will not change the operational slate of a downhole device, in step 622, rather the sonde will simply acknowledge the command signal 602 in step 644. The surface installation will listen for a carrier in step 646, receive the acknowledgment in step 648 for verification in step 650. If the surface installation does not receive the acknowledgment in step 648, the surface installation will continue to listen for a carrier in step 646. If the timers have expired in steps 652, 654, the transmission will be flagged as a bad transmission in step 620. Additionally, if the surface installation is unable to verify the acknowledgment in step 650, the surface installation will continue to listen for a carrier in step 646. If the timers in step 652 and step 654 have timed out, however, the transmission will be flagged as a bad transmission in step 620.
While this invention has been described with a 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 electromagnetic downlink and pickup apparatus for transmitting and receiving electromagnetic signals is disclosed. The electromagnetic downlink and pickup apparatus includes a subsea conductor (47) disposed beneath the sea floor (16) and a surface installation (58) for generating and interpreting signals. The subsea conductor (47) and the surface installation (58) are electrically connecting by first and second conduits (30, 51) that form a pair terminals on the subsea conductor (47) between which a voltage potential may be established, thereby providing a path for current flow therebetween. |
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BACKGROUND OF THE INVENTION
The present invention relates to a method for the monitoring of the motion of a drive-operable, one or multiple part door body, particularly an overhead door, along the movement path between the open and closed position and for the interruption of this motion, particularly by switching off and over the drive in the event of an obstacle in the path of movement which the door body runs against with the following steps:
an actual course which really occurs and dependence on the movement path or the time of a physical operating value of the movement of the door body is recorded, and
an interruption signal for the interruption of the motion of the door body being monitored is generated if the currently recorded value of the actual course differs by a previously determined amount from the corresponding value of a nominal course with the nominal course on the basis of a physical operating value being recorded and stored at least once before the putting into operation of the door for an obstacle-free normal operation along the movement path or the time, and to a means to perform the method in accordance with a door drive, a measuring element to measure the movement path, a measuring element to measure a physical operating value of the door motion, a memory to store the nominal course and/or actual course determined by the measuring elements in dependence on the movement path or the time and a control unit to evaluate the nominal course and the actual course and to generate an interruption signal.
Such a method and such a means are known from EP-B1-0 083 947. The monitoring unit disclosed therein is based on the basic idea that the actual course of the required force to drive the door body over the movement path is compared continuously with the nominal course. If the difference between actual course and nominal course exceeds a previously fixed amount, an interruption signal is generated which switches off the door body drive or reverses its direction of movement. The nominal course is here recorded and stored at least once prior to the putting into operation of the door for an obstacle-free normal operation along the movement path.
Such a monitoring system possesses an improved hazard protection over other known monitoring systems such as electrical contacts positioned underneath yielding bulges. Nevertheless cases can still occur with such a monitoring means where the criterion to generate the interruption signal is not sufficiently sensitive. If the door body edge contacts soft obstacles, for example, the motion force for the movement of the door body increases more slowly than against a hard obstacle so that a longer period passes before the interruption signal is triggered. If, therefore, the edge of the door body laterally contacts, for example, the groin of person accidentally crossing the motion path during the movement of the door body, then is it possible that the interruption signal of the monitoring device will not be triggered early enough.
SUMMARY OF THE INVENTION
It is therefore the object of the present invention to monitor as sensitively as possible the motion of movement between the open position and the closed position of doors of the type in question for any deviation from normal operation.
Based on a method of the generic type this object is solved in accordance with the present invention by the steps of an actually occurring actual change of course dependent on the movement path or the time is determined by forming the derivation according to the movement path or the time for every recorded value of the actual course, and
an interruption signal for the interruption of the motion of the monitored door body is generated if the currently determined value of the actual change of course differs to a previously determined extent from the corresponding value of a nominal change of course with the nominal change of course being determined and stored at least once before the putting into operation of the door based on the nominal course. The solution in accordance with the invention consists of the fact that in addition to the known methods a derivation of the actual course of a physical operating value of the door movement is formed at each scanned point in accordance with the movement path and that an interruption signal is generated even if a criterion is not met in accordance with the derivation determined. The nominal course of the corresponding physical operating value is here recorded and stored at least once before the putting into operation of the door for an obstacle-free normal operation along the movement path.
The advantages achieved with the present invention comprise particularly the monitoring unit reacting equally sensitively when the door contracts hard objects and/or soft objects. This improvement can be achieved here with relatively low effort over a monitoring unit of the generic type.
Preferably, for the formation of the actual change of course and/or the nominal change of course the first derivation is formed according to the movement path or the time; however, higher derivations can also be used.
The difference value to be given, by which the actual change of course has to differ from the nominal change of course in order to signal the event of an obstacle, is, on the one hand, dependent on external influences such as wind influences, slight icing and similar and, on the other hand, it takes slight changes in the run resistance into account. In accordance with a preferred embodiment a fixed difference value is fixed beforehand over the total motion run, but in principle the difference value can, however, also be measured differently over the movement path, particularly to compensate for the different wind impairment depending on the motion path already laid back.
In principle, the nominal course and the actual course can be derived from different physical operating values of the forward movement, but preferably the same physical starting values will be evaluated for both values.
In accordance with a preferred embodiment the nominal course is only recorded and stored after the installation of the door on site and then the nominal change of course should be determined and also stored. In this way, the actually occurring operating relationships can be taken into account under normal conditions in a realistic manner with the actually prevailing environmental influences. As the operating relationships can change over time due to wear or similar, the nominal course can be recorded and stored again after certain operating intervals of the door and a new nominal change of course determined from this. It is naturally, however, also possible to give and store the nominal course at the time of manufacture depending on the type of door. The nominal change of course can also be determined and stored once, but it is also possible to have the nominal change of course determined again during operation for every movement of the door body on the basis of the nominal course.
The determination in dependence on the path of a physical operating value of the door body motion can be done in various ways. Preferably, the driving force of the door body is used as the basis with this being able to be determined in turn by a direct measurement of force or also by a measurement of torque. A preferred method of measuring the torque consists of determining the torsion angle between two coupling elements connected elastically to one another and positioned behind one another as part of the path of the driving force. However, it is also possible to monitor in a known fashion the performance of an electrical drive motor or the current supplied with a constantly applied voltage.
If the above measuring values of a physical operating value of the motion of a door body are recorded in dependence on the movement path, then it is necessary for this purpose that the movement path itself also be determined by a suitable measuring device. For this purpose, preferably a pulse generator is used which is also driven by the driving motor. In connection with two switch elements which detect the opening position and the closing position of the door body, the current position on the movement path can be determined with the pulse generator within the resolution precision of the pulses emitted.
In accordance with another preferred embodiment it is provided that the rate of motion of the door body is taken as a measure of a physical operating value of the motion. Here, the rate of motion is no longer recorded in dependence on the movement path but in dependence on the time. A course of speed for normal operation without any obstacles also recorded in dependence on the time serves as the nominal course. To measure the rate of motion a tachometer generator or also a pulse generator can be used which can be driven by the door drive. While the pulses emitted by the pulse generator have still to be derived into a frequency proportional to the speed, the tachometer generator already supplies a voltage proportional to the rate of motion of the door.
Another solution of the above task in accordance with the invention consists of a device to perform the method in accordance with the invention with the control unit possessing a derivative element which generates a nominal change of course from the nominal course and/or an actual change of course from the nominal course each in dependence on the movement path or the time, the nominal change of course and/or the actual change of course can be stored in the memory and the nominal change of course and the actual change of course can be evaluated by the control unit.
In accordance with its basic design, the device comprises a door drive, a measuring element to measure the movement path, a measuring element to measure a physical operating value of the door movement, a control unit with memories for the measuring values and a derivative element.
In accordance with a preferred embodiment the control unit comprises a microcontroller in which corresponding memories and A/D converters have already been integrated. Preferably, the derivative element is also implemented on the microcontroller in the form of a software logic. However, it is also feasible that the derivative element comprises an analog derivator whose signal is also supplied to an A/D converter. In any case, the derivative element must be designed in such a way that the current derivation of the input signal in question is determined reliably independent of momentary noise interference.
In accordance with another preferred embodiment the door drive comprises an electrical motor. The power of the electrical motor supplied can here be taken directly as the measure for a physical operating value of the door motion. With a constantly supplied voltage, the current supplied to the electrical motor can also serve as the basis for a physical operating value with the current being measured then approaching a measure for the moment given by the electrical motor.
In accordance with another preferred embodiment it is provided that the interruption signal generated by the control unit results in a switching off of the electrical motor. However, it is also possible that the direction of drive of the door drive will reverse as a result of the interruption signal which can be done with a suitable electrical motor by reversing the polarity of the supply voltage or also by a suitable gear.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the invention are described in more detail by means of an embodiment shown in the drawing where:
FIG. 1 is a schematic representation of a garage door movable overhead with a block diagram of the monitoring system in accordance with the invention, and
FIG. 2a is a front view of a schematic representation of a pulse generator on an elastic coupling.
FIG. 2b is a side view of the schematic representation of a pulse generator on an elastic coupling.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The garage door from FIG. 1 possesses two vertical braces 1 to whose top end two rails 2 connect in which the door body 3 is guided. The door body 3 is further hinged to the braces 1 with a connecting rod not shown so that the door body can be opened and closed with an overhead movement. In addition, equalizing springs are provided which largely compensate the door body's own weight during the movement and which hold the door body in its defined end positions. The drive system designated with number 4 consists in total of a drag-chain drive with a drag chain 5, to which the door body 3 is hinged and which is guided over the turn pulley 6 and over a drive pulley (not shown). The drive pulley is located in the drive unit 7 and is driven by the electrical motor 9 via a gear. Also driven by the electrical motor 9 is an impulse generator 8 which is mounted on an elastic coupling and which emits a pulse after every certain angle of rotation.
The whole system is controlled by the control unit 10 which consists of a microcontroller with an integrated memory and A/D converters. The output signal of the control unit 10 is supplied to an amplifier 11 which supplies the required power to the electrical motor 9 via a current measuring element 12. The input values of the control unit include the measuring values 8a and 12a, the switch signals 13a and 14a and input signals 15 (not specified in any detail) which can include signals of an operating unit or also a voltage supply.
The signal 8a of the pulse generator is evaluated by the control unit in connection with signals from switch elements 13 and 14. Here the switch elements are actuated by the door body 3 in its end positions, that is in the vertical and in the horizontal position in each case. Signals 13a and 14a therefore each serve as start/stop signals in order to ensure a reliable upward integration of the signal 8a.
FIGS. 2a and 2b show a possible embodiment of the pulse generator 8. In an axial cross-section and in a radial section a coupling is shown which is provided between the driving wheel of the drag chain 5 and the outlet of the drive motor 9. The driven coupling half 20 is designed as a rotating, elastic coupling element with a radial intermediate layer between teeth and hub, for example in the form of a rubber ring 21. The output coupling half 22 possesses on its radial circumference teeth 23 which are sensed by the inductive generator 24. When the coupling turns, the inductive generator 24 then emits corresponding pulses due to the periodic change in the inductance.
With such an elastic coupling it is also possible to determine the torque given by the electrical motor 9 by measuring the angle of torsion between the driven coupling half 20 and the output coupling half 22. In the present embodiment this is, however, done by the current measuring element 12 which measures the current supplied to the electrical motor. The evaluation of the measuring signals 8a and 12a is described here in the following:
Before the door drive is put into operation the nominal course of the motor current for obstacle-free normal operation is recorded in dependence on the movement path. For this purpose, the signals 8a and 12a are read into the microcontroller via A/D converters at identical scan times and stored in such a way that an allocation of values of identical times is possible. Together with the control program of the drive control the nominal course thus recorded is stored in the EPROM so that the values can be reloaded into the RAM at every reset of the microcontroller.
During an opening or closing movement of the door body an actual course of the motor current according to the nominal course is recorded in dependence on the movement path. For each actual value recorded a calculation process is performed before the recording of the next actual value, that is within one scan period, which calculation process checks whether any unpermitted differences from the nominal course exist and whether accordingly an interruption signal has to be generated.
For this purpose, first each actual value recorded is compared to the corresponding nominal value for identical values of the movement path. If the actual value differs from the nominal value by a previously determined amount, then an interruption signal is generated by the microcontroller which signal results in a reversal of the drive direction of the door body.
If, in contrast, the actual course is within a permitted range, then in a next step for the currently recorded actual value the derivation is formed in dependence on the movement path. For this purpose, different methods are feasible, the simplest consists of the forming of a difference between the currently recorded actual value and the previously recorded actual value. If the actual values are particularly loaded with noise, then a smoothing of the previous values may be necessary prior to forming the difference. To do this, a certain number of previously recorded actual values are interpolated with a given function before the derivation is then formed from this interpolated function. The currently determined derivation is included in an actual change of course which is compared with a nominal change of course. This nominal change of course was also determined and stored in accordance with the method just described prior to the putting into operation based on the already recorded nominal course. If the actual change value differs from the nominal change value by a previously determined amount, then an interruption signal is generated which in the results in a reversal of the drive direction of the door body.
In accordance with the method described above, the already known criterion between nominal course and actual course is therefore supplemented by an additional criterion between nominal change of course and actual change of course which allows a more exact evaluation for the generation of an interruption signal. Of course, in addition to the derivation criterion other further criteria are feasible, in particular the nominal course can be compared more and more exactly with the actual course by forming further derivations. The limit here is formed by the already mentioned noise behavior of the two signals with a minimum tolerance width being required between the actual course and the nominal course so that the interruption signal is not triggered when not desired.
In addition to the method described for the recording of the nominal and actual courses in dependence on the movement path, it is besides also possible to record the actual and nominal courses in dependence on the time. The requirement for this is that the course of movement of the door body does not change over time. For this purpose it must be ensured that friction influences and any other interference influences can be neglected. This can be taken into account in a limited fashion by the nominal course being recorded again after regular maintenance intervals. If the interference influences can accordingly be neglected, then it is also possible to dispense with the current sensor 12 by having the rate of speed of the door body being determined over time from the signal of the pulse generator 8. | A method for monitoring motion of a drive-operable door body between open d closed positions. To monitor movement as sensitively as possible, an actually occurring course of movement is compared with a previously fixed nominal course. A signal for interrupting movement is generated when the nominal course and the actual course, and/or one of the derivations of these, differ from one another by a previously fixed amount. |
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The present invention relates to the manufacture of tilt-up concrete panels, and more particularly to a system of components for facilitating casting of panels on a casting surface without the need for penetrations, as by nails in drilled holes, of the casting surface as is common in traditional panel forming methods.
BACKGROUND
It is well known in the process of manufacturing concrete walls or wall sections to form them on a substantially flat, hard surface such as a concrete floor, and subsequently to tilt up the hardened and cured concrete section to form a wall or wall section. It is common practice in the construction industry to pour several walls or wall sections of a building on a previously poured and hardened floor of the building under construction. In doing so, a suitably large area of the floor is formed or fenced off by a plurality of wooden forms which define the edges of the final wall or section. These forms are attached to the floor so as to prevent dislocation or movement, particularly in a lateral direction. The surface of the floor is provided with a suitable bond-beaker material in order to prevent the newly formed section from adhering to the floor. A concrete mix is then poured into the area fenced off by the wooden forms. After curing and hardening of the newly poured concrete, the wooden forms are removed and the concrete wall section is lifted off the floor by a crane or other suitable device to complete a wall section of the building.
The usual practice after.the concrete floor or foundation has been poured and cured is that a wooden form is constructed on the floor into which concrete for the wall panels can be poured. The wall form: is a wooden plank, such as a 2×10 plank and which is supported by wooden brackets spaced along the form at, for example, 2 foot intervals, and nailed to the concrete floor. This type of installation involves a substantial amount of manual labor. In addition, after the concrete panel is cast into the form area, the forms and base and whatever brace members are used must be removed and, importantly, the nail holes in the floor need to be patched. This involves additional manual labor. Presently, one may end up with 1,000-10,000 such holes in the concrete floor which must be patched.
Also, a chamfer strip is added inside of the resulting form adjacent the floor and forms to suitably chamfer the edge of the concrete wall panel. If this is not done, the edge tends to crumble after the wall: is completed.
Example prior art systems can be found in U.S. Pat. No. 4,393,568, U.S. Pat. No. 4,101,111 and U.S. Pat. No. 4,042,205.
SUMMARY OF THE INVENTION
The present invention eliminates the need for nailing wooden forms to a concrete or other floor or base, and the need for adding a chamfer strip. This is accomplished by providing an elongated base track or strip and brackets attached thereto to support a wooden form between.the base and bracket. Preferably, the bracket and strip are configured so that the bracket can merely snap into a channel or longitudinal slot in the base track. The bottom of the base track has secured thereto one or more strips of two sided adhesive along the whole length of the base track to adhere the base track to the concrete floor onto which the wall section is to be poured. The base track itself has a chamfered edge for providing a chamfer on an edge of the concrete wall. This system eliminates the need for penetrating the floor with nails or other fasteners and thus also eliminates the need to patch the resulting holes. Furthermore, no separate chamfer strip is needed. Also, the components may be reusable.
In a presently preferred embodiment, a base strip and bracket are provided along with a batter clip attachable to the upper end of the bracket so as to position the wooden form at a slight angle or cant the form, so as to provide a camber at one end or side of a concrete panel which will become the top or roof line of a wall. The batter clip pushes the form away from the bracket by a small angle to create the camber. The camber created by this technique is an important feature to reduce the problem when dust collects at the top of a panel used as a wall, at the roof line. Because of this, the dust and dirt that collects on the top can work itself down inside the wall rather than down the outside. This is advantageous because if the dust works down the outside of the wall and it rains, the outside of the wall is streaked with the moist dust and dirt.
Accordingly, it is an object of the present invention to provide an improved concrete panel forming system.
Another feature of the present invention is to provide components and a system for forming tilt-up concrete panels without requiring penetration of the base surface by fasteners such as nails and the like.
Another feature of the present invention is to provide a concrete panel forming system comprising an elongated base track and support brackets which snap into a channel in the base track for supporting a wooden form.
Another feature of the present invention is a tilt-up concrete panel forming system incorporating an integral chamfer strip.
BRIEF DESCRIPTION OF DRAWINGS
These and other objects and features of the present invention will become better understood through a consideration of the following description, taken in conjunction with the drawings in which:
FIG. 1 is a perspective view of the present concrete panel forming system showing a base track and bracket thereof.
FIG. 2 is an end cross-section of the system of FIG. 1 taken along a line 2 — 2 but further showing the position and support for a wooden form,
FIG. 3 is an end view of the bracket of the system of FIGS. 1 and 2,
FIG. 4 is a view of a pre-made corner section of base strips,
FIG. 5 illustrates another embodiment of a base strip and bracket,
FIG. 6 illustrates another and preferred embodiment of a base strip and bracket,
FIG. 7 is a detailed view of the upper end of the bracket of FIG. 6,
FIG. 8 is a perspective view of a batter clip used with the bracket of FIG. 6 (and also shown in FIG. 6 ), and
FIG. 9 a is a cross-sectional diagrammatic end view of the base strip and bracket of FIG. 6 and also illustrating a wooden form and the manner in which the batter clip cants the wooden form, and FIG. 9 b illustrates a smaller version of the bracket.
DETAILED DESCRIPTION
Turning now to the drawings, the present tilt up concrete panel forming system comprises a base track or strip 10 and a bracket 12 . The base strip 10 typically is 5′ or 10′ in length and is placed on.a concrete floor 14 . The strips 10 are laid end-to-end as necessary depending on the length and width of the final wall. The base strips 10 are secured to the concrete floor 14 by one or more double sided adhesive strips 16 after the floor is cleaned, such as by vacuuming or sweeping and then picking up dust with a damp rag, preferably before any bond breaker is applied to the concrete floor. The strips 16 run the length of the base strip 10 .
The base strip 10 includes an angled side 18 which provides the function of a separate chamfer strip as used in the prior art. The strip 10 also includes a longitudinal slot 20 which has angled sides 22 and 23 as seen in FIGS. 1 and 2 into which the bracket 12 is inserted as will be discussed subsequently. Preferably, the base strip 10 is formed of a suitable plastic material which has some resiliency to facilitate the base 30 of the bracket 12 snapping into the slot 20 . A plurality of the brackets 12 are inserted into the base strip, such as at 2 foot intervals to suitably support a wooden form 26 (note FIG. 2 ).
Turning now to more details of the bracket 12 , the same includes the base 30 having angled walls 32 and 33 to fit or snap into the slot 20 of the base strip 10 adjacent to and mate with the angled walls 22 and 23 of the strip 10 . The bracket 12 further includes an upstanding support 36 which “backs up” the wooden form 26 . The bracket 12 has an angle brace 38 , the lower end 40 of which rests on the concrete floor 14 . The upper end 42 of the support 36 provides an area through which a suitable screw fastener (not shown) can be inserted as through a groove 44 as seen in the end view of the brace 12 in FIG. 3 to securely affix the bracket 12 to the wooden form 26 . The wooden form typically is a 2×6, 2×8, or the like. Preferably the brackets 12 are made in different sizes for different applications, such as for different thickness wall panels. The brackets can be formed from extruded plastic or aluminum and cut into sections to form the same or they may be injection molded of plastic.
FIG. 4 illustrates a premade corner for the base strips 10 . As can be seen, two short lengths (e.g., 1 foot), strips 10 are cut at a 45° angle as seen at 50 and glued together by suitable adhesive, such as PVC glue. This arrangement provides a premade corner to simplify installation of the present forming system.
As will be appreciated, the present system provides a relatively simple way of setting up concrete forms by merely laying down the base strips 10 which are secured to the floor 14 (after suitable preparation of the floor, e.g., to remove dust, etc. as noted above), inserting a plurality of the brackets 12 into the longitudinal groove 20 of the base strips 10 , and the wooden forms 26 are placed on the strips and secured at a groove 44 (FIG. 3) to the forms 26 . This system simplifies and facilitates setting up the forms, does not require the numerous nailing and nail holes thereby minimizing the labor for both installation and removal. Additionally, the components, namely the base strips 10 and brackets 12 , may be reusable although new adhesive strips 16 may be needed.
The present system provides a complete tilt-up concrete forming system that eliminates the need for penetrations in the casting surface, i.e., the floor or slab 14 , as is common in traditional panel forming methods. This system increases productivity and simplifies panel forming operations, and eliminates the need to patch thousands of holes which in the prior art systems are drilled in the casting surface when using traditional panel forming methods. The base track or strip 10 incorporates the continuous chamfered edge 18 thereby eliminating the need to use a separate chamfer strip and the need to nail on a separate chamfer strip after the panel forms are erected. The base track 10 can be formed from plastic material which eliminates the usual dusting effect from a chamfered edge of wood which contains natural sugars that retard concrete curing. The use of two sided adhesive strips or tape 16 to adhere the base track 10 to the casting surface 14 provides continuous support along the entire length of the panel forms to resist pressure from the concrete during the placing operation. The base tracks and brackets may be reusable, and the brackets easily snap into the base track. The angled surfaces 32 and 33 of the bracket 12 and the angled surfaces 22 and 23 of the longitudinal groove 20 of the base strip 10 prevent uplift of panel forms during the concrete placing operation. The angled rear brace 38 of the brackets 12 extend beyond the base strip 10 at 40 to contact the casting surface 14 directly to keep the form panel plumb. The upper end 42 of the bracket 12 preferably is provided with the groove 44 to facilitate alignment and guiding of a self-tapping screw to attach the bracket 12 to the wooden form 26 . Only one self-tapping screw per form bracket 12 is needed to hold the panel form 26 in place. The use of the groove for this purpose reduces labor costs which would be required if a hole had to be drilled for a nail or screw. The brackets 12 can be placed at any point along the entire length of the base strip 10 as necessary to support the form 26 , usually several feet apart. The brackets 12 can be manufactured in different sizes for varying concrete panel thickness.
Turning now to FIG. 5, the same illustrates a second embodiment which may be preferred for some applications. This embodiment is similar to that of FIGS. 1 through 3, but the base strip 110 has a deeper cavity or opening 124 so that the form 26 fits down further into the base strip. The bracket 112 is similar to the bracket 38 with a base section 130 having angled edges 132 and 133 to fit within the groove 120 and angled edges thereof 122 and 123 . The bracket 112 further includes an offset angled section 144 which allows the upstanding support 136 to properly engage and back-up a wooden form 26 . This is needed because of the offset occasioned by section 125 of the base strip 110 . As with the embodiment of FIGS. 1 through 4, this embodiment of a base strip and bracket has like features and benefits.
Turning now to the embodiment of FIGS. 6 through 9, and which is believed to be a preferred embodiment, the components are similar to those of the previous two embodiments but with some important differences. This embodiment includes a base strip 210 and bracket 212 . The base strip 210 is simpler in that a slot or groove 220 is in the form of a U-shaped channel (note particularly FIG. 9) for receiving an L-shaped foot 230 of the bracket 212 . The base strip 210 includes a cavity 224 for receiving the lower end of the form 226 (not shown in FIG. 6, but note FIG. 9 ). The base strip also includes an angled side 218 which provides the function of a separate chamfer strip as previously discussed.
The bracket 212 includes an upstanding support 236 and an angle brace 238 which has a foot 240 , all very similar to those of the preceding embodiments; however, in this embodiment the bracket 212 is of a T-beam shape as can best be seen in FIG. 6 . The upper end 242 of the bracket 212 has an aperture 244 (note also the detail of FIG. 7 ). Adjacent the opening 244 at the upper end 242 of the bracket 212 is a U-shaped boss 250 which is configured to receive and couple with U-shaped fingers 252 and 254 of a batter clip 256 . The batter clip 256 slides onto the upper end 242 of the bracket 212 around the boss 250 and engages fingers 260 and 262 of the end 242 of the bracket 212 to firmly support the batter clip 256 on the upper end 242 of the bracket 212 . The clip 256 also has a through aperture 258 (FIG. 8) as a continuation of the aperture 244 in the upper end 242 of the bracket 212 to allow the upper end 242 of the bracket 212 to be firmly attached to the wooden form (note FIG. 9) by a nail or screw.
The main purpose of the batter clip 256 is to hold the form 226 outwardly at an angle as seen in FIG. 9 to cause a camber to be provided to the edge of the concrete panel when this edge is to be the top of a concrete panel at a roof line for the purposes as previously described. That is, the camber or slight angle is provided on the edge 264 of the concrete panel 265 by the form 226 so that when dust collects on the cambered top ( 260 ) of the panel the dust can fall to the inside of the building rather than the outside of the building to minimize dirt streaking the outside wall. An exemplary angle imparted to the form by the clip 256 is approximately 7 degrees, although different angles can be provided as desired.
FIG. 9 a shows the bracket 212 , clip 256 and strip 210 of FIGS. FIG. 9 b shows a smaller version of a bracket 212 a , clip 256 a and the strip 210 . An example width at the base of the bracket 212 is 5.44 inches (and 3.345 inches on bracket 212 a ) and height of 8.76 inches (and 5.263 inches for 212 a ).
Each of the components in the embodiment of FIGS. 6 through 9 can be injection molded of a suitable material such as polypropylene, although the components can be either plastic or metal as may be desired.
While embodiments of the present invention as been shown and described, various modifications may be made without departing from the scope of the present invention, and all such modifications and equivalents are intended to be covered. | A system for tilt-up concrete panel forming for use on a casting surface comprising an elongated base strip having an elongated groove in an upper surface, having a chamfered edge, and having a bottom surface adapted to be adhesively attached to the casting surface. The base strip has a support edge on the upper surface for receiving and supporting an elongated wooden panel form. A plurality of brackets each have a bottom section for mating with the elongated groove of the base strip at spaced intervals along the base strip, and the brackets further including a support section for supporting a side of the panel forms. Suitable clips can be added to the support sections of the brackets to impart a camber to an end of the concrete panel being formed. |
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TECHNICAL FIELD OF THE INVENTION
This invention relates to sealed rotary drill bits. In a specific aspect the invention relates to sealed rotary drill bits which can be used in blast hole drilling, and in particular to sealed rotary drill bits utilizing air pressure for seal protection.
BACKGROUND OF THE INVENTION
One function of rotary drill bits is use in blast hole drilling. In general, blast holes have a depth in the range of about 50 to about 150 feet and are filled with a blasting material for breaking up the earth during mining operations. The body of the drill bit typically used for drilling blast holes is attached to a drill pipe by a threaded member on the body of the bit. The drill pipe is supported and rotated by a drilling rig. The body of the drill bit typically has three legs, each of the legs having a projecting, conical cutter-receiving journal. Three conical cutters, each having an axially extending recess open at one end, are rotatably mounted on respective journals with the use of friction reducing bearings interior to the conical cutters. Each conical cutter has rock cutting teeth or inserts on the surface of the conical cutter. The conical cutters cut through the earth when the weight of the drill pipe above the drill bit and the rotation of the drill pipe causes the conical cutters to independently rotate about their individual journals and cut through the earth.
Unlike oil field drilling where the drill bit will generally be cutting in the presence of liquid drilling mud, the blast hole drilling environment is dry and abrasive. In order to reduce interior wear of the oil field drill bit, fluid carrying conduits interior to the leg members and extending to the bearings inside the conical cutters supply lubrication to the bearings. In order to prevent loss of lubricant, typically each conical cutter of the oil field drill bits will have some sort of sealing means to retain the lubricant. The sealing means, which is located at the open end of the conical cutter recess, also prevents abrasive materials from entering through any space between the leg of the drill and the open end of the conical cutter mounted on the journal to the inside of the conical cutter to the bearings. However, since in blast hole drilling the environment is much more abrasive, the lubricating system and sealing means of an oil field drill bit are not used in many blast hole drill bits because the abrasive environment will quickly erode the seals, causing lubricant loss and drill bit failure.
Instead of supplying lubrication to the bearings to reduce wear, many drill bits circulate air through the bearings to cool the bearings and to wash away abrasive debris. For example, U.S. Pat. No. 3,921,735, by Dysart, discloses a passageway that extends through a bit body for conducting a gaseous drilling fluid to cool and clean the bearings. A cone mouth air screen is provided to screen out drilling debris. The screen material is selected so that its porous area is such that it will allow passage of all the air needed to cool and clean the bearings with a minimum of back pressure, but still fit satisfactorily into the minimal available space at the constricted cone mouth of a typical cone arm sub-assembly for a three cutter blast hole bit.
Sealing in lubricant is an effective way of lubricating the bearings and extending the life of the drill bit. There are attempts at providing sealed in lubricant for blast hole bits with means for protecting the seal from erosion from the abrasive blast hoe environment. U.S. Pat. No. 4,183,417, by Levefelt, discloses a rotary roller bit for drilling earth and rock formations which has a sealed lubrication system. The objective disclosed in that patent is to provide a barrier of air in the narrow space between the leg of the bit and the roller cutter to protect the seal from being damaged from debris. The periphery of each roller cutter is spaced from the adjacent portion of each leg so as to provide a jet slot for the discharge of air. Adjacent the slot and radially inwardly is an air chamber which is formed between an annular surface of the leg and the seal. Air is supplied through a passageway and is delivered to the air chamber and discharged from the chamber in a jet stream from the jet slot. The axial dimension of the air chamber is substantially greater than that of the slot so that the cross-sectional dimension of the path of air flow is substantially restricted as the air passes from the air chamber so as to produce a jet effect in the air flow. The air jet flowing from the jet slot is designed to prevent the entry of debris to the seal. However, one problem is that the jet slot has a dimension which is large enough for rock particles or other debris to enter. Furthermore, since the air from the air supply passageway passes into the air chamber and escapes from the jet slot wherever there is less resistance to air flow, this might create erratic air flow resulting in channeling and reverse flow conditions.
It is an object of this invention to provide a new and improved rotary blast hole bit which is sealed to retain lubricant for the bearings. Another object of the invention is to provide homogeneous air dissipation around the entire cone mouth to blow away borehole debris efficiently and uniformly, preventing air flow which results in channeling or reverse flow conditions, thereby protecting the sealing of the drill bit. It is a further object of this invention to use the homogeneous air dissipation around the cone mouth to protect an improved sealing arrangement.
SUMMARY OF THE INVENTION
This invention provides means for protecting the lubrication sealing arrangement of a rotary drill bit with air pressure. The rotary drill bit has a body with leg members with each of the leg members having a projecting, conical cutter receiving journal. A conical cutter, having an axially extending recess open at one end, is rotatably mounted onto the journal by the use of friction reducing bearings interior to the conical cutter. A main reservoir supplies lubrication fluid to conduits which extend into the bearings. When the region around the bearings is filled with lubricant, a seal positioned in a groove of the conical cutter retains the lubricant around the bearings. A porous gas restrictor is spaced outwardly from and concentric with the seal in the narrow space between the leg and the mouth of the conical cutter, thereby forming an annular chamber between the seal and the restrictor. A gas passageway interior to the body of the drill bit carries gas from a gas source into the annular chamber.
The porous gas restrictor allows dissipation of the pressurized gas, but the porosity of the restrictor is low enough that it maintains gas pressure in the annular chamber, resulting in the gas distributing evenly around the entire circumference of the annular chamber and the seal. Since the gas pressure is distributed evenly around the annular chamber, the dissipation of gas from the porous gas restrictor is a controlled dissipation with the dissipation being homogeneous at all points. This pressurized gas passing through the restrictor washes drilling debris away from the porous gas restrictor. All of the gas passageways through the porous gas restrictor are tiny pores which prevent drilling debris from getting past the restrictor into the annular chamber, while the positive gas pressure exiting through these pores keeps drilling debris away from the restrictor. If debris somehow enters into the annular chamber, the pressurized gas flowing past the seal and exiting past the porous gas restrictor keeps the debris away from the seal.
The means for protecting seals with pressurized air can be used with different sealing arrangements. One effective sealing arrangement includes an inner annular seal and an outer annular seal forming a circumferential seal gap between the seals, the seal gap being filled with lubricant. The conical cutter is adapted with seal receiving grooves at the open end of the recess to receive the inner and outer seals with the circumferential seal gap between the seals. The porous gas restrictor is spaced outwardly from and concentric with the outer annular seal, thereby forming an annular chamber between the outer seal and the restrictor. The inner seal is more resistant to lubricant under pressure than the outer seal and when a means for supplying lubricant to the circumferential seal gap is provided, lubricant in the seal gap will leak past the outer seal, and not the inner seal. The lubricant leaks into the annular chamber and past the porous gas restrictor. The lubricant and gas pressure exiting past the restrictor both help wash away drilling debris.
There are different embodiments for supplying lubricant to the circumferential seal gap. In one embodiment of the invention for supplying lubricant to the circumferential seal gap, a separate reservoir, which is preferably filled with a lubricant having a lower penetration value and a higher viscosity than the lubricant used in the bearings, supplies lubricant to conduits which open into the circumferential seal gap. A capillary size hole which opens into the bearings permits lubricant from the bearings to leak into conduits which also lead to the circumferential seal gap and to pressurize the lower penetration value lubricant. The lower penetration value and higher viscosity lubricant provides the primary protection to the seals. However, if this supply of lubricant runs low, the lubricant from the bearings backs up the supply of lower penetration value and higher viscosity lubricant and fills the circumferential seal gap.
In another embodiment, a one-way relief valve is connected to one of the bearings. When the lubricant around the bearings naturally expands from the heat of operation of the rotary drill bit, the fluid expands up a conduit past the relief valve into a relief valve reservoir. Once the lubricant is in the relief valve reservoir, it is directed to a conduit directly leading to the circumferential seal gap where it will bleed past the outer seal as described above.
In another embodiment of this invention, a separate reservoir for supplying lubricant to a conduit which opens into the circumferential seal gap is not needed. In this embodiment, the inner seal is a hydrodynamic seal. The hydrodynamic seal is designed to permit migration of lubricant from the bearings into the circumferential seal gap while preventing lubricant or contaminates from the circumferential seal gap from traveling past the hydrodynamic seal into the bearing region.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages will become apparent from the following detailed description of the preferred embodiment of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same elements or functions throughout the views, and in which:
FIG. 1 is a perspective view of a rotary blast hole drill bit of the invention;
FIG. 2 is a cross-sectional view of one leg of the drill bit in FIG. 1, illustrating one embodiment of the invention;
FIG. 3 is a cross-sectional view illustrating an enlarged view of the region around the sealed portion of the drill bit of FIG. 2;
FIG. 4 is a cross-sectional view of the drill bit on line 4--4 of FIG. 2;
FIG. 5 is a cross-sectional view of one leg of the drill bit of FIG. 1, illustrating a second embodiment of the invention;
FIG. 6 is a cross-sectional view illustrating an enlarged view of the region around the sealed portion of the drill bit in FIG. 5;
FIG. 7 is a cross-sectional view of one leg of the drill bit of FIG. 1, illustrating a third embodiment of the invention;
FIG. 8A is a partial cross-sectional view of one leg of the drill bit of FIG. 1, illustrating a fourth embodiment of the invention; and
FIG. 8B is a cross-sectional view illustrating an enlarged view of the sealed portion of the invention illustrated in FIG. 8A.
DETAILED DESCRIPTION
FIG. 1 illustrates a drill bit of the type to which the invention pertains. Drill bit 10 includes a top threaded portion 12 for threaded connection to a drill pipe (not shown). The body 14 of the drill bit has three legs 16 with conical cutters 18 attached. A nozzle 64 is also shown.
FIG. 2 illustrates a partial cross-sectional view of drill bit 10 particularly showing the interior of one of the legs 16 with a conical cutter 18 attached. From FIG. 2, it can be seen that a portion of leg 16, hereinafter referred to as the journal 20, is angled with reference to the vertical axis, which includes the threaded portion 12. Journal 20 receives conical cutter 18. Conical cutter 18 includes several cutting teeth 22 which are the elements which cut through the earth during drilling operations. Races 24, which are annular grooves, are formed on the interior of conical cutter 18 and/or the exterior of journal 20 so that when the conical cutter is placed on the journal, these races will accommodate roller bearings 26 and ball bearings 28. A thrust button 30 is placed between journal 20 and conical cutter 18 to reduce stress between the journal and the conical cutter. Roller bearings 26 and ball bearings 28 provide for rotatable engagement between conical cutter 18 and journal 20, and also serve to retain the conical cutter in assembly with the journal. During assembly of the drill bit, ball bearings 28 are fed through a ball plug hole (not shown), and when the ball bearings are in place, ball plug 32 is inserted and secured by a weld 34. Ball plug 32 also contains a conduit 36 for carrying lubricant to roller bearings 26 and ball bearings 28. FIG. 2 also illustrates a main conduit 38 which is connected into a main reservoir 40 at one end and which is connected into the ball plug conduit 36 at the other end. Main reservoir 40 is comprised of a canister 39, diaphragm 41, and chamber 43 which is open to the environment when a plug 37 is in an open position (as illustrated). A lubricant filler hole 46 plugged with plug 47 is also connected to the main conduit 38.
When the main reservoir 40 is to be filled with lubricant, a vacuum is created inside leg 16 from lubricant filler hole 46. Lubricant is then supplied through lubricant filler hole 46 prior to being plugged with plug 47. This lubricant travels through main conduit 38, to ball plug conduit 36 and to roller and ball bearings 26 and 28. Lubricant also travels up main conduit 38 into region 67 near the bottom of main reservoir 40, into the main reservoir through a hole 45 in the main reservoir. Lubricant fills canister 39 in main reservoir 40 and the diaphragm 41 is stretched back into chamber 43. Diaphragm 41 has a tendency to contract back to its unstretched position and to thereby urge lubricant from canister 39 into region 67. As discussed, a cap 37 to main reservoir 40 is shown in an open position with chamber 43 open to the environment. Thus, when cap 37 is in the open position, diaphragm 41 is also exposed to the environment. Since drill bit 10 often operates in a high air pressure environment, the air pressure can act on stretched diaphragm 41 so the diaphragm tends to contract and urge lubricant into region 67. Drill bit 10 might also operate in a liquid environment, with the pressure of the liquid tending to force diaphragm 41 to contract. In any case, diaphragm 41 has a tendency to urge the lubricant into region 67 which leads to main conduit 38, to ball plug conduit 36, and to roller and ball bearings 26 and 28. Therefore, any lubricant lost from the bearings is replenished by lubricant from main reservoir 40.
FIG. 2 also illustrates an annular seal groove 50 which is formed in conical cutter 18. Seal groove 50 accommodates annular seal 52. When leg 16 is filled with lubricant, seal 52 retains the lubricant in the region around the bearings. A porous gas restrictor 62 is spaced outwardly from and concentric with seal 52 in the narrow space between the leg 16 and the mouth of conical cutter 18, thereby forming an annular chamber 60 between the seal and the restrictor.
Also illustrated in FIG. 2 is a main gas passageway 54. A screen 56 is attached across the outer end of the main gas passageway 54. Main gas passageway 54 is designed to carry gas, typically air, from a gas source. Screen 56 is designed to prevent any debris from entering into main gas passageway 54. A passageway 58, which is in a plane perpendicular to the longitudinal axial plane of the main gas passageway 54, intersects the end of the main gas passageway opposite to screen 56. See FIG. 4. Two passageways 66 provide fluid communication from passageway 58 to chamber 60. One of the passageways 66 opens into one end of passageway 58 and extends and opens into one side of annular chamber 60. For further explanation and illustration see FIG. 4. The other passageway 66 opens into the other end of passageway 58 and extends and opens into the opposite side of chamber 60. See FIG. 4. The positioning of main gas passageway 54 and/or of main reservoir 40 can be designed such that the air pressure of the air carried in the main gas passageway will act on stretched diaphragm 41 so that the diaphragm will tend to contract and urge lubricant into region 67 and eventually into the roller and ball bearings 26 and 28. See U.S. Pat. No. 4,375,242, by Galle.
FIG. 3 illustrates an enlarged view of annular seal groove 50, seal 52, chamber 60 and porous gas restrictor 62. Seal 52 is of a face seal design such as a lip compression seal or a spring compression seal. A spring compression seal called a belleville seal is illustrated. The porous gas restrictor 62 should be made out of material strong enough to withstand the stresses of operation of the drill bit 10. A metallurgical material, such as bronze micro-beads fused together, provides suitable strength. The metallurgical material should be formed so that it is porous and so that the porous gas restrictor has a porosity of between 10%.-50%. A corporation called Mott Metallurgical Corporation makes suitable porous-metal gas restrictors.
FIG. 4 illustrates the cross-sectional view of leg 16 illustrated in FIG. 2 taken along line 4--4. The cross-sectional view illustrated in FIG. 4 is in a plane perpendicular to the cross-sectional view illustrated in FIG. 2. The entire circumference of annular chamber 60 and circumferential porous gas restrictor 62 is shown. Also shown in the view in this plane is the entire length of gas passageway 58, which has one end at approximately the three o'clock position in the reference of FIG. 4 on annular chamber 60 and another end at approximately the nine o'clock position. Passageways 66 which extend from gas passageway 58 into chamber 60 can also be seen. Main gas passageway 54 extends and opens into gas passageway 58 at the passageway end that is located at approximately the three o'clock position.
When leg 16 is filled with lubricant, seal 52 retains the lubricant in the region around the bearings and excludes foreign material from entering the region. Pressurized gas, typically air, at a pressure of 30-40 p.s.i.g. is supplied into main gas passageway 54. The pressurized gas travels through passageway 58 and passageways 66 into annular chamber 60. Although porous gas restrictor 62 allows dissipation of pressurized gas through its pores, its porosity is low enough so that it maintains gas pressure at approximately 30-40 p.s.i.g. in the groove, resulting in pressurized gas distributing evenly around the entire circumference of the groove and the seal 52. Since pressurized gas is distributed evenly around chamber 60, any dissipation of gas through porous gas restrictor 62 is a controlled dissipation and the dissipation is homogeneous at all points. The dissipation of gas past porous gas restrictor 62 has a pressure of approximately 30-40 p.s.i.g. as it exits the porous gas restrictor. The pressurized gas washes away drilling debris. Although the porous gas restrictor 62 is indeed porous, the size of the pores are tiny enough to prevent drilling debris from getting past it into chamber 60, but the positive gas pressure flowing through the gas restrictor pores keeps drilling debris away. The pressurized gas around seal 52 shields the seal from any debris that might enter into annular chamber 60. The density of the porous gas restrictor is determined prior to assembly of the drill bit 10 depending on the source volume and pressure available at the drill rig and so as to achieve the desired air dissipation through porous gas restrictor 62 and maintains the desired back pressure maintained within the annular chamber 60.
The remaining FIGURES, FIGS. 5-8B, illustrate different embodiments of the invention, but with all the embodiments each having passageways for carrying pressurized gas to a circumferential groove enclosed by a porous gas restrictor where the pressurized gas protects a seal having an exposed surface into the groove. These different embodiments illustrate improved sealing arrangements involving an inner and outer seal having a circumferential seal gap supplied with lubricant located between the seals.
As illustrated in FIG. 5, annular seal grooves 78 are formed in conical cutter 18. Seal grooves 78 accommodate an annular outer seal 80 and an annular inner seal 82 in coaxial relationship. A circumferential seal gap 84 is located between outer seal 80 and inner seal 82. A conduit 88 holds lubricant which is to be provided specifically to the circumferential seal gap 84. A capillary size hole 92 which is connected into the region of roller bearings 26 is connected to a conduit 90. Conduit 90 is also connected to conduit 88. The conduit 88 is tied to a conduit 94 which directly leads to and opens into circumferential seal gap 84.
When the leg 16 is filled with lubricant, inner seal 82 seals the lubricant into the region around the bearings. The conduit 88 is also filled with a lubricant and this lubricant is directed into the conduit 94 which directs the lubricant into the circumferential seal gap 84. The conduit 88 is provided with a Zerk fitting 87 at the end of the conduit closest to the exterior of leg 16. Zerk fitting 87 is a one-way fitting which only permits lubricant, supplied from an external source, to travel in the direction into conduit 88. As will be explained in more detail below, conduit 88 is preferably supplied with lower penetration value lubricant than the lubricant placed in main reservoir 40. As will also be explained in more detail below, the capillary size hole 92 slowly leaks out lubricant from the bearing region into conduit 90 which directs the lubricant into conduit 88. Seal gap reservoir conduit 88 directs the fluid into the circumferential seal gap conduit 94 leading to circumferential seal gap 84.
FIG. 6 illustrates an enlarged view of seals 50 and 52 and the region around the seals including seal grooves 78, circumferential seal gap 84, circumferential seal gap conduit 94, annular chamber 60, and porous gas restrictor 62. Outer seal 80 is of a face seal type such as lip compression seal or a spring compression seal. A spring compression seal called a belleville seal is illustrated in FIGS. 5 and 6. The inner seal 82 is a shaft seal such as an O-ring. An O-ring seal called a 1.4 to 1 O-ring seal is an effective seal. The outer seal 80 or face seal is designed such that when lubricant from conduit 94 directs a sufficient amount of lubricant into the circumferential seal gap 84, the pressure of this lubricant will force the outer seal 80 to open and allow the lubricant to bleed out into annular chamber 60 and past porous gas restrictor 62 into the environment. The inner seal 82 or shaft seal is designed to be more resistant to the pressures created by the lubricants and will not open under the presence of lubricant from the circumferential seal gap 84 or lubricant from the bearings. The inner seal 82 thus prevents the loss of lubricant from the bearings, and prevents lubricant or contaminates from the circumferential seal gap 84 from entering into the bearing region. The bleeding of lubricant past outer seal 80 and eventually past porous gas restrictor 62 into the environment provides other means, besides the air pressure, of washing away drilling debris. Furthermore, although inner seal 82 provides a barrier to the entry of drilling debris into the bearing region, the outer seal 80, the bleeding action past the outer seal and the lubricant filled circumferential seal gap 84 provide additional protection to the inner seal. The longer the integrity of the inner seal is protected, the longer the lubricant will stay in the bearing region and extend the life of the drill bit. Unlike in prior art patents, a main reservoir 40 is provided with a large enough supply of lubricant specifically for replenishing lubricant to the bearings because of lubricant loss past outer seal 80, such that drill bit 10 can be operated for long periods of time before requiring refilling.
The lubricant for the bearings is made of a mineral oil having a viscosity of between 50 to 200 centistokes at 40° C. (ideally 108 centistokes) mixed with a calcium complex soap base to form a grease. The grease from the bearings should have an ASTM worked penetration in the range of 310 to 400 mm, with an ideal penetration of 350 mm. A grease having a lower penetration value than the lubricant for the bearings has been found to be most effective at washing away any drilling debris and preventing the drilling debris from entering circumferential seal gap 84 and getting to the inner seal 82. The grease for the circumferential seal gap 84 should have an ASTM worked penetration of 175 to 250 mm, with an ideal penetration somewhere in the middle of this range. The lower penetration value grease is made up of mineral oil having a viscosity of 500 to 1000 centistokes at 40° C. (ideally 640 centistokes) mixed with a calcium complex soap base. Since conduit 88, the conduit 94 and the circumferential seal gap 84 can be filled with only a limited supply of this lower penetration value lubricant, means for providing a backup lubricant to the circumferential seal gap is provided as shown in the embodiment in FIG. 5. In this embodiment, the lower penetration value seal gap lubricant first fills the circumferential seal gap 84. During operation of the drill bit, the lower penetration value seal gap lubricant expands and increases in pressure from its initial pressure to a higher operating pressure due to heat and eventually some of the lower penetration value seal gap lubricant bleeds past outer seal 80. At the same time, the higher penetration value bearing lubricant from the bearings also expands and increases in pressure from its initial pressure to a higher operating pressure due to the heat of operation and slowly leaks through the capillary size hole 92 into conduit 90 leading to the conduit 88. The initial pressure of the supply of seal gap lubricant can be less than or equal to the initial pressure of the bearing lubricant in the bearings. The operating pressure of the supply of seal gap lubricant will be greater than initial pressure of the supply of seal gap lubricant and can be greater than the initial pressure of the bearing lubricant in the bearings. Similarly, the operating pressure of the bearing lubricant in the bearings can be greater than or equal to the operating pressure of the supply of seal gap lubricant. When the operating pressure of the supply of seal gap lubricant is higher than the initial pressure of the supply of seal gap lubricant, the rate of passage of seal gap lubricant from its supply into the annular seal gap increases from a first rate at the initial pressure of the supply of seal gap lubricant to a second, higher rate at the operating pressure of the supply of seal gap lubricant. Since the conduit 88 and the conduit 94 are filled first with viscous lubricant, most of the higher penetration value lubricant follows behind the lower penetration value lubricant. The higher penetration value lubricant pressurizes the lower penetration value lubricant into the circumferential seal gap 84 and past outer seal 80. Some of this higher penetration value lubricant mixes with the lower penetration value lubricant. Furthermore, in the event that all the lower penetration value lubricant is lost, the higher penetration value lubricant will solely fill the circumferential seal gap 84 and eventually bleed past outer seal 80, thereby providing continued protection of the seals.
The separate supply of lower penetration value lubricant can also be eliminated from the embodiment shown in FIG. 5. In this case, conduits 88, 90, and 94 would be initially filled with the bearing lubricant. During operation of the drill bit the capillary size hole 92 would leak additional lubricant from the bearings into conduit 90. Lubricant would then be directed to circumferential seal gap 84 and bleed past outer seal 80 to wash away drilling debris.
FIG. 7 illustrates another embodiment of the invention. As can be seen in FIG. 7, the drill bit design is essentially the same except for the means of supplying lubricant to the circumferential seal gap 84. A one-way relief valve 100 is connected into the region around the roller bearings 26 by a relief valve conduit 102. While one end of the relief valve 100 is connected to the relief valve conduit 102, the other end of the relief valve opens into a reservoir 104. Relief valve reservoir 104 is welded into place by weld 106. Relief valve reservoir 104 has an opening to which conduit 108, which leads to the circumferential seal gap 84, is tied. Normally in prior drill bits, the main reservoir is underfilled to account for the normal expansion of lubricant during operation of the drill bit. In this embodiment, main reservoir 40 is initially filled to 100% of its capacity. When drill bit 10 of this embodiment is under operation, lubricant from main reservoir 40 is supplied to the bearings as usual. However, as the lubricant expands and increases in pressure due to the normal heating of the drill bit 10 under operation, it travels up relief valve conduit 102 towards relief valve 100. When the expanding lubricant reaches relief valve 100, it travels through the relief valve into relief valve reservoir 104. Since relief valve 100 is a one-way relief valve, lubricant only travels up through relief valve conduit 102 into relief valve reservoir 104 and does not travel back into the conduit 102. Once relief valve reservoir 104 begins to fill with lubricant, this lubricant will then travel to conduit 108 which leads to circumferential seal gap 84. Thus, circumferential seal gap 84 fills with lubricant and this lubricant will bleed past outer seal 80 to protect the seals against drilling debris as explained above with regard to FIGS. 5 and 6.
FIGS. 8A and 8B illustrate another embodiment of this invention. In this embodiment, the inner seal 82 is a hydrodynamic lubricant seal of the type taught in U.S. Pat. No. 4,610,319 issued to Kalsi. To the extent that this patent teaches the design, function and use of a hydrodynamic seal, it is incorporated herein by reference. When a hydrodynamic seal is used as inner seal 82, it permits dissipation of lubricant from the bearing region into the circumferential seal gap 84 but does not permit lubricant or contaminates to travel from the circumferential seal gap past the hydrodynamic seal. Since this hydrodynamic seal provides lubricant to the circumferential seal gap, the separate means of supplying lubricant to the circumferential seal gap, in the embodiments illustrated in FIGS. 5 and 7, are not necessary.
In FIGS. 8A and 8B, the hydrodynamic seal is identified as 110. As discussed in U.S. Pat. No. 4,610,319, a hydrodynamic seal of the type including hydrodynamic seal 110 in FIGS. 8A and 8B, is provided with a different geometry on the side containing the lubricant for bearings 26 and 28, where promotion of hydrodynamic lubrication is intended, than the seal geometry on the circumferential seal gap side where avoidance of any hydrodynamic activity is desirable. Hydrodynamic seal 110 is designed in a generally circular form having a hydrodynamic shape on the side containing lubricant for bearings 26 and 28 which defines a plurality of waves 112. The amplitude and shape of waves 112 is selected to create a desirable amount of hydrodynamic film due to the relative motion at the hydrodynamic seal 110 interface. On the circumferential seal gap 84 side of the hydrodynamic seal 110, the geometry of the seal can take a number of forms which substantially prevent any hydrodynamic activity due to the relative motion between the seal and the conical cutter 18. The geometry of the hydrodynamic seal 110 on the circumferential seal gap 84 side also successfully substantially combats any wedging action of drilling debris particles due to the relative axial movement between the hydrodynamic seal on the lubricant side and the counterface of the conical cutter 18. In its simplest form, hydrodynamic seal 110 contains a series of sinusoidal waves 112 on the lip exposed to the lubricant side and a planar annular cylindrical surface 84 on the circumferential seal gap 84 side. The geometry of the waves 112 on the lubricant side is selected so as to create a film thickness of desirable magnitude but still maintain a dissipation rate as low as possible and compatible with the main reservoir 40 volume available. More specifically, on the circumferential seal gap 84 side, hydrodynamic seal 110 presents a substantially non-converging edge 114 to contaminates such as drilling fluid to prevent the drilling fluid from developing any degree of hydrodynamic lift as relative rotation occurs between the seal and the surface against which it seals. The non-converging shape also prevents any hydrodynamic lifting activity during relative axial motion between the hydrodynamic seal 110 on the lubricant side and the conical cutter 18.
At its lubricant interface, hydrodynamic seal 110 defines a surface forming a plurality of waves 112 which may be in the form of smooth sine waves or waves of differing design. The sealing element on the lubricant side is formed to define an undulating hydrodynamic geometry forming an inclined surface 116, as viewed in the cross section shown in FIG. 8B, that cooperates with the circular metal sealing surface 118 of the journal to form a hydrodynamic entrance zone of greater width toward the lubricant chamber and gradually tapering to a minimal dimension at the point of contact 120. The undulating surface geometry establishes a seal contact width that varies circumferentially depending on the location of the seal cross section being considered. The gradually tapering surface of hydrodynamic seal 110 at its point of contact 120 with the relatively rotatable metal sealing surface 118 of the journal 20 defines a merging radius to prevent or minimize any scraping activity that might interfere with the flow of lubricant film toward the circumferential seal gap 84. As relative rotation occurs between hydrodynamic seal 110 and journal 20 the undulating design of the seal at the lubricant interface surface causes development of hydrodynamic lifting forces at the contact between the seal and the relatively rotating metal sealing surface 118. These forces cause slight lifting of the sealing material of hydrodynamic seal 110 from the metal sealing surface and thus develop a minute pumping activity causing an extremely small but definite quantity of lubricant to migrate under hydrodynamic influence from the lubricant interface of the seal member toward the circumferential seal gap 84. When a sufficient amount of the lubricant migrates into the circumferential seal gap 84, this will force open outer seal 80 allowing lubricant to bleed past. Furthermore, the separation caused by the introduction of a hydrodynamic lubricant film at the seal interface of hydrodynamic seal 110 with the metal sealing surface 118 eliminates direct rubbing contact and the associated wear. It also ensures continuous maintenance of minimal friction between hydrodynamic seal 110 and the metal sealing surface 118 and maintains a low temperature environment to thus ensure enhanced operational life of the seal.
While the foregoing illustrates and discloses the preferred embodiment of the invention with respect to the composition of the drill bit, it is to be understood that many changes can be made to the drill bit design, such as the type of bearings used, and the type of porous gas restrictor, the sealing arrangement, and the application of the drill bit as a matter of engineering choices without departing from the spirit and scope of the invention, as defined by the appended claims. | A sealed rotary drill bit has a plurality of leg members, with each leg member having a projecting conical cutter receiving journal. A conical cutter has friction reducing bearings interior to the conical cutter for rotatably mounting the cutter on the respective journal. A sealing arrangement retains lubricant for the bearings. A circumferential porous gas restrictor is positioned concentric with and spaced outwardly from the sealing arrangement to form an annular gas chamber therebetween. Pressurized gas is carried by passageways into the annular gas chamber. The porous gas restrictor, which can be formed of metal particles bonded together, prevents drilling debris from getting past it, but the porosity of the restrictor allows pressurized gas to pass therethrough as a controlled dissipation and wash away drilling debris, thereby shielding the sealing arrangement from debris that might otherwise reach the sealing arrangement. The sealing arrangement can include an inner seal and an outer seal positioned concentric to each other with the circumferential seal gap therebetween filled with lubricant. |
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BACKGROUND OF THE INVENTION
This invention relates to a construction preform for use in forming an archway in walls or door frames. In particular, the preform is affixed directly to the wall support members so as to provide a base for the wallboard or drywall used on the adjacent wall.
The construction of an archway has normally required the assembly of a wooden support at the construction site. Plywood is cut in a manner to provide the outline of the arch when completed. Two sections of plywood are separated by spacers which maintain the relative position of the two sections of plywood during affixation to the adjacent studs and headers defining the unfinished opening. After affixation of the curved plywood form, it has been common practice to affix strips of drywall to support pieces serving as spacers. Since the objective is to form a continuously curved surface along the exposed face of the intermediate supports, the use of thin strips of drywall to form the exposed surface of the archway is made to approximate a curve. The process of affixation of the drywall strips is time consuming. Attempts to cut wider strips to shorten construction time is limited by the desired contour. In order to finish the irregular approximation of the desired arch curve, the use of a drywall compound in substantial thickness is normally required. The construction process can result in a nonsymmetrical arch if great care is not taken.
In an attempt to overcome problems associated with the fabrication of an archway at the jobsite from the combination of contoured plywood, drywall and the intermediate support strips, prefabricated archways made from molded foamed plastics have been used. A prefabricated archway formed of molded polyethylene is described in U.S. Pat. No. 4,601,138 to Hampton wherein a relatively light weight arch can be brought to the location of the project and nailed or otherwise affixed directly to the framing of the adjacent wall. The prefabricated plastic archway is dimensioned to be conformably received in abutting relationship to the adjacent edges of the wall surfaces. The width from one outer surface to the opposing outer surface of the prefabricated archway is equal to the distance between the finished surfaces of the opposing walls. In other words, the arches are dimensioned to form a butt-joint against the existing drywall or wallboard. The prefabricated archway is secured in place by a series of nails applied through the exposed surface of the foam into the studs and headers comprising the support members. Following affixation, conventional taping is applied to the seam between foam and adjacent drywall. In practice, the seam between adjacent drywall and the foam arch has been found to display cracking due in part to the use of dissimilar materials at the seam thereby requiring future repair and maintenance. Also, the subsequent movement of nailheads outwardly and away from the foam archway creates an unsightly appearance requiring further maintenance.
The problems mentioned above in connection with prefabricated archways formed of foamed plastic is addressed in U.S. Pat. No. 4,665,666 to Hampton wherein the use of drywall paper in the molding process is recommended. During the formation of the archway, the reference teaches lining the mold with drywall paper which then becomes permanently bonded to the molded archway. As noted in the patent, the drywall paper strengthens the finished arch by adding a fibrous laminate to its exterior surface so as to reduce cracking. Furthermore, the use of the paper is intended to eliminate the "nail pops" occurring after installation. This modification to the construction of prefabricated archways is required because of the incompatibility of foamed plastic material with the wall-defining materials used in normal construction techniques. While the molded foam prefabricated archways accomplish the goal of eliminating the construction of coarse archway forms at the construction site, the problems arising from the use of a foamed material such as seam parting, cracking, nail popping and limited resistance to applied pressure remain.
Accordingly, it is a primary objective of the present invention to provide a durable archway preform which is complete when delivered to the construction site. In addition, an objective of the present invention is to provide a preform which allows the adjacent wall material to cover both the preform and adjacent wall surface in a continuous manner thereby eliminating seam parting or cracking. Also, the invention provides a preform which can receive threaded fastening devices thereby eliminating the maintenance problems associated with nails moving from their original position and causing unsightly surface damage.
SUMMARY OF THE INVENTION
The arch preform which is the subject of the present invention is dimensioned for placement in the framed opening in the surface of a wall, either during initial construction or during a remodel. The present invention is directed to a preform that can be utilized at one corner of a framed opening with a mating preform used at the opposing corner or a single preform can be fabricated to extend between the spaced vertical support members in the framed opening. The dimensions of the opening in the wall to receive the preforms are determined by the aesthetics and functionality of the room design and normally do not require the construction of special dimensioned preforms. The use of a pair of arch preforms spaced at opposite ends of the header extending over the framed opening provides flexibility to the designer regarding the width of the opening.
The subject preform is comprised of first and second cheek members formed of sheet metal. The cheek members have two generally orthogonally disposed edges with each of these edges terminating in a free end. A curvilinear edge extends between the free ends in accordance with the general shape to be attained through the use of the preforms. A curved metal throat member of sheet metal is shaped to conform with the curvilinear edge. The width of the throat member is made equal to the width of the support members in the framed opening to enable the orthogonally disposed edges of the cheek members to be inserted adjacent to the support members defining the framed opening, and reside underneath the drywall or wall board. Thus, the wallboard or drywall used to form the adjacent walls extends outwardly over the metal cheek members without creating an exposed seam. The arch preform is secured to the adjacent support members, typically the vertical studs and the horizontal header extending therebetween, during initial construction with the sheets of wallboard or drywall then affixed to extend over the support members and metal cheek members. The edge of the wallboard is cut to have the same curvilinear edge as the cheek members.
The arch preform includes means for affixing the throat member to the curvilinear edges of the cheek members, typically by forming a flange on the curvilinear edges of the cheek members and utilizing spot welding. By fabricating the cheek members and throat member of sheet metal, the conventional drywall screws are used to affix the wall covering to the adjacent cheek member. In addition, sections of drywall can be fastened by screws to the curved metal throat member and later covered with drywall compound. The finishing of the surface of the curved portion of the archway takes place with the arch preform affixed and in position in the wall opening thereby facilitating the finishing process. A conventional flexible corner bead can be used along the corners of the covered preform, if desired.
The present invention provides a support structure which securely receives the conventional threaded fasteners used in affixing drywall and provides a finished archway in which the wall surface is formed of a continuous sheet of wall covering. No seams are present and no juncture between dissimilar materials occurs so that the tendency to exhibit cracking is essentially eliminated. Further features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective of an arch preform constructed in accordance with the present invention.
FIG. 2 is an end view of the embodiment of FIG. 1.
FIG. 3 is a view in partial cross section of a pair of arch preforms attached to a framed opening.
FIG. 4 is an end view in partial section of FIG. 3.
FIG. 5 is a view in perspective of a section of drywall for affixation to the throat of the embodiment of FIG. 1.
FIG. 6 is a view in perspective showing installation of the embodiment of FIG. 1.
FIG. 7 is an exploded view of the encircled portion of FIG. 3.
FIG. 8 is a view in perspective of a flexible corner bead for use in connection with the present invention.
FIG. 9 is a block diagram of the sequence of steps employed in practicing the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, an arch preform for attachment for a framed opening in the surface of a wall is shown. The arch preform 11 is formed of a first cheek member 12 and a second cheek member 14 interconnected by a curved throat 20. The three elements are fabricated from sheet metal. The use of this material enables the curved throat member to be readily formed in the desired curvilinear pattern. In addition, the first and second elements 12 and 14 are provided with flanges 18 and 19 extending along the curved dimension thereof.
Each cheek member has two generally orthogonally disposed edges joined at a rounded corner 13. Each of the edges terminate in a pair of free ends 15 and 16. The free ends are back cut as shown in FIG. 1 to provide a generally rounded free end to aid in installation. In the manufacture of the arch preform shown in FIG. 1, first and second cheeks 12 and 14 are initially identical planar members. After cutting to the desired shape, the curved edge is subjected to a roller which forms a one quarter (1/4") inch flange therealong. Since the flange is narrow and the bending is being conducted on a sheet metal part, no cuts or relief kerfs need be formed in the flanges. The throat 20 is generally rectangular in shape after cutting. It is then subjected to a bending step to conform to the curvilinear shape of the flanges formed on the cheek members. Next, the throat 20 is affixed to the flanges by a series of spot welds as shown in the end view of FIG. 2. The use of sheet metal in the construction of the three elements of the arch preform facilitates construction, provides durability to the unitary body and allows flexibility of the cheek members to aid in installation.
The curved throat 20 is shown in FIG. 1 as a 90 degree continuous arc. It should be noted that the cheeks 12 and 14 can be precut according to a variety of patterns which may include a pattern having a discontinuity therein. The throat is initially formed as a rectangle and is preshaped to conform with the silhouette of the curved edge extending between free ends 15 and 16. The width of the throat member 20 is equal to the width of the framing members used in defining the opening in the wall. In the case of conventional construction, a wall opening is framed as shown in FIG. 3 with a pair of studs 42 providing vertical support. The inner most stud on either side of the opening is terminated short of the ceiling beam to receive a pair of headers 41 extending therebetween. The width of these studs and headers is 31/2 to 35/8 inches. This is the actual width of the conventional two by four wood member used in framing. Since the wood members used in framing are not of the highest grade, they may contain irregularities and be subject to warping, the flexibility of the sheet metal cheek members enables the arch preform to accommodate run of the mill framing members. The installation of the arch preform is shown in FIG. 6 wherein the generally orthogonally disposed edges slide over the adjacent studs 42 and header 41. When in place as shown in FIG. 3, the portion of the throat 20 adjacent free end 15 is in contact with the inner most stud 42. Similarly, the portion of the throat 20 adjacent free end 16 is in contact with the bottom header 41. At this time in the construction process, the arch preform is nailed directly to the adjacent framing member by nails 33.
The completed installation of the arch preform is shown in FIG. 3 and the exploded portion thereof in FIG. 7 wherein the large planar wall covering 35, normally a drywall panel is attached to the framing in a conventional manner by the use of phillips head drywall screws. The panel can be precut to the contour of the preform archway by tracing an outline on the drywall prior to installation. The use of sheet metal for the first and second cheek members allows a threaded fastener to be used to affix the wall covering to the arch preform. The positive engagement provided by the threaded fasteners reduces the likelihood that there will be any backing off and resultant disturbance created on the finished surface. In the case of nails used in combination with drywall, it is common to have nail popping take place later with the result that refinishing is required to restore the wall surface to its original condition. It is important to note from FIG. 7 that the cheek members are received between the wall board panel and the stud members without creating exposed seams. Heretofore, prefabricated arches have utilized butt joints with the wall board which frequently give rise to visible cracks over extended periods of time. This undesirable result is more likely to occur when dissimilar materials are used in the butt joints as is the case with foamed archways abutting drywall panels.
The throat 20 of the device is covered by a section of drywall 30 having a multiplicity of transverse slots 31 cut therein as shown in FIG. 5. The slots or kerfs extend partially through the drywall and permit flexure of the section without damaging the surface layer. In FIG. 3, the upper end 25 of the section 30 is shown extending to the free end 16 of the preform. Similarly, the lower end 26 of drywall section 30 extends downwardly to free end 15. The drywall section 30 is affixed to the preform by the use of conventional drywall screws threaded into the throat 20. As shown in FIG. 4, drywall strips 36 and 37 are affixed to the exposed widths of header 41 adjacent ends 25 and 26 respectively. The seams between the drywall section 30 and adjacent drywall strips 36 and 37 are taped and drywall compound is applied in the normal manner. The drywall strip 30 can be made longer than the kerfed strip shown in FIG. 5 so that the seams are spaced from the free ends of the arch preform if desired. In both cases, the seam is formed between similar materials and is a conventional drywall seam formed on the width of the underlying stud. The placement of strip 30 on throat 20 is seen in the end view of FIG. 4 with vertical drywall strip 37 adjacent thereto. The drywall panels 35 are shown in cross section affixed to adjacent stud 42. A similar juncture is formed with header 41 at free end 16 of the arch preform 11.
The exposed edges of the drywall panels formed at the corners are generally covered with conventional corner bead strips. In the installation of other types of wall board coverings, the drywall section 30 is replaced with a corresponding sized panel of the flexible paneling and conventional anchors are used. Flexible corner members, typically colored plastic beading, are used to complete the juncture between panels. A typical flexible corner bead 45 for drywall is shown in FIG. 8 as comprising a lengthwise strip 46 and a segmented strip 47 affixed thereto at a right angle. The lengthwise strip 46 is located on the drywall member 30 and secured to the throat 20. The segments 47 separate to permit contouring of the corner bead. Following the installation, the drywall compound is placed in the recesses containing the drywall screws and applied to the seam tape in layers in the conventional manner. After several applications, the applied compound is smoothed and the desired final surface finish applied. As mentioned previously, the width of throat 20 is made equal to the nominal width of the support members used in framing the opening receiving the preforms. In general, this is the nominal width of the standard framing 2×4. In the preferred embodiment of the invention, the throat is affixed by spot welding to flanges formed on the first and second cheek members. The placement of the flanges on the cheek members provides a smooth planar surface for the affixation of the large area panels. The free ends of the cheek members are cut back to be rounded to facilitate the insertion of the preform beneath existing drywall in the case of remodeling of an opening as an archway. The rounded free ends enable the preform to be rotatably inserted between the wall covering and the underlined framing. It is to be noted that the use of sheet metal not only provides flexibility and durability, but enables the wall board to be affixed thereto using conventional threaded fasteners.
While the foregoing description has referred to a preferred embodiment of the invention, it is to be noted that variations and modification can be made therein without departing from the scope of the invention as claimed. | A preform for use in constructing an archway wherein opposing sheet metal cheek are spaced apart by a curved throat to permit the cheeks to reside between the adjacent wall support and the overlying wallboard or drywall. The preform is affixed directly to the support members. Drywall is fastened to the preform by screws with the seams between adjacent drywall sections being covered in the conventional manner. The attachment of the preform directly to the wall supports essentially eliminates the likelihood of joint separation or fastener movement after installation. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to connection pin assemblies for attaching replaceable implements to earthworking buckets of excavating equipment and the like. The invention also relates to a method of attachment, and to earthworking buckets with replaceable implements attached by means of the connection pin assemblies.
2. State of the Art
Earth working bucket used for heavy earthworks applications such as mining are fitted with teeth for engaging the ground surface. Due to the highly abrasive nature of the materials encountered by the teeth, they wear more quickly than the bucket. For this reason, they are detachably connected to the bucket to allow replacement.
On smaller buckets, the teeth are generally attached directly to an adapt or on the bucket by means of a connection pin. On larger buckets, intermediate adaptors are attached to the bucket nose and the teeth are attached to respective of the intermediate adaptors. Both connections are by means of connection pins, so that the teeth and intermediate adaptors can be replaced as required.
Connection pin assemblies of the type generally employed, and with which this invention is concerned, are known in the art as spool and wedge assemblies.
Prior art spool and sedge assemblies include a spool, often C-shaped with tapered engagement surfaces, which can be inserted into aligned apertures in the parts to be connected. A wedge is then inserted to contact the rear surface of the C and is driven home by sledgehammer to cause lateral expansion of the spool and wedge until it bears firmly against appropriate parts of the inner wills of the apertures to provide lateral loading and optionally a clamping action of the adaptor in the case of `Whisler` style attachments. Any part of the spool and wedge protruding above or below the aligned apertures is then cut off by oxy acetylene equipment.
The tightness of the connections must be regularly monitored, and when a tooth or intermediate adaptor works loose the spool and wedge must be tightened by hammering the wedge in further. This can be difficult as the protruding part of the wedge may already have been removed and thus the end of the wedge is not readily accessible. When the tooth or intermediate adaptor requires replacement, the spool and wedge often has to be cut out.
It will be appreciated that the fitting, monitoring, adjustment and removal of the prior art spool and wedge assemblies is time consuming and labour intensive, particularly as each bucket will have a number of teeth and an equal number of adaptors, each attached by respective spool and wedge assemblies.
Patent Application No. PCT/AU94/00035 describes a spool and wedge assembly in which a pair of spools are forced apart by a pair of wedges which are drawn together by a bolt. While that disclosure is in some respects an improvement over the prior art, there is much scope for improvement. For example, the arrangement is relatively complicated, still requires regular monitoring and adjustment and, in practice, may need to be cut out for removal.
SUMMARY OF THE INVENTION
The present invention aims to provide alternative spool and wedge assemblies.
In a first form, the invention provides a spool and wedge assembly for attaching a replaceable implement to the nose of an earthworking bucket, the spool and wedge assembly including;
at least one spool having a first surface, at
least one wedge having a second surface, the first and second surfaces co-operating to form a ramp arrangement which causes lateral expansion of the spool and wedge assembly upon relative axial movement in a first direction in which said surfaces are drawn towards each others,
bolting means for forcing said relative movement in said first direction, and
disengagement means adapted to act between said spool and/or wedge and the bolting means to cause relative movement of the spool and wedge in a second direction opposite the first direction.
Preferably, the disengagement means engages with the spool or wedge and, desirably, includes screw means bearing against the bolting means to force relative movement of the spool or wedge and the bolting means.
In a further form, the invention provides a spool and wedge assembly for attaching a replaceable implement to the nose of an earthworking bucket, the spool and wedge assembly including:
at least one spool having a first surface,
at least one wedge having a second surface, the first and second surfaces co-operating to form a ramp arrangement which causes lateral expansion of the spool and wedge assembly upon relative axial movement in a first direction in which said surfaces are drawn towards each other,
bolting means for causing said relative movement in said first direction, and
resilient means which deforms under load from said bolting means, so that when the bolting means is actuated to cause said lateral expansion the resilient means applies a resilient force urging the relative movement of the spool and wedge in said first direction.
Preferably, the resilient means comprises a resilient washer means, such as a spring washer arrangement or similar device, acting between the bolting means and the wedge.
As used herein, the expression "nose of an earthworking bucket" is to be understood as also including any intermediate adaptor fitted on the nose.
In a further form, the assembly is adapted to be inserted within aligned apertures in the replaceable implement and the bucket nose and contains a spool and a wedge with co-operating ramp surfaces as hereinbefore described, the bolting means forcing said relative movement rich that the lateral expansion causes the wedge to push forwardly against the nose and spool to push rearwardly against the implement.
Preferably, the bolting means includes a bolt with its bolt head captured by a slot in the spool, the bolt extending gene ally axially to enter an axial passage through the wedge.
Further preferred embodiments of the invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred spool and wedge assembly;
FIG. 2 is an exploded side elevation of the spool and wedge assembly of FIG. 1;
FIG. 3 is the same view as FIG. 2, after the wedge has been connected to the spool;
FIG. 4A is a cross-sectional elevation of an intermediate adaptor positioned on a bucket nose;
FIG. 4B shows the arrangement of FIG. 4A, with the spool and wedge inserted and tightened;
FIG. 5 is a side elevation of the spool and wedge assembly, in which the nut and washer are removed and replaced by a disengagement device;
FIG. 6 is an exploded perspective view of FIG. 5;
FIG. 7 is a side elevation showing a modified disengagement device; and
FIG. 8 is an exploded view of the arrangement of FIG. 7, showing also the modified nut for use with that embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-3, the spool and wedge assembly consists generally of a spool 10, a wedge 12, and a bolt 14 and nut 16 arrangement.
The spool 10 is elongated in the axial direction and is shaped to allow insertion in aligned apertures in the intermediate adaptor and the nose of a ground engaging implement, so as to engage with the back portion of the intermediate adaptor without engaging the back of the nose aperture. The illustrated spool has on one side thereof a pair of projections 18a, 18b separated by a recessed portion 20, so that that side of the spool 10 is approximately C-shaped.
The other side of the spool has ramp surfaces 22a, 22b and a block 24 for retaining the head of the bolt 14. The block 24 has an open slot 26 shaped to receive the head 28 of the bolt 14 which connects the wedge 12 to the spool 10.
The slot opens to the side of the spool opposite the projection 18a. The slot has a broader portion 32 for receiving the bolt bead and preventing its rotation, and a more narrow portion between shoulders 36 of the block to receive the part of the bolt shaft 38 adjacent the head. As can be seen from FIGS. 2 and 3, the bolt head is inserted into the slot so that the head is captured behind the shoulders 36. There is sufficient clearance behind the bolt head to allow the angular or lateral movement of the bolt to accommodate lateral expansion of the assembly as it is tightened.
The wedge 12 has ramp surfaces 40a, 40b complementary to the ramp surfaces 22a and 22b of the spool. The wedge also has an axial through-hole 42 through which the shaft of the bolt passes. The distal end of the bolt shaft has a threaded portion for attachment of the nut 16. A belleville spring washer 46 separates the nut 16 and the end of the wedge.
As the nut 16 is threaded onto the bolt shaft, the wedge is moved axially relative to the spool and the ramp surfaces 40a,40b of the wedge slide along those of the spool. This causes the spool and wedge assembly to expand laterally until it tightens against the inner walls of the apertures in which it has been inserted. Further tightening of the nut causes resilient compression of the spring washer 46.
By undergoing resilient compression, the spring washer provides self tightening of the spool and wedge assembly. If, in use, the nose to intermediate adaptor assembly works slightly loose, the spring washer will decompress, forcing the wedge further towards the bolt heed and therefore causing further lateral expansion o the assembly until the spool and wedge is again tight against the inner walls of the aligned apertures.
FIG. 4A illustrates the positioning of an excavator intermediate adaptor 48 on the nose 50.
The bucket nose has a tapering front portion 52 which is received in a corresponding tapered cavity 54 of the intermediate adaptor. When positioned properly on the bucket nose, an aperture 56 of the intermediate adaptor aligns with an aperture 58 of the bucket nose to allow insertion of the spool and wedge assembly shown in FIGS. 1-3.
FIG. 4B shows the spool and wedge assembly inserted in the aligned apertures. The spool is dimensioned to pass between the rear 60 and front 62 walls of the aperture in the bucket nose and then be positioned so that the projection 18a, 18b, come into contact with the rear walls 64 of the aperture in the intermediate adaptor without contact between the recessed portion 20 and the rear wall 60 of the aperture.
The bolt is connected to the spool before insertion of the spool in the apertures, by capturing the bolt head in the block 24 of the spool as described above with reference to FIGS. 1-3. The wedge 12 and resilient device 46 are slid along the bolt shaft, and the nut is then threaded on to the bolt shaft to cause lateral expansion of the spool and wedge so that the wedge bears against the front wall 62 of the bucket nose 58 and the spool pushes against the rear walls 64 of the aperture in the intermediate adaptor 48. This forces the intermediate adaptor rearwards relative to the nose, tightening the engagement of the tapered surfaces 52 and 54 and thereby securing the intermediate adaptor to the bucket nose.
In a modification to the arrangement shown in FIGS. 1-4B, the nut 16 may be elongated and/or capped to cover the end threads of the bolt shaft. This ensures that the end threads of the bolt remain clean so that the nut can be removed.
In further modifications, the nut may be replaced with a hydraulic nut which is initially threaded onto the bolt. Final tightening is then effected by pumping grease or other fluid into the nut to cause it to expand. Alternatively, the bolt can have a round head which allows it to rotate in the slot 26 and has a drive block at its distal end. The wedge is threaded directly onto the bolt, so that rotation of the bolt via the drive block will cause tightening and disengagement of the spool and wedge.
FIGS. 5 and 6 illustrate a first arrangement for disengaging the ramp surfaces of the spool and wedge so that the assembly can be removed. The hole 42 through the wedge is broadened at its distal end, and this portion 66 of greater diameter is provided with an internal thread. There is provided a disengagement device 68 formed generally as a short bolt with a hollowed-out shaft. The external thread of this device mates with the internal thread of hole 66 so that the device screws into the end of the wedge.
The distal end of the bolt shaft 38 is received with clearance in the axial bore 70 in the shaft until the end of the bolt contacts the end of the bore. Screwing the device 68 into the wedge pushes the bolt backwards until the bolt head 28 contacts the end of slot 26. Further screwing of device 68 then drives the spool and wedge in opposite directions, so that the spool and wedge assembly is released from its tight engagement in the aligned apertures of the adaptor and tooth and can be removed.
In the modification shown in FIG. 7 and 8, the bolt shaft 38 is shortened to end inside the wedge and the nut 16 (shown in FIG. 8) and the enlarged diameter portion 42a of the passage 42 through the wedge are lengthened correspondingly.
At the distal end of the wedge, the entrance of the hole 42 has L-shape keyways 72 along the inner surface of the passage to receive lugs 74 on an internally threaded member 76 of a removal device 78 which further comprises a bolt 80. In use, lugs 74 of the removal device are pushed into keyways 72 and twisted to form a bayonet connection, and bolt 80 is then screwed in to bear against the end of bolt shaft 38 within the wedge. Further tightening of bolt 80 drives disengagement of the spool and wedge. The removal device 78 may include an extra set of lugs 74a for use if set 74 become damaged.
While particular embodiments of this invention have been described, it sill be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description, and all changes which come within the meaning find range of equivalency of the claims are therefore intended to be embraced therein. | A spool and wedge assembly for attaching a replaceable implement to the nose of an earthworking bucket has a spool 12 and wedge 10 with ramp surfaces 22, 40 causing lateral expansion of the unit upon relative axial movement, and bolting mechanism 14, 16 for drawing the spool and wedge together so that the wedge pushes forwardly against the bucket nose and the spool pushes forward against the implement. A disengagement tool 78 acts between the wedge and the bolt 14 to force disengagement of the ramp surfaces for removal. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/674,787, filed Apr. 26, 2005.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
The present invention relates to electronic proximity switches, and in particular to an electronic proximity switch which is highly resistant to mechanical and electrical noise and to temperature changes.
Electronic proximity switches may detect the presence of an object, for example, a human hand near a switch plate, to provide an electrical signal that may be used to switch a circuit or activate a mechanism. Unlike a typical mechanical switch, an electronic proximity switch does not require moving parts, such as a button or switch operator, that may wear or break. Because an electronic proximity switch may activate at a distance, it can be more readily sealed against environmental contamination and protected from damage. Further, activation at a distance allows the switch to be activated rapidly without careful hand placement or the need for one's fingers to be free to press a button or the like.
A significant problem with electronic proximity switches is their susceptibility to unintended triggering. This can occur in electronic proximity switches that are used outdoors, such as with automotive door lock applications, where there is a risk that rain or debris carried in the wind could activate the switch. Further, the sensitive electronics of the electronic proximity switch often can be triggered by electromagnetic interference, for example, from electrical appliances, radio transmitters, or lightning discharge. The circuitry of electronic proximity detectors, which must measure small changes in electrical fields, can be sensitive to drift in the value of electronic components of the circuitry caused by aging or changes in temperature. Steps to avoid these problems can increase the complexity and cost of the electronic proximity switch, rendering it impractical for many consumer applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of a faceplate of an automotive lock that may use the proximity switch of the present invention;
FIG. 2 is a schematic diagram of the principal elements of the proximity switch of FIG. 1 ; and
FIG. 3 is a set of graphs of electrical voltage as a function of time at various points in the schematic diagram of FIG. 2 for the two cases, the first when the electronic proximity switch senses the presence of a hand or the like, and the second when the electronic proximity switch does not sense the presence of a hand or the like.
SUMMARY OF THE INVENTION
The present invention provides a simple electronic proximity switch that is highly resistant to false triggering and to changes in component values over time or with temperature.
Generally, the invention transmits an oscillator signal along two paths and then compares the relative strength of the signal along those paths. One path passes through an antenna that may couple with a sensed object to reduce the strength of the signal along that path. The use of two paths neutralizes the effect of any change in the signal strength from the oscillator that would affect the signal in both paths equally, allowing the circuit to be highly sensitive to changes caused by the sensed object.
Preferably, the comparison of the signals from the two paths is done with a second oscillator that is electrically identical to the first oscillator, so that component drift and aging affects both oscillators similarly, allowing the oscillators to track closely. The second oscillator may compare the signals of the two signal paths by giving the signals of each path different phase shifts. The second oscillator identifies the dominant signal by its greater amplitude and oscillates sympathetically with this dominant signal—the phase indicating the relative strength of the signals on the two paths. The second oscillator provides highly selective frequency and phase discrimination, rejecting external noise signals.
Specifically, the present invention provides an electronic proximity switch having an oscillator providing an electrical signal along a first and second transmission path between the oscillator and a signal strength comparator. The first transmission path communicates with a sensor antenna for a free space transmission of the electrical signal in a sensor region and the second transmission path is shielded from the sensor region. A signal strength comparator provides a switch output determined by a relative strength of the electrical signal received over the first and second transmission paths.
Thus, it is one object of at least one embodiment of the invention to provide a simple and robust circuit that is relatively insensitive to changes in the absolute strength of the oscillator signal.
At least one of the first and second transmission paths may include a phase shift element and the comparator may be a second oscillator coupling to both the first and second transmission paths to adopt a phase of the combined electrical signals so that the switch may detect the phase of the second oscillator to determine a dominant signal path.
It is thus another object of at least one embodiment of the invention to provide a highly frequency selective method of comparing signals on the two paths.
The relative phase shift between the first and second transmission paths is 180 degrees.
Thus, it is another object of at least one embodiment of the invention to provide a “snap action” in the shifting of the frequency of the second oscillator such as provides clean switching. The second oscillator will remain oscillating at one phase until the relative strength of the signals along the first and second transmission paths changes, and then will abruptly shift phase.
The first and second oscillators may have identical components and may be tuned to a same frequency.
Thus, it is another object of at least one embodiment of the invention to provide a simple method of negating the effects of component tolerances and thermal drift and aging through the use of identical oscillator and detector circuits.
The phase shift element in the second transmission path may be a capacitor providing 180 degrees of phase shift.
It is thus another object of at least one embodiment of the invention to provide a simple method of coupling the two oscillators to provide a default state.
The phase shift element in the first transmission path may be an electrical inverter and a capacitor formed by the antenna.
It is thus another object of at least one embodiment of the invention to provide a secondary coupling between the oscillators that allows signals along the two signal paths to be distinguished by phase shift.
The signal strength comparator further receives the signal from the first oscillator to determine a phase of the second oscillator
It is thus another object of at least one embodiment of the invention to provide a phase sensitive comparison that further reduces the effects of external electromagnetic interference.
The antenna structure may be at least two electrodes electrically insulated from each other, one attached to the first oscillator, and one attached to the second oscillator.
It is another object of at least one embodiment of the invention to provide a simple antenna structure that can be placed on a variety of surfaces.
The two electrodes may be attached to an automotive door handle.
It is another object of at least one embodiment of the invention to provide a switch suitable for activating the courtesy lights or the like of an automobile.
The electronic proximity switch may include a timing element requiring a given relative strength between the electrical signals of the two transmission paths of a predetermined duration before the switch output is activated.
It is yet another object of at least one embodiment of the invention to provide a switch that is resistant to short-term interference, for example, rain drops or debris in the air.
These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , the present invention provides a electronic proximity switch 10 that may, for example, form part of a keyless entry system on an automobile or the like.
In this embodiment, the proximity switch 10 provides an antenna 12 formed as part of a handle escutcheon on an automobile door 14 . The antenna 12 provides a first conductive plate 18 insulated from, but adjacent to, a second conductive plate 20 , both of which may be visible or covered beneath a plastic face of the escutcheon. A person's hand 22 approaching the antenna 12 disrupts an electrical field 15 extending between the conductive plate 18 and the second conductive plate 20 . Disruption of the electrical field is sensed to produce an electrical signal that may be used to actuate a door release mechanism or the like.
Referring now to FIG. 2 , the conductive plate 18 and second conductive plate 20 are part of a first conductive path extending between oscillator 24 and oscillator 30 and further including inverter 26 , amplifier 28 and summing node 45 . The oscillator 24 operates to produce a megahertz signal, for example, a square wave or sine wave output, preferably at about 1.3 MHz. The output from the oscillator 24 passes through inverter 26 to change the phase of the output by 180 degrees, and then through amplifier 28 providing sufficient power to produce a sufficiently strong electrical field 15 between conductive plate 18 and conductive plate 20 . The signal 42 from conductive plate 20 is received by a first input of a summing node 45 and then by the input of an oscillator 30 .
A second conductive path between oscillator 24 and oscillator 30 is provided by a coupling capacitor 32 that receives the output of oscillator 24 and provides a signal 40 to a second input of the summing node 45 to be summed with the signal 42 from the plate 20 and provided to the input of oscillator 30 . The coupling capacitor 32 is sized so that the relative phase shift between the first transmission path to the summing node 45 and the second transmission path to the summing node is substantially 180 degrees.
Referring now also to FIG. 3 , the two transmission paths between the oscillator 24 and oscillator 30 are initially set up by adjustment of the plates 18 and 20 , or the introduction of an attenuating element, such as a resistor (not shown) so that the signal 42 passing through conductive plate 18 and second conductive plate 20 in the first path is much stronger than the signal 40 passing through capacitor 32 in the second path so that an output 44 of the oscillator 30 is in phase with signal 42 . For this reason, the output signal from the summing node 45 , as it passes to the input of the oscillator 30 , will be 180 degrees out of phase with the signal 40 —the phase indicating the relative strength of the signals on the two paths.
Electrically, the relative strength of the signals on the two paths is determined by a signal strength comparator 29 formed of oscillator 30 , phase detector 33 , low pass filter 34 , integrator/charge pump 36 and output amplifier 38 , as will now be described.
Oscillator 30 is preferably electrically identical to oscillator 24 , having the same operating frequency as oscillator 24 and using the same design and component values. In this way, the natural frequency of the oscillators 30 and 24 will tend to be the same with changes in temperature and as components age. The input of the oscillator 30 may be any point in the oscillator circuit where a signal equal in frequency to that of the oscillators 24 and 30 and provided to that input will tend to shift the phase of the oscillator 30 to the phase of the signal by way of sympathetic oscillation. It will be recognized that oscillator 30 acts as a narrow band filter, and thus is largely immune to spurious noise outside of the frequency of oscillator 24 to provide a high degree of noise rejection.
Signal 40 and the output oscillator 30 are then compared by a phase detector 33 , for example, a multiplier circuit, or for a square wave signal 40 , an exclusive NOR gate whose output tends to a high state when the signal 40 and the output oscillator 30 are in-phase and a low state when signal 40 and the output oscillator 30 are out of phase. In this case, when the person's hand 22 is not present, the signal 40 and the output oscillator 30 will be out of phase and the signal 46 will be generally low.
Small phase errors, electrical noise, or interference like rain will cause minor high state excursions in signal 46 whose output is filtered by a low pass filter 34 to produce signal 48 approximating a rolling time average of signal 46 and being generally in a low state. This signal 48 is provided to a charge pump 36 which produces a falling integrated output 50 that may be provided to an output amplifier 38 , for example a Schmidt trigger, to provide a low state output signal 52 indicating that a person's hand 22 is not close to the conductive plates 18 and 20 . These stages tend to reject noise that is not in phase or 180 out of phase with signal 40 and to reject the momentary phase errors described above.
When a person's hand 22 is brought near the conductive plate 18 , the coupling between the conductive plate 18 and the second conductive plate 20 is weakened causing the coupling through capacitor 32 to provide the dominant signal causing the signal 40 and the output 44 ′ of oscillator 30 to be in phase. The relative coupling between the oscillators 24 and 30 along the first and second transmission paths can be used to adjust the distance at which the hand 22 triggers this in phase condition.
Again, signal 40 and the output oscillator 30 are compared by a phase detector 33 which will produce a generally high state signal 46 ′, which is provided to the low pass filter 34 to produce signal 48 ′ and then to the charge pump 36 to produce a rising integrated output 50 ′ that may be provided to an output amplifier 38 to provide a high state output signal 52 ′ indicating that a person's hand 22 is close to the conductive plates 18 and 20 . This signal 52 ′ may be used to trigger a switch or a mechanical lock or a courtesy light or the like.
The present invention is not limited for use in automobiles, but may be used in appliances, such as washing machines and the like. By changing the relative phase between signals 42 and 40 to less than 180 degrees, the output of the summing node 45 will vary continuously with changes in relative signal's strength. This continuous output can be used to provide distance detection.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but includes modified forms of those embodiments, including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. | An electronic proximity switch employs two oscillators coupled through two electrical paths, one associated with an antenna serving as a proximity switch sensor. Absorption by an object near the antenna changes the coupling between the oscillators producing a dramatic phase shift that may be detected and used for switching purposes. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to the field of children's play apparatus and, more particularly, to a combination cover and enclosure for a sandbox or other play area.
[0003] 2. Background
[0004] Sandboxes are widely popular as a category of children's play apparatus. When not in use, it is desirable to protect the sand in a sandbox from the elements. This helps maintain the sand in good condition for play and helps prevent the sand from being contaminated with foreign objects or substances. Therefore, many sandboxes are provided with removable covers. Many of the prior art sandbox covers are cumbersome to handle and store. Moreover, the prior art sandbox covers are not useful for providing an enclosed play environment.
SUMMARY OF THE INVENTION
[0005] The present invention provides a cover assembly for a play area, such as a sandbox, comprising a frame disposed over the play area and a covering material attached to the frame. The frame is constructed so as to be convertible between a first configuration in which the play area may be fully enclosed, yet still be accessible for play, and a second configuration in which the play area is shaded, but open to the outside.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a covered play apparatus in a closed configuration in accordance with a first embodiment of the invention.
[0007] FIG. 2 illustrates the covered play apparatus of FIG. 1 in an open configuration.
[0008] FIG. 3 illustrates a covered play apparatus in a closed configuration in accordance with a second embodiment of the invention.
[0009] FIG. 4 illustrates the covered play apparatus of FIG. 3 in an open configuration.
[0010] FIG. 5 illustrates a covered play apparatus in a closed configuration in accordance with a third embodiment of the invention.
[0011] FIG. 6 illustrates the covered play apparatus of FIG. 5 in an open configuration.
[0012] FIG. 7 illustrates a covered play apparatus in a closed configuration in accordance with a fourth embodiment of the invention.
[0013] FIG. 8 illustrates the covered play apparatus of FIG. 7 in an open configuration.
[0014] FIG. 9 illustrates a covered play apparatus in a closed configuration in accordance with a fifth embodiment of the invention.
[0015] FIG. 10 illustrates the covered play apparatus of FIG. 9 in an intermediate configuration.
[0016] FIG. 11 illustrates the covered play apparatus of FIG. 9 in an open configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0017] 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.
[0018] FIG. 1 shows a first embodiment of a covered play apparatus 100 in which the covered play area comprises a sandbox. Sandbox 102 is formed with perimeter wall members 104 , 106 , 108 and 110 . The perimeter wall members may be made of wood, plastic or other suitable material. A tent-like cover assembly 112 encloses sandbox 102 and protects it from the elements. The cover assembly also prevents intrusion by cats and other animals. The cover assembly comprises a pair of support members 114 , 116 . Support members 114 and 116 comprise first leg members 114 a and 116 a , respectively, and second leg members 114 b and 116 b , respectively. In the closed configuration of the cover assembly shown in FIG. 1 , each of the support members resembles an inverted letter “V” arcing over a respective side of the sandbox. In alternate embodiments, such as described below, the support members may be curved to resemble an inverted letter “U”.
[0019] Cover assembly 112 further comprises a covering material 118 attached to support members 114 and 116 . Covering material 118 is preferably a waterproof material that will protect the contents of sandbox 102 . Material commonly used for camping tents, such as canvas, nylon and the like, are suitable for use as covering material 118 . The covering material may be imprinted with decorative designs, such as paw prints, fossils, insects or animals, to provide a themed play apparatus.
[0020] Cover assembly 112 further comprises a panel 120 of material attached to support member 114 . A corresponding panel of material may also be attached to support member 116 . Panel 120 (and the corresponding unseen panel) may be constructed of the same material as covering material 118 . Preferably, however, these panels are made of a screen-like material for ventilation, which helps prevent mold and dry out any damp sand. The screened panels also allow sandbox 102 to be used in inclement weather. The panels preferably include an opening 121 to allow for ingress and egress. The opening may be closed with a zipper, Velcro or other suitable means.
[0021] Referring now to FIG. 2 , cover assembly 112 is shown in an open configuration. Support members 114 and 116 pivot upwards on pivots 122 , which are attached to wall member 108 . A pair of support struts 115 and 117 are pivotally attached to wall member 104 and are slidingly coupled to respective second leg members in slots 114 c and 116 c , respectively. As the support members are pivoted upwardly, the support struts 115 and 117 also pivot upwardly until reaching the ends of the respective slots, at which point the support struts lock into position to secure the support members in the open configuration. In this configuration, each of the support members resembles and inverted letter “L”. Covering material 118 remains attached to support members 114 and 116 in the open configuration, thereby providing shade for sandbox 102 . If desired, however, the covering material may be detached from the support members and stowed along wall member 108 . In the open configuration, the side panels may be furled and secured along their respective support members using straps 124 or other suitable means.
[0022] FIGS. 3 and 4 illustrate a second embodiment of a covered play apparatus 200 that is generally similar in concept to the embodiment previously described. The covering material and side panels have been omitted for clarity; however, it will be understood that these elements of the previously described embodiment are equally applicable to the embodiment illustrated here. Apparatus 200 comprises sandbox 202 and cover assembly 212 . Sandbox 202 includes uprights 203 , 205 , 207 and 209 . The uprights are primarily for decorative effect and contribute to the themed nature of the play apparatus when a decorated covering material is used as described above.
[0023] Support members 214 and 216 of the cover assembly 212 are pivotally attached to sandbox 202 at pivots 222 . In contrast to the previously described embodiment, support struts 215 and 217 are pivotally connected to support members 214 and 216 , respectively, but are not otherwise attached to sandbox 202 . To place the cover assembly in its open configuration, the assembly is pivoted up at pivots 222 and the support struts 215 and 217 are pivoted down to rest on the ground.
[0024] FIGS. 5 and 6 illustrate a third embodiment of a play apparatus 300 that is generally similar in concept to the two embodiments previously described. Support members 314 and 316 of the cover assembly are pivotally attached to sandbox 302 at pivots 322 in identical fashion to the second embodiment described immediately above. Support struts 315 and 317 are pivotally connected to support members 314 and 316 , respectively, and are fitted with clips 326 . These clips keep the support struts aligned with the respective support members while in the closed configuration.
[0025] To place the cover assembly in its open configuration, the assembly is pivoted up at pivots 322 and the support struts are unclipped from their respective support members and are rotated approximately 180° to clip to the support members on the opposite side of clips 326 . Uprights 303 and 305 each have a hook 328 to hold support struts 315 and 317 when the cover assembly is in its open configuration.
[0026] FIGS. 7 and 8 illustrate a fourth embodiment of a covered play apparatus 400 that is again generally similar in concept to the embodiments previously described. In this embodiment, support struts 415 and 417 telescope within second leg members 414 b and 416 b , respectively. In all other respects, apparatus 400 is identical to apparatus 300 described immediately above. To place the cover assembly in its open configuration, support struts 415 and 417 are slid outwardly from the respective second leg members to rest within hooks 428 on uprights 403 and 405 .
[0027] FIGS. 9-11 illustrate a fifth embodiment of a covered play apparatus 500 . Cover assembly 512 is pivotally coupled to sandbox 502 at pivots 522 in the same manner as the previously described embodiments. In this embodiment, the cover assembly comprises curved support members, each of which generally resembles an inverted letter “U”. Cover assembly 512 is supported in the open configuration by articulated support members 514 and 516 (not shown), which are pivotally coupled to sandbox 502 at 523 . A clip 527 is attached to support member 514 (and similarly to corresponding support member 516 ) to lock the support member securely in the open configuration.
[0028] 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 cover assembly for a play area, such as a sandbox, comprises a frame disposed over the play area and a covering material attached to the frame. The frame is constructed so as to be convertible between a first configuration in which children can enter and play in a fully enclosed play area and a second configuration in which the play area is shaded, but open to the outside. |
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a hollow panel, and more particularly to a hollow panel which is suitably used as a construction material such as a wall material, a floor material, and a ceiling material.
[0002] Conventionally, hollow panels having hollow portions are employed as various kinds of panels for construction. In such a hollow panel, it is possible to realize heat insulation and weight reduction. In a known hollow panel, two corrugated plates in which end faces have a corrugated shape are sandwiched between two flat plates constituting surfaces to form one panel, and hollow portions corresponding to the corrugated shape are laterally extended (for example, see JP-A-7-214712). The hollow panel disclosed in JP-A-7-214712 has a configuration in which the two corrugated plates are stacked back to back so that projections of the plates abutted against each other are sandwiched between the flat plates. In a completed state of the panel, therefore, hollow portions of different sectional areas are internally enclosed, so that a lack of sound insulation due to the coincidence effect which may be caused at a specific frequency can be improved.
[0003] Since the hollow panel disclosed in JP-A-7-214712 is configured so that the sectional areas of the hollow portions are differentiated by using the two corrugated plates, a disadvantage that the whole thickness of the hollow panel is increased, and other disadvantages that the cost burden due to the increased number of components is inevitably imposed, and that the corrugated plates must be bonded together to increase the number of assembly steps are caused.
SUMMARY OF THE INVENTION
[0004] The invention has been conducted in view of the disadvantages. It is an object of the invention to provide a hollow panel which can effectively exhibit the sound insulation performance while suppressing the panel thickness, and in which the number of components can be reduced, so that labor in the work of forming the panel can be reduced and the production cost can be reduced.
[0005] In order to solve the aforesaid object, the invention is characterized by having the following arrangement.
[0006] Aspect 1. A hollow panel comprising:
[0007] first hollow portions arranged in a substantially same plane and having a first sectional areas; and
[0008] second hollow portions arranged in the substantially same plane and having a second sectional areas different from the first sectional areas.
[0009] Aspect 2. The hollow panel according to the aspect 1, wherein the first hollow portion and the second hollow portion are alternatively arranged in the substantially same plane.
[0010] Aspect 3. The hollow panel according to the aspect 1, wherein a solid portion forming member is inserted into a specific one of the first and second hollow portions, the solid portion forming member having a section shape which substantially corresponds to a section shape of the specific hollow portion.
[0011] Aspect 4. The hollow panel according to the aspect 1, wherein a sectional shape of the first and second hollow portions is a trapezoidal.
[0012] Aspect 5. A hollow panel comprising:
[0013] first hollow portions arranged in a substantially same plane and having a first width; and
[0014] second hollow portions arranged in the substantially same plane and having a second width different from the first width.
[0015] Aspect 6. The hollow panel according to the aspect 5, wherein the first width is defined between a pair of partition walls defining the first hollow portion, and the second width is defined between a pair of partition walls defining the second hollow portion.
[0016] Aspect 7. The hollow panel according to the aspect 5, wherein the first and second hollow portions are alternatively arranged in the substantially same plane.
[0017] Aspect 8. The hollow panel according to the aspect 5, wherein a solid portion forming member is inserted into a specific one of the first and second hollow portions, the solid portion forming member having a section shape which substantially corresponds to a section shape of the specific hollow portion.
[0018] Aspect 9. The hollow panel according to the aspect 5, wherein a sectional shape of the first and second hollow portions is a trapezoidal.
[0019] Aspect 10. A hollow panel comprising:
[0020] first and second partition walls defining a plurality of hollow portions arranged in a substantially same plane, wherein a thickness of the first partition walls is different from that of the second partition walls.
[0021] Aspect 11. The hollow panel according to the aspect 10, wherein the first and second partition walls are alternatively arranged.
[0022] Aspect 12. The hollow panel according to the aspect 10 , wherein a solid portion forming member is inserted into a specific one of the hollow portions, the solid portion forming member having a section shape which substantially corresponds to a section shape of the specific hollow portion.
[0023] Aspect 13. A hollow panel comprising:
[0024] a plurality of hollow portions arranged in a substantially same plane; and
[0025] a solid portion disposed to extend over at least one of the plurality of hollow portions.
[0026] Aspect 14. The hollow panel according to the aspect 13, wherein a solid portion forming member is inserted into a specific one of the hollow portions, the solid portion forming member having a section shape which substantially corresponds to a section shape of the specific hollow portion.
[0027] In the invention, a configuration may be employed in which a solid portion forming member is inserted into a specific one(s) of the plural hollow portions, the solid portion forming member having a sectional area which generally corresponds to a sectional area of the specific hollow portion(s). According to the configuration, the solid portion forming member is placed in an arbitrary one(s) of the hollow portions, whereby the surface density can be partially differentiated. Therefore, the invention can be easily applied even to an existing hollow panel so as to suppress a lack of sound insulation.
[0028] The hollow panel of the invention can be formed by using any of various materials, and preferably formed by using wood elements. Examples of wood elements are wood flakes, wood fibers, wood chips, and wood particles. The wood elements may be shaped into a panel-like shape by die molding. As a binder which is useful in the molding, any one of a foamable binder resin, a nonfoamable binder resin, and a mixture of these binders may be employed.
[0029] The hollow panel can be produced by die molding in the following manner. A fixed amount of wood elements are sprayed into dies, and cores corresponding to the shapes of the hollow portions are then laterally arranged in a substantially same plane. A further fixed amount of wood elements are sprayed onto the arrangement. Under this state, a hot pressing process is performed. The dies are opened, and the cores are then pulled out, whereby a panel in which hollow portions are integrally formed can be shaped. The hollow panel may be obtained by another shaping method in the following manner. Two front members having a thin plate-like shape, and a single hollow portion forming member which is similar in shape to a galvanized steel sheet, or in which the end faces have a corrugated shape are separately formed. The front members are bonded together by an adequate adhesive agent so as to sandwich the hollow portion forming member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a schematic perspective partial view of a hollow panel of a first embodiment.
[0031] [0031]FIG. 2 is a partial end view of the hollow panel.
[0032] [0032]FIG. 3 is a partial end view of a hollow panel which is a modification of the first embodiment.
[0033] [0033]FIG. 4 is a partial end view of a hollow panel of a second embodiment.
[0034] [0034]FIG. 5 is a partial end view of a hollow panel of a third embodiment.
[0035] [0035]FIG. 6 is a schematic plan view of the hollow panel of the third embodiment.
[0036] [0036]FIG. 7 is a schematic plan view of a hollow panel of a fourth embodiment.
[0037] [0037]FIG. 8 is a schematic plan view of a hollow panel which is a modification of the fourth embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] Hereinafter, embodiments of the invention will be described with reference to the accompanying drawings.
First Embodiment
[0039] [0039]FIG. 1 is a schematic perspective view of a hollow panel according to a first embodiment, and
[0040] [0040]FIG. 2 is an end view of a part of the hollow panel. Referring to the figures, a hollow panel 10 that can be used as a construction material such as a wall panel, a floor panel, and a ceiling panel comprises a pair of flat outer sides 11 which are substantially parallel to each other, and plural hollow portions 12 which are positioned between the outer sides 11 so as to be arranged in a substantially same plane.
[0041] Each of the hollow portions 12 has a shape which linearly extends in a direction perpendicular to the plane of the sheet of FIG. 2. The hollow portions 12 are formed so that partition walls 13 which are arranged at predetermined intervals in the lateral directions in the figure are inclined by an approximately same angle and to alternately different directions. As a result, each of the hollow portions 12 shows an approximately trapezoidal section shape. In the embodiment, first hollow portions 12 A having a smaller lateral width W 1 , and second hollow portions having a lateral width W 2 which is larger than the lateral width W 1 are formed so as to be alternately positioned along the lateral direction in FIG. 2, so that the adjacent hollow portions 12 A and 12 B are disposed to be alternately different or nonuniform in sectional area. In the figure, the lateral widths W 1 and W 2 of the first and second hollow portions 12 A and 12 B are indicated as those at the respective middle positions in the panel thickness direction because of the following reason. Since the partition walls 13 are inclined, the thicknesses are shown with reference to the respective middle positions for the sake of convenience. Alternatively, the partition walls 13 may not be inclined, and may be modified so as to have a sinusoidal waveform, or an approximately pulse-like waveform so that the partition walls 13 are perpendicular to the outer sides in the panel thickness direction. As shown in FIG. 3, the hollow panel 10 may further comprise third hollow portions 12 C which have a more larger width.
[0042] In the hollow panel 10 , the lateral ends 10 A in FIG. 1 have a closed structure in which the hollow portions 12 are not formed. According to the configuration, the rigidity is provided so that lateral end portions of the outer sides 11 are prevented from being bent in a direction perpendicular to the panel plane, whereby the shape retention property can be maintained.
[0043] According to the thus configured first embodiment, when the whole of the single hollow panel 10 is considered, the first and second hollow portions 12 A and 12 B are formed so as to have different sectional areas, and hence the relationships are attained in which the surface densities of areas substantially corresponding to the hollow portions 12 A and 12 B are different. Therefore, a structure where the resonance frequency of the panel due to the sectional areas or sizes of the hollow portions is not uniform in the panel plane but dispersed is formed, and a lack of sound insulation caused by resonance at a specific frequency can be effectively suppressed.
[0044] Next, other embodiments of the invention will be described. In the following description, components which are identical with or equivalent to those of the first embodiment are denoted by the same reference numerals, and their description is omitted or simplified.
Second Embodiment
[0045] [0045]FIG. 4 shows a second embodiment of the invention. The embodiment is characterized in that, although the hollow portions 12 have the same sectional area, different thicknesses T 1 and T 2 of the partition walls 13 between the hollow portions 12 alternately appear. The thicknesses are set so as to have a relationship of T 1 >T 2 .
[0046] In the second embodiment also, the area of the thickness T 1 is higher in surface density than that of the thickness T 2 , or higher in rigidity. Therefore, the embodiment has a structure where the panel resonance frequency is not uniform in the plane of the hollow panel 10 , and can exert the same sound insulation effect as that of the first embodiment.
Third Embodiment
[0047] [0047]FIGS. 5 and 6 show a third embodiment of the invention. The embodiment is characterized in that a solid portion 15 is formed in a specific region where a hollow portion is to be originally formed. As shown in FIG. 6, the solid portion 15 may be formed linearly in a region corresponding to a single hollow portion, or alternatively formed so as to extend over plural hollow portions 12 . In the illustrated example, the solid portion 15 linearly extends. However, the manner of the extension is not limited to a linear one. It is possible to say that the embodiment is realized by extremely increasing the thicknesses of specific ones of the partition walls 13 .
[0048] Also the embodiment can exert the same effect as that of the afore-described embodiments.
Fourth Embodiment
[0049] [0049]FIG. 7 shows a fourth embodiment of the invention. In the embodiment, a rod-like member 16 serving as a solid portion forming member is inserted into one of the hollow portions 12 . The rod-like member has a section shape which generally corresponds to a section shape of the hollow portion. Therefore, the surface density is partially differentiated, so that the above-mentioned sound insulation effect is attained. This configuration can be easily applied to a previously shaped hollow panel, so that the invention can be applied to an existing hollow panel. When the insertion position of the rod-like member 16 is changed, it is possible to arbitrary determine the region of a different surface density.
[0050] As shown in FIG. 8, the rod-like member 16 may be placed in a direction intersecting with, for example, perpendicular to the direction along which the hollow portions 12 extend.
[0051] As described above, although the best configuration, method, and the like for embodying the invention have been disclosed in the above description, the invention is not limited to them.
[0052] Namely, although the invention has been illustrated and described with respect to specific embodiments, those skilled in the art can variously modify as required the above-described embodiments with respect the shape, the position, the arrangement, or the like without departing from the technical concept and object of the invention. For example, the embodiments and modifications can be arbitrarily combined with each other. The number of the rod-like member 16 may be adequately increased or decreased as required. Various kinds of the rod-like members 16 of different masses may be used to enable the distribution of the surface density to be finely differentiated.
[0053] As described above, according to the invention, it is possible to provide a hollow panel that exerts an excellent effect in which the resonance frequency of the panel is not uniform in the panel plane but dispersed and hence a lack of sound insulation due to resonance can be suppressed, and which cannot be exerted in the conventional art. Since the hollow portions are arranged in a substantially same plane, the thickness of the hollow panel can be reduced.
[0054] In the case where the configuration in which a rod-like member is inserted into a hollow portion is employed, a portion where the surface density is partially differentiated can be arbitrarily determined to be placed, and therefore the invention can be easily applied to suppress a lack of sound insulation. | A hollow panel ( 10 ) includes comprise hollow portions ( 12 ) between front and rear outer sides ( 11 ) having a substantially flat plate shape. In the hollow panel ( 10 ), the surface density is partially differentiated, whereby a lack of sound insulation due to the coincidence effect at a specific frequency is prevented from occurring. The surface density or the rigidity can be made non-uniform to suppress the lack of sound insulation, by differentiating sectional areas by forming plural kinds of widths of the hollow portions ( 12 ), or by differentiating the distances between partition walls ( 13 ) or the thicknesses of the walls. |
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BACKGROUND TO THE INVENTION
The present invention relates to apparatus for, and a method of, laying a pipe line composed of pipe sections arranged end-to-end.
In the construction of pipe lines it is known to excavate an open trench and to arrange pipe-sections end-to-end in the trench. One way of excavating the trench is to utilize an advanceable drive shield composed of elongate cutter planks displaceably supported by a frame or frames. The planks define and support the trench walls and are driven forwards individually or in groups to penetrate a working face at the front end of the trench.
The pipe sections can be lowered into the trench behind the shield and connected up end-to-end before the trench is refilled. In water logged ground the pipe laying operation becomes difficult and to overcome this difficulty it has been proposed to use a sealed receptacle into which the pipe sections can be lowered. This receptacle has an opening through which the previously-installed pipe section extends and the receptacle can be shifted up from time to time as the work progresses. Despite the general success of this form of apparatus there are still problems in certain areas, notably the shifting of the shield and the receptacle and general adjustment and control especially where the pipe sections are relatively large and heavy and/or where the soil is especially water laden.
A general object of the present invention is to provide an improved apparatus and method for the construction of the pipe lines.
SUMMARY OF THE INVENTION
In one aspect the invention provides an apparatus for use in laying a pipe line composed of pipe sections arranged end-to-end; said apparatus comprising an advanceable shield for excavating a trench and for supporting the walls thereof and a receptacle located rearwardly of the shield relative to the direction of advancement and serving to receive individual pipe sections, the receptacle being connected to or connectible with the shield and having an opening allowing the receptacle to be moved up with the shield along the pipe line wherein the shield and the receptacle are provided with selectively operable clamping means engageable with the walls of the trench.
In another aspect of the invention provides a method of laying a pipe line composed of pipe sections arranged end-to-end; said method comprising excavating an open trench with an advanceable shield, introducing a pipe section into a receptacle located in the trench rearwardly of the shield, arranging the pipe section in end-to-end relationship with a previously installed pipe section projecting through an opening in the receptacle, moving the receptacle to follow up the advancement of the shield and utilizing clamping means of the shield and the receptacle to selectively clamp the shield and the receptacle to the trench walls.
The movement of the shield and the receptacle would normally be accomplished by hydraulic rams as is known per se.
In the case of heavy pipe sections, and where the soil is largely unconsolidated and water laden so it tends to flow, the forces opposing the movement of the shield and the receptacle can largely negate the normal self-anchoring function of the shield. However, by operating the clamping means at selected times the shield and receptacle can be reliably anchored to provide an adequate reactive abutment for the shifting forces. Where the shield employs the known form of elongate cutter planks displaceably supported on frame means it is sufficient to provide gripping devices on some of the planks to act as the clamping means for the shield. Similar devices can be provided on the side walls of the receptacle to act as the clamping means therefor. The gripping devices are preferably expandable and contractable laterally of the trench and can be operated manually, or mechanically or by hydraulic means. In the case of the receptacle the gripping devices are preferably retractable into recesses in the side walls when not in use. At a selected stage during the pipe laying operation the gripping devices can all be operated to firmly clamp the planks in question and the receptacle. These components together with the remaining planks in frictional contact with the trench walls can collectively act as an abutment for the frame means of the shield so this can be advanced. Similarly, when the gripping devices of the planks are operated and the gripping devices of the receptacle are rendered inoperative the entire shield can act as an abutment for shifting up the receptacle which moves along the pipe line.
The receptacle and the frame means of the shield are preferably interconnected by means permitting these components to be shifted together or independently where the conditions are difficult. Where the frame means and the receptacle are to move together, mechanical coupling devices, preferably easily releasable can provide the necessary connection and preferably allow a certain degree of articulated mobility between the components. In this case the gripping devices of the planks may be operated if desired. Hydraulic piston and cyinder units can then also connect the frame means and the receptacle and by releasing the coupling device the frame means can be shifted up whilst the receptacle is clamped and then the receptacle can be released and drawn up to the frame means by operating the hydraulic units.
In accordance with a further feature of the invention the shield, or more preferably the frame means thereof, can have an adjustable bulkhead at its front end which can be adjusted to screen off selected areas of the working face of the trench. Where the face is relatively stable this bulkhead can be removed to open up the shield as is normal. Where, however, the face is relatively flowable the bulkhead can be adjusted to permit a certain part of the face to flow in the manner of an extrusion through the bulkhead into the shield as the frame means is advanced. This is especially useful where the depth of the trench is relatively great. The bulkhead adjustable in this way can be constructed in a variety of ways but one form, described in more detail hereinafter, utilizes plates with cutting edges which are raised or lowered to partly overlap one another thereby creating adjustable-width gaps between the plates. The displacement of the plates can be accomplished with the aid of hydraulic units or mechanical screws for example and after the frame means has been advanced the plates can be re-adjusted to screen-off the working face and the material allowed in the shield can be removed such as by pumping or dredging.
It is desirable to provide some means for altering the position of the pipe section installed in the receptacle. To this end an apparatus made in accordance with the invention may employ an adjustable support means in the receptacle onto which the pipe section can be lowered. The support means preferably comprises a roller bed or assembly with rollers engageable with an exterior part of the pipe section. This will also assist in guiding the receptacle as it is drawn up along the pipe line. It is desirable to be able to adjust the support means in a vertical sense as well as to be able to tilt the support means front to rear and from side to side.
Hydraulic units can be provided for this purpose. The adjustability of the support means not only facilitates alignment of the pipe section with the previously installed pipe section it also enables direction of the pipe line to be controlled to some extent in horizontal and vertical senses. It is desirable to locate an external support on the floor of the trench to align with the support means in the receptacle.
As will become apparent hereinafter apparatus made in accordance with the invention may comprise an advanceable shield for excavating a trench and for supporting the walls thereof, a receptacle located rearwardly of the shield relative to the direction of advancement and serving to receive individual pipe sections, an opening in the receptacle permitting communication between the interior and the exterior thereof whereby the pipe sections can be arranged end-to-end and the receptacle can be moved up in the direction of advancement as the pipe line is extended, means connecting the shield and the receptacle together and clamping means on the shield and the receptacle for selectively engaging the trench walls to anchor the respective components.
Apparatus made in accordance with the invention may also comprise an advanceable shield usable to excavate a trench and to support the walls thereof, the shield having a plurality of elongate members and a frame supporting the members for longitudinal displacement, adjustable bulkhead at the front end of the frame which can be adjusted to open a selected portion of the working face to the interior of the shield, and a receptacle for receiving individual pipe sections, the receptacle being disposed behind the shield and having an opening permitting communication between the interior and exterior thereof whereby the pipe sections can be arranged end-to-end and the receptacle can be moved up in the direction of advancement as the pipe line is extended.
Apparatus made in accordance with the invention may also comprise an advanceable shield for excavating a trench and for supporting the walls thereof, a receptacle located rearwardly of the shield relative to the direction of advancement and serving to receive individual pipe sections, an opening in the receptacle permitting communication between the interior and exterior thereof whereby the pipe sections can be arranged end-to-end and the receptacle can be moved up in the direction of advancement as the pipe line is extended and adjustable support means in the receptacle for supporting a pipe section introduced into the receptacle.
The invention may be understood more readily, and various other features of the invention may become apparent, from consideration of the following description.
BRIEF DESCRIPTION OF DRAWINGS
An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 is a schematic sectional side view of apparatus made in accordance with the invention;
FIG. 2 is a cross-sectional view of part of the apparatus taken along the line II--II of FIG. 1;
FIG. 3 is a cross-sectional view of part of the apparatus taken along the line III--III of FIG. 1;
FIG. 4 is an end view of part of the apparatus taken in the direction of the arrow IV of FIG. 1; and
FIG. 5 is a view of the apparatus generally corresponding to FIG. 1 but showing the apparatus in a different operating condition.
DESCRIPTION OF PREFERRED EMBODIMENT
In general a composite pipe line for water mains, sewerage, or other purposes is composed of individual pipe sections 10 arranged end-to-end and installed with the aid of the apparatus depicted in the drawings. The individual pipe sections 10, which are preferably pre-fabricated from concrete, are laid in an open trench. The pipe sections 10 may be provided with location means, such as stepped tongue and groove connections on facing ends to locate each section 10 against the previously installed section 10. As the pipe line advances the installed sections 10 are covered by soil or a similar filling to reconstitute the ground surface so that the pipe sections 10 are buried beneath the ground surface. Conveniently, the material removed to form the trench can be used as the in-filling. This means that only a sufficient length of open trench for working need be provided. As shown in the drawings, to excavate the trench in advance of the actual pipe line the apparatus uses a drive shield 11 which defines the shape of the trench and also serves to support the side walls of the trench. This shield 11 is composed of a plurality of parallel elongate plank members 13 generally arranged about the axis of the trench. The plank members 13 engage on the sides and the bottom or floor of the trench. In known manner, the forward ends of these members 13 have cutting edges and are urged forward individually or in groups in the direction of arrow V in FIG. 1 to penetrate a working end face of the trench. Each member 13 is supported for displacement in its longitudinal direction and to shift the members 13 there can be provided double-acting hydraulic rams (not shown) which are supported by a main frame 12. This frame 12 serves to support the members 13 and to guide the members 13 during their longitudinal displacement. The shifting rams can each be connected via a linkage or bracket to a respective associated member 13 or group of members 13. It is possible to provide a ram for each member 13 or alternatively each ram or some of the rams may each serve to displace a group of several members 13. In this latter case some appropriate connecting means can be provided to connect the members 13 of the group together.
In known manner the plank members 13 are driven forwards in the direction of arrow V in FIG. 1 either individually or in groups by extending the associated ram or rams. When all the members 13 have been advanced the frame 12 can be drawn up as described hereinafter.
The frame 12 is a rigid structure of generally U-shaped cross-section open at the top. The frame 12 is composed of two upstanding components 12a, 12b, (FIG. 1) interconnected by means of bracing arms 12c.
The foremost frame component 12b is inclined as shown in FIGS. 1 and 5. Rearwardly of the shield 11 relative to the working face of the trench there is provided a pipe receptacle 14 which serves to receive the individual pipe sections 10. The members 13 have rearwardly projecting end portions 13' which partly extend over the receptacle 14, preferably at all times. The receptacle 14 itself takes the form of a box-like sheet metal unit with a U-shaped cross-section open at the top to receive the pipe sections. The receptacle 14 preferably projects above ground level. As shown in FIGS. 2 and 3, the side walls of the receptacle 14 are of composite form and partly hollow with chambers 16 capable of being filled with water or some other fluid. The purpose of this is to permit control of the alignment of the receptacle 14 and to stabilize the latter. By admitting water or other fluid into certain of the chambers 16 and by removing water from others the receptacle 14 can be made to tilt about the driving direction V or about a transverse centre line. The side walls 15 of the receptacle 14 adjoin a floor portion which rests on the floor of the trench. The receptacle also has end walls 17, 20 and its interior is thus closed off from the exterior, i.e., the trench, and is made water tight. The end wall 20 is connected to the frame 12 so that the receptacle 14 as a whole is movable with the frame 12 when desired. In this construction hydraulic double-acting piston and cylinder units 21 and mechanical coupling devices 22 are provided for connecting the receptacle 14 and the frame 12. The units 21 are pivotably connected to the frame 12 and to the wall 20. The devices 22 are in the form of pivotable levers on the frame component 12a which can be hooked or locked onto pins 23 carried by the wall 20 or released therefrom.
The end wall 17 of the receptacle 14 is provided with a circular opening 18 which enables one of pipe sections 10 at the end of the pipe line to extend from the exterior into the receptacle 14. A seal or packing 19, which is preferably resilient, is mounted at the defining edge of the opening 18 and engages on the exterior of the pipe section 10 so as to seal the interior of the receptacle 14 relative to the exterior.
Both the shield 11 and the receptacle 14 are provided with clamping means capable of selectively anchoring part of the shield 11 and the receptacle 14 against the trench walls. In the case of the shield 11 at least some of the plank members 13 are provided with gripping devices 24 which can be expanded outwardly in the lateral sense to the driving direction V to engage firmly with the trench walls or contracted inwardly to permit movement of the plank members 13 in question. Claws or plates may be used in the devices 24 to actually contact the walls of the trench. The devices 24 can be operated mechanically or hydraulically, for example, by piston and cylinder units. In a similar manner, the receptacle 14 is also provided with gripping devices 25. These devices 25 are located at the bottom zone of the exterior part of the side walls 15 and the devices 25 are operated hydraulically with the aid of piston and cylinder units 26 to expand and grip the trench walls or else to contract and allow the displacement of the receptacle 14. The devices 25 are pivotably supported on hinge pins 27 mounted to the walls 15 and the devices 25 can be moved outwardly to project beyond the exterior of the associated side wall 15, as shown in FIG. 2, or retracted into a pocket-like recess 28 formed at the bottom of the side walls 15 as shown in FIG. 3.
When the frame 12 is to be advanced the gripping devices 24 of the shield 11 and the gripping devices 25 of the receptacle 14 are operated to firmly anchor the plank members 13 and the receptacle 14 against the trench walls.
The coupling devices 22 would then be released as shown in FIG. 5, and the rams of the shield 11 and the units 21 can now be operated together to move the frame 12 forwards. Thereafter when it is desired to move the receptacle 14 up the devices 25 would be retracted and the units 21 operated in the reverse sense. The receptacle 14 this moves along the pipe section 10 partly external thereof and the seal 19 relocates on the pipe section 10 formerly introduced into the receptacle 14. This pipe section 10 then projects between the exterior and interior of the receptacle 14 -- as shown at the right hand side of FIG. 1 and forms the end of the pipe line. A fresh pipe section 10 can thereafter be lowered into the receptacle 14 and arranged end-to-end with the other pipe section 10 -- as shown at the left hand side of FIG. 1. When the plank members 13 are to be advanced again the coupling devices 22 would be reconnected and the devices 25 would be extended to firmly anchor the receptacle 14. The sequence would then be repeated.
Where conditions permit, the receptacle 14 can be coupled with the frame 12 with the aid of the devices 22 when the frame 12 is shifted so that the frame 12 and the receptacle 14 move together as a composite unit in relation to the members 13. The gripping devices 25 would of course in this case be retracted while the devices 24 are operative so that the members 13 provide an abutment anchorage for the shifting forces. The units 21 would not operate in this alternative sequence. The easy releasibility of the devices 22 enables the receptacle 14 to be shifted independently of the frame 12 as described above should the working conditions deteriorate.
Support means is provided in the receptacle 14 to facilitate alignment between the pipe sections 10 and to control the direction of the resultant pipe line. This means takes the form of a roller assembly 40 located on the floor of the receptacle 14 as shown in FIGS. 2 and 5. The assembly 40 employs sets of rollers 41 arranged in arcuate configuration to match the curvature of the pipe section 10 and to engage on the lower peripheral surface of the pipe section 10 installed in the receptacle 14. The rollers 41 are rotatably supported by a trough-like carriage 42 superimposed on a base plate 43. As shown in FIG. 2, hydraulic piston and cylinder units 44 are located between the base plate 43 and the carriage 42. The units 44 permit the carriage 42 and hence the pipe section 10 lowered thereon to be adjusted. The carriage 42 is also pivoted at about the centre of the base plate 43, preferably by some form of universal joint, permitting the carriage 42 to assume inclined positions. This allows parts of the pipe line to be laid along non-rectilinear paths, e.g., to extend over a curved horizontal path or to rise or fall over certain regions. The assembly 40 also assists in guiding the receptacle 14 when the latter is displaced in the advancing direction. To facilitate connection between the pipe sections 10, hydraulic piston and cylinder units 45 are located inside the receptacle 14 and mounted to the wall 20. These units 45 can provide a thrust force to the end of a pipe section 10 installed therein.
To provide exterior support for the pipe sections 10 narrow webs or rails 50 made from concrete for example can be installed in the trench behind the receptacle 14 as shown in FIGS. 1 and 2. These webs 50 extend parallel to one another and are substantially aligned with the roller assembly 40 so as to prevent the pipe sections 10 from tilting downwards at the advancement of the receptacle 14. Even where the trench bottom is inclined the adjustability of the rollers assembly 40 permits the support provided by the rollers 41 to be aligned with the upper contact surfaces of the webs 50. It is possible to introduce fluid concrete between the webs 50 to provide support for the pipe sections 10 over a somewhat larger zone if desired.
The shield 11 is provided with an adjustable bulkhead which is preferably at least partly removable and which is particularly useful in heavy water-logged soil and in flowable materials. As shown, this bulkhead is of multi-part construction with individual bulkhead plates 29 arranged in the general sense one above another on the front inclined frame component 12b of the shield 11. The plates 29 cover over all or a part of the working face at the front end of the trench without obstructing the plank members 13. The plates 29 have lateral end portions slidably supported in staggered or offset guideways 31 in the frame component 12b permitting the plates 29 to be raised and lowered individually. Preferably mechanical screws or spindles or hydraulic means, such as the unit 51 in FIG. 4, is provided to effect such adjustment of the plates 29. A further bulkhead partition 30 is located at the central region of the frame component 12b and this partition 30 is fixed to the frame component 12b. The plates 29 can be made to overlap in a variety of positions and have cutting blades 32 at their lower edges. Hence, the plates 29 can be moved in the directions of arrows P in FIG. 1 so that for example the lowest plate 29 can be raised behind the partition 30 and the next uppermost plate 29 can be lowered behind the partition 30. By adjusting the relationship between the plates 29 in the manner of a sluice gate it is thus possible to open up or expose a certain zone of the working face to the interior of the shield 11 so that as the frame 12 is advanced material can flow from the working face and into the shield 11 via the bulkhead 29, 30. When the frame 12 has been advanced the plates 29 can be readjusted to close off the working face if the material is partly fluid. The material which accumulates inside the shield 11 can be removed by any suitable process and where the material is sufficiently fluid dredging or pumping techniques can be used. Where the use of a bulkhead is unnecessary, as in the case of compact soil, the plates 29 can be withdrawn from the guideways 31 to open up the front of the shield 11 in the normal way. | Apparatus for, and a method of, laying a pipe line utilizes an advanceable drive shield composed of parallel displaceable cutter planks supported by a frame to excavate an open trench. Behind the shield is a receptacle which is closed to the trench and receives individual pipe sections for extending the pipe line through an opening in the receptacle. Some of the cutter planks and the receptacle are provided with gripping devices selectively operable to engage the trench walls to anchor the respective components against shifting forces. The receptacle is connected with the frame for movement therewith or for independent movement. A roller bed which can be raised or lowered or tilted in a universal manner is provided in the receptacle to receive the pipe section lowered into the receptacle. The frame also has an adjustable bulkhead at its front end which can be partly opened to allow material at the working face of the trench to enter the shield for subsequent removal. |
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REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part U.S. patent application Ser. No. 356,260, filed May 24, 1989 now U.S. Pat. No. 4,913,584.
TECHNICAL FIELD
This invention relates to machines for screeding materials such as concrete and cement used in the paving of roads and the like.
BACKGROUND OF THE INVENTION
In efforts to reduce the labor intensive, time consuming screeding of paving materials, numerous types of machines for accomplishing the screeding operation have been developed. Examples of such machines are shown in U.S. Pat. Nos. 1,584,385; 2,426,702; 2,687,679; 3,377,933; 4,115,976; 4,747,726; and in the aforementioned application Ser. No. 356,260 of which this application is a continuation-in-part. In general, these machines comprise a frame supported by two or more rollers, at least one of which is driven, that roll on forms straddling the surface area to be paved and which serve as track or support rails for the machine. A screed roller is located forward on the frame and its axis of rotation is slightly elevated above the axes of the support rollers, so that the screed roller itself is elevated slightly above the support rollers and the forms. The screed roller is generally driven in a reverse direction to that of the support rollers so that as the machine advances through the paving material, which has been dumped between the forms, the screed roller flings and spreads the material ahead of the machine, flattening and leveling the piles thereof into a rough surface. The support rollers then pass over the material, further flattening and smoothing it into a fairly flat, fairly even surface. This surface can be improved by floating or troweling, which is generally done manually by work crews using bull floats or trowels.
In the aforementioned application Ser. No. 356,260, manual troweling or floating is obviated by a finishing roller attachment mounted on the rear of the screeding machine. The finishing roller, which is of smaller diameter than the screeding and support rollers, is rotatably mounted to a pair of support arms, which are pivotally mounted to the machine. Drive means mounted to one of the support arms rotates the finishing roller generally at higher revolutions per minute than the other rollers so that the finishing roller actually slips on the surface of the paving material as the screeding machine is operated. This action causes the soupy material carried in the paving material to rise to the top surface thereof where it is uniformly spread by the finishing roller to produce a highly finished surface. Means are provided for pivoting the support arms so that the finishing roller no longer engages the paving surface, in the event that a highly finished surface is not needed or desired.
While the screeding machines as just described produce an even, smooth, level paved surface, in practice it has been found that when the concrete is poured, air in the form of bubbles and pockets is trapped in the mass. Such air bubbles and pockets tend to reduce the density of the pacing material, weaken the material, and deleteriously effect the finished surface thereof. These effects can be especially damaging where great density and strength of the material is required, such as with airport runways or heavily travelled highways.
Accordingly, it is an object of the invention to provide a screeding machine and method for eliminating, to a large degree, the entrapment of air in poured paving material.
More particularly, it is an object of the present invention to incorporate into the operation of a screeding machine the operation of reducing or eliminating trapped air in the paving material.
SUMMARY OF THE INVENTION
The invention, in a preferred embodiment thereof, comprises an attachment for mounting on the front portion of a screeding machine. The attachment comprises a transversely extending rod swivelly mounted on an array of support posts which are, in turn, mounted on the frame of the machine at the rear thereof. Support arms extend toward the front of the machine and are attached to the swivelably mounted rod. Each support arm has a hanger member depending therefrom which supports a transversely extending beam, on which is mounted an array of hydraulically actuated vibrators, each vibrator having an actuating hydraulic motor mounted adjacent thereto on the beam.
Means are provided for raising and lowering the beam, and hence the vibrators, with the vibrators, in the lowered position, penetrating to a considerable depth the paving material in advance of the screeding roller. When the vibrators are actuated by the individual hydraulic motors, and when in the lowered position, the paving material is agitated to a considerable depth, thereby breaking up and dispersing any existing air bubbles or pockets and allowing the air to escape, with the net result that the paving material is made considerably more dense and air free.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a screeding machine which embodies the principles of the present invention and which is shown operating on the paving material of a road being paved, as viewed from a rear quarter.
FIG. 2 is a perspective view viewed from a front quarter of the machine of FIG. 1.
FIG. 3 is a side elevation view of the machine of FIGS. 1 and 2 with the vibrators shown in the lowered position and with the finishing roller added.
FIG. 4 is a side elevation view of the machine of FIG. 3 with the vibrators in the raised position.
DETAILED DESCRIPTION
With reference to FIG. 1, there is depicted a self-propelled screeding machine 10, such as that shown in U.S. Pat. No. 4,747,726, which has a frame that includes a front beam 11 disposed beneath a walkway 12, a rear beam 13 and an intermediate beam 14, all of which span the space between and provide support for two side platforms 15 and 16. Rotatably mounted on the frame and spanning a major portion of the width of the machine are a rear drive roller 18, a forward drive roller 19, and a screed roller 20 located ahead of the forward roller 19.
The machine 10 is provided with a hydraulic power system that includes a diesel engine within a housing 22 from which an exhaust stack 23 extends, and a master pump mounted within a pump housing 24 atop platform 16. The hydraulic system includes an hydraulic fluid reservoir 25 which is mounted on platform 15. The loads powered by the hydraulic power system include a right side hydraulic lift cylinder 27 and a left side hydraulic lift cylinder 28, each of which is mounted in a protective housing 29. The function and operation of such lift cylinders is fully explained in U.S. Pat. No. 4,747,726. Additional system loads include a hydraulic motor 30 mounted on a rear portion of platform 15 for driving the drive roller 18, and a hydraulic motor 31 mounted on a forward portion of platform 15 for driving the screed roller 20. The hydraulic system is of conventional construction and thus its hydraulic lines and controls have not, for clarity, been shown, with one exception which will be discussed hereinafter. It is to be understood that the hydraulic lines extend to and between the several elements of the system, including the loads, with those extending between system components mounted on the two platforms 15 and 16 and passing through the beams 14, which protects them from possible damage during operation. The entire system is controlled from a panel 34 which is positioned behind the reservoir 25 in front of an operator's seat or stool 35.
The rear drive roller 18 and the forward drive roller 19 are driven synchronously by power takeoff from hydraulic motor 30. This power takeoff includes a drive chain 37, as best seen in FIGS. 3 and 4, that is routed downwardly from the motor 30 through an opening in the platform 15 and about a sprocket mounted to a portion of the axle 18' that extends outwardly from an end of drive roller 18. The axle 18' is in turn coupled with the axle 19' of drive roller 19 by a chain, not shown, that is routed over sprockets mounted to the two axles. Thus, by operation of the hydraulic motor 30, the drive rollers 18 and 29 can be rotated in the counterclockwise direction indicated by the arrows shown in FIGS. 3 and 4, advancing the machine.
The screed roller 20 is driven by the motor 31 with the power transmitted from the motor to the roller by an endless chain 38 as seen in FIG. 2. Chain 38 is routed over a sprocket mounted to the axle of the screed roller 20 so that roller is driven in a clockwise direction, as indicated by the arrows in FIGS. 3 and 4. The screed roller 20 is mounted with its axle 20' slightly higher than the axles 18' and 19', hence roller 20 rotates slightly above an imaginary reference support plane extending tangentially to the lowermost points of the drive rollers 18 and 19. The tops of the C-shaped forms 40 also lie in that reference plane.
As thus far described, the screeding machine is the same as that shown in U.S. Pat. No. 4,747,726, and, as such, it is equipped with a steering mechanism for steering the machine as it advances along the forms 40, levelling and finishing the concrete surface of a roadway being paved, between the two forms. The steering mechanism includes lift cylinders 27 and 28 which, as explained in detail in the aforementioned patent, impart steerability of the screeding machine by altering the elevation of one or the other end of drive roller 19.
The screeding machine 10 can produce a smooth, even concrete road surface, but that surface may contain irregularities and pits, and may be somewhat porous, because of the presence of air bubbles ad pockets entrapped in the material. In copending application Ser. No. 356,260, there is disclosed an attachment for the machine 10 which operates to produce a hard, polished, essentially non-porous or non-pitted surface. This attachment is depicted in FIGS. 3 and 4.
In FIGS. 3 and 4, it can be seen that the attachment comprises a finishing roller 51 of approximately the same length as rollers 18 and 19, and approximately one-half the diameter of those rollers. Roller 51 extends between a pair of support arms 52 which are pivotally mounted at either side of the machine 10, at the rear thereof. Roller 51 is raised or lowered into contact with the road surface by means of a hydraulic piston assembly 57 extending between pivotable arm 52 and an upright, fixed arm 54 mounted to the machine. It is to be understood that the mounting and raising and lowering arrangements are the same at the other end of the roller 51.
Roller 51 is rotatably driven by means of another hydraulic motor 67 mounted on arm 52, which is coupled to roller 51 by means of a sprocket 68 on the motor shaft and a sprocket 69 on the end of the axle of roller 51, which are coupled by a chain 71. The ratios of the sprocket diameters and the motor speed are such that roller 51 rotates at approximately one and one-third to two times the speed of screed roller 20, but in the opposite rotary direction thereto. Roller 51 is approximately one-half the diameter of drive rollers 18 and 19, and its speed of rotation can be varied relative to the other rollers by a change in the ratio of the diameters of sprockets 68 and 69, or by variations in the speed of motor 67.
In operation, the finishing roller 51 revolves at such a speed that there is a slight slippage of the roller on the surface, which speeds up the rise of the soupy material in the concrete to the top, and which spreads and, in effect, polishes the material. The net result is a surface which, when dry, has a smooth finish with a minimum of pits and pores.
When the concrete is poured, air in the form of bubbles and pockets is trapped in the mass to a considerable depth. These pockets and bubbles not only effect the surface of the roadway, but also they reduce the density of the material, thereby weakening it to some extent. In applications such as airport runways and heavily travelled highways, any decrease in density and corresponding decrease in strength can effect the load bearing capacity and the resistance to deterioration of the paving material, and, in extreme cases, can be quite dangerous to vehicles using the surface.
In FIGS. 1 and 2 there is shown a preferred embodiment of the present invention which reduces or eliminated entrapped air in the paving material and thereby functions to increase the density and strength thereof, and to improve surface qualities. Fixedly mounted on rear beams 13 are a plurality of upstanding posts 81 the top ends of which terminate in journals 82. For strength, posts 81 are braced by angled members 83, which extend downward from posts 81 to beam 14, to which their ends are affixed.
Supported in journals 82, and free to turn on swivels therein, is a transversely extending rod 84. Attached to rod 84 and extending toward the front of machine 10 are first and second support arms 86 and 87, the forward or distal ends of which have attached thereto and depending therefrom hanger members 88 and 89, respectively. A transversely extending beam 91 is affixed to the lower ends of hanger members 88 and 89 and is supported thereby. The structure as thus far described is stiffened and strengthened by means of a truss arrangement mounted on each of the support arms 86 and 87. The truss on arm 86 comprises a stanchion 92 affixed thereto and over which passes a guy rod 93 which is affixed at its ends to the ends of arm 86, as shown. In like manner, the truss on arm 87 comprises stanchion 94 and guy rod 96. Stanchions 92 and 94 are joined by a guy rod 97 affixed at its ends to the stanchions. The distal end of arm 86 is joined to one end of beam 91 by a guy rod 98, and the distal end of arm 87 is connected to the other end of beam 91 by a guy rod 99. The truss arrangement as described results in a strong, rigid, yet lightweight structure capable of withstanding large stresses.
Arm 86 is provided with a hydraulic piston assembly 101, connected between arm 86 and beam 14, and arm 87 is provided with a hydraulic piston assembly 102, connected between arm 87 and beam 14. Piston assemblies 101 and 102 operate in unison, under control of an operator, to raise and lower arms 86 and 87, and hence beam 91, with arms 86 and 87 pivoting about the axis of rod 84. Affixed to front or forward beam 11 are first and second U-shaped stop members 103 and 104, as best seen in FIG. 2. Stop members 103 and 104 receive beam 91 and arrest its downward travel when it is in its lowered state thereby defining the lowered position as best seen in FIG. 3.
Arrayed along the length of beam 91 and affixed thereto are a plurality of spaced hydraulic vibrators 106 which are connected to a hydraulic distribution system 107 by means of hoses 108. Hydraulic motors 109, for actuating each of vibrators 106 are mounted on beam 91. Vibrators 106, may be any of a number of commercially available types, such as, for example, WYCO Tool Co. Model 419760.
The operation of the vibrator attachment can be seen with the vibrators in their lowered or operative position in FIG. 3 and the raised or inoperative position in FIG. 4. In the operative position, the vibrators are lowered into the mass of paving material in advance or ahead of screed roller 20, to a considerable depth, extending below the aforementioned reference support plane, which is governed by stops 103 and 104, and the length the of vibrators 106. It can also be seen that the vibrators penetrate the material to a depth well below the surface of the material. As the machine 10 moves forward, vibrators agitate the glutinous mass of material, breaking up and dispensing air bubbles and pockets, and permitting the air to escape. In this manner the screed roller 20 encounters material that has been purged of most of the air therein, and hence is more compacted than would normally be the case. While the action of roller 20 might introduce small amounts of air back into the material, the effect is only on the surface, while the mass of material below the surface remains substantially air free and compacted. The following rollers, 18 and 19, and finishing roller 51 then function as previously explained to impart a smooth, level, even surface to the material, the finish of which is improved because of the absence of air bubbles and pockets in the material.
From the foregoing it is seen that the described embodiment of the invention in combination with a screeding machine produces an improved paved road or the like. It is to be understood that the foregoing description is illustrative of the principles of the invention in a preferred form thereof and that numerous modifications, additions, and deletions may be made to the structure without departure from the spirit and scope of the invention as set forth in the following claims. | A screeding machine has mounted thereon, in order from front to rear, a paving material agitating means for dispersing and expelling trapped air, a screeding roller, and first and second drive rollers. For a fine finish, a finishing roller extends from the rear of the machine. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/076,971, filed Nov. 7, 2014, the disclosure of which is hereby incorporated by reference, herein, in its entirety, for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of water craft. More specifically, the present invention relates to articulating tops for water craft.
BACKGROUND
[0003] Boats can be equipped with some form of sun shade apparatus or other enclosure such as a top, canopy or bimini. Some tops can be moved between an extended, engaged, locked or radar position and a stowed, collapsed, unlocked or trailering position. Some tops are constructed out of tubular frames that articulate to at least two positions. Some such tops can be manually articulated to a desired position, while others utilize mechanical aids such as hydraulics or electric motors to power the apparatus into the desired position(s).
[0004] The manual articulation of tops often require a significant effort to move the top into the desired position(s). One common method for manually articulating a top is to manually lift the top into the desired state, such as an extended position. Then, the top can be secured in position by latching or locking a frame member, such as a bow, arm or strut, such as to hardware that is attached to the water craft. Such manual articulation requires significant strength to raise the top into position, and dexterity and balance to secure the top in position. Such manual articulation can be unsafe if undertaken by a single person.
[0005] Some tops have been designed such that they use gravity to pull the top into the stowed position when released from the extended position. However, when released, such tops violently collapse, which can injure someone in the path of the top, damage the top and/or the water craft or be noisy, potentially scaring away wildlife. Other tops may use powered mechanical systems to decrease or even eliminate the need for manual articulation. However, such powered tops are often cost prohibitive and may not be useable with all boat models, as such powered tops can require specific structural elements for mounting thereto and power.
[0006] Therefore, there is need for a cost effective top that decreases the effort required to manually articulate the top. There is also a need for a top that can be manually articulated by one person without a sudden collapsing of the top and that can be securely stowed, such as for transportation and storage.
[0007] It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an elevation view of a frame in a deployed position.
[0009] FIG. 2 is an elevation view of the frame of FIG. 1 in a collapsed position.
[0010] FIG. 3 is an enlarged elevation view of a portion of the frame of FIG. 1 attached directly to a water craft.
[0011] FIG. 4 is an enlarged elevation view of a portion of the frame of FIG. 3 .
[0012] FIG. 5 is an enlarged perspective view of a portion of the frame of FIG. 1 in a closed position.
[0013] FIG. 6 is an enlarged perspective view of the locking member of the frame of FIG. 3 .
[0014] FIG. 7 is a cross-sectional elevation view of the locking member of FIG. 3 in an opened position engaged to a structure.
[0015] FIG. 8 is a cross-sectional elevation view of the locking member of FIG. 3 in an opened position.
[0016] FIG. 9 is a cross-sectional elevation view of the locking member of FIG. 3 in an opened position.
[0017] FIG. 10 is a cross-sectional elevation view of an alternative embodiment of a locking member engaged to a structure.
[0018] FIG. 11 is a cross-sectional elevation view of an alternative embodiment of a locking member in a closed position.
[0019] FIG. 12 is a cross-sectional elevation view of the bracket of FIG. 11 .
[0020] FIG. 13 is a cross-sectional elevation view of an alternative embodiment of a locking member in an opened position.
[0021] FIG. 14 is a cross-sectional elevation view of an alternative embodiment of a locking member in a closed position.
[0022] FIG. 15 is a cross-sectional elevation view of an alternative embodiment of a locking member in an opened position.
DETAILED DESCRIPTION
[0023] As seen in FIG. 1 , a frame 10 for a marine top, canopy, bimini or other such structure is shown. The frame 10 shown in FIG. 1 is generally comprised of tubular members that support a canvas or other suitable material (not shown) for providing shade or sheltering from the elements. For example, the frame 10 in FIG. 1 includes a main or aft bow 12 that is pivotally connected to a secondary or bow bow 14 . One or more auxiliary bows 16 , 18 can be pivotally connected to the main and secondary bows. The pivotal connections allow the frame 10 to collapse into a compact folded frame as seen in FIG. 2 . Support members 20 , for example, one on the starboard side and one on the port side of the frame 10 , may also be used to support and keep the frame in the deployed and/or collapsed position.
[0024] In the embodiment shown in FIG. 1 , the support members 20 include a biasing member. The biasing member is shown in FIG. 1 as a gas shock 22 , but could also include a mechanical or pneumatic spring, shock or damper. The gas shock 22 is connected at a first end to a first end of the strut or shaft 24 , such as by a threaded end of the rod being thread into a threaded hole in the strut, and is pivotally connected directly or indirectly, at its second end to the vehicle or structure such as a boat.
[0025] The strut 24 is pivotally connected at its second end to the frame 10 or a collapsible assembly, for example the main bow 12 . For example, the strut 24 may have a bore (not shown) formed in one end and a plastic hat-style washer (not shown) inserted in each side of the hole. A frame bracket is then secured to the main bow, such as by screws or bolts. The frame bracket has flanges sized to accept the strut with hat-style washers and each flange has a hole matching the hole in the hat-style washers such that mating shoulder bolts may be inserted through the holes in the frame bracket, hat-style washers and strut 24 to pivotally connect the strut to the main bow. When the frame 10 is moved from the collapsed position, the gas shock 22 is allowed to push the rod 26 further out which in turn pushes the strut 24 out of the tube 28 and causes the main bow 12 and frame 10 to move to its deployed position. When the frame 10 moved from its deployed position towards its collapsed position, the main bow 12 will push on the strut 24 causing the rod 26 to be pushed in or withdrawn further into the gas shock 22 .
[0026] In one embodiment, the gas shock 22 could be designed to provide just less than the amount of force required to move the frame 10 from the collapsed position into the extended position such that only a small amount of additional force or effort is needed, for example by a person. Such force would also allow the frame 10 to be collapsed into the stowed position in a safe and controlled manner because the weight of the frame would only slightly overcome the force exerted by the gas shock 22 . Therefore, only a small amount of force is needed, for example by a person, to stop or slow the collapse of the frame 10 . In this embodiment, the gas shock 22 urges or biases the strut 24 to slide into the tube 28 .
[0027] By way of another example, the gas shock 22 could be designed to provide a slightly greater force than needed to move the frame 10 from the collapsed position into the extended position such that only a small amount of additional force would be used, for example by a person, to stop or slow the articulation of the frame 10 . Such force would also allow the frame 10 to be collapsed into the stowed position in a safe and controlled manner because only a small amount of additional force or effort is used to overcome the force of the gas shock 22 . In this embodiment, the gas shock 22 urges or biases the strut 24 to slide out of the tube 28 .
[0028] In the embodiment shown in FIG. 3 , the gas shock 22 is housed within a tube, housing or shroud 28 and the tube slidable receives the strut 24 . At one end of the tube 28 is a bushing or collar 30 . In FIG. 3 , the bushing 30 is located at least partially within the opening of the tube 28 . The bushing 30 can slidably receive the strut 24 and help guide the strut as it slides in and out of the tube 28 , such as, for example, by keeping the strut centered, providing a smooth surface for the strut to slide against and the preventing the strut from undesired racking or twisting. The bushing 30 could be attached to the tube 28 or the bushing could be integrally formed or made with the tube.
[0029] The support member 20 is shown attached at its second end to a mounting bracket 32 . The second end of the gas shock 22 and/or the tube 28 can be attached directly to the marine vehicle or structure, e.g. a rail or fence, as seen in FIG. 3 , or could be attached to another structure such as a mounting bracket 32 which is then attached to the marine vehicle or structure, as seen in FIGS. 1-2 . For example, the tube 28 may have a bore (not shown) that matches a hole in the flanges (not shown) of the mounting bracket. Hat-style washers (not shown) are inserted into each side of the bore in the tube 28 . Mating shoulder bolts are inserted through the hat-style washers, the tube 28 and an eyelet threadingly connected to the gas shock 22 to pivotally connect the tube and gas shock to the mounting bracket 32 . The main bow 12 can also be pivotally attached to the mounting bracket 32 .
[0030] Fixing or predetermining the relationship of the second ends of the main bow 12 and support member 20 can make installation easier because the proper relationship between the main bow and support member, e.g. angle formed by the main bow and mounting bracket 32 and distance between the second ends of the main bow and the support member, does not need to be determined or measured during installation. The proper relationship can also lead to increased safety and life of the frame 10 by, for example, inhibiting torqueing and proper distribution of the weight of the top on the main bow 12 and the support members 20 . Fixing or predetermining the relationship of the second ends of the main bow 12 and support member 20 also allows a single sized support member to be used for a variety of sized tops and frames by adjusting the size of the mounting bracket 32 .
[0031] The support members 20 can also include a locking member lock the support member in the closed position, such as when the frame 10 is deployed, and/or the opened position, such as when the frame is collapsed. In FIGS. 1-11, 13 , the locking member is a handle or lever that is pivotally connected to the strut 24 , such that the locking member is movable between opened and closed positions. For example, the handle 34 may have a bore (not shown) that matches a bore (not shown) in the strut 24 when the strut is within the handle as discussed further below. Mating shoulder bolts may be inserted through the two bores to pivotally mount the handle 34 to the strut 24 at one end of the handle. When the frame 10 is in its deployed position, the handle 34 is closed and generally in line with the support member 20 as seen in FIG. 3 . The handle 34 includes a slot 36 that is sized and positioned to accept the strut 24 when the handle is closed seen most clearly in FIG. 5 . When the frame 10 is collapsed, the handle is opened and is generally perpendicular to the support member 20 as seen in FIG. 7 .
[0032] When the frame 10 is in the deployed position and the handle 34 is in a first position or closed, as seen in FIG. 4 , the bottom surface 38 of the handle contacts, jams or engages the top or contact surface 40 of the bushing 30 to prevent the strut 24 from being pulled or sliding further within the tube 28 from the weight of the frame 10 and/or the tensile force or pull of the gas shock 22 . When the handle is in the closed position, the frame 10 is fully deployed. Thereby, the handle 34 can be used to set the length and angle of the support member at which the frame 10 is fully deployed.
[0033] When it is desired to collapse the frame 10 , e.g. when towing a marine vehicle to which the frame is attached, the handle 34 can be disengaged from the bushing by pulling the handle and rotating the handle away from the support strut as seen in FIGS. 7-9 . In this position, the handle 34 is in a second position or opened. When the handle 34 is in the open position, the strut 24 is not prevented from being pulled or sliding further within the tube 28 by the weight of the frame 10 and/or the tensile force or pull from the gas shock 22 .
[0034] The handle 34 may also include a securing component to secure the frame 10 in a collapsed position. For example, as best seen in FIG. 6 , the securing component is a socket 42 formed in the bottom of the slot 36 . In the embodiment shown in FIGS. 6-7 , the socket 42 is sized and shaped to selectively attach or fit over a structure, for example a deck button 44 .
[0035] As seen in FIG. 7 , a latch 46 is housed in and rotatably secured or pivotally connected to the handle 34 . At a first end of the latch 46 is a push button 48 . Between the push button 48 and the handle 34 is a spring 50 that urges the push button out of the handle. At the second end of the latch is a lip or flange 52 . The spring 50 also urges the lip 52 into the slot 36 .
[0036] To secure the frame 10 in the collapsed position, the socket 42 of the handle 34 is slid over the deck button 44 . As the deck button 44 contacts the lip 52 , the force pushes the lip away from the deck button and thereby, moves the latch to rotate to allow the deck button to further enter the slot 36 through the socket 42 . Once the top of the deck button 44 moves past the lip 52 , the spring 50 will cause the latch to rotate towards engagement with the deck button such that the lip 52 slides under the top of the deck button to secure the handle 34 and, thereby, the frame 10 to the marine vehicle or structure to which the deck button is attached. This is the engaged position of the latch. Although the above example uses a deck button, the socket 42 and/or latch 46 could be sized and shaped to connect to a variety of structures.
[0037] To release the frame from the deck button, for example, to move the frame to the deployed position, the push button 48 can be depressed causing the lip 52 to retreat from or disengage the deck button 44 and slot 36 . With the lip 52 out of the way, the handle 34 can be withdrawn from the deck button. This is the disengaged position of the latch.
[0038] The handle 34 can also have a biasing member. For example, as seen in FIGS. 6-7 , the handle includes a biasing member shown as a spring 54 . The spring 54 is wound, wrapped or positioned over the bolt that pivotally connects the strut 24 to the handle 34 . One end of the spring 54 is secured in a recess 56 formed in the back of the handle 34 and the other end of the spring is located in the strut 24 . The spring 54 urges or biases the handle towards the closed position.
[0039] The contact surface 40 of the bushing 30 may also cooperate with the handle 34 and spring 54 to allow the handle to return to the closed position as the frame is being moved to the deployed position or to otherwise perform as a timing device. For example, as seen in the embodiment shown in FIG. 4 , the contact surface 40 includes a raised edge 58 . The bottom surface 38 of the handle 34 includes an interference or protuberant 60 , 62 at each the front and back of the bottom surface.
[0040] When it is desired to move the frame 10 from the deployed position to the collapsed position, the handle 34 can be pulled away from the strut 24 . As the handle 34 is pulled away the raised edge 58 will ride along the bottom surface 38 of the handle until the raised edge reaches the rear interference 62 of the bottom surface. A slight increase in the amount of force used to pull the handle 34 forward may be required to cause the rear interference 62 to ride up, over and beyond or pass the raised edge 58 . In one embodiment, once the rear interference 62 is past the raised edge 58 , the handle 34 will be in the open position and the weight of the frame will push the strut 24 down into the tube 28 because the weight of the frame is slightly greater than the resistance provided by the gas shock 22 . As the strut 24 is pushed into the tube 28 , the spring 54 will urge the handle 34 to maintain contact with the raised edge 58 . The raised edge 58 will ride along the rear side 64 of the handle. As the strut 24 is being pushed into the tube 28 , the contact between the raised edge 58 and the rear side 64 of the handle will cause the handle to rotate away from the strut 24 .
[0041] In the embodiment shown in FIGS. 7-9 , the raised edge 58 will ride the rear side 64 of the handle 34 until the raised edge reaches a depression 66 formed in the rear side 64 of the handle 34 and at least a portion of the remainder of the contact surface 40 contacts the stop surface 68 near the first end of the handle, as seen in FIG. 7 . In this configuration, the handle 34 is in a third position or fully opened and can be placed onto the deck button 44 . In the third position, the interaction between the handle 34 and bushing 30 prevents the strut 24 from sliding further into the tube 28 and defines the amount the strut my slide within the tube. As seen in FIGS. 2 and 7-9 , as the strut 24 slides into the tube 28 , the handle 34 will be rotated further and further out of alignment with the strut, until the handle reaches the third position, wherein the handle is generally perpendicular to the strut.
[0042] When it is desired to move the frame 10 to the deployed position, the push button 48 can be depressed to release the deck button 44 . Once the deck button 44 is past the lip 52 and the frame is moved towards the deployed position, the strut 24 will be withdrawn from the tube 28 . As the strut 24 is withdrawn, the raised edge 58 will be withdrawn from the depression 66 and the spring 54 will cause the handle to maintain contact with the raised edge. The raised edge 58 will then ride along the rear side 64 of the handle 34 , as seen in FIGS. 8-9 , until it slides around the rear interference 62 , the strut 24 enters the slot 36 and the bottom surface 38 contacts the contact surface 40 , as seen in FIG. 4 . This returns the handle to the closed position. The bottom surface 38 of the handle 34 can also include a front or second interference 60 , to prevent the handle from being over rotated by the spring 54 thereby defining the maximum amount the spring may bias the handle.
[0043] The profile of the rear side 64 of the handle 34 and contact surface 40 of the bushing 30 can be shaped and sized to accomplish many features, functions and benefits, as can the bottom surface 38 , depression 66 and stop surface 68 . For example, the rear side 64 could have a depression at a location other than the end of the handle 34 or have an increased slope if it is not desired to have as much of the strut 24 withdrawn from the tube 28 when the frame 10 is in the collapsed position.
[0044] Another embodiment of a securing component is shown in FIG. 10 . At the bottom surface 38 of the handle 34 is a bracket 70 . The bracket 70 is sized and shaped so as to be able to connect to or clip or snap onto a structure such as a rail or fence 72 .
[0045] Another embodiment of a locking member for locking the support member 20 ′ in the engaged position is shown in FIGS. 11, 13 . As seen in FIGS. 11, 13 , the locking member includes a lever 74 that is pivotally connected to and resides partially within the strut 24 . A spring 76 is located between the bottom end of the lever 74 and the strut 24 to urge the bottom end of the lever out of the surface of the strut.
[0046] To move the frame 10 from an deployed position towards the collapsed position, the bottom portion of the lever must be pressed in towards the strut 24 , against the force from the spring 76 , such that the lever 74 and strut 24 can fit within the bushing 30 and be slid down into the tube 28 as seen in FIG. 13 . When the frame is moved from the collapsed position towards the deployed position, and the strut 24 is sufficiently extended out of the tube 28 , the spring 76 will urge the lever out of the strut 24 . Once the lever 74 is out of the strut 24 , the bottom or jam surface 78 of the lever will rest against the contact surface 40 of the bushing 30 to maintain the frame 10 in the deployed position and prevent the strut from being pushed down into the tube 28 . The support member 20 ′ could also include a bracket 80 , such as an ‘H’ bracket, similar to that described above with regards to the bracket 70 shown in FIG. 10 to allow the frame 10 to be able to be secured in the collapsed position, such as to a rail or fence.
[0047] Another embodiment of a locking member for locking the support member 20 ″ in the engaged position is shown in FIGS. 14-15 . As seen in FIGS. 14-15 , the locking member includes a spring locking pin 82 that is within the strut 24 . When the frame 10 is moved from the collapsed position towards the deployed position, and the strut 24 is sufficiently extended out of the tube 28 , a hole 84 will no longer be blocked by the bushing 30 or the tube 28 such that the pin 86 of the spring locking pin 82 will be urged out of the hole. Once the pin 86 is out of the strut 24 , the pin will rest against the contact surface 40 of the bushing 30 to maintain the frame 10 in the deployed position and prevent the strut from being pushed down into the tube 28 as seen in FIG. 14 . When it is desired to move the frame 10 from the deployed position to the collapsed position, the pin 86 of the spring locking pin 82 can be pushed into the strut 24 so that the strut is free to be withdrawn into the tube 28 as seen in FIG. 15 . The support member 20 ″ could also include a bracket 80 as previously described.
[0048] Although the invention has been herein described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. For example, although the support member is described as being used in a frame for a marine top, the support member could be used in a variety of applications including different collapsible structures. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein. | A frame for a top of a boat in accordance with the present invention can be moved into an deployed position with the aid of a biasing member such that the manual effort required is minimized. When the frame is in the deployed position a locking member may be engaged to hold the frame and top in the deployed position. When the locking member is disengaged, the frame may be manually collapsed into a stowed position in a controlled and safe manner. |
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FIELD OF THE INVENTION
This invention relates to checking mechanisms for checking the motion of a moveable member in preferably an infinite number of positions. It finds specific application as a door check for a vehicle door, or a stay for a rotatable wheel on a carriage or the like.
BACKGROUND OF THE INVENTION
Checking mechanisms stops and stays are known in the art. For example the checking mechanisms are mechanical and include a roller contained in a housing fixed to a vehicle door, the rollers having a rod passing between them and the rod normally has a number of discrete raised portions or recesses. As such a checking mechanism having discrete checking positions at each portion where the recesses are located is provided. A considerable amount of force must be applied by a passenger or operator of the vehicle to move it from the checked position to the moveable position.
It would therefor be advantageous if a simple structure were provided which allows for infinite checking of the door when the in the stopped position and ease of movement of the door when it is in the moveable positions. However, mechanical checks will generally on there own not meet this requirement.
U.S. Pat. No. 4,689,849 to Porsche describes a control mechanism for a door including a piston and a blocking valve. The blocking valve is disposed in a controlled circuit so that it may block the flow to the two working chambers of the cylinder and thus arresting the door in any arbitrary position. However, when the door handle is operated it controls the blocking valve which when released allows the flow of the fluid to the working chambers. In using such a structure it therefor is necessary for an operator opening the door to pull on the inside door handle and hold the inside door handle open while the door is being moved. This is not practical and is quite clumsy in operation. Unless, either in the inside or the outside handle is operated the door will remain in a fixed position unless an over pressure situation occurs. However, there is no discussion as to what characteristic occurs with such an over pressure situation.
It therefor would be beneficial if a door for a vehicle to be checked in position automatically when the door substantially stops its movement and which would be easy to move when the door commences its movement without the need of and operator to operate the door handles. Typically in a vehicle, an operator unlatches the lock and pushes the door open via a molded grip on the inside of the door. When exiting the door is closed merely by shutting the door depending on the model of the vehicle. It would therefor be more practical to allow for such automatic checking.
Other examples of door checks are found in the art such as U.S. Pat. No. 2,036,474, U.S. Pat. No. 3,212,122 among others.
Controlled release door holders are also known in the art, which control the motion of the door and prohibit quick opening or closing of the door. Structure such as U.S. Pat. No. 4,267,619 include accelerated closing of a door during a fire, for example. Canadian Patent 981,707 and 1,010,914 are the equivalents of the 619 reference.
Actuators such as those manufactured by Turn Act as taught in U.S. Pat. No. 4,774,875 among others are known in the art. Also known in the art are U.S. Pat. No. 4,653,141 and U.S. Pat. No. 4,756,051 embodied in a hinge. These structures include damping and shock absorbing features, but do not include checking features.
U.S. Pat. No. 4,889,151 describes a snap-action pressure relief valve which operates by taking advantage of an area 83 as seen in FIG. 1 which provides a higher force to open the relief valve, and a reduced force once the relief valve is opened subjected to the same pressure. However, such a structure is not taught within a check or stay mechanism.
Nowhere within the prior art is there found a check or stay mechanism which provides that when the member being checked is substantially stationary that it is checked automatically by the attributes of the structure and when the member being checked is free to move, it is uninhibited during such a motion until it returns to a checked stationary state.
It is therefor a primary object of this invention to provide a check, stop, or stay for a moveable member which is inhibited from moving when in the substantially stationary position and which is uninhibited automatically when the member is moved and remains in a dynamic state.
It is a further object of this invention, to provide such a mechanism in a vehicle door.
It is yet still another object of this invention, to provide such a mechanism for a rotatable caster, roller or wheel, for example material handling carts.
It is yet still another object of this invention, to provide a check, stay or stop for a moveable member in a simple economical and convenient structure.
Further and other objects of this invention will become apparent to a man skilled in the art when considering the following the summary of the invention and the more detailed description of the preferred embodiments illustrated herein.
SUMMARY OF THE INVENTION
According to one aspect of the invention there is provided a check or stop for a moveable member, the check or stop comprising actuated means actuated by the moveable member, or alternatively by separate actuating means, the actuated means being either fastened with the moveable member or being integral with the moveable member, automatic switching means to control the checking and release of the actuated means and the moveable member, the moveable member being moveable from a first state, wherein the moveable member is substantially static, checked, and exhibits a first value for a predetermined characteristic of the actuated means, (for example force, pressure, torque or the like), to a second state wherein the moveable member is substantially in motion, unchecked, and exhibits a second value of the predetermined characteristic of the actuated means, the value of the predetermined characteristic of the actuated means being available to the automatic switching means, wherein when the moveable member is in a static state the first value of the predetermined characteristic available to the automatic switching means provides checking of the actuated means and the motion of the moveable member, wherein when the moveable member is substantially in motion the second value of the predetermined characteristic available to the automatic switching means provides release of the actuated means and the moveable member to allow ease of movement thereof. In one embodiment the switching means includes sensing means to sense the value of the predetermined characteristic.
According to another aspect of the invention there is provided a check or stop for a moveable member, the check or stop comprising hydraulic actuated means actuated by the moveable member, or alternatively by separate actuating means, the hydraulic actuated means being either fastened with the moveable member or being integral with the moveable member, automatic switching means (for example a pressure relief valve) to control the checking and release of the hydraulic actuated means and the moveable member, the moveable member being moveable from a first state, wherein the moveable member is substantially static, checked, and exhibits a first value for a predetermined characteristic of the hydraulic actuated means, (for example pressure, force or the like), to a second state wherein the moveable member is substantially in motion, unchecked, and exhibits a second value of the predetermined characteristic of the hydraulic actuated means, the value of the predetermined characteristic of the hydraulic actuated means being available to the automatic switching means, wherein when the moveable member is in a static state the first value of the predetermined characteristic available to the automatic switching means provides checking of the hydraulic actuated means and the motion of the moveable member, wherein when the moveable member is substantially in motion the second value of the predetermined characteristic available to the automatic switching means provides release of the hydraulic actuated means and the moveable member to allow ease of movement thereof.
According to yet another aspect of the invention there is provided a check or stop for a moveable member (preferably a vehicle door), the check or stop comprising actuated means (preferably including a pin having two portions separated by clutch portions which engage when the moveable member is static and separate when the moveable member is in motion) actuated by the moveable member, or alternatively by separate actuating means, the actuated means being either fastened with the moveable member or being integral with the moveable member, automatic electric switching means (for example a mirco chip with a sensing circuit for sensing the value of the predetermined characteristic, for example a strain gauge) to control the checking and release of the actuated means and the moveable member, the moveable member being moveable from a first state, wherein the moveable member is substantially static, checked, and exhibits a first value for a predetermined characteristic of the actuated means,(for example force, torque, impedance or the like), to a second state wherein the moveable member is substantially in motion, unchecked, and exhibits a second value of the predetermined characteristic of the actuated means, the value of the predetermined characteristic of the actuated means being available to the automatic switching means, wherein when the moveable member is in a static state the first value of the predetermined characteristic available to the automatic switching means provides checking of the actuated means and the motion of the moveable member, wherein when the moveable member is substantially in motion the second value of the predetermined characteristic available to the automatic switching means provides release of the actuated means and the moveable member to allow ease of movement thereof.
According to yet another aspect of the invention there is provided a check or stop for a moveable member (preferably a vehicle door), the check or stop comprising fluid actuated means (preferably a hinge) actuated by the moveable member, or alternatively by separate actuating means, the fluid actuated means being either fastened with the moveable member or being integral with the moveable member, preferably biased pressure relief means to control the checking and release of the actuated means and the moveable member, the moveable member being moveable from a first state, wherein the moveable member is substantially static, checked, and exhibits a first value for a fluid pressure of the actuated means, to a second state wherein the moveable member is substantially in motion, unchecked, and exhibits a second value of the fluid pressure of the actuated means, the value of the fluid pressure of the actuated means being available to the biased pressure relief means, wherein when the moveable member is in a static state the first value of the fluid pressure available to the biased pressure relief means provides checking of, the actuated means, and the motion of the moveable member, wherein when the moveable member is substantially in motion the second value of the fluid pressure available to the biased pressure relief means provides release of, the actuated means, and the moveable member, to allow ease of movement thereof.
According to yet another aspect of the invention the check or stop may further comprise actuated means wherein the actuated means is a hinge including an integral hydraulic actuator. In one embodiment the actuator has at least one wiper blade dividing the actuator into two halves, preferably each half being in communication with the pressure relief means, preferably integral with the hinge. In one embodiment check valve means are provided in paths of communication with the pressure relief means.
According to yet another aspect of the invention the check or stop may further comprise actuated means wherein the actuated means is a hinge including an integral hydraulic gear pump. In one embodiment the pump has two rotors rotatable in opposite directions effecting fluid flow in two directions, the fluid flow being in communication with the pressure relief means, preferably integral with the hinge. In one embodiment check valve means are provided in paths of communication with the pressure relief means.
In another embodiment the actuated means is a hydraulic cylinder operable in two directions and being divided into two chambers preferably each chamber being selectively in communication with the pressure relief means. In one embodiment check valve means are provided in paths of communication with the pressure relief means.
In preferred embodiments of the embodiments of the invention described above, the pressure relief means is a pressure relief valve wherein means are provided with a housing containing the valve or with the valve to allow fluid to by pass the valve. Preferably the housing or valve includes means on the face of the valve piston or with the housing proximate the face of the valve piston to isolate a portion of the face when the valve is closed and to exert the fluid pressure on that isolated portion of the face only until the valve opens, wherein the fluid pressure is exerted on the full face of the valve piston. In another embodiment the means to isolate the portion of the face of the valve piston is an extension of the piston face which extends to a fluid inlet of the housing when the piston face is nearest the housing.
In one embodiment the automatic switching means may comprise a diaphragm having an integral resilient spring formed therewith. Preferably the diaphragm also includes checking means integral therewith.
In another embodiment the pressure relief means may comprise a diaphragm having an integral resilient spring formed therewith. Preferably the diaphragm also includes checking means integral therewith.
In another embodiment the check or stop may comprise a an actuator portion and a relief valve portion, the relief valve portion having a cover having an opening, the cover engaging the actuator portion when the cover and actuator are assembled wherein the opening is adjacent the actuator, the hinge having disposed between the cover and the actuator portion a diaphragm portion having a resilient spring portion, preferably being shaped as a truncated cone, and retained in the opening of the cover, the spring portion having adjacent thereto with the actuator portion ports for hydraulic oil, whereat the spring is compressible in the opening when subjected to the pressure of the hydraulic oil, preferably the diaphragm also includes checking flaps formed with the diaphragm or alternatively formed with a separate diaphragm, the checking flaps being located adjacent the openings of the actuator portion, the openings providing the ability of the checking flaps to move towards the actuator portion but not away from that portion thus providing one way checking.
Some examples of structures which would benefit from the checks or stops of the instant invention besides checks for vehicle doors includes stops for baby carriages or material handling trucks or the like wherein the stop may be integral with the hub of the wheels of the carriage or cart. The actuated means may therefor be a portion of the hub rotatable by the wheel. Any structure including hinges or the like would benefit from the instant invention.
According to yet another aspect of the invention there is provided a hinge with infinite door checking capability, the hinge comprising a body half and a door half and a door check connected to both halves, wherein the door check includes a check valve contained within an actuator, the actuator being moveable when the hinge is operated and thus providing infinite door checking of the door being checked. Preferably, the check portion including a resilient diaphragm or spring which compresses because of the hydraulic pressure generated by the actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a hinge illustrated in a preferred embodiment of the invention.
FIG. 1A is a schematic view of an alternative embodiment of the invention.
FIG. 2 is a schematic view of the hinge of FIG. 1 showing the internal workings therein illustrated in a preferred embodiment of the invention.
FIG. 2A is a close-up schematic view of the zone in ghost line in FIG. 2 illustrated in a preferred embodiment of the invention.
FIG. 3 is identical to FIG. 2 with the exception that the hinge is free to rotate and is in an unchecked position, illustrated in a preferred embodiment of the invention.
FIG. 4 is an alternative embodiment of the invention.
FIG. 5 is an alternative embodiment of the invention.
FIG. 6 is identical to FIG. 1 with the exception that electric leads W1 and W2 are included.
FIG. 7 is identical to FIG. 6 and is cut away in part to view the clutch assembly contained with the hinge illustrated in a preferred embodiment of the invention.
FIG. 8 is a schematic view of the internal workings of the hinge of FIG. 7 to illustrate the components therein illustrated in a preferred embodiment of the invention.
FIG. 9 is identical to FIG. 8 but illustrate the hinge of FIG. 7 in a free to rotate position.
FIG. 10 is a graph of the performance characteristics of the hydraulic check of FIG. 1 illustrated in the preferred embodiment of the invention.
FIG. 11 is a illustration of a chart the performance characteristics of the electric check of FIG. 6.
FIG. 12 is a perspective view of a hinge similar to FIG. 1 illustrated in an alternative embodiment of the invention.
FIG. 12A is a view similar to FIG. 3 wherein the piston has been replaced with a diaphragm illustrated in an alternative embodiment of the invention.
FIG. 13 is a close-up view of the portion 26 of FIG. 12 illustrated in one embodiment of the invention.
FIG. 14 is a plan view of the diaphragm 28 of FIG. 13 illustrated in a preferred embodiment of the invention.
FIG. 15 is a top view of a hinge embodying the door check illustrated in an alternative embodiment of the invention.
FIG. 15B is a cut away view along the section X X of FIG. 15 wherein the housing is not illustrated.
FIG. 15A is a top view of the door check portion of FIG. 15 with the top removed illustrated in an alternative embodiment of the invention.
FIG. 16 is a detailed view of the resilient spring of FIG. 15A contained within the door check illustrated in FIG. 15 and illustrated in a preferred embodiment of the invention.
FIG. 17 is a cross-sectional view of the seal of the resilient wiper illustrated in FIG. 16 and illustrated in a preferred embodiment of the invention.
FIG. 18 is a perspective view of the seal S1 of FIG. 15A illustrated in a preferred embodiment of the invention.
FIG. 19 is a schematic view of the resilient spring contained within the wiper of FIG. 16.
FIG. 20 is a perspective view of the resilient spring of FIG. 19.
FIG. 21 is a schematic view of the operation of the resilient spring when pressure is exerted upon it developing a similar characteristic to that described in relation to FIG. 13 and FIG. 12A.
FIG. 22 is a perspective view of the wiper portion of FIG. 15A illustrating the recesses in which the seal S2 is retained illustrated in a preferred embodiment of the invention.
FIG. 23 is a close-up cross-sectional view of the recess of FIG. 22 containing the seal S2 of FIG. 15A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 there is illustrated a hinge generally indicated as 10 which is mounted to a vehicle door (not illustrated) by a mounting plate 30 attached to the door and the housing 25 of the hinge attached to the frame of the vehicle. Of course, the attachments may be reversed without effecting the operation of the invention. Mounting plate 30 has openings 31 and 32 for mounting purposes. A pin 40 extends generally through the hinge body 25 from top to bottom of the hinge.
Alternatively, it is illustrated in FIG. 1A hub portion H illustrated in side view is embodied with a wheel WH which rotates in a direction T1. The pin 40 extends through the hub H which contains the instant invention. In this embodiment of the invention the stop or check may be used to check a rotating wheel when the wheel WH is stationary, and may be released from the check position when the wheel rotates in a direction T1. The components of the hub are similar in operation to the components of the hinge body 25 illustrated in FIG. 1. A frame portion in (not illustrated) is attached to the pin 40. The frame portion may extend to a carriage or a material handling cart or the like.
Referring now to FIG. 2, the internal components of the hinge body 25 or the hub H are illustrated wherein the pin 40 of the housing 20 of FIG. 1 includes a wiper portion 41 moveable within the housing 25. Hydraulic oil fills the space within the housing 25. At one end of the housing are located openings 21, 22, 23, 24 which are aligned respectively with check mechanisms A, B, C and D which include a spring biasing device A1, B1, C1 and D1, and a ball bearing A2, B2, C2 and D2. Flow paths L1, L2, L3 and L4 are therefor defined integral with the hinge 10 or the hub H of FIGS. 1A or 1. The wiper therefor moves clockwise or counter clockwise on pin 40 and forces fluid through line L3 or L2 depending on the direction motion of the wiper 41. The structure of the wiper and the housing is similar to that of a hydraulic actuator. Located within the housing or hub and in communication with lines L3 and L2 which allow for fluid to flow from the actuator, is disposed a relief valve 50 including a piston 55 which is resiliently biased by a spring 60 anchored at end 65 of the housing 67. There is a space 62 defined between the housing 67 and the piston 55. The space 62 is tapered as illustrated in FIG. 2 to allow for more fluid to by-pass the piston the higher the piston 55 travels while maintaining to lift the piston by providing sufficient pressure to so. Disposed in the housing at the bottom seated position of piston 55 is an opening 61 which has a ghost line around it. The opening 61 has a cross sectional diameter that provides an area which is reduced from the area of the cylinder in which the piston 55 travels.
Referring to FIG. 2A, clearly the piston 55 is illustrated adjacent the outlet 61, wherein the piston has a face F2 and seal 51 which closes the opening 61. Any hydraulic pressure within opening 61 will therefor be exerted upon the seal 51 which has a reduced area F1 to the face F2 of the piston 55. The pressure is exerted on a smaller area F1 of seal 51 than the face F2 while the piston is closed, then a larger force is required to raise the piston sufficiently to expose the face F2 to the hydraulic pressure wherein the seal is lifted from its bottom position. The force then required to raise the piston is reduced substantially as best illustrated in relation to FIG. 10.
The seal 51 is retained within an opening 55k of the piston 55 as seen in FIG. 2A. The seal is generally arcuate in shape and made of rubber. When seated within the opening 55k the piston 55 is prevented from bottoming out near opening 61. This structure is convenient as it allows greater flexibility in in manufacture of the piston. The seal 51 therefore provides a slight gap between the piston face A2 and the bottom cylinder wall to ensure proper working of the relief valve, and to ensure the piston bottoms out on the seal.
Referring to FIG. 3 in relation to FIG. 2, and 2A the wiper 41 is moving in the direction R1. The hinge or hub is no longer in the locked position of FIG. 2 but is now in the moving position. Therefor, the hydraulic fluid within the housing 25 is displaced along line L2 through check C, while inhibited by the check mechanism D from entering the line L1. As the fluid enters along the line L2 toward the relief valve 50, the piston 55 is raised sufficiently to allow the hydraulic pressure to be exerted against the full face F2 of the relief valve 50. The hydraulic fluid however is prevented from entering the line L3 by the check mechanism B and has no alternative path. The fluid therefor displaces the piston 55 in the direction indicated, and by-passes because of the extended channel 62 adjacent the piston 55, and travels down line 4 through check mechanism A, unable to pass to line 1, since the rotor is rotating in the direction R1 closing the check mechanism D. The piston 55 remains lifted from its bottom dead center position until such time as the actuator wiper 41 stops, at which time the hydraulic fluid will mostly return back to the the actuator 25 through checks A and D and the piston will bottom out again as illustrated in FIG. 2. Therefor, a greater force will be required to overcome the static condition of the wiper held by the pivot 40 of the hinge of FIG. 1 or the hub of FIG. 1A.
Referring to FIG. 4 there is illustrated a structure identical in terms of the relief valve to FIGS. 3 and 2 but not in relation to the actuator 25. In this case the actuator 25 has been replaced with a gear pump 70 which includes a set of rotors 71 and 72 which rotate in opposite directions and have lines L5, L6, L7 and L8 in communication with the relief valve through check valves A, B, C and D setup identically in relation to description of FIGS. 2 and 3. The pin 40 may be located on one or the other of the gear pump rotors 71 or 72, the other being a slave in operation. Therefor, if the valve 55 is to be raised in relation to FIG. 2A, a greater force is required on the hub or on the vehicle door for example, to overcome the force required to lift the relief valve as described in relation to FIGS. 2 and 3. The rotors therefor may rotate in a direction B and C which will cause the piston to raise the hydraulic fluid to pass through the openings 62 in the cylinder and return to the gear pump through checks A and D. The operation otherwise would be identical.
Referring now to 5 an alternative embodiment of the invention is illustrated wherein the actuator in FIG. 2 is replaced by a cylinder 80 which contains a piston 85 which is a by directional piston moveable to either end E1 or E2 of the cylinder. The piston rod 82 proximate end 81 prevents the piston 85 from passing the check B. Further the stop 81 when the piston moves toward end E2 prevents the piston 85 from passing the check C. Therefor the cylinder 80 and piston 85 therein acts as a pump similar to the actuator in FIGS. 2 and 3 and provides for the passages of fluid through lines L4, L3, L2 and L1 exactly as in the case of FIG. 3. The cylinder 80 would therefor be a portion of the enclosure of for example, a door check in a vehicle door, located in a stationary position in the door. The piston rod 82 would provide the check arm which is fastenable to a vehicle pillar not shown at one end and to the door at the other end. The structure of FIG. 5 would therefor entail the housing of the door check and provide the checking function of the door.
Referring now to FIG. 6 there is illustrated a hinge identical to FIG. 1 with the exception that electrical wires W1 and W2 extend from the hinge body for illustration purposes only. The wires may extend in any direction from the bottom or top or back of the hinge. The hub structure of FIG. 1A would benefit from the embodiments which will be described in relation to FIG. 6, wherein a pin including clutch means would be located within the hub of FIG. 1A much the same as the illustration of FIG. 7.
Therefor in FIG. 6 there is provided the hinge body 20 and hinge portions 30 and 25 about a pivot pin 40 having a fastening plate and the openings therethrough 31, 32 to be fixed to either the door or the vehicle frame. In the case of FIG. 1A, as with the previous description, the wheel WH would be rotating about a center 40 which is a pivot about a hub H. The wheel when it rotates would rotate in the direction T1. The structure of FIG. 7 would equally fit within the hub of FIG. 1A and any description in relation to FIG. 7 and following would be implied to just as workable as FIG. 1A.
Referring to FIG. 7 there is disclosed the hinge of FIG. 1 wherein an electric check mechanism 44 is provided within the housing 25 of the hinge 20. Electrical leads W1 and W2 will be described hereinafter. A pin having two parts 42 and 48 represents the pivot pin 40 which is affixed at one end to a resilient spring 44A to allow for the thrusting motion of the upper portion 42 of the pin 40. A solenoid 45 is provided around the pin. The pin portion 42 has a strain gauge 43 located thereon, which stain gauge is in communication with a micro chip not shown in FIG. 7. As best illustrated in relation to FIG. 8, the clutches 46 and 47 are separable and allow for the checking of the hinge when the clutches are abutting one another by the adjacent surfaces and the free motion of the pin 40 when the clutch plates 47 and 46 are separated. Score lines are provided on the circumference of the clutch plate 46 which as best seen in relation to FIG. 8 are detected by motion sensors which may be a fibre optics unit interconnected with a transducer which translates the optical signal to electrical signal to be transferred to the micro chip. The lines 46A therefor as best seen in FIG. 8 provided the sensing of such motion. Alternative methods would just as easily be applicable.
Referring now to FIGS. 7, 8 and 9 the electrical supply W1 and W1 are provided through a relay or the like which is in communication with a micro chip which is designed to accept the feed back signals and provide feed forward signals as required by the system. For example, the mircochip would include a sensing loop to sense the torque via the strain gauge 43 and would not engage the solenoid via the switching relay until such time as a torque condition is sensed at the strain gauge 43. When therefor the torque is sensed at a predetermined level the micro chip will inform the relay to close providing power to the solenoid to allow the clutch plate 47 and a pin portion to move upwardly away from the portion 48, thus separating the clutch plates 46 and 47. At this position the pin is free to rotate without any limitations and will move freely in comparison to the force required to overcome the friction between the two clutch plates 47 and 46. Therefor a lower force is required to maintain the pin in motion once the clutch plates are separated as compared to the force required to separate the clutch plates initially.
When the pin is stationary and not rotating and no force is being exerted upon the door of the hinge or on the hub then there is no torque at 43 either. However, the motion censor informs the mircochip that the clutch is not moving and the pin is not rotating and thus one can discreetly identify the two conditions of static loading and dynamic loading on the pin.
Therefor, Applicant's have provided examples of checking or stop mechanisms which may be designed hydraulically or which may be formed a electro/mechanically as in relation to FIGS. 7 and 8.
Referring to FIGS. 10 and 11 the characteristic which Applicant provides in its structures is described by the characteristic curves as in relation to FIGS. 6 and 7.
Referring to FIGS. 10 and 11 the characteristic which Applicant provides in its structures is described by the characteristic curve for both a hydraulic check and an electrical check. The force F (Actuate) initially required to move the door for example, or the wheel is high. This high actuating force requirement therefor ensures the checking of the mechanism being checked without need for supplementary portions. The fact that it is static and has a speed approaching zero or a displacement of hydraulic fluid approaching zero, provides a high force which must be overcome. This force in FIG. 10 is developed by the pressure in the line acting against a reduced area of the piston. Since force is the product of the pressure and the area the initial force to start the motion is established. Once the force required to slightly raise or flex the piston is overcome the effort required to maintain the vehicle door or wheel in motion drops dramatically. This is because the fluid has overcome the resistance of the spring or biasing force and the fluid acts on a larger area thus requiring less pressure to keep the spring compressed and therefore keep the valve open for relatively free flow of the fluid resulting in a reduction in the applied force required to maintain the mechanism in motion. When the door or wheel stops and as the speed or displacement approaches zero, the force returns to the first level of the characteristic as indicated in relation to FIGS. 10 and 11.
If a force is applied at the actuator of F1 this results in a pressure P1 in the system which force F1 is not sufficient to overcome the bias of the spring or rubber material. Instantaneously when a force F2 is applied sufficient to overcome the bias then a higher pressure P2 results in the system and the piston is flexed or raised. However as it is raised the pressure P2 is immediately drastically reduced as the fluid acts on a larger area of the piston. This effect results in an immediate drop in the force applied to the actuator. In practise this drop in the force is comparable to the ratio of the areas effected by the pressure when the piston bottoms and when it is raised.
The characteristic of FIG. 11 is developed more simply in a manner similar to a switch. If the clutch is closed the force to move the actuator is high. Once a torque is sensed and the clutches are separated the force is substantially reduced. The reduced effort will be present as long as the clutches are separated and motion is sensed. If no motion is sensed then the clutches close and the force required to overcome the static position of the actuator is again instantaneously high.
It is therefor the dual characteristic which we have embodied in various example structures which are simple and easy to use which is the essence of the instant invention. Any structure which provides stopping or checking whether it be embodied in a check or a combination hinge check or whether it be embodied in a hub of a wheel can be formed to exhibit the characteristics of FIGS. 10 and 11. Applicant therefor does not restrict its invention to those disclosed in the preferred and alternative embodiments which are provided as examples only of the instant invention.
Referring now to FIGS. 12, 12A, 13, and 14 there is illustrated an alternative embodiment of the invention wherein the piston has been replaced by a rubber diaphragm 28 which is able to withstand hydraulic oil. Therefore similar to FIG. 1 there is illustrated a hinge generally indicated as 10 which is mounted to a vehicle door (not illustrated) by a mounting plate 30 attached to the door and the housing 25 of the hinge attached to the frame of the vehicle. Of course, the attachments may be reversed without effecting the operation of the invention. Mounting plate 30 has openings 31 and 32 for mounting purposes. A pin 40 extends generally through the hinge body 25 from top to bottom of the hinge.
The internal components of the hinge body 25 are illustrated wherein the pin 40 of the housing 20 of FIGS. 12 and 12A includes a wiper portion 41 moveable within the housing 25. Hydraulic oil fills the space within the housing 25. At one end of the housing are located openings 21, 22, 23, 24 which are aligned respectively with check mechanisms K, L, M, and N which include a spring biasing device A1, B1, C1 and D1, and a ball bearing A2, B2, C2 and D2 as seen in FIG. 2. Flow paths 25d, 25c, 25b and 25a are therefor defined integral with the hinge 10. The wiper therefor moves clockwise or counter clockwise on pin 40 and forces fluid through line 25b depending on the direction motion of the wiper 41. The structure of the wiper and the housing is similar to that of a hydraulic actuator. Located within the housing or hub and in communication with lines which allow for fluid to flow from the actuator, is disposed a rubber diaphragm 28 including a resilient piston 29 which is a truncated cone contained within the opening 26h of the housing 26 the piston 29 is resiliently biased because of the flexibility of the rubber as it is compressed against the cover 26a. Disposed in the housing at the bottom seated position of piston 29 is an opening 61. The opening 61 has a cross sectional diameter that provides an area which is reduced from the area of the piston contained in opening 26h.
Referring to FIGS. 12 and 13 there is illustrated the hinge 10 which is modular and includes an actuator portion 25 and a relief valve portion 26. The relief valve portion includes a cover 26a and an area 26b of the actuator portion 25 which the cover 26a engages when assembled by conventional means. Located between the cover 26a and the actuator portion 26b is a diaphragm 28 as best seen in FIG. 14. The diaphragm portion 28 has a piston portion 29 being shaped as a truncated cone and retained in an opening 26h defined between the portions 26a and 26b. This piston portion 29 behaves similar to the previously described piston portions in use. Adjacent the piston portion 29 on the actuator portion 26b are located inlets and outlets for hydraulic oil 26c and 26d respectively. The diaphragm also includes four checking flaps 28b located at the other end of the module 26. These checking flaps 28b are located adjacent pairs of openings 26e and 26f of the actuator portion 26b (only one of each pair being illustrated in FIG. 13), and openings 26g and 26j (only one of each pair being illustrated in FIG. 13) of the portion 26a. The openings 26g and 26j provide the ability of the checking flaps 28b to move towards the portion 26a but not away from that portion thus providing one way checking. The necessary paths of fluid flow required within the portions 26a and 26b, similar to FIGS. 3 and 12A, are not illustrated as the operation of one way checking is identical whether flaps or ball bearings are used.
Referring now to FIG. 14 the modular diaphragm 28 is illustrated which provides in a one piece construction the resilient piston 29 and the checking flaps 28b. The position of the openings 26a and 26d are illustrated to orient the piston 29 in relation to the openings. Of course as presented in FIG. 12A it is not necessary that the checking flaps be provided with the diaphragm 28. The standard assembly using ball bearings may be used as well. For cost reasons and compactness of the finished assembly its is however preferred.
Referring to FIG. 12A the operation thereof is similar to FIG. 3. When the actuator is rotated in the direction R1 fluid flows through opening 23 and engages the area of the piston 29 adjacent the opening 61. The piston 29 is part of the diaphragm 28 which does not include checking flaps. The resilient piston compresses therefore in the opening 26h and causes the portion of the piston around the opening 61 to flex into the opening 26h thereby presenting to the fluid a greater area of the resilient piston 29, which area is generally concave, sufficient to allow communication of the fluid with the return port 25d. The structure of the piston 29 being a truncated cone is deliberate as the piston will deflect about its perimeter and its centre, to compress the top, the top having a difference in cross-section, than the bottom of the piston. The housing is vented at 25r to prevent an excessive vacuum from forming when the actuator is moving. This is an important consideration as it is required that there be no excessive vacuum developed for the correct operation of the unit. Any alternative means of achieving this end would be acceptable. This principle of course applies to the other examples as well.
Referring now to FIGS. 12, 13 and 14, the operation thereof is identical to that described above in relation to FIG. 12A with the exception that the checking flaps are included in the design of the diaphragm. When the actuator integral with the hinge 10 is rotated in the direction shown in FIG. 12A the resilient piston 29 will compress as shown in FIGS. 13 or 12A into the opening 26h and the appropriate checking flaps 28b will allow passage of fluid because they will move into the openings 26g and 26j under the pressure of the fluid. The remaining checking flaps cannot move toward portion 26b as no openings are provided therein to do so. Otherwise the operation of the module is very similar to the operation of the unit of FIG. 12A.
Referring now to FIG. 15, there is illustrated an infinite door check integral with a hinge assembly. The door check 100 being assembled as a hinge, having a body portion or a half 102 and a door half 101 as is illustrated in relation to FIG. 1. The door check portion, however, 100 in this description is similar in operation to the diaphragm portion described in relation to FIGS. 12, 13, 14 and 12A presenting a similar action in use.
The door check portion 100 the silhouette of which is best seen in relation to FIG. 15A has a cut out located adjacent the door half portion 101 in order to assemble the hinge. The hinge pin 40 engages with the body half 102 so that the turning moment developed when the hinge is operated is resolved through the hinge pin and also at the joint between the door check 100 and the door half 101. The hinge pin 40 has a seal about the circumference thereof in order to prevent the weeping of hydraulic fluid past the hinge pin.
Referring now to FIG. 15B, the cross-sectional view of the hinge 40 is presented to illustrate the assembly of the body half, the door half and the check. Therefore, the hinge pin carries the body half 102 as well as the door half 101 having upper and lower portions as well as the check 100. The hinge pin is riveted at one end 105A to complete the assembly.
Referring now to FIG. 15A there is illustrated a housing 110 for the door check 100. The housing is fastened via rivet or screw openings 111 to the top end of the check, not shown. The door check housing 110 has a seal extending around the circumference thereof at 110A to prevent leakage of hydraulic fluid. The opening 110B includes an actuator or wiper 120 supported by a hinge pin 40 preferably made from metal and having an opening 138 and 139 extending through each end. The wiper 120 is similar to a sector of a circle having a generally pie shaped form and having contained therein a resilient, flexible spring or diaphragm 130 which is made from rubber or any other resilient material which can withstand being exposed to hydraulic fluid. The resilient diaphragm or spring portion 130 has contained therein voids V1 and V2 which may either comprise an air pocket in each void V1 and V2 or be filled with resilient closed cell foam such as sponge which restores its original shape after being compressed. A circumferential recess or groove is established about the perimeter of the wiper 120 as best seen in relation to FIG. 22 within which a circumferential seal S2 rests. The circumferential seal S2 has a wiper arm which extends in one direction as best seen in FIG. 17 which seals against passage of hydraulic fluid in the opposite direction to the extension of the wiper arm of the seal S2. This will be described hereinafter. A seal S1 is located proximate the hinge pin the details of which are best seen in relation to FIG. 18 to divide the volumes 110B in half on either side of the wiper W1 and W2. Therefore when the wiper 120 is moved in a direction R2, fluid will pass through the opening 138 under pressure and flow in the direction R5 and will compress the diaphragm or resilient spring 130 around the opening 138 adjacent that spring 130 to allow the passage of fluid through the cut-out portion AX through the spring 130 and through the circumferential seal S2 in order to exit to volume W2. The movement of the oil in this fashion is similar to the passage of hydraulic fluid through the diaphragm of FIG. 13 and provides the same characteristic as described in relation to FIG. 10.
Referring now to FIG. 16, the details of the wiper 130 are presented to illustrate the passage of hydraulic fluid through the openings 138 or 139 depending on the direction of the rotation of the wiper 120. In this illustration the resilient spring 130 includes metal reinforcing portions 135 which may or may not be included, and a singular void V3 filled with closed cell resilient foam such as sponge. When the wiper moves in the direction indicated in FIG. 15A, the fluid will flow in a direction A through opening 138 and will pass in a corresponding direction A around the seal S2. If the fluid moves in the opposite direction wherein the wiper 120 would be moving in a direction opposite to R2 in FIG. 15A, then the fluid will flow through the opening 139 causing the same characteristic as illustrated in relation to FIG. 10 and compress the spring portion 130 into the void V3 allowing the fluid to pass through the seal S2 in a direction B and the characteristics sought by the instant invention.
Referring to FIG. 17, a close-up of the detail of the seal S2 is illustrated abutting the housing 110 and contained within a recess 120A of the wiper 120. The recess 120A is best seen in relation to FIG. 22 wherein the seal has a head H and a tail T which engages the side walls of the recess 120A to anchor the seal in position and to allow the leg of the wiper portion L to abut the housing 110 in one direction and prevent the passage of fluid in the direction R5 when the housing is assembled as shown in the compressed state in ghost out line. The seal will allow fluid flow however in the direction R6 which is generally in the same direction of extension of the leg L when it abuts the housing 110.
Referring now to FIG. 18 a perspective view of the seal S1 is presented which provides cut-out portions 1 and 2 at each end and at each side of the seal to allow for deflection of the seal and improved sealing in use.
Referring now to FIG. 19, a schematic view of the resilient diaphragm or spring 130 is presented illustrating the cut-out channel AX at the top thereof which may equally be at the bottom thereof or on both sides which allows for passage of fluid in both directions. Of course the void is present either filled with air or closed cell resilient foam such as sponge.
FIG. 20 is a perspective view of FIG. 19 with all of the attributes thereof.
FIG. 21 is a close-up view of the opening for example 138 in the resilient spring or diaphragm portion 130 adjacent the opening 138 of the wiper 120 illustrating the deflection of the spring portion 130 in the direction of the oil pressure similar to that illustrated in relation to FIG. 12A and FIG. 13. The hydraulic fluid will therefor flow through the opening 138 and through the opening AX and about the seal S2 in the appropriate direction depending upon the rotation of the wiper 120.
FIG. 22 is a view of the wiper 120 illustrated in perspective view mounted on the hinge pin 40 illustrating the details of the recess 120A within which the seal S2 is contained as best illustrated in relation to FIG. 23. The wiper 120 is formed with an integral collar 40A through which the hinge pin 40 fits when the check is assembled with the hinge.
As may changes can be made to the preferred embodiments of the invention without departing from the scope thereof; all matter contained herein is to be considered illustrative of the invention and not in a limiting sense. | A check or stop for a moveable member, the check or stop comprising actuated means actuated by the moveable member, or alternatively by seperate actuating means, the actuated means being either fastened with the moveable member or being integral with the moveable member, automatic switching means to control the checking and release of the actuated means and the moveable member, the moveable member being moveable from a first state, wherein the moveable member is substantially static, checked, and exhibits a first value for a predetermined characteristic of the actuated means, to a second state wherein the moveable member is substantially in motion, unchecked, and exhibits a second value of the predetermined characteristic of the actuated means, the value of the predetermined characteristic of the actuated means being available to the automatic switching means, wherein when the moveable member is in a static state the first value of the predetermined characteristic available to the automatic switching means provides checking of the actuated means and the motion of the moveable member, wherein when the moveable member is substantially in motion the second value of the predetermined characteristic available to the automatic switching means provides release of the actuated means and the moveable member to allow ease of movement thereof. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention lies in the field of ladders, especially marine ladders used on swim floats, docks, and seawalls, for example. The invention relates to a quick release bracket for mounting a ladder, for example, to a dock, or releasing the ladder from the dock easily and quickly without a tool.
[0002] In the prior art, the ladders are generally mounted to a dock with a tie-down member that is fixed to the dock surface by nuts and bolts. Whenever a ladder needs to be removed, for example, for storage during the winter or to prevent against theft, it is necessary to remove the nuts and bolts and install them back again. Whenever a ladder needs to be relocated, the screws need to be undone and secured at the new location.
[0003] Therefore, there is a need for a device that can be used to quickly and easily release and relocate the ladder without needing a tool.
SUMMARY OF THE INVENTION
[0004] It is accordingly an object of the invention to provide an improved bracket that can be used to easily secure and remove a ladder to and from the position at which it is to be used.
[0005] With the foregoing and other objects in view, there is provided, in accordance with the invention, in a ladder system having a ladder with a tie-down member, the ladder to be secured at a fixing location, a quick release bracket comprising:
[0000] a frame receiving therein the tie-down member in a form fit and being formed with pinholes, the frame to be removably fixed at the fixing location; and
[0000] removable pins shaped to fit into the pinholes, the pins fixing the ladder to the frame when the pins are inserted into the pinholes.
[0006] In accordance with another feature of the invention, the frame is approximately U-shaped to define an interior shape; and the tie-down member has an exterior shape substantially corresponding to the interior shape of the frame.
[0007] In accordance with a further feature of the invention, there is provided at least one securing device for fastening the pins to the frame.
[0008] In accordance with an added feature of the invention, the securing device is a spring-loaded ball bearing for removably fastening the pins to the frame.
[0009] In accordance with an additional feature of the invention, the securing device is a cable connecting a respective one of the pins to the frame.
[0010] In accordance with yet another feature of the invention, there is provided a fastening assembly mounting the frame to the fixing location.
[0011] In accordance with yet a further feature of the invention, the fastening assembly is at least one nut and bolt assembly.
[0012] In accordance with yet an added feature of the invention, each of the pins has an expanded portion at one end and a projecting part at another end; the expanded portion has a diameter larger than a diameter of at least one of the pinholes; and the projecting part removably locks the pin in position in one of the pinholes.
[0013] In accordance with yet an additional feature of the invention, the frame has a safety portion defining an interior chamber for accommodating therein at least a portion of at least one of said pins.
[0014] In accordance with again another feature of the invention, the frame has two sides, one of the sides being formed in an approximate upside-down U-shape and another of the sides being formed in an approximate upside-down L-shape.
[0015] In accordance with again a further feature of the invention, the upside-down U-shape has an inner leg with pinholes and an outer leg without pinholes.
[0016] With the foregoing and other objects in view, there is also provided, in accordance with the invention, a quick release bracket for a ladder to be removably fixed at a fixing location and having a tie-down member, comprising:
[0000] an approximately U-shaped frame for receiving the tie-down member, the frame being formed with pinholes, the frame to be removably fixed at the fixing location; and
[0000] removably pins to be inserted into the pinholes and fix the ladder to the frame when the pins are inserted into the pinholes.
[0017] With the foregoing and other objects in view, there is also provided, in accordance with the invention, a ladder assembly, comprising:
[0000] a ladder having a ladder body and a tie-down member; and
[0000] a quick release bracket having:
[0000]
a U-shaped frame receiving the tie-down member of the ladder therein, the frame being formed with pinholes; and
pins shaped to be removably inserted into the pinholes and removably secure the ladder to the bracket.
[0020] With the foregoing and other objects in view, there is also provided, in accordance with the invention, a removable ladder kit, comprising:
[0000] a ladder to be secured at a fixing location and having a tie-down member; and
[0000] a quick release bracket having:
[0000]
a frame to be removably fixed at the fixing location, the frame:
receiving therein the tie-down member in a form fit; and being formed with pinholes; and
removable pins shaped to fit into the pinholes, the pins fixing the ladder to the frame when the pins are inserted into the pinholes.
[0025] With the foregoing and other objects in view, there is also provided, in accordance with the invention, a quick release bracket for a ladder having a tie-down member with an exterior shape, comprising:
[0000] at least one removable securing device; and
[0000] a frame having:
[0000]
a frame body defining an interior shape substantially corresponding to the exterior shape of the tie-down member for receiving the tie-down member therein;
a safety portion defining an interior chamber for accommodating therein at least a portion of the at least one removable securing device; and
a connecting portion shaped to removably receive the at least one removable securing device for removably securing the tie-down member to the frame.
[0029] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0030] Although the invention is illustrated and described herein as embodied in a quick release ladder bracket, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0031] Additional advantages of the invention will be set forth in part in the description which follows, and in part will be clear from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a perspective view of a ladder mounted to a dock by a quick release bracket according to the invention;
[0033] FIG. 2 is an exploded perspective view of the ladder and the quick release bracket of FIG. 1 before they are assembled together;
[0034] FIG. 3 is a fragmentary, enlarged perspective view of the quick release bracket of FIG. 1 and the corresponding attachment portion of the ladder;
[0035] FIG. 4 is a cross-sectional view of the bracket and ladder of FIG. 1 along the section line IV-IV in FIG. 1 ;
[0036] FIG. 5 is an enlarged, partially hidden, fragmentary, elevational side view of the quick release bracket of FIG. 2 with the corresponding connecting portion of the ladder viewed from the interior of the ladder; and
[0037] FIG. 6 is an enlarged, partially cross-sectional, partially hidden, and plan view of the quick release bracket of FIG. 1 with the corresponding connecting portion of the ladder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The invention may be understood more readily by reference to the following detailed description of preferred embodiments of the invention.
[0039] Before the invention is disclosed and described, it is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise.
[0040] The invention will now be described in detail with reference to the accompanying drawings.
[0041] Referring now to the figures of the drawings in detail and first, particularly to FIGS. 1 and 2 thereof, there is shown a ladder 100 , which is mounted to a dock 200 by a quick release bracket 300 according to the invention. The ladder 100 has a ladder body 110 and a tie-down member 120 to be mounted to the dock 200 .
[0042] As can be seen more clearly in FIG. 3 , the quick release bracket 300 has a U-shaped frame 310 for receiving the tie-down member 120 of the ladder 100 . The U-shaped frame 310 is formed with four pinholes 320 , two on each side thereof. The pinholes 320 on one side of the U-shaped frame 310 align with the pinholes 320 formed on the other side of the U-shaped frame 310 . Two pins 330 are attached to the U-shaped frame 310 by cables 340 and are to be inserted into the pinholes 320 . Of course, the U-shaped frame 310 may be formed with more pinholes and more pins can be used to increase stability. Also, it is not necessary to secure the pins 330 to the frame 310 .
[0043] As can be seen in FIG. 4 , the U-shaped frame 310 of the quick release bracket 300 is fixed to the dock 200 by nut and bolt assemblies 400 (only one nut and bolt assembly 400 is shown in FIG. 4 ). The U-shaped frame 310 as shown in FIG. 4 has a cross-section in which one side 314 of the U-shaped frame 310 has an upside-down U-shape and the other side 312 of the U-shaped frame 310 has an upside-down L-shape. The inner leg 313 of the upside-down U-shaped side 314 is formed with pinholes 320 . In contrast, the outer leg 315 of the upside-down U-shaped side 314 does not have pinholes 320 . Therefore, the upside-down U-shaped side 314 forms a chamber 317 , which partially accommodates the pins 330 . Not only does the chamber 317 provide protection for the pins 330 , more importantly, the outer leg 315 forming the chamber 317 guards the distal ends of the pins projecting from the inner leg 313 and, thereby, prevents a person from catching their foot on the pin 330 . The left side 314 as viewed in FIG. 4 need not be in the squared-off U-shape. To further prevent injury to a user, the cross-section can have a curve at the top. Thus, the two corners shown in FIG. 4 are eliminated. Another alternative is to form the left side 314 with a hemispherical cross-section.
[0044] The outer side 315 of the upside-down U-shape side 314 may limit the distance that the pins 330 can extend. The upper side 316 of the upside-down L-shape side 312 may also, to certain extent, protect the pins 330 . Preferably, the pins 330 have an expanded portion 332 at one end thereof, which has a diameter slightly larger than the diameter of the pinhole 320 to prevent over-insertion of the pins 330 . The pins 330 may also have a projecting part 324 at the other end thereof, which can lock the pins 330 in position, but can be inserted into and pulled out of the pinhole 320 with slight force. The preferred embodiment of the projecting part 324 is a spring biased ball bearing that can be pressed into the shaft of the pin 330 when the projecting part 324 is passing through the pinholes 320 (having a diameter substantially equal to the outer diameter of the pin 330 ).
[0045] FIGS. 5 and 6 are side and top views of the quick release bracket 300 with the corresponding portion of the tie-down member 120 of the ladder 100 in assembled condition.
[0046] The quick release bracket 300 according to the invention has the advantage that the ladder 100 can be secured to and released from the dock 200 quickly without using any tools. The ladder 100 can be quickly mounted to the dock 200 by lowering the tie-down member 120 into the U-shaped frame 310 of the quick release bracket 300 (which is already secured to the dock 200 ) and inserting the pins 330 into the pinholes 32 u formed in the U-shaped frame 310 . The ladder 100 can also be quickly removed from the dock 200 by removing the pins 330 from the pinholes 320 and lifting the ladder 100 from the U-shaped frame 310 of the quick release bracket 300 . This facilitates the storage and repair of the ladder. In other words, the bracket 300 can be fixed to the dock and left there permanently or semi-permanently, but the ladder can be removed at any time and stored somewhere else after use until the next time it is needed. In this way, the life span of the ladder 100 can be extended. | A quick release bracket for a ladder having a tie-down member includes a frame receiving therein the tie-down member in a form fit and being formed with pinholes. The frame is to be removably fixed at a fixing location. The quick release bracket also includes removable pins shaped to fit into the pinholes. The pins fix the ladder to the frame when the pins are inserted into the pinholes. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the transmission of information between a downhole location and a surface location, and more specifically to an apparatus and method for the transmission of information between downhole and surface locations during the conduct of a subterranean drilling operation using air or gas as the energy source for a downhole drilling motor.
2. State of the Art
Drilling for oil and gas with downhole motors employing dry air, mist, or foams (all referred to hereinafter generically as "air") as a drilling fluid has been contemplated and practiced with some limited success for a number of years. Use of air as the drilling fluid, because of its low density, can result in faster penetration rates. Moreover, air drilling is less damaging to the producing formation than oil- or water-based drilling fluids. However, the reduced hydrostatic head of the air drilling fluid cannot effectively control formation pressures nor support borehole wall against collapse, and therefore air drilling is substantially limited to competent formations and requires religious use of blow-out preventors ("BOP's").
The foregoing limitations notwithstanding, air drilling has many applications, and improved motor technology has popularized its use in recent years, particularly in navigational drilling operations where a bottomhole assembly including a drilling motor may be steered to drill either a curved path or straight ahead. When drilling a nonlinear path, the bottomhole assembly is oriented in a particular direction, and drilling proceeds under power of the motor alone. For straight ahead drilling, the drillstring is rotated to negate the drill bit tilt angle or offset from the longitudinal axis of the bottomhole assembly. One suitable and recently developed bottom hole assembly for air drilling is the Navi-Drill Mach 1/AD, employed by Eastman Christensen Company of Houston, Tex., which assembly includes a positive displacement Moineau-type air motor and an adjustable bent sub between the motor and the drill bit, the bent sub providing the desired bit tilt angle for nonlinear drilling. An additional bent sub may be placed above the motor to enhance the assembly's kick off abilities, but such an arrangement precludes drillstring rotation and straight ahead drilling.
When drilling directionally or navigationally it is, of course, imperative to track the azimuth and inclination of the actual borehole against the intended well plan. Many survey, steering and measurement-while-drilling ("MWD") devices and techniques have been developed and employed over the years, but experience has confirmed many deficiencies and limitations of the prior art apparatus and methods when employed in an air drilling environment.
Conventional survey instrumentation, and particularly high accuracy gyroscopic instrumentation, is somewhat delicate for use in air drilling, as the drilling fluid does not provide dampening of deleterious vibration and resonance effects. Moreover, when conducting a navigational drilling operation, drilling torque may drastically change the toolface orientation and thus the borehole path over a short drilling interval, and survey techniques only confirm such changes after the fact.
Conventional MWD systems employ pressure pulses in the drilling fluid to transmit information from the downhole probe to the surface. As air is highly compressible, it cannot be pulsed effectively, and so conventional mud-pulse MWD technology is inoperative in air-drilled boreholes. Electromagnetic MWD ("EM MWD") systems, which employ the drillstring as the transmission media for electromagnetic waves, have been employed in air-drilled holes with mixed results. Rougher drilling conditions in air-drilled holes commonly cause tool failure, and EM MWD use can be severely hampered by formation resistivity. Finally, use of EM MWD requires a conductive drilling fluid, and therefore cannot be used for dry air drilling.
A steering tool offers significant advantages while navigationally drilling, as it provides continual surface readout of survey data while drilling, including the highly important toolface readout, solving the problem of reactive torque effects causing toolface orientation change. Steering tools also offer almost instantaneous information, unlike MWD tools, which do not continuously transmit data between the downhole location and the surface. Wireline-controlled steering systems have been employed in directional drilling, such systems including a side-entry sub and split kelly for the wireline to maintain contact with the probe. With a side-entry sub, the wireline is on the outside of the drillstring, and therefore subject to kinking, wear and breakage. If the probe signal is lost, the drillstring must be pulled out of the hole to the location of the side-entry sub, and the probe retrieved. Moreover, these systems preclude rotation of the drillstring due to the exterior location of the wireline. If a swivel assembly is used instead of a side-entry sub, the steering tool must be round-tripped out of the hole whenever a drill pipe joint connection is made, although in this case the drillstring may be rotated for straight ahead drilling. Finally, use of a wireline exterior to the drillstring precludes full closure of the BOP's unless the wireline is seuered.
Wet-connect systems have been developed wherein a steering tool probe having a wireline leading to a connection on the upper end thereof is run into the drillstring at the kickoff point, the upper end clamped off at the connection, and an upper wireline section with a mating connection on the lower end thereof is run into the drillstring to electrically connect the probe for directional drilling. While effective, such systems cause lost rig time due to the necessity for wireline retrieval prior to drillstring rotation.
Horizontal air-drilled wells provide additional problems as, at well inclinations exceeding 70 degrees from the vertical, a steering or survey tool will no longer fall down the drillstring, nor will air passing by the tool generate enough drag to carry it downhole. Currently, two methods are used to address this problem. In the first, the drillstring is pulled from the hole until the bit is at 70 degrees of inclination, a side-entry sub installed and a survey or steering tool run on electric line to a latching assembly above the drill bit, and the drillstring tripped back to bottom with the wireline above the side entry sub on the outside of the drillstring. A survey is then taken, the drillstring tripped back out to the side-entry sub, the survey tool and side-entry sub removed, and the drillstring run back to bottom to continue drilling. Obviously, a great deal of rig time is wasted with this method, and the driller learns of deviations from the well plan after the fact. The second method reduces time somewhat, by running a survey tool on a slickline with a releasing overshot when the drillstring has been pulled to the 70 degree inclination point. Upon reaching the monel drill collars, a monel sensor activates the releasing overshot, disconnecting the survey tool from the slick line, which is then removed from the hole. The drillstring is tripped back to the bottom to take the survey, subsequent to which the drillstring is pulled to 70 degrees, and the survey tool retrieved with a standard overshot run in on slickline. It will be appreciated that significant rig time is still involved with this method.
SUMMARY OF THE INVENTION
In contrast to the prior art apparatus and methods, the apparatus and method of the present invention allows a bottom hole assembly employing an air-powered drilling motor to be employed as a steerable drilling system combining directional and straight hole drilling capabilities to provide precise directional control.
The present invention provides a realtime survey system having the capability of withstanding the air harmonics and vibration attendant to air drilling operations. The major system components include a steering tool incorporated in a probe or latch down assembly which is releasably securable to a latching module located within the non-magnetic drill collars of a drillstring above the downhole motor, a first wireline extending upwardly to carry a signal from the steering tool to a clamp-off sub secured in the drillstring whereat the wireline is electrically connected to the free, lower end of a cable spooled on a cable cartridge secured in the drillstring, from which point a second wireline extends upwardly from the upper end of the cartridge cable to a pressure-tight rotating slip ring assembly at the surface. A surface cable transmits the signal from the slip ring assembly to a surface processing unit which provides data to a driller's remote display and a computer.
For highly deviated and horizontal boreholes, the steering tool may be a tri-axial steering tool of the type such as is commercially available from Eastman Christensen Company or Sharewell, Inc., both of Houston, Tex., to provide inclination, azimuth and toolface orientation. Such tools are shielded against pressure and temperature effects of downhole use to the degree required for the well being drilled.
The clamp-off sub provides mechanical support for the connection of the first wireline from the steering tool to the cable from the cartridge, and is secured between the pin and box of a drill pipe connection after the probe or latch down assembly is run and latched into the drillstring at the kick off point of the borehole, where the inclined portion thereof is commenced. The cartridge is initially secured at the pipe joint next above the clamp-off sub, and the second, upper wireline connected to the cartridge cable extends to the slip ring assembly above the kelly for transmission of data during drilling. After the kelly is made up and first pipe joint is drilled down, the wireline cartridge is pulled upwardly through the next joint after connection to the top of the drillstring, reconnected electrically to the slip ring assembly, the kelly made up and drilling recommenced. If a single cartridge does not provide sufficient cable, additional cartridges may be added sequentially as drilling progresses.
Since no wireline or other cable is exterior to the drillstring, rotation thereof for straight ahead drilling is possible, the use of the cartridge eliminates tripping of the drillstring when pipe joints are added, and operations of the BOP's is unaffected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 of the drawings is a schematic representation of the major components of the data transmission apparatus of the present invention;
FIG. 2 is an elevation of a suitable steering tool probe assembly for use with the present invention;
FIGS. 3A and 3B are schematic elevations showing the latching of the steering tool probe assembly into the non-magnetic drill collars above the downhole motor;
FIG. 4 is a schematic of a clamp-off sub for use with the present invention;
FIG. 5 is an elevation of the wireline cartridge assembly employed in the present invention;
FIG. 5A is an enlarged partial sectional elevation of the cartridge body of the wireline cartridge of FIG. 5;
FIGS. 6A, 6B and 6C are, respectively, schematic elevations showing a wireline cartridge locked in a connection between two pipe joints, a wireline cartridge with a landing assembly removably positioned within a pipe joint connection, and a wireline cartridge during upward withdrawal though a joint of drill pipe;
FIG. 7 is an exploded schematic view of the components of a float valve bypass assembly of the present invention; and
FIG. 8 is a schematic of a slip ring sub assembly for use in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts the major elements of the data transmission apparatus 10 of the present invention. From the bottom of the drawing, steering tool probe 12 is assembled into a probe or latch down assembly 40 (see FIG. 2) by which it is mechanically and electrically connected to a lower single conductor electric wireline 14, which extends to a clamp-off sub 16 for mechanically and electrically connecting wireline 14 to cable 18 extending from the lower end of cable cartridge 20. The cable 18 of cable cartridge 20 is mechanically and electrically connected at the upper end of cartridge 20 to an upper single conductor electric wireline 22, the latter extending upwardly to a rotating slip ring assembly 24 located above the kelly 23, slip ring assembly 24 providing a pressure-proof rotatable electrical connection to surface output cable 26 extending to processing unit 28. With such an arrangement, information such as inclination, azimuth and toolface from steering tool probe 12 may be transmitted uphole to processing unit 28, the output of which is graphically depicted on driller's remote display 30 and/or on the monitor of computer 32, whereat the processed information from steering tool probe 12 may also be stored. Elements 12 through 22 of apparatus 10 of the present invention are disposed within a string of drill pipe (shown schematically at 34) during the drilling operation, the drillstring 34 also including below steering tool probe 12 a steerable bottomhole assembly (not shown) of the type previously described. It is also contemplated that the information transmission apparatus of the present invention may be employed to transmit commands from the surface to the steering tool, which in some future applications may be employed to actively change the path of the borehole.
FIG. 2 depicts the components of a probe or latch down assembly 40 which includes steering tool probe 12. At the top of probe or latch down assembly 40 is cable head 42, by which probe assembly 40 is lowered into the drillstring on wireline 14, which is secured to a rope socket in cable head 42. Cable head also 42 includes a fishing head 44 at the top thereof, for retrieval of probe or latch down assembly 40 via an overshot should wireline 14 part. Below cable head 42, probe 12 (in a ruggedized, pressure-proof housing) is secured to and bracketed by upper and lower centralizers 46 and 48, respectively, below which are secured one or more spacers bars 50 having centralizing fins 52 thereon, the number of spacer bars 50 being determined by calculation of the required magnetic isolation from the bottom hole assembly below probe 12. Shock absorber 54 is located below the lowermost spacer bar 50 to provide longitudinal and preferably radial shock isolation for probe 12 during landing of probe or latch down assembly 40 in the non-magnetic drill collars. Stinger 56 at the bottom of probe or latch down assembly 40 positively latches into a latch down module at the bottom of the string of non-magnetic drill collars at the lower end of drillstring 34 to secure probe or latch down assembly 40 thereinto, and also to properly rotationally orient probe 12 via exterior profile 58 with respect to the drill bit for proper toolface readings. The housing of steering tool probe 12, as noted previously, comprises a pressure barrel, and may include flexible rubber fins on the exterior thereof for centralization of the probe within the non-magnetic drill collars. The use of rubber fins permits the probe to pass through a 21/8" diameter drill collar bore followed by re-expansion of the fins to centralize the probe in a 2 13/16" non-magnetic drill collar bore below the constriction. However, it has been difficult to achieve a good compromise between fin flexibility for passage through the constriction and rigidity required for centralization. Therefore, it has also been proposed to utilize radially inwardly extending fins on the non-magnetic drill collar bore for support and centralization of the probe. Such an arrangement has been disclosed in U.S. patent application Ser. No. 750,615, filed Aug. 27, 1991, assigned to the assignee of the present invention, and incorporated for all purposes herein by this reference. Use of internal drill collar fins obviously eliminates the problem of probe passage through the constricted drill collar bores.
FIGS. 3A and 3B depict, respectively, the lowering of probe or latch down assembly 40 into latch down module 60 at the bottom of a string of non-magnetic drill collars 62 above steerable bottom hole assembly 70. The latch down module 60 includes a latch down sleeve 64 which engages stinger 56 to retain probe or latch down assembly 40 against upward motion, and which, via key 66, interacts with exterior profile 58 to rotate probe or latch down assembly 40 as previously mentioned. The stinger 56 and latch down module 60 may be of any design previously known in the art, but it has been discovered that the retention capability of the latter should be increased for use in air drilling, in order to prevent inadvertent upward release of probe or latch down assembly 40 due to pressure differentials when air pressure is bled off from the drillstring, such as when new pipe joints are being added.
Probe or latch down assembly 40 is lowered into drillstring 34 when a predetermined depth has been reached and the wellbore is to depart from the vertical. Wireline 14 is pulled taut after engagement of stinger 56 with latch down sleeve 64. Clamp-off sub 16 is then placed around wireline 14 in the bore back of the uppermost joint of drill pipe at the surface, clamped about wireline 14, and wireline 14 is then severed above clamp-off sub 16. Clamp-off sub 16 preferably comprises two mating sections, each having a vertical recess therein to define a passage for wireline 14, the passage being of smaller diameter than the wireline 14 so that the wireline 14 is clamped and held therebetween when the two sections of the clamp-off sub 16 are transversely bolted together.
FIG. 4 depicts clamp-off sub 16, whereat wireline 14 terminates and is electrically joined to cable 18 extending from a cable cartridge 20. As noted above, clamp-off sub 16 employs technology well known in the art for wireline cable heads to mechanically grip and support the upper end of wireline 14. The lower end of cable 18 is also mechanically locked in transition section 80 of sub 16, so that the electrical connection of the two, made within transition section 80, remains mechanically unstressed. As drilling progresses, collar 82 of clamp-off sub 16 rests between a pin 84 of one tool joint 86 and the box back 88 of the adjacent joint 86, so as to prevent movement of the clamp-off sub 16 within the drillstring. Collar 82 includes apertures therethrough so as to permit passage past clamp-off sub 16 of air to drive the drillstring motor of the bottom hole assembly. Those components of data transmission apparatus 10 from clamp-off sub 16 and below remain in position until the wellbore reaches its end point, unless a bit, motor or other lower drillstring component is changed.
FIG. 5 illustrates cable cartridge 20 including landing assembly 90 secured to the top of cartridge head 94, and fishing head 92 secured to the top of landing assembly 90. Cartridge head 94 has cable spool 96 secured to the bottom thereof, a portion of which is shown enlarged in partial section in FIG. 5A. Cable 18 is wrapped transversely about inner mandrel 98 of cable spool 96 in a single layer, and protected by heat shrink tubing 100 which is applied to mandrel 98 after cable 18 is wrapped thereabout. The upper end of cable 18 is secured to cartridge head 94, terminating at a connector such as a keystone seat, by which the cable 18 may be positively mechanically secured and electrically connected to an upper wireline 22 leading to slip-ring assembly 24 or to the lower end of another cable from another cable cartridge 20 in the drillstring. The design of cable cartridge 20 is based upon a cartridge design developed by Sharewell, Inc., of Houston, Tex. for use in pipelines, utility conduits, and river crossings, and the principle of operation remains the same. If cable is pulled from the bottom of mandrel 98, friction will stop the payout of cable after three to four feet, at most. However, if cable cartridge 20 is moved upwardly, cable will pay out for the upward distance the cartridge is moved. A patent application was filed on the Sharewell, Inc. cartridge design on Feb. 9, 1990 and assigned Ser. No. 477,720 and has now issued as U.S. Pat. No. 5,105,878. The original Sharewell cartridge had concentric inner and outer mandrels, with a plastic or elastomeric sleeve surrounding the cable inside the outer mandrel. Furthermore, the original Sharewell design employed spring-loaded dogs to lock the cartridge against downward or backward movement in the pipe or conduit, requiring the size of the dogs to be changed for each pipe or conduit I.D.
The cable cartridge design of the present invention employs a landing assembly 90 removably secured to the top of cartridge head 94, landing assembly 90 including three pivotally mounted, coil spring-loaded, downwardly and radially outwardly extending legs 102 to accommodate different drill pipe bore diameters. The spring loading of the portion of the legs 102 inside the landing assembly 90 can be adjusted upwardly for use of the landing assembly in a large bore drill pipe, or downwardly for use in a small bore drill pipe. Additionally, a landing seat plate or hold down ring 104, is employed with cartridge head 94 when landing assembly 90 is not in use. Finally, the cartridge design employed in the present invention is of much smaller diameter and greater length than the Sharewell design, to accommodate small diameter drill pipe while providing an acceptable length of cable, approximately 380 feet, or ten pipe joints.
With reference to FIGS. 6A, 6B and 6C, the use of cartridges 20 will be hereinafter discussed. After the lower end of a cable 18 is secured to clamp-off sub 16, the next pipe joint 86 to be connected to the top of drillstring 34 is picked up with the elevators, an overshot is dropped through the pipe joint, locked onto fishing head 92 and cable cartridge 20 including cartridge head 94 and landing assembly 90 is pulled upwardly into the next pipe joint 86 (See FIG. 6C). The pipe joint 86, with cable cartridge 20 in its bore, is connected to the pipe string and the string is lowered until the box of the uppermost pipe joint 86 is on the surface. The overshot is then retrieved, pulling the cable cartridge 20 through the pipe bore to the box connection 88 on surface. In that position, landing seat plate or hold down ring 104, preferably having a beveled or chamfered periphery, as shown, and having a U-shaped mouth or aperture therein extending between the center and one side thereof is inserted about neck 106 of cartridge head 94 and cable cartridge 20 is lowered into the bore back 88 of box 87 (see FIG. 6A). Landing assembly 90 with attached fishing head 92 is then removed from the top thereof. The kelly 23 is picked up, positioned above the drill pipe box 87 on surface and upper wireline 22 extending from slip ring sub 24 through the kelly 23 is connected to the upper end of cable 18 at the cartridge head 94. The kelly 23 is made up and drilling commences. Cartridge 20 is supported in the box back 88 of the pipe joint 86, and the pin of the kelly 23 prevents upward movement of cartridge 20. The foregoing procedure is employed every time a cable cartridge is added to the drillstring. Drilling may progress either with or without drillstring rotation, with the steering tool latched into the non-magnetic drill collars being employed for guidance in the latter instance.
The drillstring 86 is drilled down to the top of the kelly 23, the slips are set and the drillstring is pulled up so that the uppermost pipe joint box is on surface, the kelly 23 broken from the drillstring, upper wireline 22 disconnected from cartridge head 94, the landing assembly 90 resecured to cartridge head 94, and hold down ring 104 removed. Cable cartridge 20 is again lowered into the top pipe joint 86 until the landing assembly legs 102 seat into the bore back 88, landing assembly 90 maintaining cable cartridge 20 in position (see FIG. 6B). The next joint of drill pipe is picked up by the kelly 23 from the mouse hole, lowered onto the box connection containing the cable cartridge 20, and made up. The slips are removed, and the drillstring lowered until the highest drill pipe box (at the new top pipe joint) is on surface. The slips are again set, the kelly 23 broken from the drill pipe, and moved to one side. An overshot 108 is run into the top joint 86 to engage fishing head 92 on top of landing assembly 90, and cartridge 20 pulled (see FIG. 6C) above the top of the top pipe joint 86, where the hold down ring 104 is reinstalled and cable cartridge 20 lowered into the box bore back 88. The landing assembly 90 is removed, the kelly 23 brought across and positioned above the drill pipe box on surface, wireline 22 retrieved and reconnected to cable head 94. The kelly is made up and drilling again proceeds. This process continues joint by joint until the cable 18 is fully payed out from a cartridge, whereupon the lower end of a cable from another cable cartridge 20 is connected to the cable at the cartridge head 94 according to the procedure described above with respect to the first cable cartridge 20.
FIG. 7 depicts a float valve bypass assembly 200 including a float valve 202 of standard design, a float valve sub 204, and a float valve bypass sleeve 206 which accommodates the passage of cartridge cable 18 in channel 208 past float valve 202 installed therein while preventing pressure bypass thereof. Several float valves will be employed in the drillstring, commencing with a hammer float at the drill bit, a standard float valve above the motor, and several others in the string above the clamp-off sub. The float valve bypass assembly 200 of the present invention accommodates the use of the cable cartridges 20, and permits bleedoff of only the top portion of the drillstring between the uppermost float valve 202 and the surface, reducing the time required for connecting each new tool joint. Seals 210 are located at the top and bottom of the channel 208, and O-rings disposed in grooves 212 about the periphery of bypass sleeve 206 for sealing against the bore wall of float sub 204.
Slip ring sub assembly 24, depicted schematically in FIG. 8, fits above the kelly and includes a pack-off 300 in slip ring sub 302 which enables upper wireline 22 extending from the inside of the kelly below slip ring subassembly 24 to electrically contact the slip ring in a pressure-tight manner, the slip ring rotating with the slip ring sub 302, kelly and the drillstring (See FIG. 1). The outer stationary sub 304 of the assembly 24 contacts the rotating slip ring via collector brushes (not shown), information thus being transferred to processing unit 28 via surface cable 26. Slip ring subs and wireline pack-offs being known in the art, no further description thereof will given herein.
In certain drilling conditions, such as when continual jarring of the drillstring is required, cartridges cannot be used due to cable stretch and/or resonance, and so an alternative approach must be contemplated. Similarly, the operator may not tolerate the continual presence of cable in the drillstring above the clamp-off assembly. Therefore, it is also contemplated that the present invention may be used with a wet connect device, wherein the lower half of the wet connect is secured to the clamp-off assembly. When a survey is desired, the drillstring pulled to a point of suitable inclination, and the upper half of the wet connect run into the drillstring down to the mating wet connect at the clamp-off assembly, at which point the string is lowered to bottom, and a survey taken. After the survey, the upper portion of the wet connect is pulled. Of course, drilling may proceed with the engaged wet connect if desired or required by the operator.
A novel and unobvious apparatus and method has thus been disclosed in terms of a preferred embodiment. However, additions, deletions and modifications to the invention as disclosed will be readily appreciated by one skilled in the art, and such may be made without departing from the scope of the claimed invention. | An apparatus and method for the transmission of information between downhole and surface locations through a drillstring. The apparatus includes a wireline extending from instrumentation at the downhole location to a clamp-off sub in the drillstring where it is connected to the lower end of a cable spooled on a cable cartridge above the clamp-off sub in the drillstring. The cable cartridge is moved upwardly through successive pipe joints added to the drillstring as drilling progresses, to permit rotation of the drillstring and use of blowout preventors without retrieving the wireline or cable. Cartridge cable is releasably connected at its upper end to a wireline extending through a pack-off to a slip ring assembly at the surface, for transmitting data from downhole instrumentation to surface equipment. Multiple cable cartridges may be sequentially added in series if drilling proceeds beyond the length of cable in a single cartridge. |
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CROSS-REFERENCE TO RELATED APPLICATIONS(S)
[0001] The present application is a divisional of U.S. patent application Ser. No. 13/700,429 filed on Jun. 7, 2011, which is a U.S. national stage filing under 35 U.S.C. §371 of International Application No. PCT/US2011/001039, filed on Jun. 7, 2012, which is a continaution-in-part under 35 U.S.C. §120 of U.S. patent application Ser. No. 12/796,625, filed on Jun. 8, 2010, now U.S. Pat. No. 9,027,307, titled “Construction System And Method For Constructing Buildings Using Pre-manufactured Structures,” and is also a continuation-in-part under 35 U.S.C. §120 of U.S. patent application Ser. No. 12/796,603, filed on Jun. 8, 2010, now U.S. Pat. No. 8,950,132, titled “Pre-manufactured Structures For Constructing Buildings.” The entirety of these applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the construction industry, and relates more specifically to a lift-slab construction system and method for constructing multi-story buildings using pre-manufactured structures.
BACKGROUND OF THE INVENTION
[0003] Conventional pre-manufactured building construction has typically focused on single-story buildings or building room modules or components for incorporation into new or pre-existing building structures. Conventional pre-manufactured building structures have been promoted based on the purported cost, timing, and efficiency advantages of having construction pre-manufactured at manufacturing plants or factories prior to delivery and installation at a building site. Conventional pre-manufactured building structures may be delivered either as complete structures that require minimal installation, e.g., mobile homes, or may be partial building structures or components that require labor and costly on-site installation. Installation of these pre-manufactured structures generally occur using conventional construction techniques.
[0004] It is not always cheaper, faster and more efficient to pre-manufacture building structures at manufacturing plants or factories to be delivered to the building site for further installation and/or integration and finishing on site. Handling of such structures can be extremely difficult, time-intensive and cost-prohibitive due to weight, bulk, and craning issues. Shipping modular structures or spaces can raise transportation issues due to weight and space problems. Due to the size of some building structures, transport may be inefficient as trucks may only fit one to two modules for delivery to a construction site. Huge cranes may be required to lift the modules to and from the trucks, or other transport means, at the manufacturing plants as well as the building sites.
[0005] With regard to multi-story building construction, on-site construction is conventionally preferred over use of pre-manufactured constructs because pre-manufactured structures are not typically adapted for building multi-story structures.
[0006] Conventional lift-slab construction for building multi-story buildings involves the lifting of heavy slabs by strand jacks located on top of columns. After the slab is lifted into position, it must be secured to the supporting columns which are typically located underneath a lifted slab. Securing such lifted slabs requires construction workers to undesirably and unsafely engage in the dangerous activity of working underneath heavy unsecured slabs in order to adequately secure the slabs to the columns. Such unsecured slabs may fall and crush or kill persons located underneath the slab.
[0007] The present invention utilizes pre-manufactured structures together with a lift-slab building process to overcome the limitations of utilizing pre-manufactured structures when constructing multi-story buildings.
[0008] The present invention offers several advantages over known construction systems and methods in addition to adapting the concept of pre-manufactured structures for use in multi-story building construction.
[0009] Advantages of the present invention include increased ease and efficiency of construction, reduced construction time, reduced construction cost, minimal use of scaffolding, minimal use of field welding, safer construction, higher quality construction, construction of a consistent quality, the practice of more environmentally sound construction practices including “green” building construction, reduced maintenance costs, increased ease of access to intelligently designed building spaces for residential, institutional and/or commercial use, the ready ability to permit limited interior space and finishing details customization by the governments, municipalities, townships, builders, consumers, occupants and/or other purchasers or users of these buildings, the ready ability to manage the cost, delivery, timing, and experience expectations of governments, municipalities, townships, builders, consumers, occupants and/or other purchasers or users of these buildings due to the buildings' familiar and repeated pre-manufactured components and the ability to use experience gained by virtue of constructing other similar buildings in accordance with the present invention.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention integrates the use of pre-manufactured structures with minimal on-site installation and lift-slab construction to achieve the construction of multi-story building, while at the same time making building construction easier, more efficient, faster, cheaper, safer, of higher quality and consistency, environmentally advantaged, energy-efficient, easier to maintain, intelligently designed, and customizable. The buildings of the present invention also result in an enhanced building experience for all those involved in the purchase, construction and use of the buildings due, at least in part, to the ability to manage cost, delivery, timing, and experience expectations based on experiences garnered from other similar buildings constructed according to the present invention.
[0011] The present invention comprises a set of pre-manufactured structures designed for ready integration with each other and with limited on-site lift-slab construction. The present invention incorporates use of innovative lift-slab construction techniques. The pre-manufactured structures themselves are designed so that they may be arranged to create buildings and interior building units of various sizes and functionality. The pre-manufactured structures are designed so as to be readily integrated with both horizontal and vertically adjacent building components, including lift-slab components and/or other pre-manufactured structures, so that multiple building stories may be readily and securely stacked, one on top of the other. The pre-manufactured components permit development of flexible design plans for institutional, residential, office and other types of buildings, and may be provided with various finish packages customized to order.
[0012] The pre-manufactured structures preferably involve the use of as many repetitive and self-sustaining construction methods and as many preassembled and prefinished structures as possible. Preassembled and prefinished structures are constructed in a manufacturing facility, transported to the construction site and installed within and/or on the lift-slab structure in conjuction with other components to create a fully finished, comfortable and weather-tight living environment. The present invention also contemplates use of semi-or largely prefinished components that may be fully and finally finished at the construction site. The pre-manufactured structures are preferably sized and packaged to eliminate wasted shipping space to facilitate efficiency of transport.
[0013] Standardizing the pre-manufactured structures and constructing them in a manufacturing facility provides the advantages of, among other things, reduced materials waste, reduced energy costs, quality control, faster production, consistent production, safer production, and increased labor productivity. The initial assembly of the components may eventually become automated. However, another advantage of the present invention is that construction may be carried out by less skilled labor under the supervision of qualified managers. Given that assembly will occur in an environmentally controlled setting, the potential for mold or materials damage due to exposure may also be reduced.
[0014] As will be explained in greater detail below, the lift-slab construction involving the pre-manufactured structures of the present invention provides for “top-down” construction. That is, once the building's foundation and any parking or floors below or at grade and the supporting external columns and/or beams are in place, the buildings of the present invention may be built from the top down, starting with the roof and moving sequentially down through each level until construction is complete. Roof slabs and floor slabs are lifted into place using multiple strand jacks located on top of the external columns and/or beams. The external columns and/or beams may be located around the exterior perimeter of the building slabs. Once a slab is lifted into place, connections located at the slab edge are used to secure the slab to the external columns and/or beams. The slab may be connected by various means, including but not limited to, bolted or pinned connections and/or the use of welding. The preferred method of the current invention is the use of bolts and/or pins to secure the slabs to the columns and/or beams to allow for an efficient and quick installation method. The slabs may be readily secured to the external columns and beams via access created by the exterior walkways of the present invention, or by using a man-lift or other similar means. This means of connection eliminates the potential unsafe and hazardous activity of workers being underneath an unsecured slab utilized in previous conventional lift-slab construction.
[0015] The present invention advantageously reduces, and in some cases, completely eliminates the need for exterior scaffolding. The exterior walkways are utilized for access to the utility walls, while the window walls are securely attached to the lifted slabs from the interior of the unit. The end walls at each end of a multi-story building are the only location where exterior scaffolding might be necessary. This need can potentially be eliminated if the end walls are fully prefinished with the exterior components installed prior to being set in place. In this case, a man-lift or other similar means may be used to install final panels to the exterior wall. The lift-slab construction system also reduces, and in some cases, largely eliminates the need for construction cranes. By reducing the need for, and or eliminating entirely, the need for scaffolding and construction cranes, the present invention significantly and advantageously reduces the time and costs involved in multi-story building construction. Furthermore, the present invention limits or eliminates the time consuming and costly practice of field welding. The structural steel may arrive at the site shop welded where necessary and ready for installation. All field connections, whether between the structural members themselves, or between the structural steel and the floor slab, may be bolted and/or pinned connections.
[0016] The present invention's top-down lift-slab construction beneficially provides enclosure of the buildings from roof to grade during construction, thus protecting the building's interior space and construction workers from the elements such as rain, snow and wind. Construction of the multi-story building from the top-down also increases the security and safety of partially constructed multi-story buildings as access to the upper building doors is limited during construction. Further, the present invention also permits multiple construction crews to be actively working on completing building construction with, for example, one crew finishing installation and/or final finishing of pre-manufactured building structures on floor slabs that have been secured into place and another crew dedicated to preparing floor slabs and/or pre-manufactured structures to be lifted.
[0017] The present invention may reduce construction time by approximately 50%, or one-half. That is, a building constructed according to the present invention that has about 100 units on five or six floors, may be completed in six (6) to eight (8) months from the podium level to the roof. By contrast, construction of a similarly sized building using conventional construction techniques would be expected to take about twelve (12) to sixteen (16) months. The present invention is well-suited for the construction of many types of multi-story buildings, including mid-rise buildings.
[0018] The present inventions comprises, in no particular order: pre-manufacturing a plurality of finished, or mostly finished, non-weight bearing walls; pre-manufacturing a plurality of finished, or mostly finished, interior components adapted to connect to the non-weight bearing walls; pre-manufacturing finished, or mostly finished, exterior components adapted to attach to the exterior building surfaces; transporting the pre-manufactured non-weight bearing walls, interior components, and exterior components to a building site; preparing a multi-story building foundation at the building site to support a plurality of load-bearing structural columns and/or beams; forming a plurality of floor slabs and a roof slab to attach to the structural columns and/or beams at each building level; constructing the load-bearing structural columns and beams at the building site; lifting the roof slab and each floor slab to attach to structural columns and/or beams at each level; installing stairs and elevators which attach to the structural columns, beams and/or slabs; installing the non-weight bearing walls and the interior components at each building level; and installing the plurality of exterior components on exterior building surfaces. The non-weight bearing walls, interior component, and exterior components are assembled and installed to provide the multi-story building with the plurality of units which may be identical or have different floor plans and may, optionally, include a retail level with amenity space and underground parking.
[0019] The present invention may be used to construct various buildings with a plurality of institutional, office, commercial, and/or residential units including, for example, studio units, one or multiple bedroom units, and/or a mix of such units.
[0020] The non-weight bearing walls of the present invention may include: demising walls that are pre-manufactured, pre-wired, pre-plumbed, prefinished, pre-bundled, preassembled, and may me include preassembled sections, electrical wiring and electrical radiant heat, acoustic insulation, studs for framing, fire rated sheathing, interior finish material, and may include plumbing for sprinklers; end walls that are pre-manufactured, pre-wired, pre-plumbed, prefinished, pre-bundled, preassembled, and may include preassembled sections, electrical wiring and electrical radiant heat, acoustic insulation, studs for framing, fire-rated sheathing, interior finish material, vapor barrier, thermal insulation, fire rated exterior sheathing, weather resistive barrier, an exterior cladding system, and may include plumbing for sprinklers; exterior walls that are pre-manufactured, pre-wired, pre-plumbed, prefinished, pre-bundled, preassembled, and may include preassembled sections, electrical wiring and electrical radiant heat, acoustic insulation, studs for framing, fire-rated sheathing, interior finish material, vapor barrier, thermal insulation, fire rated exterior sheathing, weather resistive barrier, an exterior cladding system, and may include plumbing for sprinklers and an optional window or door; utility walls that are pre-manufactured, pre-wired, pre-plumbed, prefinished, pre-bundled, preassembled, and may include features that permit stacking of the utility walls, heating, ventilating, and air conditioning (HVAC) electrical and communications wiring for adjacent walls, an electrical service panel, kitchen and bath plumbing, including kitchen and/or bath supply and waste lines and vent ducting, exhaust vents/fans and vent trims, and toilet mounting support with a water-resistant, interior surface, interior sheathing, vapor barrier, acoustic insulation, plumbing chase, studs for framing, exterior sheathing, weather resistive barrier, and an exterior cladding system, and exterior window walls that are pre-manufactured prefinished, preassembled, pre-bundled and that may be pre-glazed and pre-bundled with a unitized wall system, and may include windows, insulation, insulated aluminum or glass and weather seal. Optionally, pre-manufactured, pre-wired, prefinished and preassembled ceiling panels that may include electrical wiring and acoustical paneling may also be used as part of the present invention. Each of the above components may also be pre-manufactured so as to be only partially prefinished and/or preassembled, with complete finishing and assembly to be done upon or after installation.
[0021] The present invention may optionally incorporate several environmentally friendly and/or green building practices. The present invention may utilize recycled products and materials, use low volatile organic compounds (VOC) finishes for improved indoor air quality, provide an abundance of natural day lighting for user comfort and well-being, provide operable windows for natural cross ventilation, incorporate use of alternative energy sources such as solar panels and wind powered turbines, provide solar thermal panels for domestic hot water and radiant heating, aid water and collection retention with green and vegetated roofs and water cisterns, utilize gray water recycling methods, provide water features and landscaping within the courtyard, and may increase cooling by introduction of green walls. The present invention optionally includes the use of external rain screen system on the building itself. The rain screen system may be located directly adjacent to the building exterior and or may include an air gap of, for example, between about 1″ to 3,″ between the insulation and the cladding to allow for air movement within the cavity to provide a means of drying potential moisture behind the cladding material. The external cladding may be comprised of various materials allowed by code, such as, but not limited to, composite panels, phenolic resin panels, metal panels, cement board, lightweight precast concrete panels, wood siding, gypsum fiber reinforced cement panels, ceramic tile, and stone panels, and may be attached to metal or wood furring channels set apart from the insulation with an air gap.
[0022] The precise sequence of steps involved in the lift-slab method used to produce a multi-story building according to the present invention may be re-ordered and executed in various different sequence steps, including, for example, those methods disclosed in U.S. patent application Ser. Nos. 12/796,625 and 12/796,603, the contents of which are fully incorporated by reference herein.
[0023] The methods and sequence of construction steps disclosed in connection with production of identical unit and mixed unit residential buildings described in detail immediately below are provided as exemplary embodiments of the present invention only and are, in no way, intended to be limiting.
[0024] One method of constructing a multi-story building with a plurality of units comprises: (a) pre-manufacturing a plurality of non-weight bearing walls with a finished exterior including all electrical, insulating, plumbing and communications components; (b) pre-manufacturing a plurality of interior components adapted to connect to the non-weight bearing walls; (c) pre-manufacturing a plurality of exterior components adapted to attach to the building's exterior surfaces; (d) transporting the non-weight bearing walls, the interior components, and the exterior components to a building site; (e) preparing a multi-story building foundation at the building site to support a plurality of load-bearing structural columns and/or beams; (f) forming and pouring a plurality of floor slabs and a roof slab to attach to the structural columns and beams at each building level; (g) constructing the load-bearing structural columns and/or beams at the building site (h) installing the exterior walkways to the structural columns and/or beams; (i) installing stairs and elevators to attach to the structural columns, beams and/or slabs, (j) loading the plurality of exterior components on the first slab; (k) lifting and securing the first slab from the poured slabs up to top of the building; (l) loading the plurality of non-weight bearing walls, the interior components, and the exterior components to the second slab; (m) lifting and securing the second slab to the structural columns and beams forming the top door, (n) repeating steps (l) through (m) until all building levels are completed; (o) installing exterior components on exterior building surfaces; (p) installing demising walls in a direction perpendicular to the longitudinal direction of the slab and partially enclosing each of the units; installing end walls on the exterior sides of the units at building's ends in a direction parallel to the demising walls and partially enclosing each of the units located at the building's ends; (r) installing utility walls on the interior sides of the units in a perpendicular direction interfacing with the demising walls and connecting with the demising walls to partially enclose each of the units; (s) installing exterior window walls on exterior sides of the units and substantially enclosing each of the units; (t) installing entry doors in line with the utility walls and completely enclosing each of the units; (u) installing kitchen and bathroom components to the utility walls; and (v) installing interior partitions within each of the units for separating rooms and configuring each of the units. Using this method of construction, the non-weight bearing walls, the interior components, and the exterior components may be assembled and installed to provide the multi-story building with units having identical or different floor plans and, optionally, a retail level with underground parking.
[0025] Another method of constructing a multi-story building with a plurality of units comprises, (a) pre-manufacturing a plurality of non-weight bearing walls with a finished exterior including all electrical, insulating, plumbing and communications components: (b) pre-manufacturing a plurality of interior components adapted to connect to the non-weight bearing walls; (c) pre-manufacturing a plurality of exterior components adapted to attach to the building's exterior surfaces; (d) transporting the non-weight bearing walls, the interior components, and the exterior components to a building site; (e) preparing a multi-story building foundation at the building site to support to a plurality of load-bearing structural columns and/or beams; (f) forming and pouring a plurality of floor slabs and a roof slab to attach to the structural columns and beams at each building level; (g) constructing the load-bearing structural columns and/or beams at the building site; (h) installing stairs and elevators to attach to the structural columns, beams and/or slabs; (i) installing exterior roof components on the top slab surface; (j) lifting and securing the first slab from the poured slabs up to top of the building; (k) installing the non-weight bearing walls other than exterior window walls and some of the interior components on a second slab located beneath the first slab; (l) loading the exterior window walls and rest of the interior component on the second slab; (m) lifting the second slab with the non-weight bearing walls and the interior components whether installed or loaded to the floor level immediately beneath the first slab; (n) attaching the second slab securely to load-bearing structural columns and/or beams to form a top floor; (o) installing the remaining non-weight bearing walls, exterior window walls, the rest of the interior components on the second slab to complete the top level; (p) repeating steps (k) through (o) until all building levels are secured. Using this method of construction, the non-weight bearing walls, the interior components, and the exterior components may be assembled and installed to provide the multi-story building with units having identical or different floor plans and, optionally, a retail level with underground parking.
[0026] The foregoing and other objectives, features, and advantages of the 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
[0027] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments.
[0028] FIG. 1 illustrates a multi-story building according to an embodiment of the present invention.
[0029] FIGS. 2A-B illustrate a building plan with various unit layouts of FIG. 1 .
[0030] FIG. 3 illustrates a side elevation view of the multi-story building.
[0031] FIG. 4 illustrates a side sectional view of an exemplary portion of the multi-story building of FIG. 3 .
[0032] FIGS. 5A-B illustrate a floor plan of an exemplary portion of the various floor plans of FIG. 1 .
[0033] FIGS. 6A-B illustrate various embodiments of a single unit for the building of FIG. 1 .
[0034] FIG. 7 illustrates the structural framing of the multi-story building of FIG. 1 .
[0035] FIG. 8 illustrates the structural framing of the multi-story building of FIG. 1 for the floor and roof assembly before the floor slabs and roof slab are assembled into place.
[0036] FIG. 9 illustrates the structural framing of the multi-story building of FIG. 1 for the floor and roof assembly after the floor slabs and roof slab are assembled into place.
[0037] FIGS. 10A-B illustrate a components plan of an exemplary efficiency studio unit for various walls and components before and after assembly.
[0038] FIGS. 11A-F illustrate a perspective view of different phases of assembling an exemplary efficiency studio unit.
[0039] FIGS. 12A-B illustrate a components plan of an exemplary standard studio unit for various walls and components before and after assembly.
[0040] FIGS. 13A-F illustrate a perspective view of different phases of assembling an exemplary standard studio unit.
[0041] FIGS. 14A-B illustrate a components plan of an exemplary one bedroom unit for various walls and components before and after assembly.
[0042] FIGS. 15A-F illustrate a perspective view of different phases of assembling an exemplary one bedroom unit.
[0043] FIGS. 16A-B illustrate a components plan of an exemplary two bedroom unit for various walls and components before and after assembly.
[0044] FIGS. 17A-F illustrate a perspective view of different phases of assembling an exemplary two bedroom unit.
[0045] FIGS. 18A-D illustrate side and top views of the exterior window wall assemblies for various units.
[0046] FIGS. 19A-C illustrate sectional base and head details of structural members before attaching the demising wall to the slab.
[0047] FIGS. 20A-C illustrate sectional details of steps to securce the demising wall base to the slab.
[0048] FIGS. 21A-C illustrate sectional details of steps to secure the demising wall head to the slab.
[0049] FIG. 22 illustrates cross sectional head and base details of the demising wall attached to the slab.
[0050] FIG. 23 illustrates sectional details for attaching the exterior or end wall to the slab.
[0051] FIGS. 24A-C illustrate sectional head details of structural members before attaching the utility wall to the slab.
[0052] FIGS. 25A-C illustrate sectional base details of structural members before attaching the utility wall to the slab.
[0053] FIG. 26 illustrates sectional details tor attaching the utility wall to the slab.
[0054] FIGS. 27A-B illustrate plan details of the end wall and demising wall interfacing with the exterior window wall after attaching the exterior window wall to the slab.
[0055] FIGS. 28A-B illustrate sectional details for attaching the exterior window wall to the slab.
[0056] FIGS. 29A-D illustrate a side view of an entry way and attachment to the floor slab.
[0057] FIG. 30 illustrates a top view of an entry way with utility wall and demising wall installed.
[0058] FIGS. 31A-B illustrate a detailed view of an entry way interfacing with the end wall and demising wall with an adjacent entry door.
[0059] FIGS. 32A-B illustrate an elevation view of the utility wall without bath and kitchen components in place as well as the utility wall with bath and kitchen components in place.
[0060] FIGS. 33A-B illustrate top and side views of a bathroom.
[0061] FIGS. 34A-B illustrate various shower pan and drain options.
[0062] FIGS. 35A-C illustrate cross-sectional details of the interior glass partitions and bathroom doors before and after attachment to the slab.
[0063] FIGS. 36A-B illustrate cross-sectional details of the bedroom glass partition before and after attachment to the slab.
[0064] FIGS. 37A-C illustrate cross-sectional details of the bedroom entertainment wall before and after attachment to the slab.
[0065] FIGS. 38A-B illustrate cross-sectional details of installing a parapet wall component over a roof.
[0066] FIGS. 39A-B illustrate cross-sectional details of installing a garden roof drain next to the parapet wall component.
[0067] FIG. 40 illustrates cross-sectional details of constructing exterior common walkways.
[0068] FIG. 41 illustrates in a cut away view the components that make up the completed utility wall.
[0069] FIG. 42 illustrates the component parts of the utility wall, including the supply and waste piping and vent ducting to pre-designed locations, and installation of the water heater within the wall cavity.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0070] Before describing the invention and the figures, some of the terminology should be clarified. Please note that the terms and phrases may have additional definitions and/or examples throughout the specification. Where otherwise not specifically defined, words, phrases, and acronyms are given their ordinary meaning in the art. Exemplary embodiments may be better understood with reference to the drawings, but these embodiments are not intended to be of a limiting nature.
[0071] As used herein, “prefinished” refers to a component or components that arrive at the building site partially or fully completed and ready to be installed, and may include application of both the interior and exterior finish materials to the component(s).
[0072] As used herein, “pre-bundled” refers to a pre-manufactured component or components that are partially or fully protected, packaged, secured or otherwise made ready for transportation to the building site.
[0073] As used herein, “preassembled” refers to the partial or full assembly of a pre-manufactured component or components that occurs wholly or in part at a location other than the building site.
[0074] The exterior window wall may be an aluminum and glass panel with the possibility of containing an operable window unit. The exterior window wall may include the use of spandrel or fritted glass, as well as metal panel within the frames. The exterior window wall may also include an integral sliding door and railing to create an open wall with a flush ‘Juliet’ balcony or a full balcony bolted onto the structural frame. A first type of exterior window wall may be used in a straight configuration. A second type of exterior window wall may be used in corner units located adjacent to a building's corners. All of the exterior window walls may be fully weather-sealed and may be able to provide a U-factor of at least about 0.40. A U-factor measures the rate of heat transfer through a building element over a given area.
[0075] The entry doors may be a pre-fabricated, pre-bundled entry door unit with operable transom panel above, inner and outer frames, and all associated door hardware with preassembled sections that may include electrical wiring and may include plumbing for sprinklers. The entry door may be set in place at the final exterior wall or adjacent to the utility walls. A threshold may be provided for installation after the entry door is in place.
[0076] The kitchen unit may be a pre-fabricated and preassembled kitchen unit and may include cabinets, preinstalled plumbing, plumbing connections, electrical wiring, vent ducting, countertops, at least one sink, exhaust vents/fans and light fixtures that may be installed on, or connected to, the kitchen on the utility walls.
[0077] The cabinets may be pre-manufacutred and preassembled cabinets that may include integral exhaust fans, light fixtures, refrigerator and/or washer and dryer to be installed on, or connected to, the utility walls.
[0078] The bathroom vanity may include at least one sink and preinstalled plumbing that may be installed on, or connected to, the bathroom on the utility walls.
[0079] The parapet wall may be a pre-manufactured, prefinished, and preassembled wall at the top portion of the exterior window wall, end wall, exterior wall, or utility wall that may connect to a roof slab and accommodate a building's roofing and/or garden roof conditions.
[0080] The exterior walkway may be a pre-fabricated, pre-bundled walkway with preassembled sections that may support railing and decking for rapid installation. The exterior walkway may be used in place of scaffolding during construction. Specifically, the exterior walkway may be used to provide access to secure slabs to the structural columns and/or beams and to provide ease of access for connecting utilities.
[0081] It should be noted that although these embodiments are described in relative terms as prefinished, preassembled and/or pre-bundled, the present invention is not limited to pre-manufactured building structures that are completely prefinished, preassembled and/or pre-bundled in the factory or at a site other than the building site. The present invention also encompasses the final finishing or assembly of the pre-manufactured structures and/or the use of non-pre-bundled components at the building site. The use of partially prefinished, preassembled and/or pre-bundled pre-manufactured structures may be determined on a project by project basis.
[0082] Referring now in detail to the drawing figures, FIG. 1 illustrates an exemplary embodiment of a building 100 built according to the construction system and method of the present invention. FIG 1 illustrates an exemplary six-story building 100 that is part of a development including several residential buildings 101 and 102 with a plaza or retail floor 110 at street level for commercial activity and secure, below-grade parking underneath the building 100 . All of the residential buildings 101 and 102 in this development are to be constructed using the same construction system and method of the present invention.
[0083] FIGS. 2A-B illustrate a building plan 200 of the exemplary building 100 of FIG. 1 . As shown in FIG. 2A , all of the buildings share common exterior walkways. The inventors also note that the present invention may be readily adapted to include courtyards which may provide shared community or amenity space. By enclosing these exterior spaces within courtyards, building residents may enjoy the outdoor shared space and may also enjoy improved security if these spaces are closed off from access external to the building. FIG. 2B illustrates a detailed plan view of exemplary building plan 200 of FIG. 2A with four variations of floor plans 200 A-D. Floor plans 200 A-D are provided as examples only, and are not limiting with regard to the present invention.
[0084] FIG. 3 illustrates a side elevation view of an exemplary six-story building. This exemplary building comprises second through sixth levels of residential units 210 , 220 , 230 , 240 , 250 above a main, retail floor 110 for commercial development at the street level and a level of below-grade parking (shown in FIG. 4 ).
[0085] FIG. 4 illustrates a side sectional view of an exemplary portion of the multi-story building of FIG. 3 . As shown in FIGS. 3 and 4 , the retail floor 110 for commercial activity is shown with residential levels 210 , 220 , 230 , 240 , 250 above the retail floor 110 . Every residential level from second through sixth 210 , 220 , 230 , 240 , 250 may be identical in building floor plan and configuration. The present invention may comprise, but is not limited to, identical building floor plans and configurations for every floor. The present invention allows the number of bedrooms in any given residential unit and the layout of the units on any given floor to be modified by the simple relocation of a demising wall. However, with the present invention, the location of the utility wall should remain vertically stacked in order to maintain many of the efficiencies that are currently realized by this invention. These modifications to the layout of the units or number of bedrooms also do not require changing out of the window wall components. Furthermore, depending on the specific circumstances, there may be additional modifications to the exterior walls to accommodate different floor plans and layout of the units for various floor levels. A below grade parking level 20 b is shown for parking cars for commercial and/or residential use.
[0086] FIGS. 5A-B illustrate a floor plan 200 A from FIG. 2B of the building plan 200 . The floor plan 200 A of the building plan 200 illustrates many different layout types of units 200 A- 1 to 200 A- 8 .
[0087] FIGS. 6A-B illustrate exemplary floor plans 300 A-H and 300 J of the different types of units and layout variations to be implemented into any floor level 210 , 220 , 230 , 240 , 250 of a multi-story building 100 . An efficiency plan 300 A is illustrated in the first exemplary unit type. A studio plan 300 B is illustrated in the second exemplary unit type. A one-bedroom plan 300 C, as possible corner units, is illustrated in the third exemplary unit type. A two-bedroom efficiency plan 300 D, as possible units, is illustrated in the fourth exemplary unit type. A two-bedroom plan 300 E, as possible end units, is illustrated in the fifth exemplary unit type. In 300 F, a two-bedroom with two bathrooms is illustrated in the sixth exemplary unit type. A three-bed room with three beds and two bathrooms 300 G, as possible end units, is illustrated in the seventh exemplary unit type. A two-bedroom with two bathrooms plan 300 H on a corner is illustrated in the eighth exemplary unit type. A three-bedroom with two bathrooms plan 300 J on a corner is illustrated in the ninth exemplary unit type. It should be noted that this figure is not meant to limit the types and arrangements of possible unit layouts in the present invention.
[0088] The lift-slab construction of the multi-story building 100 is described in detail for the load bearing assembly of the structural frame 400 and floor slabs 450 . More specifically, FIG. 7 illustrates the structural frame 400 of the exemplary multi-story building 100 of FIG. 1 . The structural frame 400 material is preferably steel even though other materials with similar strength and durability may be used for constructing the building 100 . Therefore, utilizing steel for the structural frame 400 is not meant to be limiting. The structural frame 400 can also be made out of cast-in-place concrete, concrete masonry unit, precast concrete or similar materials. Vertical columns 405 , horizontal beams 406 , and diagonal brace frame members 407 are used for this load bearing assembly of the structural frame 400 . Structural steel framing occurs only at the perimeter of the building's slabs. All primary steel framing members are positioned exterior to the building for providing support. The steel framing 400 is delivered to the site in as-complete-of-an-assembly as possible, only limited in size by shipping or trucking restrictions. Vertical columns 405 , horizontal beams 406 and diagonal brace frames 407 may be hoisted by crane and braced and bolted into place. The perimeter steel framing 400 for the building 100 may be placed prior to or after the building's slabs 450 A-F are poured in place (shown in FIG. 8 ). Strand jacks are strategically located atop the support columns and/or beams. The number of strand jacks used is dependent on the length and shape of the floor slabs to be hoisted. Cables are lowered to reach the first slab and securely attached to the slab at predetermined attachment locations. The slab is then hoisted to the upper most level and secured to the steel framing 400 .
[0089] For preconstruction and excavation prior to building the structural frame 400 , conventional methods of surveying, excavation and shoring may be utilized that are appropriate for the existing soil/ground conditions and preferred depth required for excavation. For example, deeper excavations may require shoring and possible below-grade waterproofing. Shoring may be constructed using concrete or wood, or other suitable material, depending on the best option for the area. Locating, trenching and extending the existing utilities to the new structure may utilize conventional methods of construction and may occur in conjunction with excavation and construction of the foundation.
[0090] For foundation construction, including basements if applicable, footings are first applied, spread and matted evenly. Any forming, reinforcing, and casting of footings and foundation walls may utilize conventional methods of concrete construction. For basements, formwork and reinforcing of below-grade walls may utilize conventional slip-form concrete construction. Slip-form construction refers to a method by which large towers or bridges are built front concrete by pouring concrete into a form and moving the hardened concrete. Typically, slip-form construction minimizes the materials used in formwork and labor, reduces the amount of concrete waste produced, and also allows for the foundation walls to be erected with the rapid speed. Unlike other concrete methods, slip-form construction does not produce over-shot concrete structures and requires very little cleanup or hauling away of waste concrete product. All site utilities may be extended to the building's service points while staged and protected for future connections. Similarly for elevator and stair foundation, excavation and forming of the foundation for the elevator and stair systems may be carried out in conjunction with the rest of the building's excavation and forming. Formwork may be properly placed, reinforcement added, and the foundation concrete may be placed and finished.
[0091] For concrete slab-on-grade construction, conventional construction practices may be utilized. A slab-on-grade may occur either at the basement level or at grade level if no basement is built. Utilities may be extended so that they are about 6 to 8 feet above the top of the slab either at the basement level or at grade level. Once this step is finished, the steps of placing the backfill, providing compaction, installing gravel, positioning vapor barrier, if required for local geotechnical review, and securing the slab reinforcement may be followed by placing and finishing the concrete slab. If a particular design incorporates below grade parking, the step of constructing a ramp may be implemented. Alternatively, the step of constructing a ramp may occur after the slab-on-grade is positioned into place. Typically, the ramp's formwork may be placed and followed by the step of securing and installing of the slab reinforcement. After these steps, the ramp's concrete slab may be placed and finished.
[0092] Assuming that only one level of parking is constructed below grade, the steps of positioning the shoring and forming the slab-on-grade level may be carried out after the basement slab and ramp are placed. Afterwards, the steps of securing slab reinforcement, any block-outs or sleeves required for the building's mechanical, plumbing, electrical, communications, site planter drainage, irrigation, parking control systems and electrical connections for security and lighting may be implemented. The steps of pouring, finishing and sealing concrete may then be implemented. If a commercial or retail level is being considered for the at grade level, then the concrete slab at the second story may be placed by conventional shoring and forming methods.
[0093] For constructing a plaza 110 for retail at the street level with an exterior courtyard, a residential terrace may be constructed at the level immediately above the retail level as shown in FIGS. 1, 3 and 4 . Conventional methods, including cast-in-place concrete construction, may be used for all construction up to and including the terrace level slab. Cast-in-place concrete construction may be used for foundations, slabs-on-grade, structural support such as walls, beams, columns, floors, roofs, large portions of bridges, pavements, and other infrastructures by transporting concrete in its unhardened state to the site for placement in forms. The step of placing slab reinforcement, any block-outs or sleeves required for the building's mechanical, plumbing, and electrical and communications systems as well as any walkway drains, and electrical connections for security and lighting may be implemented. Once reinforcement and block-outs are placed, concrete may be poured, finished and sealed. Columns for the plaza at the street/retail level 110 may utilize cast-in-place concrete construction. The reinforcement for the columns is placed first. Thereafter, the column formwork is placed before pouring the concrete for forming the columns. These steps may be carried out prior to erecting any shoring for the terrace slab 205 as shown in FIG. 4 . Shoring may then be placed to support any decking made of wood or other similar materials and other formwork for the terrace slab 205 at the second story level above the plaza/retail level 110 . This step may be followed by the step of placing the slab reinforcement, any block-outs or sleeves required for the building's mechanical, plumbing, electrical and communications systems as well as for any courtyard drains, irrigation supply lines and electrical connections for security and lighting. Once the reinforcement and block-outs are placed, the terrace slab 205 of concrete may be poured, finished and sealed.
[0094] FIGS. 8-9 illustrate the steps of forming the floor and roof slabs 450 -A-F and placing the floor slabs and roof slab 450 A-F at each level by lifting up the slabs 450 A-F and securing the slabs 450 A-F at their appropriate elevation level. The floor slabs and roof slab 450 A-F above the plaza/retail level 110 utilize a method of construction wherein slab formwork may be reused. Determining whether the slabs are poured one-on-top-of-the-other and hoisted to their appropriate elevation or the roof slab is placed first and then the formwork is lowered after the placement of each slab, depends on a general contractor's decision based on the local conditions and logistics of each site. The preferred method is pouring the slabs 450 A-F one-on-top-of-the-other which are then hoisted to their appropriate elevation level. In the preferred method, a bond breaking solution is applied to the surface of the lower slab between each pour of the successive slab to ensure adequate separation between the slabs 450 A-F.
[0095] As noted earlier, the forming and pouring of the floor slabs and roof slab 450 A-F may occur prior to or after the building's structural frame 400 is erected. If using the plaza/retail level 110 slab as a base, the building's typical floor slabs and the roof slab 450 A-F are poured one on-top-of the other, using the slab 450 A below as the formwork for the slab 450 B above. All of the slabs 450 A-F will remain stacked on the plaza/retail level 110 surface until the slabs 450 A-F have cured and reached the desired design strength. Upon curing, the slabs 450 A-F are ready to be hoisted or lifted up to their finished elevation via a series of strand jacks strategically located atop the support columns and/or beams. The number of strand jacks used is dependent on the length and shape of the floor slabs to be hoisted. Upon the forming, pouring and curing of all of the slabs 450 A-F, each of the floor slabs and roof slab 450 A-F will then be loaded with a plurality of non-weight bearing walls, a plurality of exterior window walls, a plurality of interior components, and a plurality of exterior components, followed by lifting or hoisting up to the appropriate elevation level so that every slab 450 A-F is securely positioned and attached at every building level so that non-weight bearing walls, exterior window walls, interior components, and exterior components may be installed at every level in-between floor slabs and roof slab 450 A-F. Each hoisted floor slab contains numerous concrete embedded steel plates that will align with steel plates securely attached to the structural beams and/or columns 405 , 406 as the slabs are hoisted into position. Upon reaching the appropriate position and the plates become aligned, a bolted or pinned connection may be used to securely attach the slabs 450 A-F to the structural frame 400 . The exterior walkways, exterior beams 410 A-F and/or the use of man lifts may be used as a means of accessing the connections points, thereby eliminating any unnecessary hazards of having workers located under the unsecured slabs to access the connection points.
[0096] An alternate method may include installing exterior roof components on the cured top or roof slab 450 F and lifting the top or roof slab 450 F all the way to the top of the building via a series of strand jacks strategically located atop the support columns and/or beams. The number of strand jacks used is dependent on the length and shape of the floor slabs to be hoisted. Immediately after securing the top slab 450 F, a plurality of non-weight bearing walls, exterior window walls, and some of the interior components, including the shower pan, kitchen and bathroom components are installed on a second slab 450 E beneath the first slab 450 F that is not yet lifted. Upon installation of the non-weight bearing walls and some of the interior components, and upon loading of the exterior window walls and rest of the interior components on the second slab 450 E below, the second slab 450 E with non-weight bearing walls, exterior window walls, and interior components, is lifted or hoisted up under the first slab at the top 450 F and securely attached to the load bearing structural frame 400 to make the top floor or level. Each hoisted floor slab contains numerous concrete embedded steel plates that will align with steel plates securely attached to the structural beams and/or columns 405 , 406 as the slabs are hoisted into position. Upon reaching the appropriate position and the plates become aligned, a bolted or pinned connection may be used to securely attach the slabs 450 A-F to the structural frame 400 . The exterior walkways, exterior beams 410 A-F and/or the use of man lifts may be used as a means of accessing the connections points, thereby eliminating any unnecessary hazards of having workers located under the unsecured slabs to access the connection points.
[0097] The next sequence of steps involves installation of elevators and stairs. The pre-fabricated, pre-bundled stairs with preassembled sections is delivered to the site. Lower sections of the stairs are set and anchored into place simultaneously with the placement of the street level slab or at grade slab 430 . Installation of the stairs will track closely with the installation of the building's structural frame 400 . Installation of the structural framing for the elevator enclosure will track in conjunction with installation of the rest of the building's vertical columns 405 .
[0098] Upon securely attaching the second slab 450 E to the load bearing structural columns and beams 405 , 410 E, the loaded exterior window walls and the rest of the interior components including the entry doors and interior partitions are installed to the second slab 450 E to complete the building's top level. Non-weight bearing walls, the exterior window walls, kitchen and bathroom components are next installed on a third floor slab 450 D beneath second slab 450 E. Similar to the previously described process for constructing the top level, the exterior window walls and the rest of the interior components are loaded on the third slab 450 D below, and the third slab 450 D with the non-weight bearing walls and the interior components, whether installed or loaded, is lifted up or hoisted under the second slab 450 E and securely attached to the load-bearing structural columns and beams 405 , 410 E to make a level beneath the top level. This process of loading and installing the non-weight bearing walls, the exterior windows, and the interior components is repeated until all the building levels are completed.
[0099] Upon suspending the slabs 450 A-F at their appropriate elevation levels, each slab 450 A-F is bolted or pinned to the vertical columns 405 and horizontal beams 410 A-F which make up the load bearing steel framing 400 . For example, the roof slab 450 F is securely attached to the vertical columns 405 and the top horizontal beam 410 F. The top floor slab 450 E is securely attached to the vertical column 405 and the fifth horizontal beam 410 E. The fourth floor slab 450 D is securely attached to the vertical columns 405 at the fourth horizontal beam 410 D. The third floor slab 450 C is securely attached to the vertical columns 405 at the third support beam 410 C. The second floor slab 450 B is securely attached to the vertical columns 405 at the second support beam 410 B. The first floor slab 450 A is securely attached to the vertical columns 405 at the first support beam 410 A. The present invention limits or eliminates the time consuming and costly process of field welding, however the use of field welding is not prohibited in the present invention.
[0100] Conventional steel reinforcing bars and post tensioned cables may be used in the slabs 450 A-F. The span of the slab 450 A-F is set at a distance that can be supported within the depth and width of the slab 450 A-F. Upon placing the slabs 450 A-F at appropriate elevation levels, they will fully support their spans without the use of supplemental beams or columns. Electric radiant heat coils may be incorporated into the concrete floor slabs 450 A-F to heat each unit. The structural floor slabs 450 A-F may act as the finished floor slab for the unit above or the finished ceiling for the unit below. Acoustical and impact isolation at the slab 450 A-F is required and may either be accomplished by coverage on the floor and/or by including optional pre-fabricated ceiling panels which may also include acoustical paneling.
[0101] FIGS. 10A-B illustrate a components plan of an exemplary efficiency studio unit 300 A from FIG. 6A for various walls and components before and after assembly. As shown in FIGS. 10A-B of the exemplary efficiency studio unit 300 A, the efficiency studio unit 300 A is enclosed by the exterior window walls 530 B, exterior window wall panels 530 D, demising walls 500 A-B, and utility wall 520 . The efficiency studio unit 300 A further includes interior components kitchen unit 600 A, bathroom vanity 610 , toilet 611 , shower pan 612 A and shower partitions 620 A-B. The exterior window wall panels 530 D are part of the exterior window wall system and positioned in-between the exterior window walls of each unit. On the opposing side of the exterior window walls 530 D in a parallel direction, the utility wall 520 is installed for connecting the bathroom and kitchen components. The entry door 540 is positioned between the utility walls 520 and demising wall 500 B for easy entry into the efficiency studio unit 300 A.
[0102] Each of the demising walls 500 A-B are positioned directly opposite of each other in a parallel direction to enclose the studio unit 300 A. The shower 612 A (later shown in FIGS. 33A-B ) is partitioned off by the first and second shower partitions 620 A-B. The bathroom is partitioned off by the sliding bathroom door 621 attached to the second shower partition 620 B and kitchen unit 600 A. The kitchen unit 600 A is installed in a perpendicular direction against the utility wall 520 and has a kitchen sink 601 , cooktop 602 A, and cabinets (not shown in FIG. 10 ). Other internal furniture such as a bed, desks, chairs, dresser, coffee table, and couches may be placed anywhere.
[0103] FIGS. 11A-F illustrate a perspective view of different phases of assembling an exemplary efficiency studio unit and its interior components. FIG. 11A illustrates an exemplary efficiency studio unit floor 460 of the slab with a recess 470 for a possible recessed shower pan. After the slabs 460 are in place, the demising walls 500 A-B are delivered to the site. Each of the demising walls 500 A-B can be installed in place in the studio unit. In this particular embodiment, the demising walls 500 A-B are single components. However, depending on the overall plan, the dimensions of the demising walls 500 A-B are easily changeable and not limited to these dimensions. The demising walls 500 A-B shown in FIG. 11B are delivered to the site as preassembled, pre-wired and prefinished components. The demising walls 500 A-B and all other components can either be installed after the slabs are hoisted or installed in their final position prior to the slabs 460 being lifted.
[0104] As shown in FIG. 11C , a utility wall 520 is installed so that a bathroom vanity 610 (not shown) and toilet 611 (not shown) can be installed against the utility 520 . As shown in FIG. 11D , window walls 530 B, 530 D are installed to further enclose the studio unit. In the next step as shown in FIG. 11E , the entry door 540 may be installed either after or before installation of the bathroom and kitchen components. The shower pan 612 A is fitted into the slab recess 470 , if a recess is provided, before installing the bathroom and kitchen components. As shown in FIG. 11F , immediately adjacent to the bathroom is a kitchen unit 600 A with a kitchen sink 601 and a countertop, cooktop 602 A, and cabinets 603 . The shower partition 620 A-B separates the shower and bathroom from the living space area with a sliding door 621 . An upper glass partition 641 is installed above the kitchen unit 600 A to further separate the bathroom from the kitchen area. The details of attachment of the demising walls 500 A-B, window walls 530 B, 530 D, utility wall 520 , entry door 540 , and interior components of the exemplary efficiency studio unit to the slab 460 are described further in detail in FIGS. 19-37 .
[0105] FIGS. 12A-B illustrate a components plan of an exemplary standard studio unit 300 B from FIG. 6A for various walls and components before and after assembly. As shown in FIGS. 12A-B of the exemplary standard studio unit 300 B, the standard studio unit 300 B is enclosed by the exterior window walls 530 C, exterior window wall panels 530 D, demising walls 500 A-B, and utility wall 520 . The standard studio unit 300 B further includes interior components kitchen unit 600 B, bathroom vanity 610 , toilet 611 , shower pan 612 A and shower partitions 620 A-B. The exterior window wall panels 530 D are part of the exterior window wall system and positioned in-between the exterior window walls of each unit. On the opposing side of the exterior window walls 530 C in a parallel direction, the utility wall 520 is installed for connecting the bathroom and kitchen components. The entry door 540 is positioned between the utility wall 520 and demising wall 500 B for easy entry into the efficiency studio unit 300 B.
[0106] Each of the demising walls 500 A-B are positioned directly opposite of each other in a parallel direction to enclose the studio unit 300 B. The shower 612 A (later shown in FIGS. 33A-B ) is partitioned off by the first and second shower partitions 620 A-B. The bathroom is partitioned off by the sliding bathroom door 621 attached to the second shower partition 620 B and the storage cabinet 630 A. The kitchen unit 600 B is installed against the utility wall 520 that has a kitchen sink 601 , cooktop 602 A, and cabinets (not shown in FIG. 12 ). Other internal furniture such as a bed, desks, chairs, dresser, coffee table, and couches may be placed anywhere.
[0107] FIGS. 13A-F illustrate a perspective view of different phases of assembling an exemplary standard studio unit and its interior components. FIG. 13A illustrates an exemplary standard studio unit floor 461 of the slab with a recess 470 for a possible recessed shower pan. After the slabs 461 are in place, the demising walls 500 A-B are delivered to the site. Each of the demising walls 500 A-B can be installed in place in the studio unit. In this particular embodiment, the demising walls 500 A-B are single components. However, depending on the overall plan, the dimensions of the demising walls 500 A-B are easily changeable and not limited to these dimensions. As shown in FIG. 13B , the demising walls 500 A-B are delivered to the site as a preassembled, pre-wired and prefinished components. The demising walls 500 A-B and all other components can either be installed after the slabs are hoisted or installed in their final position prior to the slabs 461 being lifted.
[0108] As shown in FIG. 13C , a utility wall 520 is installed so that a bathroom vanity 610 (not shown) and toilet 611 (not shown) can be installed against the utility wall 520 . As shown in FIG. 13D , window walls 530 C, 530 D are installed to further enclose the studio unit. In the next step as shown in FIG. 13E , the entry door 540 may be installed either after or before installation of the bathroom and kitchen components. The shower pan 612 A is fitted into the slab recess 470 , if a recess is provided, before installing the bathroom and kitchen components. As shown in FIG. 13F , immediately adjacent to the bathroom is a kitchen unit 600 B with a kitchen sink 601 and a countertop, cooktop 602 A, and cabinets 603 . The shower partition 620 A-B separates the shower and bathroom from the living space area with a sliding door 621 . An upper glass partition 641 is installed above the storage cabinet 630 A to further separate the bathroom from the kitchen area. The details of attachment of the demising walls 500 A-B. window walls 530 C, 530 D, utility wall 520 , entry door 540 , and interior components of the exemplary standard studio unit to the slab 461 are described further in detail in FIGS. 19-37 .
[0109] FIGS. 14A-B illustrate a components plan of an exemplary one bedroom unit 300 C from FIG. 6A for various walls and components before and after assembly. As shown in FIGS. 14A-B of the exemplary one bedroom unit 300 C, the one bedroom unit 300 C is enclosed by the exterior window walls 530 A-B, exterior window wall panels 530 D, demising walls 500 A-B, and utility wall 520 . The one bedroom unit 300 C further includes interior components kitchen unit 600 C, bathroom vanity 610 , toilet 611 , shower pan 612 B, shower partitions 620 A-B, and a sliding bedroom glass partition 640 that separates the bedroom from the living room. The exterior window wall panels 530 D are part of the exterior window wall system and positioned in-between the exterior window walls of each unit or room. On the opposing side of the exterior window walls 530 A-B in a parallel direction, the utility wall 520 is installed for connecting the bathroom and kitchen components. The entry door 540 is positioned between the utility wall 520 and demising wall 500 B for easy entry into the one bedroom unit 300 C.
[0110] Each of the demising walls 500 A-B are positioned directly opposite of each other in a parallel direction to enclose the one bedroom unit 300 C. The shower 612 B (later shown in FIGS. 33A-B ) is partitioned off by the first and second shower partitions 620 A-B. The bathroom is partitioned off by the sliding bathroom door 621 attached to the second shower partition 620 B and the storage cabinet 630 B. Ihe kitchen unit 600 C is installed against the utility wall 520 that has a kitchen sink 601 , cooktop 602 B, and cabinets (not shown in FIG. 14 ). Other internal furniture such as a bed, desks, chairs, dresser, coffee table, and couches may be placed anywhere.
[0111] FIGS. 15A-f illustrate a perspective view of different phases of assembling an exemplary one bedroom unit and its interior components. Similar to assembling the standard studio unit as shown in FIGS. 13A-F , the demising walls 500 A-B are delivered to the site as preassembled, pre-wired and prefinished components and installed prior to installation of the exterior window walls 530 A-B. The utility wall 520 is similarly installed next to continue to enclose the one bedroom unit. All the internal bathroom and kitchen components are similarly installed as described in FIGS 13A-F . The window walls 530 A-B are then tilted into place to partially enclose the one bedroom unit 300 C. As illustrated in FIG. 15F , the bedroom is separated from the living area by a sliding bedroom glass partition 640 which terminates at a storage cabinet 630 B and window wall panel 530 D. The bathroom has a sliding bathroom door 621 that is attached to the shower partition 620 B that also separates the bathroom. An upper glass partition 641 is installed above the storage cabinet 630 B to further separate the bathroom from the kitchen area. The details of attachment of the demising walls 500 A-B, window walls 530 A-B, 530 D, utility wall 520 , entry door 540 , and interior components of the exemplary one bedroom unit to the slab are described further in detail in FIGS. 19-37 . On the side of the utility wall 520 , an entry door 540 is installed to fully enclose the one bedroom unit.
[0112] FIGS. 16A-B illustrate a components plan of an exemplary two bedroom unit 300 F from FIG. 6B for various walls and components before and after assembly. As shown in FIGS. 16A-B of the exemplary two bedroom unit 300 F, the two bedroom unit 300 F is enclosed by the exterior window walls 530 A-B, exterior window wall panels 530 D, demising walls 500 A, and utility walls 520 . The two bedroom unit 300 F further includes interior components kitchen unit 600 C with sink 601 and a countertop, cooktop 602 B, bathroom vanity 610 , toilet 611 , shower pan 612 B shower partitions 620 A-B, sliding bedroom glass partition 640 that separates the first bedroom from the living room. Furthermore, two bedroom unit 300 F includes entertainment wall 642 and glass pocket doors 643 that separates the second bedroom from the living room, and storage cabinets 630 B-C. The exterior window wall panels 530 D are part of the exterior window wall system and positioned in-between the exterior window walls 530 A-B. On the opposing side of the exterior window walls 530 A-B in a parallel direction, the utility walls 520 are installed for connecting the bathroom and kitchen components. The entry door 540 is positioned between the utility walls 520 for easy entry into the two bedroom unit 300 F.
[0113] Alternatively, the exemplary two bedroom unit can be configured in a number of various ways. Any of the layouts are flexible and walls as well as components can be changed around. For example, the entry door 540 can be positioned adjacent to storage cabinet 630 B and kitchen unit 600 C moved adjacent to storage cabinet 630 C; storage cabinets 630 B-C can be interchanged; sliding bedroom door 640 and entertainment wall 642 are completely interchangeable with each other.
[0114] FIGS. 17A-F illustrate a perspective view of different phases of assembling an exemplary two bedroom unit. The process for assembling exemplary two bedroom unit 300 F shown in FIG. 6B is similar in nature to assembling exemplary one bedroom unit 300 C shown in FIG. 6A as described above in FIGS. 15A-F . In addition, exemplary two bedroom unit 300 F contains an additional storage cabinet 630 C, entertainment wall 642 with glass pocket doors 643 , and could contain an additional bathroom and all of its components. Sequence and installation of these additional components for exemplary two bedroom unit 300 F are constructed along the same timeline as the similar components as exemplary one bedroom unit 300 C.
[0115] FIGS. 18A-D illustrate side and top views of various configurations of the exterior window walls 530 A-D for various units. The exterior window walls have operable windows 531 A-B for easily opening the windows for outside access. The operable windows open by swinging, sliding or by any other mechanisms used to open windows. The quantity, location, and spacing of the operable windows can vary from unit to unit and from building to building. The exterior window walls 530 A-D may contain clear glass, spandrel glazing with backup insulation or metal panel with backup insulation. Any of these exterior window walls 530 A-D may be installed to accommodate different layouts of units. All of the exterior window walls 530 A-D are delivered to the site pre-glazed for rapid installation.
[0116] In an effort to keep the construction as efficient as possible for on-site staging, storage of materials, walls and components are minimal. All of the building's fundamental elements are delivered to the site as pre-fabricated and prefinished components. These pre-fabricated and prefinished components include all exterior walls, demising walls, interior partitions, all kitchen and bathroom units, and other components. Walls are typically delivered in a minimum of ten foot lengths and may be as large as 20 foot lengths or more unless noted otherwise, and may be hoisted directly from the truck or other transport means to their final location for immediate installation.
[0117] The floor slabs and roof slab 450 A-F are either lifted and secured to the load bearing structural frame 400 or the floor slabs and roof slab 450 A-F are loaded, lifted and secured to the load bearing structural frame 400 . The step of constructing a building for the present invention may involve placing or installing the demising walls 500 A-B as shown in FIGS. 19-22 in their final position either prior to or after the slabs are lifted and secured in place. The exemplary demising wall 500 A has a head track 700 A and a base track 700 B as shown in FIGS. 19A-C . The demising wall 500 A is composed of staggered metal stud framing 701 with acoustical blanket insulation layer 702 , electrical connections, sprinklers, and communications components. The acoustical insulation layer 702 is preferably about 2″ to 3″ thick, weaved through the studs and contributes to a sound transmission class (STC) rating for the entire assembly of about 50 or higher. The electrical wiring is pre-installed at the factory and connected at the site while installing the demising walls 500 A to the other components. Both sides of the demising wall 500 A receive a layer of fire-rated wall sheathing 703 . The preferred method for finishing the demising wall 500 A is to attach a finish panel 704 over both sides of the demising wall 500 A at the site using wood or metal cleats 705 installed on the wall sheathing 703 . Several options are available for the exemplary finish panel 704 , including but not limited to, stain, paint, magnesium-oxide board, wood veneer, wood paneling, plaster, metal, wallpaper, and cork. A preferred application for the sheathing material 703 is a 12 mm magnesium oxide board, however, other similar fire-rated panels or materials may be used. Alternately, the finish panel 704 and cleats 705 may be omitted and the wall sheathing finished in a more conventional manner. More specifically, the wall sheathing may be taped and painted so as long as it achieves the required fire rating per local building codes.
[0118] The first step of installing the demising wall 500 A utilizes prefinished, acoustically sealed L-shaped support members 706 A-B and fasteners 707 which are secured to the top and undersides of the floor slab 450 . As shown in FIGS. 20A and 21A , the horizontal section of the L-shaped base and head support member 706 A-B has a pre-drilled hole (not shown) to receive the fastener 707 for securely attaching the L-shaped support member 706 A-B to the slab 450 . Therefore, the support members 706 A-B are securely attached to the top portion and underside of the slab 450 by drilling the base fastener 707 through the hole, the neoprene pad 708 at the base and into the slab 450 . The pad 708 is positioned immediately beneath the horizontal section of the base support member 706 A. Adjacent to the pad 708 , fire-sealant tape 709 is placed on each side of the pad 708 before drilling the base fastener 707 into the slab 450 .
[0119] As shown in FIGS. 20B and 21B , upon securely attaching the support members 706 A-B to the top and undersides of the slab 450 , the entire demising wall 500 A is set onto the base support member 706 A and secured into place. Simultaneously, the head section of the demising wall 500 A is placed adjacent to and inside the L-shaped head support member 706 B and securely positioned into place. The next step is to insert a support fastener 707 horizontally from the vertical side of the base and head support member 706 A-B through the demising wall 500 A as shown in FIGS. 20B and 21B . The head support member 706 B has pre-drilled holes (not shown) to allow vertical movement from slab 450 after support fastener 707 has been attached between the vertical side of the base and head support member 706 A-B. The next step as illustrated in FIG. 20C is to cover the inner side of the demising wall 500 A by attaching the base trim 710 A, preferably made of metal or other similar materials. More specifically, the base trim 710 A is preferably made of similar material as the L-shaped base support member 706 A. Base trim 710 A is attached with fastener 707 .
[0120] As shown in FIG. 21C , the next step in securing the demising wall is filling the horizontal gap created between the underside of the slab 450 and the head portion of the demising wall 500 A with fire-safe materials 711 . After installing the fire-safe material 711 , the next step is sealing any open spaces between the slab 450 and the head portion of the demising wall 500 A with caulk, preferably fire-resistant caulk, to prevent any fire from getting through the space. Caulk or similar fire-resistant material is also used to seal the space between the horizontal portion of the head support member 700 A and the underside of the floor slab 450 whereby the fire-safe materials 711 , backer rod and sealant 715 are inserted. This horizontal gap whereby the fire-safe materials 711 are filled also allows vertical movement of the slab 450 due to deflection. Upon sealing the open spaces between the demising walls 500 A and the slab 450 , the head trim 710 B is attached, preferably made of metal or other similar materials. More specifically, the head trim 710 B is preferably made of similar material as the L-shaped head support member 706 B. Head trim 710 B is attached on the inner side of the demising wall 500 A with fastener 707 . FIG. 22 illustrates a completely installed demising wall 500 A to floor slab 450 .
[0121] The next step of constructing a building using the present invention may be installing end walls 510 , particularly when a unit is not located in the middle of a building. A living unit that is located in the middle of a building is enclosed between two demising walls 500 A-B that are parallel to one another. In this case, both demising walls 500 A-B are placed one after the other. However, for a living unit that is located at the end of a building, the end unit requires installation of an end wall 510 in lieu of a second demising wall 520 B or an exterior window wall 530 A-C. The preferred sequence is to install the end wall 510 with its structural members immediately followmg installation of the demising walls 500 A-B as described in previous figures. This sequence helps to enclose the construction as soon as possible.
[0122] FIG. 23 illustrates cross-sectional details of end wall 510 . An exemplary end wall 510 is composed of metal stud framing 701 with thermal batt insulation 801 , sprinkler plumbing, electrical and communications components. The wiring and plumbing are pre-installed at a factory and connected at the site. The interior side of the end wall 510 receives a layer of fire-rated sheathing 703 , with a finished panel 704 . The inner wall sheathing 703 is preferably a 12 mm magnesium oxide board, however, other types of fire-rated wall panels with safety mechanisms may be used. The preferred method for finishing the end wall 510 is to attach a finish panel 704 over the end wall 510 at the site using wood or metal cleats 705 installed on the wall sheathing 703 . Several options are available for the exemplary finish panel 704 , including but not limited to, stain, paint, magnesium-oxide board, wood veneer, wood paneling, plaster, metal, wallpaper, and cork. Alternately, the finish panel 704 and cleats 705 may be omitted and the wall sheathing finished in a more conventional manner. More specifically, the wall sheathing may be taped and painted so as long as it achieves the required fire rating per local building codes. A final interior trim piece 710 A-B is installed with fastener 707 in a similar manner to the demising wall 500 A as described above following the secure placement of end wall 510 .
[0123] The exterior side of the end wall 510 receives exterior sheathing 803 , a weather resistive barrier 802 , furring channels 804 , preferably metal or similar material, rigid insulation 805 , associated flashing pieces 806 , exterior fasteners 807 and an exterior cladding material 800 . A section of exterior cladding 800 , metal furring channels 804 , rigid insulation 805 , associated flashing pieces 806 , and exterior fasteners 807 is temporarily left off the end wall 510 at the slab edge 450 as a means of providing the connection of the end wall 510 to the floor slab 450 as described below.
[0124] The steps to attach the end wall 510 to the floor slab 450 are illustrated in FIG. 23 and described as follows: base and head plates 808 A-B are attached at the face of the slab 450 with fasteners 807 that are drilled at the base and head conditions of the floor slab 450 prior to the end wall 510 being moved into place from the interior side of the building. The end wall 510 utilizes thermally insulated anchors 807 that are securely attached to the slab 450 prior to installing the end wall 510 . The portion of the plate 808 A-B that is attached to the exterior sheathing 803 has pre-punched slots (not shown in the figures) through which the fastener 807 is screwed horizontally to accommodate vertical movement of the end wall 510 due to movement of the slab 450 . Consequently, a horizontal gap allows slight, vertical deflection of the slab 450 . This gap may be filled with rigid insulation 805 or fire-safe materials 711 prior to attaching the dual exterior cladding panel.
[0125] Upon attachment of the plates 808 A-B to the slab 450 with fasteners 807 , the end wall 510 is moved into place with the exterior wall sheathing 803 abutting the base and head plates 808 A-B. Fasteners 807 are installed in the horizontal direction along the end wall 510 through the weather resistive barrier 802 and into the exterior sheathing 803 to securely attach the end wall 510 to the floor slab 450 . The next step is to attach a “peel and stick” weather resistive barrier 809 over the base and head plates 808 A-B at the base and head of the wall and the floor slab 450 of the end wall 510 . The final step involves attaching the final exterior cladding 800 , metal furring channels 804 , rigid insulation 805 , and associated flashing pieces 806 with fasteners 807 that was temporarily left off allowing access to attachment points of the end wall 510 to floor slab 450 . The installation of this final panel 800 completes the installation of the end walls 510 creating a weather-tight and watertight system.
[0126] After the demising walls and end walls are secured in place, the next step involved in constructing the building using the present invention may be to attach utility wall 520 as to further enclose the unit. Each unit 300 A-H and 300 J as shown in FIGS. 6A-B has a utility wall 520 at the end of every kitchen and bathroom. The utility wall 520 houses common mechanical, plumbing and electrical risers that serve the units 300 A-H and 300 J. All of the utilities to and from the units are accessed at the utility wall 520 . These utility walls 520 are delivered to the site as preassembled, pre-plumbed, pre-wired and prefinished components. The utility walls 520 arrive on-site with all the wall plumbing associated with the kitchen sink, toilet, and shower already in place. The utility walls 520 also include all plumbing supply, vent and drain lines, fire protection, shower valves, shower head, and associated wiring. The utility wall 520 further contains the unit's electrical panel and associated wiring. Refer to FIGS. 41-42 for the various components related to the utility wall 520 .
[0127] FIGS. 24A-C and FIG. 25A-C illustrate the exemplary components that compose the utility wall 520 . The exemplary utility wall 520 has a head track 720 A and a base track 720 B that encompass all framing members of the utility wall 520 . It is further composed of an interior side metal stud frame wall 701 with acoustical blanket insulation layer 702 , wall sheathing 703 and an interior finish material 721 . The utility wall 520 is further composed of an exterior side metal stud frame wall 701 with thermal batt insulation 801 , exterior sheathing 803 , weather resistive barrier 802 , furring channels 804 , rigid insulation 805 , associated flashing pieces 806 , exterior fasteners 807 and an exterior cladding material 800 . Possible cladding materials may be comprised of various materials allowed by code, such as, but not limited to, composite panels, phenolic resin panels, metal panels, cement board, lightweight precast concrete panels, wood siding, gypsum fiber reinforced cement panels, ceramic tile, and stone panels. A preferred application for both interior and exterior sheathing material 703 , 803 is a 12 mm magnesium oxide board, however, other similar fire-rated panels or materials may be used. A section of exterior cladding 800 , furring channels 804 , exterior sheathing 803 , rigid insulation 805 , associated flashing pieces 806 , and exterior fasteners 807 is temporarily left off the utility wall 520 at the slab edge 450 (not shown) as a means of providing the connection of the utility wall 520 to the floor slab 450 as providing an acesss point for connection of the utilities within the utility wall 520 .
[0128] As shown in FIG. 26 , the utility wall 520 attaches to the floor slab 450 as follows: base and head plates 808 A-B are attached at the face of the slab 450 with fasteners 807 that are drilled at the base and head conditions of the floor slab 450 prior to the utility wall 520 being moved into place from the interior side of the building. The utility wall 520 utilizes thermally insulated anchors 807 that are securely attached to the slab 450 prior to installing the utility wall 520 . The portion of the plates 808 A-B that are attached to the exterior sheathing 803 has pre-punched slots (not shown in the figures) through which the fastener 807 is screwed horizontally to accommodate vertical movement of the utility wall 520 due to movement of the slab 450 . Consequently, a horizontal gap allows slight, vertical deflection of the slab 450 . This gap may be filled with rigid insulation 805 or fire-safe materials 711 prior to attaching the final exterior cladding panel 800 .
[0129] Upon attachment of the plates 808 A-B to the slab 450 with fasteners 807 , the utility wall 520 is moved into place with the exterior wall sheathing 803 abutting the base and head plates 808 A-B. Upon connection of the utilities through the exterior side of the utility wall 520 utilizing the exterior walkway for access, or by other means, the portion of exterior sheathing 803 that was previously left off is attached using fasteners 807 . The utility wall 520 is then securely fastened to the head and base plates 808 A-B with fasteners 807 installed in the horizontal direction along the utility wall 520 through the weather resistive barrier 802 and into the exterior sheathing 803 to securely attach the utility wall 520 to the floor slab 450 . The next step is to attach a “peel and stick” weather resistive barrier 809 over the base and head plates 808 A-B at the base and head of the wall and the floor slab 450 of the utility wall 520 . The final step involves attaching the final exterior cladding 800 , metal furring channels 804 , rigid insulation 805 , and associated flashing pieces 806 with fasteners 807 that was temporarily left off allowing access to attachment points of the utility wall 520 to floor slab 450 as well as to allow for a connection point of utilities within the utility wall 520 . The installation of this final panel 800 completes the installation of the utility wall 520 creating a weather-tight and watertight system.
[0130] After the demising walls 500 A-B, end walls 510 , and utility wall 520 are secured in place, the next step involved in contracting the building using the present invention may be to attach the exterior window wall 530 A-D to substantially enclose the unit. Window wall sections are installed in a linear arrangement starting at the end wall as shown in FIG. 27A . The window wall compensation channel 820 C is abutted to the metal stud framing 701 of the exemplary end wall 510 as previously described in FIG 23 . The window wall frame 820 is next securely attached to the compensation channel 820 C and the window wall installation progresses in a linear direction across the exemplary unit. Sealant 713 is installed between the edge of the end wall 510 interior sheathing 703 and the window wall compensation channel 820 C. Upon installation of the sealant 713 , a finish wall trim 714 is attached to the wall sheathing 703 . The interior finish panel 704 is further installed as described in FIG. 23 to complete the interior portion of the interface between the exemplary end wall 510 and the window wall 530 A. Exterior sealant and backer rod 849 is installed on the exterior directly adjacent to the window wall compensation channel creating a weather-tight and watertight system.
[0131] FIG. 27B illustrates a plan view of the interface between a demising wall 500 A with exterior window wall panel 530 D. Window member 820 A is attached to an adjacent window member not shown in the figure. Closure panel 821 is slid into place attaching to the window member 820 A and then securely attached to the floor slab 450 (as described in FIG. 28 ). Window member 820 B is next positioned on the slab and is slid into place and securely attached to closure panel 821 . This process continues across the slab until the entire window wall system is securely in place. Upon secure attachment of the exterior window walls 530 A-D to the floor slab 450 (shown in FIG. 28 ), the fire-safe material 711 , fire caulk 712 , sealant 713 and wall trim 714 are provided between the demising wall 500 A and the exterior window walls 530 A-D.
[0132] FIGS. 28A-13 illustrate sectional details for attaching exterior window walls 530 A-B to the floor slab 450 . In order to install exterior window walls 530 A-B, an anchor 822 in the shape of an L with outer ledges bent inwardly is first placed and anchored to the slab 450 by vertically inserting a fastener 823 at the middle portion of the bottom side of the anchor 822 into the slab 450 . The anchor 822 is positioned on and anchored to the slab 450 to leave room for at least half of a large flexible flashing 824 to fit on the remaining portion of the slab 450 towards the edge. The large flexible flashing 824 is shaped around the adjacent components to make a step-like structure with two upper and lower horizontal portions and two upper and lower vertical portions. The large flexible flashing 824 , which is waterproof, is positioned immediately next to the anchor 822 so that the exterior, vertical side of the anchor 822 fits with the upper vertical side of the large flexible flashing 824 and the lower horizontal portion of the large flexible flashing 824 fits snugly on the slab 450 . Half of the lower horizontal portion of the large flexible flashing 824 protrudes out at the edge of the slab 450 as shown in FIG. 28B .
[0133] A slip member 825 A is then anchored firmly to the underside of the slab 450 at the ceiling, or head, portion of the exterior window wall 530 B. The slip member 825 A is shimmed so that it is perfectly level to receive the bottom exterior window wall 530 B with the head support member 826 and rests at its exact elevation. The exterior window walls 530 A-B are constructed to allow approximately ⅝″ of shim space at the top and bottom for leveling and alignment. A third fastener 823 is used to attach a head blocking 827 to the underside of the slab 450 . The small flashing 828 is used to seal the head blocking 827 . Upon anchoring the slip member 825 A to its proper position under the slab 450 , the exterior window wall 530 B with the head support member 826 is inserted into the slip member 825 A. Upon securing the head portion of the exterior window wall 530 B with the slip member 825 A, the bottom portion of the exterior window wall 530 A is positioned tightly against the anchor 822 and at the bottom side of the exterior window wall 530 A. As shown in FIG. 28A , a bottom sill blocking 829 is attached on top of the slab 450 with the large flexible flashing 824 in-between before positioning the exterior window wall 530 A against the anchor 822 . A final closure piece 825 B is attached at the window head. It should be noted that although head blocking 827 is described in the above invention, the blocking 827 may be omitted. The exterior window wall system contains integrated insulating panels 830 which are included during manufacturing. The completely assembled exterior window walls 530 A-B are shown in FIG. 28B .
[0134] The final step in completely enclosing exemplary units 300 A-H and 300 J involves the installation of the entry door 540 . The entry door 540 is a preassembled, pre-glazed, and prefinished component. FIGS. 29A-D illustrate the exemplary components of the entry door 540 . The entry door 540 comes with a door portion 840 , inner frame 841 to house the door portion 840 , outer frame 842 to support the entry door 540 , and an operable transom 843 positioned above the door portion 840 within the outer frame 842 . All associated hardware for the door portion 840 and operable transom 843 is pre-installed except for thresholds or covers 844 and the electrical closure chase 845 . The entry door 540 may come in a right-hand or a left-hand door configuration to accommodate different unit layouts. Electrical connections to be made between walls such as the demising walls 500 A-B and the utility wall 520 are made in an electrical closure chase 845 located adjacent to the transom head 846 and the underside of the floor slab 450 .
[0135] FIGS. 29B-D illustrate the steps for attaching the base and head portions of the entry door 540 to the floor slab 450 . As illustrated in FIG. 29B , at the head portion of the entry door 540 , blocking and shims 847 are installed against the underside of the floor slab 450 . It should be noted that although head blocking 847 is described in the present invention, the blocking 847 may be omitted. The tansom head frame 846 is secured against the blocking 847 or the underside of the floor slab 450 with fasteners 807 . The head frame 846 is shimmed so that it is perfectly level to receive the transom 843 and rests at its exact elevation. As illustrated in FIG. 29D , at the base of the entry door 540 , a weather resistive barrier 802 is placed in the slab depression and integrated into the door threshold 844 . A bed of sealant and rigid insulation 805 is installed prior to the door threshold 844 to create a watertight and thermally isolated installation. The entry door 540 is constructed to allow approximately ⅝″ of shim space at the top and bottom for leveling and alignment.
[0136] Upon anchoring the head frame 846 to its proper position under the slab 450 , the transom 843 is inserted into the head frame 846 . Upon securing the head portion of the transom 843 with the head frame 846 , the bottom portion of the entry door 540 is positioned tightly against the anchor at the bottom side of the entry door 540 . A closure trim piece 848 is snapped into place into the transom head 846 . An electrical closure chase 845 adjacent to the transom head 846 is snapped into place following the installation of cleats 705 and fasteners 707 on the blocking 847 and the underside of the floor slab 450 . The electrical chase 845 is preferably made of aluminum, however, other types of materials can be used to enclose the conduit. The electrical chase 845 is preferably made of the same material as the entry door frame 842 .
[0137] FIG. 30 illustrates the top view of the entry door 540 attached adjacent to the utility wall 520 and perpendicularly attached to the demising wall 500 B. The door portions can be made of glass or any other type of material. The door threshold 844 (not shown) extends out and over the gap created by the walkway (described later) and the floor slab. On the opposite side at the demising wall 500 B whereby the first entry door 540 is adjacently attached to a second entry door 540 A and interfacing perpendicularly with a demising wall 500 B, a closure panel 850 is placed in-between the two entry doors 540 , 540 A so as to provide a watertight installation. This interface as well as the interface of the entry door 540 with the utility wall 520 is further described in FIGS. 31A-B below.
[0138] FIG. 31A illustrates a detailed top view of the outer frame 842 connecting adjacent to the utility wall 520 A. The weather resistive barrier 802 is wrapped into the entry door frame 842 prior to the frame 842 being installed. Shims 847 are installed to create a plumb installation of the entry door 540 . Sealant and backer rod 849 is further installed between the exterior sheathing and the outer frame 842 such as to create a watertight installation. As shown in FIG. 31B , the closure panel 850 is inserted and attached between the two entry doors 540 , 540 A, more specifically the two outer frames 842 of the two entry doors 540 , 540 A. The first door member 540 is positioned on the right side of the closure panel 850 . Closure panel 850 with integral insulation 830 is slid into place attaching to the entry door frames 842 and then attached at the floor slabs 450 (as similarly described in FIG. 28A-B ). The second entry door 540 A is placed to the left of the closure panel 850 and secured in the same manner. The entry doors 540 , 540 A are attached on the door members 842 on each side of the closure panel 850 . The entry doors 540 , 540 A, more specifically, the door portions, are swinging doors and are attached to the door members 842 of the closure panel 850 . Similar to the demising wall 500 A interface with the window wall 530 A as described in FIG. 27B , the void between the demising wall 500 B and the closure panel 850 needs to be made watertight. Upon secure attachment of the closure panel 850 to the floor slab 450 , the fire-safe material 711 , fire caulk 712 , sealant 713 and wall trim 714 are provided between the demising wall 500 B and the closure panel 850 in a similar process as described in FIG. 27B .
[0139] After the exemplary units 300 A-H and 300 J are fully enclosed utilizing the steps outlined above, the next step of constructing a building is connecting utility components and installing fixtures. All of the unit's utility connections occur at the utility wall 520 . The electrical and communications main lines run vertically in the utility wall 520 . At each unit, the electrical service feeds directly into the utility wall's 520 breaker panel. Wiring connections to other wall components occur via pre-installed wiring. Electrical and communications connections are carried out at the time of installation of each adjacent utility wall 520 . In FIG. 32A , a side view of the utility wall 520 is shown without the bath and kitchen components in place. The shower pan 612 A with the integral drain 613 is set in grout after installing the utility wall 520 (described later). The utility wall 520 has exhaust vents 614 A-B located respectively in the bathroom and kitchen on upper portions of the utility wall 520 . The utility wall 520 also has first and second plumbing 615 A-B for supply and waste for connecting a bathroom sink 610 , a kitchen sink 601 , as well as a toilet outlet 619 for connecting toilet 611 . There is a plurality of outlets 616 located in the utility wall 520 for the bathroom and kitchen. The utility wall 520 that arrives on-site also has a pre-integrated shower head 617 and shower valves 618 .
[0140] FIG. 32B illustrates the utility wall 520 with bathroom and kitchen components installed on the utility wall 520 . Installation of plumbing fixtures may occur immediately after utility connections are made to the utility wall 520 . The toilet 611 is installed on the utility wall 520 , bathroom vanities 610 arrive on-site preassembled with the sink and associated out-of-wall plumbing pre-installed and ready for immediate connection to the building's systems. Kitchen units 600 C are pre-fabricated, prefinished kitchen upper and base cabinets. These kitchen units 600 C arrive at the site pre-drllled and trimmed for plumbing, electrical connections and vent ducting. Cabinets 603 have integral exhaust fans and light fixtures to be installed on the utility wall 520 . The bathroom mirror/medicine cabinet 650 is installed at the same time as the other bathroom fixtures. All wiring within a given unit feed back to the unit's electrical panel.
[0141] The shower pan 612 A and integral drain 613 are set on the slab or into a recess within the floor slab 450 . In FIG. 33A , the first shower partition 620 A is shown to divide the shower portion from the bathroom portion. The bathroom vanity 610 and toilet 611 are also shown. FIG. 33B illustrates the recess or depression is cast into the slab 450 and shaped to receive the shower pan 612 A. The shower pan 612 A may be field set in grout after the installation of the utility wall 520 . FIGS. 34A-B illustrate the shower pan 612 A-B set into the slab 450 recess with the integral drain 613 running vertically through the slab 450 , or as shown in FIG. 34B , horizontally through the slab 450 and into the cavity of the utility wall 520 . Thus, the recess with the integral drain 613 permits controlled passage of water from slab 450 into the cavity of the utility wall 520 . The shower pan as currently described is fiberglass 612 A or an integrated stainless steel pan 612 B. Ihe present invention does not limit the other possible material choices for the shower pan. In addition, a slab recess may be omitted from the present invention.
[0142] The next step of construction is installing interior bathroom partitions 620 A-B, and 621 as shown on FIGS. 10 through 18 for separating the shower area from the bathroom and the bathroom area from the living area. The shower and bathroom partitions preferably, but without limitation, include about a ½″ full height frosted or clear tempered glass panel and a full height frosted sliding glass door panel. The head portions of the bathroom partitions 620 A-B and 621 as shown in FIGS. 10 through 17 are used to attach to the bottom side of the ceiling slab 450 . A rigid C-shaped receptor channel 735 is attached to the underside of the floor slab 450 or to the underside of blocking 734 using a head anchor 733 as illustrated in FIGS. 35A . It should be noted that although head blocking 734 is described in the above invention, the blocking 734 may be omitted from the present invention. The receptor channel 735 is preferably approximately 2″ deep and ″ wide so that the top portion of the glass partition 730 is inserted at least half way into the receptor channel 735 . Sealant will be provided at vertical wall joints where the glazing acts as a shower enclosure.
[0143] The bottom portions of the shower and bathroom partitions 620 A-B and 621 are used to attach to the floor slab 450 . A rigid C-shaped bottom receptor channel 732 is attached to the floor slab 450 by a bottom anchor 736 to insert the glass partition 730 as illustrated in FIG. 35A . The partition 730 is fully positioned within the bottom receptor channel 732 so that it rests securely in the receptor channel. Sealant 713 is applied to both sides of the glass partitions 730 to make for a secure and light assembly. Furthermore as illustrated in FIG. 35B , at sliding door panel 731 , a sliding door guide 738 is adjacently positioned on the floor slab 450 next to the bottom receptor channel 732 and attached to the floor slab 450 by drilling two bottom anchors 736 through the flat portions of the sliding door guide 738 and into the floor slab 450 . The door panel 731 is then positioned into the head receptor channel 735 and into the sliding door guide 738 at the floor slab 450 . As shown in FIG. 35C , to complete the assembly of the shower and bathroom partitions 620 A-B, a trim piece 737 , preferably made of aluminum, is sealed against the head blocking 734 and receptor channel 735 .
[0144] The next step of construction is installing interior bedroom partitions 640 , 642 for separating rooms or configuring rooms with different layouts as shown in FIGS. 10 through 18 . Interior partitions 640 and 642 are minimal and in most cases, the bedroom partitions 640 and 642 are removable, and the location of the partitions is easily adjustable. The partitions 640 , 642 are typically used to help establish privacy between the bedroom and the living area with exemplary unit 300 C-H and 300 J. The two main exemplary types of partitions include a tempered glass sliding bedroom glass partition 640 and a removable entertainment wall 642 with tempered glass sliding pocket doors. These two types of partitions are completely interchangeable within exemplary unit 300 C-J.
[0145] FIGS. 36A-B illustrate an exemplary sliding glass partition 640 as shown in FIGS. 14-17 . The sliding bedroom glass partitions 640 are suspended from a sliding door track 742 mounted to the underside of the floor slab 450 . The sliding bedroom glass partitions 640 are further sitting over a sliding door guide 741 on the slab 450 . Blocking and shims 734 are used to perfectly level the sliding door track 742 at the underside of the slab 450 . Head anchors 733 and base anchors 736 attach directly to or drill into the surface of the floor slab 450 . A sliding bedroom partition 640 , whether made of glass or other materials, is attached to a sliding door guide 742 previously attached to the underside of the floor slab 450 via a head anchor 733 . The sliding door guide 736 basically guides the sliding bedroom glass partiotion 640 so that it can slide open and close easily. The protruding frame 743 from the top portion of the sliding bedroom glass partition 640 extends into the sliding door track 742 . Upon completion of the installation as described above, finish trim pieces 737 are attached to conceal the sliding partition track 742 and blocking and/or shims 734 .
[0146] FIGS. 37A-C illustrate an exemplary entertainment wall 642 and glass pocket door 643 as shown in FIGS. 16-17 . The exemplary entertainment wall 642 and glass sliding pocket door 643 that can be utilized in addition to, or in lieu of, the glass sliding partition 640 to further separate bedroom areas from living areas. The first partition of exemplary entertainment wall 642 is brought to the construction site as a pre-fabricated and prefinished component ready for installation. As illustrated in FIGS. 37A , the components of this wall include metal stud framing 701 and wall sheathing 703 located only on one side of the wall. The cavity side of the wall is left as bare metal stud framing 701 . This open cavity wall is set into place over a neoprene pad 708 and secured into place with head anchor 733 and base anchor 736 .
[0147] As illustrated in FIG. 37B , the glass sliding pocket door 643 is installed similarly to the process for installing exemplary bedroom partition 640 as described in FIGS. 36A-B above. The glass sliding pocket door 643 is suspended from a sliding door track 742 mounted to the underside of the floor slab 450 . The sliding bedroom partition 640 is further sitting over a sliding door guide 741 on the slab 450 . Blocking and shims 734 are used to perfectly level the sliding door track 742 at the underside of the slab 450 . Head anchors 733 and base anchors 736 attach directly to or drill into the surface of the floor slab 450 . A glass sliding pocket door 643 , whether made of glass or other materials, is attached to a sliding door guide 742 previously attached to the underside of the floor slab 450 via a head anchor 733 . The sliding door guide 736 basically guides the glass sliding pocket door 643 at the top portion so that it can slide open and close easily. The protruding frame 743 from the top portion of the glass sliding pocket door 643 extends into the sliding door track 742 .
[0148] To complete the installation of the entertainment wall 642 as illustrated in FIG. 37C , a second prefabricated and prefinished framing wall is brought to the construction site ready for installation. The components of this wall include metal stud framing 701 and wall sheathing 703 located only on the room side. The cavity side of the wall is left as bare metal stud framing. This wall will arrive to the construction site with the lower portion of interior sheathing left off at the head and base of the wall as a means of allowing access to attach the base and head to the slab with anchors 733 and 736 respectively. Upon attachment of the second prefabricated wall, the interior sheathing strips are attached to wall frame 701 . The next step is to cover the inner side of the entertainment wall 642 by attaching the base and head trim 710 A-B, preferably made of metal or other similar materials. Base and head trim 710 A-B is attached with fastener 707 on both interior sides of the wall. Prefinished panels 704 are further attached to the entertainment wall 642 with cleats 705 to compete the installation previously described in FIGS. 19-22 relating to the demising wall.
[0149] The final step of construction may be assembling the parapet for the roof as shown in FIGS. 38-39 . In this application, the installation of the parapet, roof insulation and the roof membrane occur simultaneously with the installation of the interior components. In the preferred application, the parapet, roof insulation, roof membrane and associated components will occur prior to the roof slab being hoisted and set into place. This is one of several options for a unitized prefabricated system of enclosing the roof of the building that may include panelized overhangs, shading devices, canopies, solar panels, and/or fabric tent structures. Therefore, this example is not to be limiting in nature. The exemplary parapet connects to the roof slab 450 and accommdates the building's roofing membrane flashing and garden roof conditions.
[0150] As illustrated in FIG. 38A , the parapet consists metal stud framing 701 and exterior sheathing 803 on both sides. Furthermore, it typically contains integral flashing to prevent water penetrations between the parapet wall and the top of the exterior window wall 530 B or the end wall 510 . The exterior sheathing 803 is preferably a 12 mm magnesium oxide board, however, other types of wall sheathing panels may be used. Exemplary prefabricated parapet walls may be delivered to the project site in varying lengths, but are preferably about 10 feet in length. As shown in FIG. 38B , the parapet wall is securely anchored on top of the roof slab 450 using a similar method as the end wall 510 as described previously in FIG. 23 . Base plates 808 A are attached at the face of the slab 450 with fasteners 807 that are drilled at the base condition of the floor slab 450 prior to the parapet wall being moved into place from the roof side of the building as shown in FIG. 38B . The parapet wall utilizes thermally insulated anchors 807 that are securely attached to the slab 450 prior to installing the parapet wall.
[0151] Upon attachment of the plate 808 A to the slab 450 with fasteners 807 , the parapet wall is moved into place with the exterior wall sheathing 803 abutting the base plate 808 A. Fasteners 807 are installed in the horizontal direction along the parapet wall through the weather resistive barrier 802 and into the exterior sheathing 803 to securely attach the parapet wall to the floor slab 450 . The next step is to attach a “peel and stick” weather resistive barrier 800 over the base plate 808 A at the base of the wall and the floor slab 450 of the parapet wall. The exterior cladding 800 , metal furring channels 804 , rigid insulation 805 , and associated flashing pieces 806 with fasteners 807 are then applied to the exterior portion of the parapet wall 760 and integrally flashed with the window wall 530 B or end wall.
[0152] As shown in FIG. 38B , the roof membrane 860 is next applied over the roof slab 450 , up the exterior sheathing 803 on the parapet wall, over the blocking 863 and also over the sheathing layers 803 of the parapet wall and integrally connected into the flashing of the exterior window wall 530 B or end wall 510 . A flashing cap member 861 is attached over the top of the parapet wall. The cap support member 862 is placed on top of the parapet wall and attached to the upper, roof side of the parapet wall. The cap support member 862 supports the top, horizontal part of the flashing cap member 861 . The top portion of the exterior cladding catches the vertical part on the exterior side of the flashing cap member 861 , to tightly keep the flashing cap member 861 over the parapet wall.
[0153] The majority of the building's roof is a flat membrane roof. In one of the exemplary applications, the roof area has a garden roof system. The garden roof system is a low-maintenance, vegetated roof system which helps reduce heat island effects, retains storm water runoff, and provides insulation benefits. This vegetated roof system may include recycled material in either a complete vegetated system, or a modular vegetated system. The cover provided by the planting minimizes the impact from UV and varying temperatures on the surrounding environment and increases the life of the roof system. In one of the exemplary applications, an Inverted Roof Membrane Assembly (IRMA) also called a Protected Roof Membrane (PRM) system may be installed after the parapet wall is installed. A monolithic, thermoplastic roofing membrane 860 is placed directly on the concrete roof slab 450 . This monolithic, thermoplastic roofing membrane 860 is a fully adhered, seamless, self-healing membrane that can be mopped onto the top of the roof slab 450 . Upon applying the roofing membrane 860 , the roof is covered with a fiberglass-reinforced protective layer or roof barrier, and additionally covered with a layer of CFC-free, closed cell rigid insulation 864 as an air barrier. The thickness of the insulation layers 864 are determined by the local environment and governing thermal design values.
[0154] As shown in FIGS. 39A , the tapered rigid insulation layer 864 is applied over the roof membrane 860 which is covered by a water retention mat 865 that provides drainage and aeration for the planting 867 . The mat 865 also retains some of the run-off water and provides plant irrigation via capillary action. This mat 865 is further covered with soil filter fabric and then a lightweight engineered soil or growth media 866 as illustrated in FIG. 39B . The lightweight growth media 866 is further covered with a wind barrier planting fabric. The wind barrier planting fabric reduces soil erosion and dust while allowing the planting 867 to grow. The planting 867 is a lightweight planting providing superior water holding capacity. If an irrigation system is to be installed, the irrigation system can be installed in conjunction with the placement of growth media 867 . Plants used in the planting 867 are typically of shallow root and drought-tolerant variety, but these embodiments are not intended to be of a limiting nature. The planting 867 may be delivered to the site in pre-planted blankets or in pre-planted modular grids.
[0155] Sloped roofing may be used in selective locations such as independent walkways, areas with stairs and elevator landings. Translucent roof panels may be used at sloping roofs to allow as much natural light as possible to the areas below. Any run-off from the roof surfaces are collected and stored as gray water for irrigating plants on the vegetated roof and in-the-site landscape.
[0156] The application of the exterior walkways is preferably attached to the columns and/or beams 405 , 410 immediately following the erection of the structural frame 400 and is determined by the overall building configuration and the need for structural framing adjacent to the face of the building. This preferred sequencing allows the exterior walkways to be utilized in attachment of the slabs to the structural frame as well as allowing easy access to the individual units. In FIG. 40 , a continuous horizontal beam 410 is attached between vertical columns 405 on all elevations. The horizontal beams 410 act as drag struts for the brace frame and helps provide torsional restraint for the vertical columns 405 under jacking loads. A column support member 871 A-B, or a bolt-on system, may be used for all exterior walkways. The column support member 871 A-B is bolted 872 to the horizontal beam framing system 410 . Pre-fabricated and prefinished planks 870 are placed on top of the structure 410 , 871 A-B to provide the walking surface for the exterior walkways. The preferred material is precast concrete, but this is not meant to be limiting in nature. Alternatively, common walkways can be part of the unit floor slab 450 and utilize the same support system as the unit slabs 450 . In these conditions, a thermal break is cast into the slab 450 under a unit's exterior wall. The extension of the slab 450 helps reduce reinforcing requirements in the main portion of the slabs 450 , and there is no horizontal beam 410 framing to interfere with lifting.
[0157] As further illustrated in FIG. 40 , a pre-fabricated and pre-bundled guardrail system 875 may be attached and secured to the walkway support system utilizing bolts 872 . The preferred guardrail in the present invention includes a glass panel 876 , receptor channels 873 , and horizontal pickets 874 , but this is not meant to be limiting. Several other options include, but are not limited to, aluminum, metal and cable systems.
[0158] FIGS. 41-42 refer to the various components of the utility wall as previously described in FIGS. 24-26 . As shown in FIG. 41 , the utility wall 520 is delivered to the site as a pre-manufactured, pre-plumbed, pre-wired, prefinished, preassembled and pre-bundled component. Possible cladding materials may be comprised of various materials allowed by code, such as, but not limited to. composite panels, phenolic resin panels, metal panels, cement board, lightweight precast concrete panels, wood siding, gypsum fiber reinforced cement panels, ceramic tile, and stone panels. The utility wall 520 may be an all-encompassing finished unit on both the interior and exterior sides. This invention does not preclude the elimination of one or more parts of this component to achieve a more efficient installation method in the field. For example, the utility wall 520 could arrive on-site without the furring channels 804 , rigid insulation 805 , exterior cladding 800 , interior finish material 704 , and access panel 880 and vent hood 881 . Utility wall 520 is composed of metal stud framing 701 , an integrated acoustical blanket insulation layer 702 within the interior stud of the utility wall 520 , an interior sheathing panel 703 and an interior finish material 704 . The utility wall 520 arrives on-site with all the wall plumbing and necessary blocking associated with the kitchen sink, counters, cabinets, toilet, and shower already in place. The utility wall 520 also includes the shower valves, shower head, and associated trim. The utility wall 520 further contains the unit's electrical panel 882 and water heater 883 behind an accessible panel 880 . The present invention also contemplates use of a utility wall that does not contain a separate water heater, but instead uses a shared water heater or other similar device. The exterior side of the utility wall 520 is composed of metal stud framing 701 , an integrated thermal batt insulation layer 801 within the exterior stud of the utility wall 520 , fire-rated exterior sheathing board 803 , weather resistive barrier 802 , furring 804 , rigid insulation 805 , exterior cladding 800 and an access panel 880 .
[0159] As shown in FIG. 42 , the supply and waste lines 884 A-B are extended beyond the top plate 885 as a means of connecting risers in a vertical orientation within a multi-story building. In an exemplary multi-story building, units are identically stacked vertically on each level of the multi-story building. The utility walls 520 are similarly identical in construction of each unit and are also stacked vertically on each level of the multi-story building. The supply and waste piping extensions of one exemplary utility wall 520 extend through the top plate 885 enough to extend through the floor system and into the bottom plate 886 of the second exemplary utility wall 520 located on the level above of a multi-story building. In an exemplary multi-story building, units and levels are identically stacked vertically throughout the building with the exemplary utility wall 520 stacked as described above. As the utility wall 520 is placed into position, the piping extensions 884 A-B penetrate through the top plate 885 and the floor system and into the bottom plate 886 of the utility wall 520 above. The utility wall 520 is subsequently anchored into position using a variety of methods available. After secure attachment of the utility wall 520 to the floor, connections are made through the lower portions of the exemplary utility wall 520 for supply and waste piping 884 A-B. This process is repeated for as many levels as required to complete the multi-story building.
[0160] Two through four bedroom units.
[0161] The steps described in FIG. 19-42 describe the sequence of assembling a standard sized studio or one bedroom unit 300 B-C of FIG. 6A . The present invention may be readily adapted to create units with multiple bedrooms and bathrooms, as described in the next steps for exemplary two through four bedroom units.
[0162] A two bedroom unit of the present invention may be one and half times longer than a studio unit. Four bedroom units are typically twice the size of a standard studio unit. There are also standard plans for two and three bedroom corner units and efficiency units as shown in FIG. 6B . Standard wall and partition components are available which accommodate the larger units. If the overall plans for the building include a mix of unit types, the following sequence of assembly is applicable for multiple bedroom units. Living units that are 30 feet and wider may have a room against the exterior wall at the chase wall side of the unit. If these rooms are to be used as bedrooms, building code may require that a door or window be provided that is large enough to accommodate egress. In these types of conditions, exterior walls can be used. The exterior wall is composed and anchored in exactly the same manner as the end walls 510 as shown in FIG. 23 . The exterior walls are provided in a different configuration than the end walls 510 since the exterior walls have a window or door included.
[0163] The first step of constructing multiple bedroom units is delivering and staging of demising walls 500 A-B as described in FIGS. 19-22 . As previously described in FIGS. 19-22 , the demising walls 500 A-B are delivered to the site and staged in each unit for installation.
[0164] The next step of constructing multiple bedroom units is placing end walls 510 A-B for units as described in FIG. 23 . The longer two and four bedroom units utilize the same end walls 510 A-B as a standard studio unit. However, in order to accommodate the longer multi-bedroom unit, an additional exterior wall is to be provided. The exterior walls are composed and anchored in exactly the same manner as the end walls 510 A-B. The exterior walls may be provided in a different configuration than the end walls 510 A-B and may have a window or door included. If the exterior wall encloses a bedroom, then the building code may require that a door or window be provided that is large enough to accommodate egress within the exterior wall.
[0165] Similar to the end walls 510 as shown in FIG. 23 , exterior walls are composed of metal stud framing 701 with thermal batt insulation 801 , sprinkler plumbing, electrical, and communications components. The wiring and plumbing are pre-installed at a factory and connected at the site. The interior side of the exterior wall receives a layer of fire-rated sheathing 703 , with a finished panel 704 . The inner wall sheathing 703 is preferably a 12 mm magnesium oxide board, however, other types of fire-rated wall panels with safety mechanisms may be used. The preferred method for finishing the exterior wall is to attach a finish panel 704 over the exterior wall at the site using wood or metal cleats 705 installed on the wall sheathing 703 . Several options are available for the exemplary finish panel 704 , including but not limited to, stain, paint, magnesium-oxide board, wood veneer, wood paneling, plaster, metal, wallpaper, and cork. Alternately, the finish panel 704 and cleats 705 may be omitted and the wall sheathing finished in a more conventional manner. More specifically, the wall sheathing may be taped and painted so as long as it achieves the required fire rating per local building codes. A final interior trim piece 710 A-B is installed with fastener 707 in a similar manner to the demising wall 500 A as described above following the secure placement of exterior wall.
[0166] The exterior side of the exterior wall receives exterior sheathing 803 , a weather resistive barrier 802 , furring channels 804 , preferably metal or similar material, rigid insulation 805 , associated flashing pieces 806 , exterior fasteners 807 and an exterior cladding material 800 . A section of exterior cladding 800 , metal furring channels 804 , rigid insulation 805 , associated flashing pieces 806 , and exterior fasteners 807 is temporarily left off the exterior wall at the slab edge 450 as a means of providing the connection of the exterior wall to the floor slab 450 as described below.
[0167] Similar to the end walls 510 as shown in FIG. 23 , the exterior walls are attached to the floor slabs as follows: upon attachment of the plates 808 A-B to the slab 450 with fasteners 807 , the exterior wall is moved into place with the exterior wall sheathing 803 abutting the base and head plates 808 A-B. Fasteners 807 are installed in the horizontal direction along the end wall 510 through the weather resistive barrier 802 and into the exterior sheathing 803 to securely attach the exterior wall to the floor slab 450 . The next step is to attach a “peel and stick” weather resistive barrier 809 over the base and head plates 808 A-B at the base and head of the wall and the floor slab 450 of the exterior wall. The final step involves attaching the final exterior cladding 800 , metal furring channels 804 , rigid insulation 805 , and associated flashing pieces 806 with fasteners 807 that was temporarily left off allowing access to attachment points of the exterior wall to floor slab 450 . The installation of this final panel 800 completes the installation of the exterior wall creating a weather-tight and watertight system.
[0168] The next step of construction is placing the utility wall 520 as previously described in FIGS. 24-26, 41 and 42 .
[0169] As previously described in FIGS. 27-28 , the next step of constructing multiple bedroom units is installing the exterior window walls 530 A-D. Ihe sequence for the delivery and installation of the exterior window walls 520 A-D and components are described in FIGS. 27-28 .
[0170] The next step of constructing multiple bedroom units is installing the entry door 540 A-B and its associated parts. Installation of the entry door 540 A-B is described in FIGS. 29-31 .
[0171] The next step of constructing multiple bedroom units is connecting utility components and installing fixtures. The sequence of the utility connections and placement of the plumbing fixtures are described in FIG. 32-33 .
[0172] The next step of constructing multiple bedroom units is inserting a shower pan 612 A-B with an integral drain 613 into a recess 470 within the floor slab 450 as described in FIG. 34 .
[0173] The next step of constructing multiple bedroom units is installing interior partitions for separating rooms or configuring rooms with different layouts as described in FIGS. 35-37 .
[0174] The final step of constructing outer structures such as the parapet wall, roof, and exterior or common walkways are the same as previously described in FIGS. 38-40 . The sequencing of the installation of the roof and exterior walkways may occur prior to the slabs being hoisted as a means of accessing the attachment points of the slabs to the structural framing.
[0175] It should be noted that relative terms are meant to help in the understanding of the structures and are not meant to limit the scope of the invention. Similarly, the term “head” is meant to be relative to the term “base,” and the term “top” is meant to be relative to the term “bottom.” It should also be noted that the term “right” is meant to be relative to the term “left,” and the term “horizontal” is meant to be relative to the term “vertical.” Furthermore, the present invention is described in terms of perpendicular and parallel in direction, the terms are not meant to be limiting. It should be further noted that although the present invention is described in terms of first and second walls, the terms are not meant to be limiting. It should be futher noted that although the present invention is described using certain structures such as fasteners, however, any other types of means can be used to attach the walls.
[0176] The terms and expressions that have been employed in the foregoing specification are used as terms of description and not of limitation, and are not intended to exclude equivalents of the features shown and described. This application is intended to cover any adaptations or variations of the present invention. It will be appreciated by those of ordinary skill in the art that any arrangemnt that is calculated to achieve the same purpose may be substituted for the specific embodiment shown. | The present invention integrates the use of pre-manufactured structures with minimal on-site installation and lift-slab construction to achieve the construction of multi-story buildings. The pre-manufactured structures are designed to be readily integrated with both horizontal and vertically adjacent building components, including lift-slab components, so that multiple building stories may be readily and securely stacked, one on top of the other. The present invention advantageously permits top-down lift-slab construction for multi-story buildings. The present invention also provides for the development of flexible design plans for institutional, residential, office and other types of buildings. The present invention advantageously provides for easier, more efficient, faster, cheaper, safer, higher quality and more consistent, environmentally advantaged, energy-efficient, easier to maintain, intelligently designed, and customizable multi-story building construction. |
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FIELD OF THE INVENTION
[0001] The present invention relates to a container and a method of receiving, retaining and accessing a sample, such as a core sample from a subterranean formation.
DESCRIPTION OF BACKGROUND ART
[0002] Extracting core samples from subterranean formations is an important aspect of the drilling process in the oil and gas industry. The samples provide geological and geophysical data enabling a reservoir model to be established. Core samples are typically retrieved using coring equipment, which is transported to a laboratory where tests can be conducted on the core sample. However, on occasion it is advantageous if a core sample can be inspected on-site after retrieval.
[0003] Core samples are conventionally collected in aluminium tubes. In order to view the sample on site it would be necessary to withdraw the sample axially from the tube or to make a longitudinal cut along the tube. Both of these methods of sample extraction have the potential to damage the sample.
BRIEF SUMMARY OF THE INVENTION
[0004] According to a first aspect of the invention, there is provided a container for receiving and retaining a sample from a subterranean formation, wherein the container is arranged to be removably accommodated within a coring assembly, the container comprising at least one receptacle, wherein the or each receptacle is arranged to receive and retain a sample and wherein the or each receptacle has at least two receptacle portions and a connecting means for connecting each receptacle portion to the adjacent receptacle portion, such that the receptacle portions are separable on disengagement of the connecting means.
[0005] According to a second aspect of the invention, there is provided a method of receiving, retaining and accessing a sample from a subterranean formation, comprising the steps of:
[0006] a. forming a receptacle by providing at least two receptacle portions and connecting each receptacle portion to the adjacent receptacle portion using a connecting means;
[0007] b. accommodating the receptacle within a coring assembly;
[0008] c. receiving and retaining a sample within the receptacle;
[0009] d. removing the receptacle from the coring assembly; and
[0010] e. accessing the sample by disengaging the connecting means and removing one or more of the receptacle portions.
[0011] According to a third aspect of the invention, there is provided an apparatus for receiving, retaining and accessing a sample from a subterranean formation, wherein the apparatus comprises a container arranged to be removably accommodated within a coring assembly, the container comprising at least one receptacle, wherein the or each receptacle is arranged to receive and retain a sample and wherein the or each receptacle has at least two receptacle portions and a connecting means for connecting each receptacle portion to the adjacent receptacle portion, and wherein the apparatus further comprises a tool for disengaging the connecting means to separate the receptacle portions.
[0012] Removal of one or more of the receptacle portions provides easy access to the sample after recovery and the connecting means allow the receptacle portions to be separated with minimal or no damage to the sample. Provision of the receptacle portions is advantageous since the sample does not then have to be withdrawn axially from the receptacle for analysis, which generates friction and could result in the sample being damaged. Rather, the sample can be accessed and exposed by disengaging the connecting means to enable one or more of the portions to be lifted away from the sample without direct manipulation of the sample.
[0013] The method can include providing a tool and accessing the sample by disengaging the connecting means using the tool.
[0014] Each receptacle portion can have two long edges and two short end edges. The long edges of each receptacle portion can be arranged to connect with the long edge of the adjacent receptacle portion.
[0015] The tool of the third aspect of the invention is usable with the container of the first aspect of the invention to disengage the connecting means and separate at least one of the receptacle portions. The tool can be provided to force the connecting means to disengage.
[0016] The tool can comprise a bar having a pointed or bevelled end for insertion between the receptacle portions. Movement of the bar, following insertion of the end between the receptacle portions, can act to disengage the connecting means and force at least one of the receptacle portions away from the other receptacle portion(s).
[0017] The end of the bar can be inserted between the two long edges of the receptacle portions. An outer portion of the or each long edge of the or each receptacle portion can be chamfered to facilitate access of the tool to the join between the long edges.
[0018] The or each receptacle can be substantially cylindrical. Preferably, the receptacle portions and the connecting means are complementary to form a receptacle in the shape of a substantially hollow cylinder. According to the embodiment where the receptacle is substantially cylindrical, a cylinder axis can be defined by the long axis extending through the cylinder. The receptacle portions can be connected along a line parallel to a cylinder axis of the receptacle.
[0019] The two or more receptacle portions can be separable along the line extending between the two ends of the portions, typically substantially parallel to the cylindrical axis, so that the two or more receptacle portions can be separable laterally from one another. Preferably at least one of the two or more receptacle portions are movable radially away from the sample on disengagement of the connecting means.
[0020] Typically, each receptacle comprises two receptacle portions and the receptacle portions are in the form of half-shells.
[0021] The connecting means are typically arranged to maintain the long edges of each receptacle portion in contact with one another when the container is receiving a sample.
[0022] The connecting means can be integral with the or each receptacle portion. The connecting means can comprise moulded long edges of the receptacle portions.
[0023] According to one embodiment, the connecting means can comprise a shaped recess disposed on at least a part of the long edge of a receptacle portion and a shaped protrusion disposed along a corresponding part of the long edge of an adjacent receptacle portion wherein the shaped protrusion can mate with the shaped recess. Each receptacle portion can have a protrusion disposed along one long edge and a recess disposed along the other long edge. The protrusion can be formed with a head having a width greater than an opening of the recess. Both the recess and the protrusion can be shaped to have a neck and a wider diameter head portion in section.
[0024] Alternatively, the connecting means can comprise a separate shaped insert and each receptacle portion can be provided with recesses disposed along the long edges for receiving the shaped insert. The long edges of the receptacle portions can be formed with recesses shaped to securely receive the inserts. The recesses can have an opening that widens to an enlarged portion. The insert can have a head portion that is oversized relative to the width of the opening. The inserts can be substantially dumb-bell shaped.
[0025] According to an alternative embodiment of the invention, the connecting means can comprise long edges of the receptacle portions having a centrally disposed recess such that the long edges of adjacent receptacle portions can be aligned to form one or more apertures between adjacent receptacle portions. The apertures can extend along the connection between the receptacle portions. The aperture can be filled with fluid. The fluid is typically air. The aperture can be sealed to restrict fluid communication between the aperture and the ambient environment. A length of sealing material can be provided parallel to and adjacent each side of the aperture. Typically, a change in hydrostatic pressure occurs during transit from the subterranean formation (with a high ambient hydrostatic pressure) to the surface (with a relatively lower atmospheric pressure) and thus the fluid trapped in the aperture can cause a pressure differential to exist between the recess and the ambient environment thereby urging the portions into sealing engagement.
[0026] The above-described embodiments of the connecting means have the advantage that each receptacle portion can be manufactured from the same pattern and therefore a universal mould can be used. Shaping each long edge of the receptacle is simple to achieve by adding a shape to the mould through which the receptacle portions are extruded during manufacture. Thus the cost of manufacture of the receptacle portions is maintained at a low level. The receptacle portions can be manufactured from aluminium.
[0027] The connecting means can comprise a weakened region. The weakened region can include an area of reduced wall thickness. Preferably, the region of reduced wall thickness is spaced away from an inner surface of the receptacle portions.
[0028] The connecting means can comprise at least one binding member arranged to apply a radial compressive force to the receptacle portions. Each binding member can comprise a sleeve arranged to circumscribe the circumference of the receptacle portions. The sleeve can be of a length less than the length of the receptacle portions. The sleeve can be formed from a polymer such as a heat-shrinkable polymer or any other heat shrinkable fabric. According to this embodiment, the sleeve can be heated to cause shrinkage and apply a radial compressive force to the receptacle portions. Disengagement of the connecting means can be achieved by cutting along the binding member to relieve the compressive force applied by the binding member to the receptacle portions.
[0029] The binding member can be used in conjunction with any other connecting means where suitable.
[0030] Alternatively, the tool can comprise a cutting means for making a cut through the weakened region and/or the binding member of the or each receptacle portion.
[0031] The sample can be a core sample.
[0032] The or each receptacle can be disposable. According to some embodiments, use of the tool to disengage the connecting means is likely to damage the receptacle and thus render the receptacle unsuitable for reuse. The or each receptacle can be reconfigured prior to reuse. Alternatively, the or each receptacle can be recycled and reformed.
[0033] The container is preferable sealed to prevent fluid ingress and egress. The container can comprise seal means to provide a fluid tight seal across the container. Each long edge of the receptacle can be provided with a line seal. The or each short edge can also be provided with seals therealong. Alternatively, or additionally, an inner surface of the or each receptacle towards each end can be provided with an annular seal means. The annular seal means can include O-rings, lip-type seals and seals containing a fluid pocket to cause selective dilation of the seal in response to a pressure differential. Preferably the ends of the container are also sealed. The seal means can be elastomeric.
[0034] The container can comprise a plurality of receptacles and wherein the short end edge of each receptacle is arranged to be coupled to the short end edge of the adjacent receptacle by a joining member.
[0035] The joining member can be arranged to engage adjacent receptacles to couple the receptacles to one another.
[0036] An outer surface of each receptacle can comprise a recess and the joining member can be provided with at least two keyed parts, wherein each keyed part is arranged to engage the respective receptacle.
[0037] A securing means can be provided for securing the joining member in position for engaging with adjacent receptacles.
[0038] The securing means can comprise two securing members arranged to abut the joining member on either side thereof and retain the joining member in its position. The securing members can be provided with corresponding threads.
[0039] According to another embodiment, the joining member can comprise a threaded connector and the receptacle can be provided with a partially threaded outer surface towards each end for engaging with the connector.
[0040] Alternatively, the receptacle can have threaded end regions. A first end region having a reduced diameter relative to the remainder of the receptacle can have threads on an outer surface and a second end region can have threads on an inner surface such that the first end of one receptacle can be received within and threadedly coupled to the second end of an adjacent receptacle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Embodiments of the invention will now be described with reference to and as shown in the following drawings, in which: —
[0042] FIG. 1 is a sectional view of a receptacle within a core barrel;
[0043] FIG. 1 a is a sectional view of detail A;
[0044] FIG. 2 is a sectional view of an alternative receptacle in a core barrel;
[0045] FIG. 2 a is a sectional view of detail B;
[0046] FIG. 3 is a sectional view of another receptacle within a core barrel;
[0047] FIG. 3 a is a sectional view of detail C;
[0048] FIG. 4 is a sectional view of another receptacle within a core barrel;
[0049] FIG. 4 a is a sectional view of detail D;
[0050] FIG. 5 is a sectional view of another receptacle within a core barrel;
[0051] FIG. 5 a is a sectional view of detail E;
[0052] FIG. 6 is a sectional view of another receptacle within a core barrel;
[0053] FIG. 6 a is a sectional view of detail F;
[0054] FIG. 7 a is an end view of the receptacle of FIG. 2 ;
[0055] FIG. 7 b is a side view of the receptacle of FIG. 7 a;
[0056] FIG. 8 is an exploded perspective view of two receptacles similar to that of FIG. 7 b arranged end to end with a joining and securing assembly therebetween;
[0057] FIG. 9 is a sectional view of the assembled container of FIG. 8 ;
[0058] FIG. 9 a is a part-sectional, part-side view of the section A-A of the container of FIG. 9 .
[0059] FIG. 9 b is a view of detail B from FIG. 9 a;
[0060] FIG. 10 a is an end view of another receptacle;
[0061] FIG. 10 b is a side view of the receptacle of FIG. 10 a ; and
[0062] FIG. 11 is an exploded perspective view of two receptacles similar to that of FIG. 10 a arranged end to end with a joining and securing assembly therebetween.
DETAILED DESCRIPTION OF THE INVENTION
[0063] FIG. 1 is a sectional view of a receptacle shown generally at 26 . The receptacle 26 is constructed from two receptacle portions 20 , 21 that are semi-cylindrical and hollow in shape. Each receptacle portion 20 , 21 has two long linear edges and two semicircular end edges. The long edges of the portion 20 are arranged to contact the long edges of the portion 21 to form a hollow cylinder joined by a connecting means along a line parallel to an axis of the cylinder. The join between the two portions 20 , 21 is preferably provided with a line seal (not shown) to prevent ingress of muds in the receptacle 26 .
[0064] The receptacle 26 of FIG. 1 is shown housed within and co-axial with a core barrel 10 from a core barrel assembly (not shown). The receptacle 26 is centralised within the barrel 10 by a hexagonal centraliser 12 . Similarly, each receptacle described and shown with reference to FIGS. 2-6 is centralised within the core barrel 10 by the centraliser 12 .
[0065] According to this embodiment, the connecting means comprise mating portions integrally formed along the long edges of the receptacle portions 20 , 21 . A centrally disposed recess 22 extends along one of the linear long edges of each portion 20 , 21 . A centrally disposed protrusion 24 extends along the other linear long edge of each portion 20 , 21 . The centrally disposed recess 22 has an opening 22 o and a narrow portion 22 n leading away from the opening 220 to an enlarged portion 22 h , wherein the enlarged portion 22 h has a greater maximum width than the narrow portion 22 n . Similarly, the centrally disposed protrusion 24 has a neck 24 n and an enlarged head 24 h . The detail A of FIG. 1 a shows the protrusion 24 disposed on the long edge of the portion 20 and the recess 22 disposed on the long edge of the portion 21 . The dimensions of the enlarged head 24 h of the protrusion 24 are selected such that it can be forced through the opening 220 and the narrower portion 22 n that must part slightly to allow passage of the head 24 h therethrough. The enlarged head 24 h can then be retained within the enlarged portion 22 h of the recess 22 .
[0066] FIG. 2 shows a receptacle 36 comprising two receptacle portions 30 , 31 that are hollow and semi-cylindrical in shape. Each portion 30 , 31 has two long linear edges provided with seals and two circular end edges. The long edges of the portion 30 are arranged to contact the long edges of the portion 31 to form a hollow cylinder and join along a line parallel to an axis of the cylinder. Each long edge of the portions 30 , 31 has a recess 32 with a narrow opening 320 leading to an enlarged portion 32 h.
[0067] An insert 34 has a central neck portion 34 n and two wider diameter end portions 34 h . The end portions 34 h of the insert 34 can be forced through the narrower opening 320 of the recess 32 to nest within the enlarged part 32 h of the recess 32 to thereby retain the portions 30 , 31 into engagement to form the receptacle 36 .
[0068] FIG. 3 shows a receptacle 46 constructed from two hollow semi-cylindrical portions 40 , 41 each having two long linear edges and two semi-circular end edges. The portions 40 , 41 are generally hollow and semi-cylindrical in shape and arranged to engage one another along adjacent long edges as previously described in connection with the first and second embodiments. The long edges of the portions 40 , 41 have centrally disposed semi-cylindrical recesses 42 and one long edge of each portion 40 , 41 has lengths of seal 44 arranged parallel and on both sides of the recess 42 . Thus, when the portions 40 , 41 are positioned to form a receptacle 46 , the long edges of the portions 40 , 41 engage and are arranged so that the corresponding recesses 42 form a cylindrical air pocket 48 that is sealed on either side by the seals 44 .
[0069] The air pockets 48 will also need to be sealed at each end. Lengths of air pockets 48 can be laid end to end by joining a plurality of receptacles 46 end to end as described hereinafter. However, the outermost regions of the air pockets are required to be sealed. This can be achieved by plugging the outermost ends with sealing material. The seals 44 and sealing material preferably isolate the air pocket 48 and prevent fluid communication between the interior of the air pocket 48 and the ambient environment. The seals 44 and sealing material can be any type of seal able to withstand the temperatures and pressures associated with the downhole environment in which they are used. Elastomeric seals are useful in this regard. The seal means can be manufactured from rubber or plastics material or the like and some useful embodiments can be formed from Viton™.
[0070] FIG. 4 shows a receptacle made from two semi-cylindrical hollow portions 50 , 51 having two long linear edges provided with seals and two end edges. The portions 50 , 51 are generally hollow and semi-cylindrical in shape as previously described in connection with the foregoing embodiments. The portions 50 , 51 join along their long edges parallel to an axis of the cylinder. One long edge of each portion 50 , 51 is provided with a protruding barb 54 having a neck 54 n leading to a head 54 h with a pointed end 54 p and a secondary point 54 b . The other long edge has a recess 52 with a narrow opening 520 that is slightly wider then the neck 54 n of the protruding barb 54 . The recess 52 is shaped corresponding to the form of the barb 54 . The narrow opening 520 of the recess 52 is sufficiently deformable to allow the head 54 h of the barb 54 to be forced therethrough. Thereafter, the barb 54 is retained within the recess 52 to secure the portions 50 , 51 to one another and form a cylindrical hollow receptacle 56 .
[0071] FIG. 5 shows a receptacle 66 having two semi-cylindrical hollow portions 60 , 61 that are integrally formed with a waisted bridging portion 64 therebetween. The waisted bridging portion 64 has a reduced wall thickness compared with the wall thickness of the portions 60 , 61 . The bridging portion 64 is recessed away from an inner surface of the portions 60 , 61 as shown in detail E, so that the inner diameter of the bridging portion 64 is wider then the inner diameter of the portions 60 , 61 .
[0072] FIG. 6 shows a receptacle 76 comprising two semi-cylindrical hollow portions 70 , 71 , each portion having two long edges provided with seals and two end edges. The long edges of each portion 70 , 71 are arranged to align and engage one another to form a hollow cylindrical receptacle 76 . An outer part of the portions 70 , 71 in the region of the long edge is provided with an L-shaped recess 72 facing towards the long edge. The L-shaped recess 72 creates a shoulder 73 . A length of spring clip 74 having inwardly protruding ends 75 is removably accommodated within the L-shaped recess 72 and retained therein by the shoulder 73 , as shown in detail F.
[0073] According to another embodiment, the connecting means comprise a heat shrinkable sleeve formed from any suitable polymer such as a polyolefin, PVDF (polyvinylidene difluoride), PTFE (polytetrafluoroethylene) and FEP (fluorinated ethylene propylene). The sleeve is selected to be of a length slightly less than that of the end to end length of the receptacle portions. The shrink ratio can be varied depending on the required amount of compressive force. The sleeve is fed over the sealed receptacle portions and heated such that the sleeve shrinks around the exterior of the receptacle portions to apply a radial compressive force thereto. The sleeve can also be used in addition to the various connecting means described with reference to FIGS. 1 to 6 a.
[0074] FIG. 7 a is an end view of the portions 30 , 31 of FIG. 2 prior to assembly. FIG. 7 b shows each portion 30 , 31 having an end region 38 with a recessed circumferential band 37 . The portions 30 , 31 can be connected using the insert 34 such that a recessed annular band 37 is formed at each end region 38 .
[0075] The exploded view of FIG. 8 shows another receptacle 136 arranged to be joined end to end with the receptacle 36 . The receptacle 136 is similar to the receptacle 36 and like parts of the receptacle 136 have been allotted like reference numerals with a prefix “1”.
[0076] The receptacles 36 and 136 are positioned with the end regions 38 , 138 immediately adjacent one another. A joining member 88 comprises two hollow semi-cylindrical parts 80 , 81 having two joining edges and two arcuate end edges. Each joining edge is arranged to abut the joining edge of the adjacent part 80 , 81 such that the parts 80 , 81 are complimentary to form an annular band. Each part 80 , 81 also has two parallel tracks 83 (shown in FIG. 9 b ) along an inner surface proximate each arcuate end edge. The tracks 83 are shaped to engage the recessed bands 37 , 137 provided in each end region 38 , 138 respectively.
[0077] A first and second threaded securing member 82 , 84 respectively are also provided to secure the joining member 88 in position. The inner diameter of the securing members 82 , 84 is slightly larger than the outer diameter of the portions 30 , 31 to allow the securing members 82 , 84 to be positioned thereover. The first threaded securing member 82 has a stepped outer surface 82 s and a screw thread 82 t . An inner surface of the first securing member 82 has an end portion formed with a depression 82 d that corresponds with the length of the joining member 88 as shown in FIG. 9 b . The second securing member 84 has a step 84 s on its inner surface to allow the end of the first securing member 82 to shoulder out on the step 84 s . The second securing member 84 also has a threaded portion 84 t on an inner surface thereof to engage with the threads 82 t of the first securing member 82 .
[0078] Before use within a core barrel assembly, the container is assembled. The portions 30 , 31 are connected by forcing the insert 34 into the recesses 32 along the long edges of the portions 30 , 31 to form the receptacle 36 . The or each additional receptacle 136 is also assembled in the same way. The first securing member 82 can then be slid over the end region 38 of the receptacle 36 . Similarly, the second securing member 84 is slid over the end region 138 of the receptacle 136 .
[0079] The joining member 88 engages the receptacles 36 , 136 and is arranged such that the joining edges of each part 80 , 81 are positioned perpendicular to the long edges along which the receptacle portions 30 , 31 are connected. This arrangement avoids an area of the container having a weak link. The tracks 83 of the parts 80 , 81 engage with the recessed bands 37 , 137 thereby joining the receptacles 36 , 136 . The first securing member 82 can then be moved such that the depression 82 d abuts the joining member 88 that protrudes slightly relative to the outer diameter of the portions 30 , 31 . The second securing member 84 is screwed along the first securing member 82 such that the threads 84 t engage with the threads 82 t until the step 84 s abuts the opposing side of the joining member 88 . This has the effect of securing the joining member 88 in position so that the assembled receptacles 36 , 136 are in secured engagement. Additional receptacles can be added using similar joining members 88 and securing members 82 , 84 to form a container.
[0080] Prior to insertion in a coring assembly (not shown), the container comprising a plurality of receptacles 36 , 136 , etc. securely fastened to one another and sealed along its length is assembled in the manner described above. The container is then located within the core barrel 10 and centralised therein using hexagonal centralisers 12 . A leading end of the coring assembly (not shown) has a plurality of cutters provided to engage a geological formation and cut a core sample therefrom. The cutters are actuated and a core sample is collected within the container. During collection, if the core sample is entering the container at a slightly offset angle, there may be a tendency for the core sample to catch on an inner surface of the receptacles. However, radial separation of the portions 30 , 31 is resisted by the enlarged end portions 34 h of the insert 34 retained within the recesses 32 . Once the sample has been collected within the container a spring catcher (not shown) is actuated and the sample is sealed within the receptacle so that it is isolated from downhole drilling muds. The coring assembly can then be pulled out of the hole to retrieve the sample.
[0081] Once the coring assembly is retrieved to surface, the container can be removed therefrom. Typically, the container and the core sample within is divided into lengths corresponding to the length of each receptacle 36 , 136 using a cutting tool. If on-site inspection of the core sample is required a tool such as a crow bar has its flattened end inserted into the join between the receptacle portions 30 , 31 . The crow bar can then be moved such that it acts as a lever to apply a force to separate the receptacle portions 30 , 31 by urging the enlarged end 34 h through the narrow opening 32 o such that the inserts 34 are urged out of engagement of the recesses 32 allowing at least one of the portions 30 , 31 to be lifted radially away from the core sample. In order to facilitate the separation of the receptacle portions 30 , 31 , the leading outer edges of the portions 30 , 31 can be chamfered to provide a purchase for the tool in use. The act of separation may have damaged the or each portion 30 , 31 , which is thus treated as disposable and may be recycled or reconfigured for reuse.
[0082] The outer surface of each of the receptacles 26 , 46 , 56 , 66 , 76 shown in FIGS. 1, 1 a and 3 - 6 a can similarly be provided with recessed bands 37 and secured to like receptacles using joining members 88 and securing members 82 , 84 .
[0083] A similar procedure for collection, retrieval and inspection of the core sample can be followed for the receptacle 26 shown in FIG. 1 and the receptacle 56 is shown in FIG. 4 .
[0084] The receptacle 46 shown in FIG. 3 is assembled to form part of a container assembly in a similar manner as described with reference to FIGS. 8 to 9 b . As the receptacle 46 is assembled prior to insertion downhole, the air pocket 48 is at ambient atmospheric pressure. However, since the receptacles 46 making up the container assembly are transported downhole, the pressure of the environment gradually increases towards the subterranean formation. The pressure differential increases since the air pocket 48 is sealed from the ambient environment downhole by the seals 44 . This urges the portions 40 , 41 into contact with one another. Thus, during collection of the sample separation of the receptacles 46 is resisted by the pressure differential across the air pocket 48 acting to maintain the portions 40 , 41 in engagement. Withdrawal of the coring assembly from the downhole environment reduces the pressure differential across the air pocket 48 until the coring assembly and the receptacle 46 is once again subject to atmospheric pressure. In the absence of a pressure differential the two portions 40 , 41 are easily parted on the surface and one or more of the portions 40 , 41 can simple be lifted away to provide access to the core sample on-site.
[0085] The receptacle 66 shown in FIG. 5 is integrally formed and has a waisted bridging portion 64 . Several such receptacles can be assembled end to end to form a container. Once a core sample has been retrieved to surface following collection from the subterranean formation, a cutting tool (not shown) can be used to cut along the length of the waisted bridging portion 64 of the receptacle 66 . Spacing the waisted portion 64 away from the inner surface of the receptacle 66 by the depth of the recess 62 significantly reduces the risk that the core sample will be damaged during the cutting operation. Furthermore, a smaller cutting force is required to divide the waisted section 64 having a smaller wall thickness than the wall thickness of the portions 60 , 61 .
[0086] The portions 70 , 71 of the receptacle 76 shown in FIG. 6 are retained by a spring clip 74 having retaining ends 75 that abut shoulders 73 of the L-shaped recess 72 . The clips 74 are deformable and can be removed following retrieval of the coring assembly to surface, thus providing access to the core sample.
[0087] Each embodiment of the connecting means described with reference to FIGS. 1 to 6 enables the core sample to be accessed by lifting one or more of the receptacle portions therefrom. Thus, axial withdrawal of the sample from the container is not necessary.
[0088] An alternative joining and securing means is shown in FIGS. 10 a to 11 . FIGS. 10 a shows a receptacle having receptacle portions 230 , 231 and a shaped insert 234 similar to those described with reference to FIG. 7 b . The receptacle portions 230 , 231 have two end regions 238 , 239 . The end region 238 has threads 237 provided on an outer surface and the end region 239 has threads 237 provided on an inner surface.
[0089] FIG. 11 shows a similar receptacle with like features labelled with the prefix “3”, rather than “2”. Before use, the inserts 234 , 334 are used to couple the receptacle portions 230 , 231 , 330 , 331 in the manner previously described. A joining and securing member 188 is provided with internal threads adapted to engage with the threads 237 , 337 at the end regions of the receptacle portions 230 , 231 , 330 , 331 .
[0090] This method of joining receptacle portions end-to-end can be used in preference to that described with reference to FIGS. 7 a to 9 b and can also be used with any of the described connecting means.
[0091] Modifications and improvements can be made without departing from the scope of the invention. | A container for receiving and retaining a sample from a subterranean formation, wherein the container is arranged to be removably accommodated within a coring assembly. The container comprises a receptacle, formed from at least two receptacle portions and a connector for connecting each receptacle portion to the adjacent receptacle portion, such that the receptacle portions are separable on disconnection of the connector. The receptacle portions can be complementary to form a receptacle in the shape of a substantially hollow cylinder. A cylinder axis can be defined by the long axis extending through the cylinder. The receptacle portions can be connectable along a line parallel to the cylinder axis of the receptacle such that at least one of the receptacle portions is movable radially away from the sample on disconnection of the connector. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to what is conventionally known as a hat box design. More specifically, the present invention discloses a two piece plasticized container with a lid and a base and which incorporates a novel interlocking arrangement established therebetween to permit the lid to be angularly supported upon the base in a first open configuration and, upon being rotated to a closed position, linearly displaced forwardly to establish a tactile and snap-shut configuration.
[0003] 2. Description of the Prior Art
[0004] The prior art is well documented with examples of either hat box or other article holding/supporting containers. In one application, it is desirable to be able to interlock together in a stacking arrangement a plurality of item holdable containers.
[0005] A first example of such an assembly is set forth in U.S. Pat. No. 6,237,772 and U.S. Pat. No. 5,964,350, both issued to LaMarche et al., and which teach an assembly of interconnected containers, each exhibiting an upper portion permanently connected to a lower portion by a hinge or hinges, and with the upper portion having a pair of elongated generally parallel upwardly open channels. The container also has a pair of generally parallel downwardly projecting flanges structured to engage an upwardly open channel of an adjacent container and adjacent containers having either at least one of the channels engaged by a flange of an adjacent container or at least one of its flanges engaged in a channel of an adjacent container or both. The channels preferably communicate with at least one open end so as to permit relative sliding removal and insertion of the containers from and into the assembly. The channels are disposed closer to each other than are the flanges. In one embodiment, the upper portion has the upper sidewalls diverging downwardly therefrom and the lower wall has a pair of lower sidewalls diverging upwardly therefrom. The containers may be transparent and molded as a unit with integrally formed hinges. Support structure may be provided within the container to support one or more articles disposed therein. Individual containers for use in such an assembly are disclosed.
[0006] U.S. Pat. No. 6,129,505, issued to Jupille et al., teaches a plurality of stackable trays and methods for stacking the same. Each tray exhibits two side walls, each having a top channel along its top edge and a bottom channel along its bottom edge, each channel further having an inner and an outer channel wall, where the width of two adjacent top channel outer channel walls is less than the width of the bottom channel, whereby two such top channel walls may slide into a bottom channel of a stackable tray of like kind, and where the width of two adjacent bottom channel outer channel walls is less than the width of the top channel, whereby two such bottom channel walls may slide into a top channel of a stackable tray of like kind.
[0007] U.S. Pat. No. 5,074,410, issued to Fries et al., teaches a portable hat box for a brimmed hat having an upper member and a lower member. The upper member is pivotal relative to the lower member about a pivot axis and between closed and open positions. The members in the closed position completely enclose a hat chamber. Each of the members includes a platen surface. The lower member platen surface is substantially complementary in shape to the upper member platen surface. The platen surfaces are positioned adjacent to one another, having a substantially constant vertical clearance therebetween in the closed position, as well as being non-adjacent and obliquely related in the open position.
[0008] Finally, U.S. Pat. No. 5,022,515, issued to Agostine, teaches a hat storage container wherein outer walls define a body and a bill, enclosing a space including a main body chamber and a bill-shaped container adapted to receiving a hat bill. The main body chamber is adapted to receive the main body portion of one or more corresponding billed hats. Preferably, the main body chamber is longer than the main body portions of the hats to be stored therein, whereby the main body chamber is adapted to receive a shingled array of a plurality of the hats; the bill-receiving chamber being adapted to receive the corresponding shingled array of bills.
SUMMARY OF THE PRESENT INVENTION
[0009] The present invention discloses a two piece storage container, such as in particular for a hat box, and which is an improvement over other prior art designs in that it provides for improved locking and upwardly arrayed support of a first volume defining lid relative to an opposing and volume defining base. The lid exhibits a substantially rectangular shape, with interconnecting sides and ends defining therebetween a recessed interior and further includes a plurality of spaced apart lips extending from a selected end.
[0010] The base corresponds generally in outline with the lid and includes an equal plurality of upwardly projecting hinge supports, these being located proximate to an associated end of the base arrayed in opposing and communicable fashion relative to the lips, upon positioning of the lid over the base. The spaced apart lips are angularly supported within the hinge supports in a first open rotated position and, upon rotating the lid to a closed position, the lips are further linearly displacing in a direction against the hinge supports, in order to lock the lid to the base.
[0011] Additional features include each of the lid and base further including a handle subset portion associated with further selected edges opposite those associated with the lip and hinge support, the subset portions mating upon rotating the lid to the closed position to define a carrying handle. The lips are further each configured to include an angled ramp portion, and upon which is situated an integrally formed superstructure. The base defined hinge supports each further include upwardly extending primary and succeeding secondary embossments, these overlaying a perimeter defined aperture formed upon a flat edge location, in order to both support the lid in its upwardly angled position as well as to effectuate a tactile and “snap shut” feel upon rotating the lid to the closed position and sliding inwardly against the base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:
[0013] FIG. 1 is an assembled perspective view of the two piece container according to a preferred embodiment of the present invention;
[0014] FIG. 2 is an exploded view of the container as shown in FIG. 1 ;
[0015] FIG. 3 is a top plan view of the container design of FIG. 1 ;
[0016] FIG. 4 is a cutaway view taken along line 4 - 4 of FIG. 3 and showing the respective points of engagement established between a first handle supporting end and a second hinged end;
[0017] FIG. 5 is a cutaway view taken along line 5 - 5 of FIG. 4 and showing biasing engagement of a selected hinge location according to the present invention;
[0018] FIG. 6 is a partial perspective view illustrating, in exploded fashion, an interengagement of a hinged connection established by a lid and a base in the closed position;
[0019] FIG. 7 is a partial top plan view of a hinged portion associated with a lid and base in a laterally separated and pre-closing position;
[0020] FIG. 8 is a succeeding view to that shown in FIG. 7 and illustrating the lid in a laterally translated, closed and locked position relative to the base;
[0021] FIG. 9 is a lineal cutaway view of a selected hinged arrangement established between a lid and base and illustrating a first centerline position of a lid inserting lip portion relative to a base receiving location and during upward rotation of the lid;
[0022] FIG. 10 is a succeeding lineal cutaway view illustrating the rearward displacement of the inserting lip centerline upon fully upward rotation of the lid to a stationary and supported upright position; and
[0023] FIG. 11 is a further cutaway view taken along line 11 - 11 of FIG. 3 and illustrating the lengthwise extending and mating grooves established between the lid and base.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring now to FIG. 1 , an assembled perspective view is illustrated at 10 of a two piece container according to a preferred embodiment of the present invention. As previously described, the present invention discloses an improved item holding container assembly, typically a hat box configuration, and which in particular discloses an improved hinge construction (interlocking arrangement) established between a base and a separable lid, such that the lid is capable of being angularly supported upon the base in a first open configuration and, upon being rotated to a closed position, linearly displaced forwardly to establish a tactile and snap-shut configuration to permit the assembled item to be transported.
[0025] Referring again to FIG. 1 in combination with the exploded view of the container as shown in FIG. 2 , the container includes a lid 12 and a base 14 . Each of the lid and base are, in one variant, constructed of a plasticized material produced from such as a vacuum forming or, potentially, an injection molding process.
[0026] In a preferred embodiment, each of the lid and base exhibit a rectangular configuration (although it is contemplated that any suitable and polygonal shaped article is contemplated) with four interconnecting sides and ends which bound a recessed and volume defining interior. In particular, the lid 12 includes sides 16 and 18 and interconnecting ends 20 and 22 . Concurrently, the base 14 includes sides 24 and 26 and interconnecting ends 28 and 30 .
[0027] The lid 12 further includes a recessed interior surface 32 and the base 14 likewise includes a corresponding surface 34 . Each of the sides and ends of the lid 12 further include outer perimeter defining and flattened edges, these being referenced at 36 , 38 , 40 and 42 . The sides and ends of the base 14 concurrently include outer perimeter defining and flattened edges, as respectively shown at 44 , 46 , 48 and 50 , these opposing the corresponding edges 36 - 42 of the lid in the closed and slid/snap shut configuration as will be subsequently described.
[0028] The lid 12 further includes a plurality of extending lips, such as shown by end defined and spaced apart lips 52 , 54 , 56 , et seq. (see again FIGS. 1 and 2 ). It is further understood that any plurality of lips can be employed ranging from two upwards, and in order to achieve the desired upward support and snap shut positions of the lid.
[0029] As best shown in FIG. 6 , illustrating in partial perspective and exploded fashion, is an interengagement of a hinged connection established by a lid and a base in the closed position and which in particular illustrates additional features of selected lip 52 including an angled ramp portion 58 and upon which is situated an integrally formed superstructure 60 . The ramp portion 58 further includes a bottommost and substantially planar shaped layer 62 and an intermediate layer 64 exhibiting a progressively inwardly/downwardly angled layer formed upon the planar shaped layer 62 and in a direction away from the superstructure 60 .
[0030] The configuration illustrated in the partial illustration of FIG. 6 is understood to apply to each of the other corresponding and spaced apart lips, a repetitive description of each being avoided for purposes of simplicity in the present description. As again referenced in FIG. 6 , the lip support superstructure 60 further includes, as shown, a top, sides, and a downwardly/outwardly flared front (see in particular at 66 ) terminating in a top surface 68 of the intermediate layer 64 .
[0031] Referring again to FIGS. 2 and 6 , the base 14 exhibits a like plurality hinge supports, see at 70 , 72 , 74 , et seq., each being interengageable with an associated lip 52 , 54 , 56 . Referencing the selected hinge support 70 referenced in the enlarged partial view of FIG. 6 , each further includes an inwardly facing perimeter edge (hidden from view in FIG. 6 but referenced at 76 in each of FIGS. 7 and 8 ) defined in the corresponding flattened end edge 48 , this defining an aperture at that location.
[0032] Additional features corresponding to each of the hinge supports include a primary embossment 78 substantially overlaying the aperture 76 and including sloping edges connecting to the aperture defining perimeter in the flattened edge 48 , this further revealing an open and communicable edge 80 opposing and seating a selected lip. A secondary and angular embossment 82 projects upwardly from a location of the primary embossment 78 and seats a selected superstructure, e.g. that shown again at 60 for selected lip extending portion 52 , and in either the upwardly hinge supported or translated (snap-shut) configurations established between the lid 12 and base 14 .
[0033] Referring again to the several illustrations, including FIG. 6 , the perimeter defined aperture 76 has a selected shape and size and defines a further widthwise projecting portion (see as shown by slot shaped portion defined by inner communicating edge 84 in FIG. 6 ), this extending beyond the primary embossment 78 and contiguous with the open edge. A pair of lateral-most positioned primary embossments, see as best represented in FIG. 7 at 84 for selected hinge support 70 , correspond to one corner edge location of the base end 48 , each further including a lengthened outermost edge, see at 84 . An associated planar shaped layer of an inserting lip edge, see as represented in each of FIGS. 7 and 8 at 86 , includes a lateral tab seating within the lengthened edge 84 in the closed and linearly displaced position (see again in particular FIG. 8 ).
[0034] FIG. 3 illustrates a top plan view of the assembled lid 12 and base and in particular showing a handle subset portion, see at 88 and 90 for lid 12 and base 14 , respectively, associated with further selected opposite end edges, see at 42 and 50 , opposite those associated with the interengageable lip 52 , 54 , 56 and hinge 70 , 72 and 74 supports, the subset portions mating upon rotating the lid to the closed position and in order to collectively define a carrying handle. Referencing further FIG. 4 , a cutaway view taken along line 4 - 4 of FIG. 3 is shown which illustrates the respective points of engagement established between a first handle supporting end and a second hinged end.
[0035] FIG. 5 illustrates a cutaway view taken along line 5 - 5 of FIG. 4 and showing a biasing engagement of a selected hinge location, established between lip 54 and hinge support 72 , according to the present invention. In particular the seating arrangement is referenced in end cutaway and which is established between the inner surface of the primary hinge support embossment and the intermediate ramp layer of the corresponding and inserted lip. The illustration of FIG. 5 , in cooperation with what is shown in the partial view of FIG. 8 , illustrate the tactile and snap-shut fashion of the lid relative to the base in the overall illustration of FIG. 1 .
[0036] FIG. 9 is a lineal cutaway view of a selected hinged arrangement established between a lid and base, such as lip 52 and associated hinge 70 described in FIG. 6 , and illustrating a first centerline position 92 of the lid inserting lip portion relative to the base receiving location, and such as during upward rotation of the lid. FIG. 10 is a succeeding lineal cutaway view illustrating the rearward displacement of the inserting lip centerline, to location 94 upon fully upward rotation of the lid to a stationary and supported upright position. In this fashion, the lid 12 is maintained in the upright supported position relative to the base 14 and across a centerline established in crosswise extending fashion proximate the edge 48 of the base 14 .
[0037] FIG. 11 is a further cutaway view, taken along line 11 - 11 of FIG. 3 , and illustrating a lengthwise extending arrangement of mating grooves 96 and 98 established between the side edges, see for example at 36 and 44 , established between the lid 12 and base 14 . The grooves 96 and 98 can include either “U” shaped, “V” shaped or other cross-sectionally shaped mating grooves, these further defining lengthwise extending rails or recesses and which establish lengthwise extending and slidably interengaging portions associated with opposing and parallel disposed side edges of the base 14 and lid 12 and in order to facilitating sliding motion of the lid relative to the base, such as during locking thereto.
[0038] As best further illustrated in each of FIGS. 1 and 2 , one or more lengthwise extending and recessed exterior surfaces, see at 100 , 102 , 104 , et seq., are associated with the interior 32 of the lid and which constitute a plurality of parallel, spaced apart and lengthwise interengaging portions between individual container assemblies. Corresponding lengthwise extending and recessed exterior surfaces, see at 106 and in phantom at 108 in FIG. 2 , are associated with the recessed base surface 34 , these further typically being provided as a pair of outermost and lengthwise interengaging portions which are selectively seatable within selected ones of the recessed lid surfaces 100 , 102 , 104 , further such that a lid of a first selected container may support thereupon a base of a second selected container.
[0039] An additional feature illustrated in the exploded view of FIG. 2 , is a first pair of substantially circular and ramped embossments 110 and 112 projecting from edge surfaces of the base 14 , at locations along edge surface 50 and proximate its associated subset handle portion 90 . A second pair of substantially circular shaped recesses project from an opposing edge surface 42 of the lid 12 (only a first of which is shown at 114 , the second being hidden from view) and proximate its associated subset handle portion 90 , further such that the circular recesses seat within the opposing circular base embossments in the closed position. The circular embossments 110 and 112 and corresponding recesses (e.g. at 114 ) may be reversed in arrangement, and further are typically angled or tapered to assist in establishing the tactile snap shut arrangement of the lid when translated to the position shown in FIG. 1 .
[0040] Having now described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims. | A two piece storage container including a lid having a rectangular shape with sides and ends defining therebetween a recessed interior, the lid including a plurality of spaced apart lips extending from a selected end. A base corresponding generally in outline with the lid and including an equal plurality of upwardly projecting hinge supports which are located proximate to an associated end of the base arrayed in opposing and communicable fashion relative to the lips upon positioning of the lid over the base. The lips are angularly supported within said hinge supports in a first open rotated position and, upon being rotated to a closed position, capable of being linearly displaced against said hinge supports to lock said lid to said base. |
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BACKGROUND OF THE INVENTION
The present invention relates generally to operations performed in conjunction with a subterranean well and, in an embodiment described herein, more particularly provides apparatus including a high strength water soluble plug.
For economy of manufacture, convenience of assembly and use, etc., it would be quite desirable to fabricate certain components of apparatus used in operations performed in conjunction with subterranean wells of soluble polymeric material. In this manner, operation of the apparatus could be controlled, at least in part, by controlling contact between the polymer and the fluid in which it is soluble.
For example, it would be desirable to construct a plug apparatus in which a plug member blocking flow through a fluid passage included a soluble polymer. Subsequent contact between the polymer and the fluid in which it is soluble would enable the plug member to be dispersed, thereby permitting flow through the fluid passage.
As another example, it would be desirable to construct an apparatus in which a displacement member displaces in operation of the apparatus, and in which a blocking member blocks displacement of the displacement member. Subsequent contact between the polymer and the fluid in which it is soluble would permit displacement of the displacement member, thereby controlling operation of the apparatus.
Therefore, it would be advantageous to provide apparatus in which a soluble polymer is utilized to control, at least in part, operation of the apparatus. It is accordingly an object of the present invention to provide such apparatus.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with embodiments thereof, apparatus is provided which is used in conjunction with operations performed in a subterranean well. In one embodiment, a plug member of a plug apparatus includes a soluble polymer. In another embodiment, an apparatus blocking member, which includes a soluble polymer, blocks displacement of a displacement member.
In one aspect of the present invention, a plug apparatus includes a plug member blocking flow through a fluid passage. The plug member is constructed of a polymer soluble in a fluid. The fluid is placed in contact with the soluble polymer, thereby permitting the plug member to be dispersed and permitting flow through the fluid passage. The plug member may also include other soluble material, such as salt, and crack initiator material, such as sand.
In another aspect of the present invention, an apparatus includes a displacement member and a blocking member preventing displacement of the displacement member. In an embodiment of the apparatus disclosed herein, the apparatus is a valve in which displacement of a closure member is blocked by a member constructed of a polymer soluble in a fluid. The fluid is placed in contact with the soluble polymer, thereby permitting the closure member to displace and operate the valve.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a quarter-sectional view of a first apparatus embodying principles of the present invention;
FIG. 2 is a schematic cross-sectional view of a second apparatus embodying principles of the present invention;
FIG. 3 is a schematic quarter-sectional view of a third apparatus embodying principles of the present invention; and
FIG. 4 is a schematic quarter-sectional view of a fourth apparatus embodying principles of the present invention.
DETAILED DESCRIPTION
Representatively illustrated in FIG. 1 is a plug apparatus 10 which embodies principles of the present invention. In the following description of the plug apparatus 10 and other apparatus and methods described herein, directional terms, such as “above”, “below” “upper”, “lower” etc., are used for convenience in referring to the accompanying drawings. Additionally, 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., without departing from the principles of the present invention.
The plug apparatus 10 is similar in many respects to the plug apparatus described in U.S. patent application Ser. No. 09/031,632, filed Feb. 27, 1998 and entitled Plug Apparatus Having a Dispersible Plug Member and a Fluid Barrier. The disclosure of that patent application is incorporated herein by this reference.
The plug apparatus 10 includes an outer housing 16 and a plug member 12 , which blocks flow through a fluid passage 14 formed generally axially through the plug apparatus. The plug member 12 includes a material 18 , and closures 20 , 22 above and below the material. The closures 20 , 22 prevent contact between the material 18 and fluid 24 in the fluid passage 14 .
To permit flow through the fluid passage 14 , the material 18 is contacted with a fluid in which at least a part of the material is soluble. The material 18 may be at least partially soluble in the fluid 24 in the fluid passage 14 , and/or the material may be soluble in another fluid 26 , which may be selectively introduced into contact with the material via another fluid passage 28 formed in the plug apparatus 10 . The material 18 is contacted with a fluid in which it is soluble, thereby weakening the material and permitting the material to be dispersed by, for example, creating a pressure differential across the plug member 12 , thereby expelling the closures 20 , 22 and the at least partially dissolved material 18 .
In this embodiment of the present invention, the material 18 is a soluble polymer. Specifically, the material 18 may include a water soluble polymer, such as polyacrylic acid. However, the polymer may be produced from any water soluble monomer which can be polymerized to form a water soluble polymer. For example, the monomer may be acrylic acid, 2-hydroxyethylacrylate, vinyl pyrrolidone, N,N-dimethylacrylamide, etc. Additionally, copolymers, terpolymers, or any combination of water soluble monomers could be used.
Other components may be included in the material 18 . For example, the material 18 may include a material which aids in the formation of crack propagation sites, so that the material may be easily broken up for dispersal. An acceptable crack initiation material is sand. Another acceptable crack initiation material is salt, which is also water soluble, and which also aids in the formation of voids in the material if the fluid brought into contact with the material is water.
Referring additionally now to FIG. 2, another plug apparatus 30 embodying principles of the present invention is representatively and schematically illustrated. The plug apparatus 30 is similar in many respects to the plug apparatus 10 described above, but differs in at least one substantial respect in that a plug member 32 thereof blocking fluid flow through a fluid passage 34 is constructed of a material 36 having a coating 38 applied thereto.
The coating 38 isolates the material 36 from contact with a fluid 40 in the fluid passage 34 . However, the material 36 may be at least partially soluble in a fluid 42 selectively introduced into contact with the material via another fluid passage 44 formed in the apparatus 30 . The material 36 may be similar to the material 18 described above, or it may be another material, without departing from the principles of the present invention.
The coating 38 is preferably made of a material which is not soluble in the fluid 40 . The coating 38 may be a non-water soluble plastic or polymeric material. For example, the coating 38 could be made of polystyrene, polycarbonate, epoxy resin, etc.
Beneficial results may be obtained by making the coating 38 of a relatively brittle material, so that the coating may be selectively fractured to thereby permit contact between the material 36 and the fluid 40 . For example, a rod, bar or other structure 46 could be lowered into the fluid passage 34 and impacted with the coating 38 to fracture the coating.
Referring additionally now to FIG. 3, another apparatus 50 embodying principles of the present invention is representatively and schematically illustrated. In the apparatus 50 , a plug member 52 initially blocks flow through an opening or fluid passage 54 formed through a sidewall of a tubular housing 56 of the apparatus. The plug member 52 isolates an inner fluid passage 58 from communication with the exterior of the housing 56 . As shown in FIG. 3, the plug member 52 and opening 54 are specially constructed to resist a pressure differential directed from the exterior of the housing 56 to the fluid passage 58 , but the plug member and opening could also be constructed to alternatively resist an oppositely directed pressure differential, or to resist pressure differentials from both directions.
The plug member 52 includes a material 60 , which may be similar to the materials 18 , 36 described above. The material 60 may have a coating 62 isolating the material 60 from contact with fluid 64 in the fluid passage 58 and/or from contact with fluid 66 external to the housing 56 .
To disperse the plug member 52 and thereby permit flow through the opening 54 , a fluid 68 in which at least a portion of the material 60 is soluble may be selectively introduced into contact with the material via a fluid passage 70 formed in the apparatus 50 , or the material may be placed into contact with one or both of the fluids 64 , 66 . For example, a rod, bar or other structure, such as the structure 46 shown in FIG. 2, may be lowered in the fluid passage 58 and impacted with an inwardly extending portion 72 of the plug member 52 . Such application of force to the portion 72 by the structure will cause fracture of the coating 62 , or complete dislocation of the portion 72 from the remainder of the plug member 52 , thereby permitting contact between the fluid 64 and the material 60 .
Note that either or both of the plug members 32 , 52 described above may be constructed to have a predetermined strength, so that when a predetermined pressure differential is created across the plug member, the material 36 , 60 will break, thereby permitting flow through the respective fluid passage 34 , 54 .
Referring additionally now to FIG. 4, another apparatus 80 embodying principles of the present invention is representatively and schematically illustrated. The apparatus 80 is depicted as including a valve 82 for selectively permitting and preventing flow through an opening or fluid passage 84 formed through a housing 86 of the valve. However, it is to be clearly understood that the apparatus 80 is merely representative of a wide variety of types of apparatus which may embody principles of the present invention. For example, an apparatus constructed in accordance with the principles of the present invention does not necessarily include a valve or other flow control device.
The valve 82 includes a displacement member or sleeve 88 , which displaces relative to the housing 86 in operation of the apparatus 80 . Specifically, the sleeve 88 is a closure member which permits flow through the opening 84 when the sleeve is positioned as shown in FIG. 4, but which prevents flow through the opening when it is downwardly displaced relative to the housing 86 . A spring or other bias member 90 biases the sleeve 88 downward, but the sleeve is prevented from displacing downwardly by a blocking member 92 .
The blocking member 92 includes a material 94 which may be similar to any of the materials 18 , 36 , 60 described above. The blocking member 92 may be dispersed, to thereby permit the bias member 90 to downwardly displace the sleeve 88 relative to the housing 86 , by selectively introducing a fluid 96 into contact with the material via a fluid passage 98 formed in the apparatus 80 . Alternatively, a portion (similar to portion 72 shown in FIG. 3) of the blocking member 92 could extend inwardly into an inner fluid passage 100 formed through the apparatus 80 , so that a structure (similar to structure 46 shown in FIG. 2) could impact the blocking member and thereby provide contact between the material 94 and a fluid 102 in the fluid passage 100 . When the fluid 96 and/or fluid 102 contacts the material 94 , the material at least partially dissolves in the fluid, thereby permitting the blocking member 92 to be dispersed sufficiently for the bias member 90 to displace the sleeve 88 downwardly, so that flow is prevented through the opening 84 .
Note that the blocking member 92 may be constructed with a predetermined strength, so that when a predetermined force is applied to the blocking member, for example, by the bias member 90 , the material 94 will break, thereby permitting displacement of the displacement member 88 in operation of the apparatus 80 .
As described above, the materials 18 , 36 , 60 and 94 may include a polymer material soluble in a fluid. The material may be a mixture of a water soluble polymer, such as polyacrylic acid, along with salt and/or sand.
For example, the applicants have found that an acceptable material results from a mixture of 100 g acrylic acid, 700 g salt of {fraction (14/20)} grain size, along with 0.1 g of a polymerization initiator dissolved in 5 ml water, or a proportionate multiplication of these constituents. The initiator may, for example, be 2,2′-Azobis (N,N′-dimethyleneisobutyramidine) dihydrochloride marketed by Wako under the trade name VA-044. Other acceptable material may result from the following examples of mixtures:
a) 45 g acrylic acid, 200 g sand of {fraction (20/40)} grain size, along with 0.15 g polymerization initiator dissolved in 5 ml water;
b) 100 g acrylic acid, 700 g sand of {fraction (20/40)} grain size, along with 0.3 g polymerization initiator dissolved in 3 ml water;
c) 100 g acrylic acid, 700 g salt of {fraction (14/20)} grain size, along with 0.3 g polymerization initiator dissolved in 5 ml water;
d) 100 g acrylic acid, 700 g salt of {fraction (14/20)} grain size, along with 0.6 g polymerization initiator dissolved in 5 ml water;
e) 100 g acrylic acid, 350 g sand of {fraction (20/40)} grain size, 350 g salt of {fraction ( 14 / 20 )} grain size, along with 0.3 g polymerization initiator dissolved in 5 ml water;
f) 100 g acrylic acid, 700 g salt of {fraction (14/20)} grain size, along with 0.3 g polymerization initiator dissolved in 3 ml water;
g) 100 g acrylic acid, 700 g salt of {fraction (20/40)} grain size, along with 0.3 g polymerization initiator dissolved in 3 ml water; and
h) 100 g acrylic acid, 350 g sand of {fraction (20/40)} grain size, 350 g salt of {fraction (20/40)} grain size, along with 0.3 g polymerization initiator dissolved in 3 ml water.
To prepare the material, the monomer is placed in a suitable container or mold and mixed with crack initiator material and/or other soluble material, such as sand and/or salt, if any. Nitrogen is bubbled through the mixture to remove Oxygen from the monomer solution. The initiator dissolved in water is then added to the mixture. The mixture is then heated to the appropriate polymerization temperature.
Of course, a person skilled in the art would find it obvious to make modifications, substitutions, deletions, additions and other changes to the embodiments described herein, and these 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. | Apparatus for use in operations performed in conjunction with a subterranean well is provided by the present invention. In one described embodiment, a plug apparatus includes a soluble polymer material, which is utilized in a plug member for blocking flow through a fluid passage. In another described embodiment, a soluble polymer material is utilized in a blocking member for blocking displacement of a displacement member of an apparatus. |
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation of prior International Patent Application Number PCT/US2009/031306, filed Jan. 16, 2009, said international application hereby incorporated herein in its entirety and itself claiming benefit of and priority to U.S. Provisional Patent Application No. 61/021,505, filed 16 Jan., 2008, said provisional application also incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
Generally, the inventive technology relates to the field of bar retention. More specifically, the inventive technology, in embodiments, relates to bar coupling sleeve apparatus (e.g., rebar coupling sleeve apparatus), bar end portion retainer apparatus and bar retention methods that may find particular application in, e.g., the reinforced structure construction industry.
BACKGROUND ART
In reinforced concrete construction, including buildings, bridges, and other structures, reinforcing steel (e.g., rebar) is used to resist tensile and shear stresses. Since the concrete is relatively inefficient in resisting or withstanding such stresses, reinforcing steel is added where these stresses occur in a structure to significantly increase the overall strength of the structure. In addition to adding strength to a structure, reinforcing steel also enhances the ductility of the structure. In other words, it increases the structure's ability to absorb energy, which is a desirable characteristic for any structure that may be subject to, e.g., seismic forces.
In many structures, for the reinforcing steel to be effective, the reinforcing steel must “continuously” extend for a certain length, meaning that it must not have any discontinuities at any point along that given length. If this length is greater than the length of a bar that can reasonably be placed into position, the reinforcing steel bar must be “spliced” (or connected end-to-end) with another length of reinforcing steel bar. Typically, this splice is created by lapping the two reinforcing bars creating a “lap splice.” The length of the overlap of the lap splice is governed by commonly accepted codes and standards and depends on numerous factors including, but not limited to, reinforcing bar diameter, grade of reinforcing bar, compressive strength of concrete, concrete cover. The most common standard in the US, from which many codes are formed, is “Building Code Requirements for Structural Concrete” by the American Concrete Institute (ACI), more commonly know as ACI 318 . ACI 318 provides for three types of splices—lap splices, mechanical splices, and welded splices. ACI 318 requires mechanical and welded splices—in addition to lap splices—to be capable of withstanding, in tension or compression, a design force such as 125% of the force that would cause a stress equal to the yield strength of the spliced reinforcing bar. The device of the inventive technology falls into the category of a mechanical splice; it must have a design strength such that it can withstand, without failure, 125% of the yield strength of the reinforcing bar.
Another common occurrence in concrete construction is the need to terminate a reinforcing bar at a specific location in or at the end of the structure. Often the entire strength of the reinforcing bar is required a short distance from the end of the bar. However, because forces are transferred from the reinforcing bar to the concrete primarily by the mechanical keying of the reinforcing bar deformations, a certain length of bar, and therefore a certain number of deformations, is required to develop the full strength of the bar. ACI 318 refers to the length as the “development length” of the bar. When the development length of the bar exceeds the distance from the end of the bar to the point where the full strength of the bar is required, special provisions must be employed to shorten the development length of the bar. Typically, this is done by creating a bend, or hook, in the reinforcing bar. Another viable option is to use a mechanical anchor, which is typically flanged to engage more concrete and which can develop 125% of the capacity of the bar at a point where such strength is needed. Without such provisions, adequate strengths are not observed at all locations needed. Particular embodiments of the inventive technology, such as those depicted in FIG. 2 , are able to provide code strengths (design strength) at such “terminal” locations.
BRIEF SUMMARY OF THE INVENTION
Preferred embodiments of the inventive technology provide a device—a contiguity—may, in embodiments, be described as a simple high-strength steel sleeve with holes at each end and that continue towards the longitudinal center of the cylinder, defining chambers. The inner surface of the chambers can be deformed (in at least one embodiment, they may be concentrically deformed, in another, helically deformed). In preferred embodiments, the smallest diameter of the chambers, occurring at the top of the deformations (e.g., the most intra-radial portion of the deformations), may be slightly larger than the diameter of the reinforcing bar. An adhesive (a non-cementitious material) may be placed into one of the holes and, thereafter, the reinforcing bar may be inserted into the hole, thereby forcing the adhesive into the valleys formed by the deformations of the device. As is the case with other reinforcement splices, two important functionalities of the inventive technology are the transfer of tensile forces from one deformed reinforcing bar to the other, and the transfer of compressive forces from one deformed reinforcing bar to the other.
In embodiments with deformations of the inner surface of the contiguity, such deformations may serve several functions. First, the deformations (in particular their size relative to the reinforcing bar and the gap formed thereby) may be sized to provide passages through which the adhesive can flow to surround the entire reinforcing bar. Such, as an ancillary functionality, increases the surface area of the bar that is in contact with the adhesive, allowing more bonding between the adhesive and the reinforcing bar. Additionally, the deformations provide a mechanical anchorage for the adhesive. The deformations mechanically engage the adhesive to resist the tendency of the adhesive to be withdrawn from the device when a tension force is applied to the reinforcing bar. As should be understood, in particular embodiments of the inventive technology, deformations on the inner surface of the holes aid in force transfer through wedging action on the cured adhesive. It is also of note that no special tools are required for installation and that no special treatment of the deformed reinforcing bars is required for installation.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of at least one embodiment of the inventive technology.
FIG. 2 shows a cross-sectional view of at least one embodiment of the inventive technology usable at the end of a concrete structure.
FIG. 3 shows a cross-sectional view of at least one embodiment of the inventive technology, in particular showing the forces observed in response to a tensile force applied to the bar, where such forces are applied by the deformations on the outside of reinforcing bar established inside the coupler, through cured adhesive to the deformations on the inside of an inventive coupler.
FIG. 4A shows a side view of at least one embodiment of the inventive technology in use coupling two bars.
FIG. 4B shows a cross-sectional side view of at least one embodiment of the inventive technology in use coupling two bars.
FIG. 5A shows a cross-sectional side view of at least one sleeve embodiment of the inventive technology.
FIG. 5B shows a cross-sectional side view of at least one single bar embodiment of the inventive technology.
FIG. 5C shows a side view of at least one sleeve embodiment of the inventive technology.
FIG. 5D shows a side view of at least one single bar embodiment of the inventive technology.
FIG. 6A shows a cross-sectional side view of a portion of the single or two bar apparatus, showing deformations as may be found in certain embodiments of the inventive technology. Of course, a myriad of other possible deformations may be used.
FIG. 6B shows a cross-sectional side view of a portion of the single or two bar apparatus, showing deformations as may be found in certain embodiments of the inventive technology.
DETAILED DESCRIPTION OF THE INVENTION
As mentioned earlier, the present invention includes a variety of aspects, which may be combined in different ways. The following descriptions are provided to list elements and describe some of the embodiments of the present invention. These elements are listed with initial embodiments, however it should be understood that they may be combined in any manner and in any number to create additional embodiments. The variously described examples and preferred embodiments should not be construed to limit the present invention to only the explicitly described systems, techniques, and applications. Further, this description should be understood to support and encompass descriptions and claims of all the various embodiments, systems, techniques, methods, devices, and applications with any number of the disclosed elements, with each element alone, and also with any and all various permutations and combinations of all elements in this or any subsequent application.
At least one embodiment of the inventive technology may be described as a bar coupling sleeve apparatus that comprises: a rigid contiguity 1 defining a longitudinal axis 6 , and having two ends 7 and an opening 9 at each the ends for reception of bar end portions (e.g., rebar end portions); a fluid impervious barrier 8 (through which, of course, fluid cannot pass) established as part of the contiguity to define an end of each of two fluidically non-communicative chambers 10 within the contiguity, each of the chambers sized to accommodate a different one of the bar end portions and a curable wet fluid (e.g., adhesive) 3 ; and two fluid outlet ports 4 , each associated with a different one of the chambers, and each enabling fluidic communication (the passage of a fluid such as air or adhesive) between its associated chamber and an environment external 20 of the contiguity. As in certain other embodiments, each of the two fluid outlet ports may enable fluidic communication between the environment and a barrier proximal end portion 21 of its associated chamber. Further, the curable wet fluid (e.g., adhesive such as epoxy), upon curing, retains the bar end portions in a different one of the chambers. Of course, fluid can not directly pass from one fluidically non-communicative chamber to the other (a theoretically possible passage of air from one chamber, out its associated fluid outlet port, out to the environment external of the contiguity, and then through a fluid port associated with a different chamber is not considered a type of fluidic communication that the term “fluidically non-communicative” excludes; the term primarily excludes any sort of fluid port through a barrier between the two chambers).
At least one embodiment of the inventive technology may be described as a bar coupling sleeve apparatus that comprises: a rigid contiguity 1 defining a longitudinal axis 6 and two fluidically non-communicative chambers 10 , each having an opening 9 for non-contact reception of an end portion 2 of bar of a design size; a fluid impervious barrier 8 established as part of the contiguity to define an end of each of the two fluidically non-communicative chambers; and deformations 5 established on interior walls 22 that at least partially define the chambers (perhaps it is also defined by walls of a fluid impervious barrier), wherein the interior walls and the deformations are sized so that the end portions of the bar of design size may be established within the chambers without contacting the deformations. A bar of design size is the bar for which a coupling apparatus is intended; in certain embodiments, the interior surface of such apparatus may allow for a clearance of from 1 mm to 10 mm (as one exemplary, but preferred, range) between the bar and the deformations. Of course, merely because a bar may be established within the chambers without contacting the deformations does not mean that, during field insertion of a bar end into a chamber of the apparatus, there will definitely not be contact; it merely means that such absence of contact is possible, and that fluidic clearance between the bar and the inner walls exists.
At least one embodiment of the inventive technology may be described as a bar coupling sleeve apparatus that comprises: a rigid contiguity 1 defining a longitudinal axis 6 , and having two ends 7 and openings 9 at each of the ends for reception of bar end portions; at least one fluid outlet port 4 , each enabling fluidic communication between an environment 20 external of the contiguity and one of two chambers 10 , each of which is at least partially defined by interior walls 22 of the contiguity; and deformations 5 established on the interior walls 22 , wherein the each fluid outlet port 4 is established substantially at a closed end (e.g., a barrier proximal end 21 ) of a different one of the chambers. It is of note that the apparatus, in particular embodiments, has a total of two chambers; such chambers may be fluidically non-communicative. The apparatus may further comprise a fluid impervious barrier 8 established as part of the contiguity to define an end of each of the two fluidically non-communicative chambers. It is also of note that, particularly in the two chamber embodiments, the at least one fluid outlet port may comprise at least two fluid outlet ports, each established substantially at a longitudinal midpoint of the rigid contiguity and each enabling fluidic communication between an environment external of the contiguity and a chamber at least partially defined by interior walls of the contiguity. It is of note that the term “substantially at a longitudinal midpoint of the rigid contiguity” includes up to a ¼ length portion centered at the midpoint.
At least one embodiment of the inventive technology may be described as a bar coupling sleeve apparatus that comprises: a rigid contiguity 1 defining a longitudinal axis 6 and having two ends 7 and openings 9 at both the ends for reception of bar end portions 2 ; and a fluid impervious barrier 8 established as part of the contiguity to define an end of each of two fluidically non-communicative chambers 10 within the contiguity, each of the chambers sized to accommodate a different one of the bar end portions. As in other embodiments, each of the chambers is sized to also accommodate a curable wet fluid (e.g., adhesive such as epoxy). The apparatus may further comprise two fluid outlet ports 4 , each associated with a different one of the chambers, and each enabling fluidic communication between its associated chamber and an environment external of the contiguity. Each of such two fluid outlet ports may enable fluidic communication between an environment external of the contiguity and a barrier proximal end portion of its associated chamber.
At least one embodiment of the inventive technology, more particularly focusing on the single bar retention apparatus, may be described as a bar end portion retainer apparatus that comprises: a rigid contiguity 11 defining a chamber 30 that has an opening 39 at a first end of the contiguity for reception of a bar end portion 2 ; a flange 16 established at a second end 34 of the rigid contiguity; and a fluid outlet port 14 enabling fluidic communication between the chamber 30 and an environment 20 external of the contiguity. In particular embodiments, the fluid outlet port is established proximal a terminal end 35 of the chamber 30 .
At least one embodiment of the inventive technology, more particularly focusing on the single bar retention apparatus, may be described as a bar end portion retainer apparatus that comprises: a rigid contiguity 11 defining a chamber 30 that has an opening 39 at a first end 40 of the contiguity for reception of a bar end portion 22 ; a flange 16 established at a second end 34 of the rigid contiguity; and deformations 15 established on interior walls 22 that at least partially define the chamber. The apparatus may further comprise a fluid outlet port 14 enabling fluidic communication between the chamber and an environment external of the contiguity 20 ; such fluid outlet port may be established proximal a terminal end of the chamber 35 . As with other embodiments, interior walls and the deformations may be sized so that a bar end portion of design size may be established within the chambers without contacting the deformations.
Of course, in any of the embodiments disclosed herein deformations may be established on interior walls 22 that at least partially define the chambers. Interior walls and the deformations are typically (but not necessarily always) sized so that the end portions of the bar of design size may be established within the chambers without contacting the deformations. A cross-section of the deformations in a plane that is parallel to the longitudinal axis (see FIGS. 6A and 6B ) may show a pattern having at least one section that defines a normal vector 50 that (a) has a component that is opposite to a bar withdrawal direction 51 ; and that (b) is at least 20 degrees (see angle 53 ) relative to a plane 54 that is orthogonal to the longitudinal axis. Such at least one section (that defines a normal vector with a component having limitations (a) and (b)) may be either curved (see, e.g., FIG. 6A ) or linear (see, e.g., FIG. 6B ). The at least one section may define at least one valley 55 , and the at least one section may be repeated. It is of note that even if the entire vector is in a certain direction, that it is still said that such vector has a component in that certain direction. Deformations can be made in a number of known ways, including but not limited to mechanical stress induced deformations, material addition (material addition is considered a type of deformation). Further, deformations can be of a myriad of shapes; shown in the figures are only a few examples. It is also of note that even a chamber having a substantially circular cross-section (whether with deformations or without) is viewed as having walls (plural).
In certain preferred embodiments, insertion of adhesive 3 (e.g., epoxy) into the chambers, and subsequent insertion of the bar end portions into the chamber, results in a design strength coupling after curing. In preferred embodiments, the adhesive is insertable into the chambers without pressure (application of a caulking gun is not considered a pressurized insertion, as the adhesive, after exiting the gun and while being deposited into the chamber, is not under pressure). It is of note that, in preferred embodiments, design strength is achievable without heat application or welding.
In certain embodiments having fluid outlet ports, the apparatus may be the to be configured such that when adhesive (e.g., epoxy) is inserted into the chambers and then a different one of the bar end portions is thereafter inserted into the adhesive containing chambers, fluid flows through the fluid outlet ports 4 , 14 . Indeed, the inventive apparatus may be described as including adhesive established in the chamber(s).
Of course, as alluded to throughout this description, a primary, but not exclusive, application of the various inventive technologies is rebar coupling and rebar retention. As such, the bar end portion(s) comprise rebar end portions. It is also of note that in those embodiments with a barrier (e.g., a fluid impervious barrier 8 ), such barrier may be an integral part of the contiguity (e.g., instead of being screwed or snapped into place, it is, for example, molded concurrently with the molding of the entire contiguity). The contiguity itself may be made from any of a number of materials, a metal such as steel being preferred, but certainly not the only option.
At least one embodiment of the inventive method technology may be described as a bar retention method that comprises the steps of: pressure-free packing adhesive 3 in each bar accommodative chamber 10 , 30 of a rigid contiguity; then manually establishing a bar end portion 2 in each the chamber 30 while expelling fluid through a fluid outlet port 4 , 14 ; and then curing, without heat application, the adhesive to achieve a design strength. It is of note that design strength, as used herein, may be governed by applicable code. Further, the term “pressure-free packing adhesive” merely implies placement of adhesive into the chamber without the need to overcome a pressure inside the chamber.
In those method embodiments where the rigid contiguity defines only one bar accommodative chamber, the step of pressure-free packing adhesive in each bar accommodative chamber of a rigid contiguity may comprise the step of pressure-free packing adhesive in the only one bar accommodative chamber of the rigid contiguity (see FIG. 5B , e.g.). As in other single chamber embodiments, the rigid contiguity may comprise a flange.
In those method embodiments where the rigid contiguity defines only two bar accommodative chambers, the step of pressure-free packing adhesive in each bar accommodative chamber of a rigid contiguity may comprise the step of pressure-free packing adhesive in the only two bar accommodative chambers of the rigid contiguity (see FIG. 5A , e.g.). Of course, as in other two chamber embodiments, the rigid contiguity may be described as a sleeve. Regardless of the number of chambers, the step of manually expelling fluid may comprise the step of manually expelling adhesive and/or air (e.g., through fluid outlet port(s)).
At least one embodiment of the inventive method technology may be described as a bar retention method that comprises the steps of: pressure-free packing adhesive 3 in each bar accommodative chamber 10 , 30 of a rigid contiguity 1 , 11 ; manually establishing a bar end portion 2 in each the chamber; and curing, without heat application, the adhesive to achieve a design strength. In embodiments where the rigid contiguity defines only one bar accommodative chamber, the rigid contiguity may comprise a flange 16 ; in embodiments where the rigid contiguity defines only two bar accommodative chambers, the rigid contiguity may be a sleeve. Regardless of the number of chambers, the step of expelling fluid (air and/or adhesive) through a fluid outlet port may be performed while performing the step of manually establishing. In certain embodiments, the step of manually establishing is performed after the step of pressure-free packing adhesive.
In any of the method embodiments, it is preferred that the method does not comprise the step of welding or applying heat. Also, in preferred embodiments, whether method or apparatus, end caps (that cap the open end of the chamber(s)), whether integral to the contiguity or not, are not used or needed. Further, in certain embodiments, the step of manually establishing can be performed without contacting walls 22 of each bar accommodative chamber, and each bar accommodative chamber is at least partially defined by interior walls with deformations. Of course, such deformations may be oriented as described elsewhere in this application.
It is of note that in any of the embodiments, specialized equipment (e.g., welder, pressurized adhesive applicators) may not be required (a caulking gun is not considered specialized equipment). Further, preferred embodiments do not require any screwing of any parts, as threads are preferably absent from preferred embodiments. Additionally, it should be clear that the sleeve apparatus may be used to couple a bars of different diameters. In such case, the internal diameter of the chambers may be different (although different, but closely sized rebar might not require such a difference in diameter).
As can be easily understood from the foregoing, the basic concepts of the present invention may be embodied in a variety of ways. It involves both coupling techniques as well as devices to accomplish the appropriate coupling. In this application, the coupling techniques are disclosed as part of the results shown to be achieved by the various devices described and as steps which are inherent to utilization. They are simply the natural result of utilizing the devices as intended and described. In addition, while some devices are disclosed, it should be understood that these not only accomplish certain methods but also can be varied in a number of ways. Importantly, as to all of the foregoing, all of these facets should be understood to be encompassed by this disclosure.
The discussion included in this application is intended to serve as a basic description. The reader should be aware that the specific discussion may not explicitly describe all embodiments possible; many alternatives are implicit. It also may not fully explain the generic nature of the invention and may not explicitly show how each feature or element can actually be representative of a broader function or of a great variety of alternative or equivalent elements. Again, these are implicitly included in this disclosure. Where the invention is described in device-oriented terminology, each element of the device implicitly performs a function. Apparatus claims may not only be included for the device described, but also method or process claims may be included to address the functions the invention and each element performs. Neither the description nor the terminology is intended to limit the scope of the claims that will be included in any subsequent patent application.
It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. They still fall within the scope of this invention. A broad disclosure encompassing both the explicit embodiment(s) shown, the great variety of implicit alternative embodiments, and the broad methods or processes and the like are encompassed by this disclosure and may be relied upon when drafting the claims for any subsequent patent application. It should be understood that such language changes and broader or more detailed claiming may be accomplished at a later date (such as by any required deadline) or in the event the applicant subsequently seeks a patent filing based on this filing. With this understanding, the reader should be aware that this disclosure is to be understood to support any subsequently filed patent application that may seek examination of as broad a base of claims as deemed within the applicant's right and may be designed to yield a patent covering numerous aspects of the invention both independently and as an overall system.
Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. Additionally, when used or implied, an element is to be understood as encompassing individual as well as plural structures that may or may not be physically connected. This disclosure should be understood to encompass each such variation, be it a variation of an embodiment of any apparatus embodiment, a method or process embodiment, or even merely a variation of any element of these. Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms or method terms—even if only the function or result is the same. Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled. As but one example, it should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action. Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates. Regarding this last aspect, as but one example, the disclosure of a “coupler” should be understood to encompass disclosure of the act of “coupling”—whether explicitly discussed or not—and, conversely, were there effectively disclosure of the act of “coupling”, such a disclosure should be understood to encompass disclosure of a “coupling” and even a “means for coupling” Such changes and alternative terms are to be understood to be explicitly included in the description.
Any acts of law, statutes, regulations, or rules mentioned in this application for patent; or patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference. Any priority case(s) claimed by this application is hereby appended and hereby incorporated by reference. In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with a broadly supporting interpretation, common dictionary definitions should be understood as incorporated for each term and all definitions, alternative terms, and synonyms such as contained in the Random House Webster's Unabridged Dictionary, second edition are hereby incorporated by reference. Finally, all references listed in the list of References To Be Incorporated By Reference In Accordance With The Patent Application or other information statement filed with the application are hereby appended and hereby incorporated by reference, however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these invention(s) such statements are expressly not to be considered as made by the applicant(s).
Thus, the applicant(s) should be understood to have support to claim and make a statement of invention to at least: i) each of the coupler devices as herein disclosed and described, ii) the related methods disclosed and described, iii) similar, equivalent, and even implicit variations of each of these devices and methods, iv) those alternative designs which accomplish each of the functions shown as are disclosed and described, v) those alternative designs and methods which accomplish each of the functions shown as are implicit to accomplish that which is disclosed and described, vi) each feature, component, and step shown as separate and independent inventions, vii) the applications enhanced by the various systems or components disclosed, viii) the resulting products produced by such systems or components, ix) each system, method, and element shown or described as now applied to any specific field or devices mentioned, x) methods and apparatuses substantially as described hereinbefore and with reference to any of the accompanying examples, xi) the various combinations and permutations of each of the elements disclosed, xii) each potentially dependent claim or concept as a dependency on each and every one of the independent claims or concepts presented, and xiii) all inventions described herein.
With regard to claims whether now or later presented for examination, it should be understood that for practical reasons and so as to avoid great expansion of the examination burden, the applicant may at any time present only initial claims or perhaps only initial claims with only initial dependencies. The office and any third persons interested in potential scope of this or subsequent applications should understand that broader claims may be presented at a later date in this case, in a case claiming the benefit of this case, or in any continuation in spite of any preliminary amendments, other amendments, claim language, or arguments presented, thus throughout the pendency of any case there is no intention to disclaim or surrender any potential subject matter. It should be understood that if or when broader claims are presented, such may require that any relevant prior art that may have been considered at any prior time may need to be re-visited since it is possible that to the extent any amendments, claim language, or arguments presented in this or any subsequent application are considered as made to avoid such prior art, such reasons may be eliminated by later presented claims or the like. Both the examiner and any person otherwise interested in existing or later potential coverage, or considering if there has at any time been any possibility of an indication of disclaimer or surrender of potential coverage, should be aware that no such surrender or disclaimer is ever intended or ever exists in this or any subsequent application. Limitations such as arose in Hakim v. Cannon Avent Group, PLC, 479 F.3d 1313 (Fed. Cir 2007), or the like are expressly not intended in this or any subsequent related matter. In addition, support should be understood to exist to the degree required under new matter laws—including but not limited to European Patent Convention Article 123(2) and United States Patent Law 35 USC 132 or other such laws—to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept. In drafting any claims at any time whether in this application or in any subsequent application, it should also be understood that the applicant has intended to capture as full and broad a scope of coverage as legally available. To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular embodiment, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative embodiments.
Further, if or when used, the use of the transitional phrase “comprising” is used to maintain the “open-end” claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term “comprise” or variations such as “comprises” or “comprising”, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps. Such terms should be interpreted in their most expansive form so as to afford the applicant the broadest coverage legally permissible.
Finally, any claims set forth at any time are hereby incorporated by reference as part of this description of the invention, and the applicant expressly reserves the right to use all of or a portion of such incorporated content of such claims as additional description to support any of or all of the claims or any element or component thereof, and the applicant further expressly reserves the right to move any portion of or all of the incorporated content of such claims or any element or component thereof from the description into the claims or vice-versa as necessary to define the matter for which protection is sought by this application or by any subsequent continuation, division, or continuation-in-part application thereof, or to obtain any benefit of, reduction in fees pursuant to, or to comply with the patent laws, rules, or regulations of any country or treaty, and such content incorporated by reference shall survive during the entire pendency of this application including any subsequent continuation, division, or continuation-in-part application thereof or any reissue or extension thereon. | Particular embodiments of the inventive technology relate to a device for connecting the ends of two concrete reinforcing bars in which a metal sleeve has chambers at each end to accommodate the end of one reinforcing bar. Forces may be transferred from one bar to the other through, the use of, inter alia, an adhesive established within the space between the outside of the reinforcing bars and the deformed inner surface of the sleeve. The chambers are, preferably, separated by a fluid impervious barrier. One port associated with each chamber may be established to allow fluid such as air to escape, preventing air voids in the adhesive. Another configuration of the inventive device would be intended for the retention (under load, of course) of only one reinforcing bar, with an enlarged flange for anchoring the end of one reinforcing bar, perhaps at and outer surface of, e.g., a concrete slab. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention concerns a covering panel consisting of a metal cladding comprising a supporting structure, and cladding members consisting of extruded aluminum or synthetic sections, said sections having quick fastening means which form a rigid interconnection between each juxtaposed pair.
Various covering systems using crimped metal panels are known in the art. These panels are positioned and attached using a multitude of screws or rivets, which is a lengthy, detailed operation. Furthermore, such metal panels generally can have only simple shapes, since the crimping process is not conducive to elaborate, creative forms. Finally, the crimped panels cannot be easily connected, as they must be juxtaposed and individually attached to the supporting structures with many screws or rivets. This not only detracts from their appearance, but also makes them poorly adaptable to the architecture of the underlying structure.
BACKGROUND OF THE INVENTION
Covering panels consisting of extruded, laterally interlocking elements have been designed to overcome these practical and aesthetic drawbacks. Such panels are described, for example, in U.S. Pat. Nos. 3,085,367 and 4,063,396, as well as German Patent Application No. DE-A-1 297 836. However, these panels are not particularly easy to attach, since each panel must be individually fastened to a conventional supporting structure, which is a complicated, expensive and unwieldy procedure.
SUMMARY OF THE INVENTION
To overcome these disadvantages, the present invention proposes a facade panel as described above, characterized by having longitudinal sections which are longitudinally or vertically disposed at regular intervals, and further comprising an axial longitudinal channel with interior walls having grooves parallel to the axis, said channels being designed to receive the screws for fastening the cladding members. The screws having a threaded shaft which cooperates with the grooves in the channels of the longitudinal sections.
According to a preferred embodiment, said longitudinal sections are extruded and made of aluminum alloy.
The longitudinal sections are generally T-shaped, with the central portion of the T comprising the axial longitudinal channel and with a spline in the extension of the channel. The transverse portion splits into two lateral flanges respectively situated on either side of the channel.
Said axial longitudinal channel preferably extends along only one side of the top of the central T-shaped portion.
According to a preferred embodiment, said supporting structure also comprises angled brackets, one arm of which has at least one opening for a wall fastening screw, and the other arm o which has an opening which receives at least a portion of the spline of the central T-shaped portion.
In this preferred embodiment, the arm with the opening has a generally cylindrical housing along its entire width, which receives a blocking screw of a longitudinal section when the spline of the central T-shaped portion engages said opening.
The blocking screw is preferably self-boring and the cylindrical housing is preferably divided along its axis.
According to a preferred embodiment, the distance separating the lateral walls of the channel in the longitudinal sections, as measured from the base of the opposing grooves, is generally equal to the dimension of the shaft of the fastening screw measured on the exterior of the screw threads.
According to a particularly advantageous embodiment, said cladding members have openings for concealing lights.
Preferably, said cladding members have both quick assembly means and means for interlocking them in pairs.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood with reference to the description of some exemplary embodiments and to the attached drawings, wherein:
FIG. 1 is a horizontal or front-to-rear cross-section of two cladding members comprising the covering panel according to the invention;
FIGS. 2, 3 and 4 show several variations of cladding members for covering panels according to the invention;
FIG. 5 is a front-to-rear cross-section showing the means for attaching the cladding members to a supporting structure;
FIG. 6 is a perspective showing the attachment means of FIG. 5; and
FIGS. 7, 8 and 9 show a specific application of the covering panel according to the invention, wherein the cladding members are designed for the installation of indirect lighting.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, covering panel 10 consists of a unit of cladding members 11 in the form of longitudinal panels mounted side by side to form an exterior surface with a uniform appearance. These cladding members are made of aluminum, an aluminum based alloy, or a synthetic material, using a well-known extrusion manufacturing technique.
Because of the extrusion technique, the cladding members have quick assembly means 12 and locking means 13 for connecting them to each other and locking them in position. This reduces considerably the number of screws 14 required to attach the cladding members to a supporting structure 15, which will itself be affixed to the building to be sided. The quick assembly means 12 preferably consists of a slot 12a running along one side of each cladding member 11 and of a rim 12b running along the other side of each cladding member 11. Slot 12a and rim 12b are shaped so that the rim 12b of a first cladding member 11 engages slot 12a of another cladding member 11 which is adjacent the first cladding member. They interlock in such a way that from the outside, two cladding members 11 placed together appear to have a continuous, unbroken surface.
The locking means advantageously consists of two legs 13a and 13b on the rear surface of cladding member 11, with two tips 13d and 13c, respectively, which are somewhat flexible. Leg 13a with its tip 13d extends from one of the walls defining slot 12a and is located along the side of cladding element 11 which has the slot. Leg 13b and corresponding tip 13c are located on the rear surface of cladding element 1 near the edge with rim 12b. Therefore, the extremities of legs 13a and 13b overlap and tips 13d and 13c engage each other when two cladding elements 11 are connected, that is, attached side by side.
In addition, the portion of cladding elements 11 with slot 12a and leg 13a has a disengaging element 16 defining a contact surface 17 so two cladding elements can be simultaneously attached to longitudinal support element 15 of the supporting structure. Contact surface 17 is essentially flat to facilitate this and disengaging element 16 is deep enough to cover the head of screw 14 and regulate the distance between the cladding member and the supporting structure.
The extrusion technique obviously adapts to many differently shaped elements and any interlocking system similar or identical to those described above. More specifically, FIGS. 2, 3 and 4 show other embodiments of the cladding members which can be made with this technique. As before, the cladding members have a quick assembly means 12 and a locking means 13 on either edge so that after connection, the elements appear to be a continuous unit when the panel is completely attached to a building facade.
FIGS. 5 and 6 show in greater detail how the cladding members are attached to the supporting structure. The supporting structure comprises longitudinal sections 20, preferably made of extruded aluminum, with an axial longitudinal channel 21 which receives screws 14 which attach cladding members 11. Longitudinal sections 20 are connected to a masonry wall 22 with brackets 23 which are also made of an extruded aluminum piece formed of sections. Longitudinal sections 20 are generally T-shaped, with the central portion comprising said axial longitudinal channel. This channel has interior walls with grooves 21a parallel o its axis, and the distance between these walls, as measured from the base of opposite grooves, is generally equal to the diameter of the shaft of the attachment screw measured around the screw threads, so the screws are held tightly within the groove. The transverse portion of the T splits into two lateral flanges 20a, 20b located on either side of the channel, respectively. These flanges contact the longitudinal support element 15 to which cladding members 11 will be attached. Note that axial longitudinal channel 21 extends rearwardly only partially along the central portion of the T. The remainder of that portion forms a spline 25 located rearwardly of the extension of the axis of channel 21.
Brackets 23, which form right-angles, have one arm 23a and one arm 23b, with arm 23a designed for attachment to masonry wall 22 and arm 23b designed for attachment to longitudinal section 20. For this reason arm 23a has an oblong opening 26 for a bolt or an attachment screw 27. The oblong opening regulates the position of bracket 23. Arm 23b has a slit 24 which receives spline 25 of the central T-shaped portion of longitudinal section 20. Arm 23b is also provided with a generally cylindrical housing 29 spanning its width, which receives blocking screw 28. Cylindrical housing 29 is preferably divided along its entire length. Blocking screw 28 is preferably self-boring and the screw head has blocks to prevent it from loosening due to vibration.
Once the brackets have been placed, longitudinal sections 20 are appropriately positioned. The position of these elements, i.e., the distance from the masonry wall, is defined by how far spline 25 penetrates openings 24 in arms 23b of brackets 23. One way to regulate this is by providing an insulating layer and varying the thickness of the layer. Auto-boring blocking screw 28 maintains sections 20 in position.
Complex structures such as the grooves inside channel 21 and housings 29 for blocking screws 28 which maintain longitudinal sections 20 in position can be simply and effectively designed because the elements are manufactured by extrusion.
FIGS. 7 through 9 show a particular embodiment for incorporating indirect lighting in the metal cladding. To achieve this, each cladding member 11, the exterior surface of which may be any shape corresponding to the elements shown in FIGS. 1 through 4, comprises a lateral extension 30 which defines an opening 31 for mounting a light 32.
The two enlarged views in FIGS. 8 and 9 show two particular embodiments of the tips of the locking means for cladding elements 11. These elements can be simply and effectively manufactured in any shape by extrusion, whereas conventional manufacturing of such devices would involve complicated, expensive crimping and soldering.
Because all the embodiments of the cladding members have quick assembly and locking features, the number of screws or rivets required to fasten them to the supporting structure is greatly reduced in comparison to the number of attachment means required by systems known in the art.
The present invention is not limited to the embodiments described herein. In particular, the shape of the elements comprising the cladding members can vary. The quick assembly interlocking means and the locking means may be modified. However, both of these functions must take place quasi-simultaneously so the cladding members can be attached quickly, effectively and economically. | A covering panel consisting of a metal cladding with a supporting structure (15) and cladding members (11) attached via fastening screw (14). The cladding members (11) consists of extruded aluminum sections and comprise quick fastening members (12) and locking members (13) for interconnecting the sections. The cladding members (11) are joined to the supporting structure (15) by evenly spaced longitudinal T-shaped sections (20) each having an axial longitudinal channel (21) with grooved walls for engagement with the screws (14) for fastening the cladding members. The sections are adjustably spaced from the wall (22) via brackets (23) engageable with the longitudinal sections (20). |
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REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 10/910,072, filed Aug. 3, 2004, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to metal dock system of the type that use alumin and other decking pieces and, in particular, to components, systems and methods that improve the assembly, use, and/or cost of such systems.
BACKGROUND OF THE INVENTION
[0003] In many warm climates, boat docks may be permanently installed and left in the water without concern for ice flows, for example. In colder climates, however, most smaller recreation dock must be removed from the water because freezing conditions and ice movement may destroy the structure. As such, the combination of lightweight and ease of installation are essential. There have been many inventions relating to dock systems, including methods and apparatus for dismantling before the onset of winter and re-assembling in the spring.
[0004] As a first example, U.S. Pat. No. 2,948,121 relates to portable sectional piers, and more particularly to such devices combined with means for installing and removing the pier sections. However the described system is overly complicated, very expensive to manufacture, and cannot accommodate sideways construction.
[0005] In U.S. Pat. No. 3,421,327 a hinge for use with boat docks or the like comprises first and second hinge sections which are secured to the ends of first and second support members. The hinge sections are detachably secured together by pivoting one of the hinge sections with respect to the other hinge section whereby a pair of posts on one of the hinge sections will be received by a pair of slots on the other hinge section. Although this system offers some versatility, it does not allow down ramping.
[0006] U.S. Pat. No. 3,686,876 teaches a removable pier having at least two sections pivotally joined end to end and extending from a footing on a shore into a body of water. The pier sections are removably supported on permanent footings for stability. Booms having cable guides are removably mounted on leg extensions of the inner pier section. Cables, driven by winches, pass through the cable guides on the boom and engage the outer pier section for its removal from the water by rotation about its pivotable connection with the inner pier section. The booms are transferred to mounts on the shore at the sides of the pier for removal of the inner pier section from the water with the outer pier section in overlying position. The outer pier section is preferably slightly shorter than the inner pier section so that both pier sections can be stored in upright position on the shore ready for repositioning in the water.
[0007] Though not dock-related, U.S. Pat. No. 4,048,960 discloses a floor for use in animal husbandry consisting of a number of elongated extruded aluminum floor lengths each of which has a slotted top surface with longitudinally and transversely spaced apart slots, each length having a multiplicity of integral vertical support beams extending from the undersurface of the slotted surface and terminating in footed ends, one longitudinally extending side of the slotted surface having an arcuate male connector configuration and the other longitudinally extending side having a correspondingly dimensioned female connector configuration whereby adjacent lengths are pivotally connectable to one another.
[0008] According to U.S. Pat. No. 4,126,006 a boat dock is assembled from portable sections hingedly connected to each other and provided with foldable and adjustably extensible leg assemblies. Each section is formed from tread retaining decking members made of extruded metal sections interconnected in close parallel spaced relation by interlocking elements. Pivotally separable half-shell foot elements are connected to the leg assemblies for stabilized support of the dock sections. A drawback with this design is that a separate hinge component is required and gaps are created between sections.
[0009] U.S. Pat. No. 4,398,849 is directed to a portable dock and dock sections used therewith, characterized by each of the dock sections have a plurality of frame members forming a rectangular deck frame for supporting a deck assembly, a pair of adjustable legs extending from adjacent one end of the rectangular deck frame and a first coupling unit disposed on a frame member at the other end of the deck frame. Preferably, an additional or second coupling unit, which is adapted to cooperate with a first coupling unit, is arranged either on an end or side frame member or both at the one end to enable connecting sections together to form either a straight line pier or a pier with a “T” or “L” shape. The portable dock also includes an anchor section having an anchor member with a similar coupling unit which co act with the first coupling unit of a first dock section for securing the first dock section to the beach or shoreline. Again, the hinges are separate from the deck, the deck cannot ramp down, and there are gaps between sections.
[0010] The disclosure of U.S. Pat. No. 4,645,380 relates to a dock that is purportedly easily assembled and disassembled. The dock comprises a number of dock sections, each of which is provided with a leg portion that engages the bottom of a lake or body of water. The opposite end of each dock section from the leg portion thereof is engaged with a preceding dock section by a locking system that facilitates erection of the dock system and maintenance thereof in the assembled condition. Again, the deck cannot ramp down, and there are gaps between sections.
[0011] U.S. Pat. No. 4,948,300 resides in a multiple pier section and installation assembly includes a plurality of modular pier sections, a dolly for transporting, installing and removing the individual pier sections, and a dolly locator. The pier sections have a hinged pier section interconnection system which utilizes a dual pin/slot arrangement that resists both lateral and longitudinal as well as vertical movement of the installed pier. Adjustable pier legs which can be raised or lowered from atop the pier to accommodate variations in water depth are mounted to one end of each modular pier section. The dolly includes a chassis and a pivotally mounted pier section support unit, a dolly hold down system and a pier section hold down system. The dolly and dolly locator cooperate to assure proper alignment and positioning of the dolly during installation and removal of the pier sections. Like other prior-art systems, gaps are created between sections such that a ramping up or down would create raised portions that could result in user tripping.
SUMMARY OF THE INVENTION
[0012] According to one aspect of the invention, first and second coupling elements are provided, each associated with a respective one of the decking side edges. The first coupling element including a lengthwise member with a partially cylindrical outer surface, and the second coupling element including a lengthwise cradle with a partially cylindrical inner surface. Using this configuration, the lengthwise member may be hinged into the lengthwise cradle to couple. The associated pieces of decking to one another while allowing a certain degree of pivoting therebetween. An important element is the shorter length since a typical 8 foot or 10 foot section using identical new art would be for heavier and the angle of release would require the far end to be lifted very high to assemble. While these sections could be set on the previous section vertically and tilted down, a 8 foot or greater section would require a boom to tilt it in without operator danger.
[0013] In a preferred embodiment, the partially cylindrical inner and outer surfaces are in substantially intimate contact when the associated pieces of decking are coupled to one another. This is achieved with a configuration wherein the first coupling element includes a lower lip spaced apart from a portion of the cylindrical outer surface, thereby creating a partial J-shaped cavity, and the lengthwise cradle forms part of a partial J-shaped lip. This allows the J-shaped lip to be at least loosely retained in the J-shaped cavity when the associated pieces of decking are coupled to one another.
[0014] According to the invention, the first and second coupling elements may be disposed on opposing edges of the same piece of decking pieces, or on opposing edges of different decking pieces coupled to one another using one or more dovetail joints. A different aspect of the invention provides a member adapted for fastening to a stringer providing one of the first or second coupling elements to add transverse decking pieces. A further, patentably distinct aspect of the invention resides in a member adapted for fastening to a stringer to provide a resilient outer bumper.
[0015] In a system wherein the stringers and decking pieces are suspended using vertical poles on the outer sides of each stringer, the vertical poles being coupled to one another through a transverse member disposed beneath the decking pieces, the improved assembly system further includes a patentably distinct coupler having a first bore that clamps onto one of the vertical poles and a second bore that clamps onto one of the transverse members. According to this invention, the first bore is at least slightly larger than the second bore, allowing a vertical pole to be rotated, installed or removed with the second bore clamping a transverse member.
[0016] A different yet patentably distinct invention resides in a connector base having a distal end with a auger and a hollow proximal end with a cut-away portion, allowing the auger end to be positioned into the ground below water and a vertical pole to be breech-loaded into the hollow proximal end. Yet a further patentably distinct invention provides a plurality of stackable bumper sleeves that may be placed on vertical poles above or below the decking pieces to prove cushioning.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a simplified rendition of a prior-art aluminum dock used to introduce inventive concepts disclosed herein;
[0018] FIG. 2 is a cross-sectional view of a piece of decking according to the invention;
[0019] FIG. 3 is a cross-section of a first coupling element, including preferred dimensions;
[0020] FIG. 4 is a cross-section of a mating coupling element, also including preferred dimensions;
[0021] FIG. 5A is a drawing that shows the way in which the coupling elements of FIGS. 3 and 4 may be hinged into position;
[0022] FIG. 5B is a drawing showing the first and second coupling elements joining two pieces of decking to create a substantially flush upper surface for walking;
[0023] FIG. 6 is a drawing which shows two alternative pieces of decking and associated coupling elements providing a partial retrofit to existing systems;
[0024] FIG. 7 is a drawing which shows how preassembled dock sections may be stored in nested fashion during periods of non-use;
[0025] FIG. 8 is a drawing which illustrates an inventive stand-off which allows the dock section of FIG. 7 , for example, to be stacked with less damage;
[0026] FIG. 9A is a cross-sectional drawing of a separate piece that may be mounted against the outer surface of a stringer to permit transverse sections of dock for corners, T-configurations, and so forth;
[0027] FIG. 9B shows the member of FIG. 9A mounted to the outer surface of an existing stringer;
[0028] FIG. 10 illustrates an inventive assembly which may be mounted to the sides or ends of a stringer system to provide a bumper cushion;
[0029] FIG. 11 is a drawing which shows an inventive hinge clamp that allows vertical members to be rotated while rigidly coupled to transverse members located under dock sections;
[0030] FIG. 12 is a drawing of an inventive auger connector base that may be left in-ground below water between seasons;
[0031] FIG. 13 is a drawing which shows how the connector base of FIG. 12 would ordinarily be used; and
[0032] FIG. 14 is a drawing which shows an inventive bumper extension sleeve to protect larger and smaller watercraft from hitting an assembled dock.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The reader's attention is now directed to the drawings, FIG. 1 in particular, which depicts an existing, prior-art modular dock system which will be helpful in understanding the various improvements and inventions disclosed and described herein. Such a system, depicted generally at 100 , includes one or more dock sections 104 made up of deck pieces 108 held on either side by stringers 106 , 107 . Though not shown, a decorative trim piece would also be placed at the end of the dock to cover the ends of the side stringers.
[0034] The dock sections are held suspended above the water through vertical posts 120 which, in turn, are coupled to one another transversely utilizing lower poles 130 and clamps 122 having orthongonally oriented bores to fit the vertical members 120 and transverse 130 , respectively.
[0035] Although docks of this kind may accommodate pieces of decking constructed from wood, plastic and other materials, this invention relates more generally to metal decking pieces and extruded aluminum decking pieces, in particular. The inset drawing of FIG. 1 illustrates the way in which two decking pieces 108 are now joined, that is, through an extruded bead 110 and mating longitudinal groove 112 , thereby forming a dovetail-type coupling. One disadvantage of this arrangement is that each new piece of decking that must be assembled to one or more previous pieces must be carefully aligned so that the bead 110 can slide easily in the groove 112 until the ends are flush. Once a number of decking pieces are assembled in this manner, the stringer pieces 106 , 107 are disposed on either side, and various fasteners are used in each corner and elsewhere to hold the assembly in a rigid configuration.
[0036] Having described a typical prior-art system, reference is now made to FIG. 2 , which shows an improved system for coupling pieces of decking. More particularly, as opposed to a dovetail-type joint which must be precisely aligned and slid into position, the improved system utilizes a first coupling member 200 which mates with a second coupling member 201 through a more forgiving hinging process. This not only allows the pieces to be assembled more easily, without sliding, it also allows a certain degree of pivoting between two pieces without coming apart, as may be desired when one level of decking transitions to a different level of decking, as may be the case in going to or from a shoreline, retaining wall, or the like.
[0037] The first coupling mechanism 200 , includes a longitudinal element 202 that runs the length of the piece of decking, and which, in the preferred embodiment, is generally cylindrical in shape, but for extensions 204 from the edge of the piece of decking. Note that the upper surface of the circular cross-section of the member 202 is substantially tangent to the upper, walking surface of the deck piece. Below the member 202 is a spaced-apart lower lip 206 , which also runs the length of the decking piece, thereby creating a generally J-shaped channel 210 .
[0038] The second coupling member 201 includes a longitudinal cradle 212 , preferably with a partial cylindrical cross-section with a cutaway portion below creating a generally J-shaped extension 216 . Members 220 , 222 , 224 , though not technically necessary, are preferably provided for strengthening. FIG. 3 is a cross-sectional view of the first coupling element showing preferred dimensions. FIG. 4 is a cross-sectional view of a second coupling element also showing preferred dimensions. FIG. 5A is a drawing in cross-section which shows the way in which the first and second coupling elements are hinged into position, and FIG. 5B shows the coupling elements connected to one another to form a substantial and flush upper walking surface. Although the two upper thick surfaces are shown flush in FIG. 5B , a certain degree of pivoting is allowable between two pieces of decking while still being coupled to one another. This capability is useful for constructing ramps to transition from an upper deck to a lower deck, or to the shoreline, for example. FIG. 6 is a drawing in cross-section which shows two additional pieces of decking 602 , 604 according to the invention which would be useful in retrofitting with existing docks of the type depicted with respect to FIG. 1 . In particular, according to the invention, a first piece of decking 602 may be provided having, on one edge, a coupling member of the type depicted at 200 in FIG. 2 , but at the other edge including a groove for the type of prior-art joint shown in FIG. 1 at 112 . Such a piece of decking 602 would allow one or more existing decking members of the type shown in FIG. 1 to be used within a section of dock, while allowing one end to utilize the new system depicted herein. An advantage of this capability is that, with the existing prior-art pieces of decking, the groove and bead associated with the dovetail-type joint do not extend sufficiently beyond the ends of the side stingers to permit use of the new system described herein. However, by replacing one or both of the end decking pieces, there is enough single “platy” in the remaining dovetailed pieces to permit the new end decking pieces to be used with the existing decking pieces particularly to respect to transitions in level.
[0039] FIG. 7 is a drawing which shows the way in which sections of dock may be turned upside down and stored with the legs in tact. This would have been far less practical with prior-art systems, which tend to utilize much longer sections of dock which are already very heavy without the legs assembled. According to this invention, however, the length of each dock section is made shorter, and the stand-offs “B” of FIG. 8 are preferably utilized along the lower edges of the stringer to permit the dock sections t be stacked in a manner shown in FIG. 7 though on a staggered basis to accommodate the single set of legs which remains attached to each section.
[0040] To accommodate transverse dock sections which might be found in 90 degree turns, “T” configurations, the component shown in FIG. 9A is provided according to the invention. FIG. 9A also shows the preferred dimensions of the component. The component of FIG. 9A is mounted against the outer side wall of an existing stringer, thereby providing a cradle 912 of the type shown as 212 in FIG. 2 . As such, with the component 904 mounted as shown in FIG. 9B , a section of dock including one of the first coupling members may be hinged into the component 904 for a change in direction of the dock. Unlike current art, transverse sections are no longer limited to the area between the straight sections. Current art typically requires transverse sections to be mounted near the legs of the straight sections since to do otherwise would require the straight section to bear the load of the transverse section at its weakest point (midspan). The only remedy would be much heavier sections. However, the new sections are much shorter and therefore any transverse section is inherently close to the legs.
[0041] FIG. 10 is a drawing which illustrates a different component 1002 , which enables a bumper 1004 to be easily and conveniently mounted to the outer wall of a stringer, thereby providing a decorative yet functional added value. As with the invention described with reference to FIG. 8 , the invention of FIG. 10 is considered patentably distinct, in that such devices may be used with any appropriate stringer, including those now in use. The component of FIG. 10 preferably includes a C-shaped bracket that fits over the edge of the stringer, and held in position with fastener 1110 , while providing opposed channels into which a resilient member 1004 is journaled. Whereas the component 1002 is preferably extruded aluminum, the bumper member 1004 is a compressible/resilient material such as rubber, synthetic rubber, or the like, and may be replaced.
[0042] FIG. 11 is a drawing which depicts a different patentably distinct idea in the form of a clamp that may also be used with existing dock assemblies. Such a clamp includes two pieces 1102 , which, when properly mated, provide two orthogonal, clampable bores 1104 , 1106 , one to receive upright members such as 120 shown in FIG. 1 , and another to receive transverse members such as 130 depicted in FIG. 1 . While clamps of this kind do exist, as shown at 122 in FIG. 1 , a distinct disadvantage is that the inner diameter of both bores is substantially the same, such that both clamps must be loosened in order to loosen only one of the members. This is a distinct disadvantage when installing and removing a dock system, since is often the case that the clamps holding the transverse members 130 should be left assembled, while permitting the other clamp to be loosened for auguring, removal, and other operations that ordinarily take place through the installation and/or removal of dock systems of this type.
[0043] According to the clamp of FIG. 11 , however, the inner diameter of the bore associated with the vertical members is slightly larger than the inner diameter of the bore associated with the transverse members and all corners are radiused. As such, the transverse members may be tightly clamped, and held in place, while the other side of the clamp is loosened, permitting the vertical members to be rotated as necessary for a given operation. Using the preferred dimensions shown in FIG. 11 , there is enough “springiness” in the metal comprising the clamp to then tighten the clamp associated with the vertical members once the operation is complete.
[0044] FIG. 12 shows yet a different patentably distinct invention, in this case a connector base that may be installed in the ground below water surface, allowing vertical members to be positioned and removed therefrom with a precise positioning left in place for each season. The component of FIG. 12 , depicted generally at 1202 , includes a distal end 1204 with a cast auger, and a proximal end with a cutout section 1210 in a main pipe 1211 having a bolt hole 1220 . Also included in the main pipe 1211 is an inner pipe 1212 or some other feature creating a stop 1214 .
[0045] FIG. 13 shows the way in which the component of FIG. 12 may be used. In particular, a section of dock 1300 including a hinge portion 1302 , is assembled to an installed section 1301 through a hinged joint 1302 . This is done with a vertical leg 120 assembled and mounted to the dock section 1300 in advance. With the component 1202 in place under the water, the dock section 1300 may be pivoted into position, since the lower ends of the legs 120 fit into the cutout section of the proximal end of the component 1202 , after which time, with a slight amount of encouragement, the bottom ends of the legs 120 slip into the pipe of the connector base until hitting the stops. A bolt hole is provided if necessary in extreme wave conditions that mates with a hole in the 120 member.
[0046] FIG. 14 is a drawing which shows yet a different patentably distinct invention, in this case an extendable bumper sleeve that may be used to extend existing bumper guards on existing docks, both upwardly and downwardly. This is advantageous since a larger boat might ‘miss’ the covers over the existing clamps, and smaller newer watercrafts such as jet skis and so forth, may be too short. Accordingly, the existing bumpers guards may be extended in either direction through the use of the device shown in FIG. 14 , which has a flared portion on either or both ends, allowing them to be stacked and nested. Additionally, as these may be provided in multiple colors, an attractive design may be achieved. | Metal dock systems of the type wherein the side edges of metal decking pieces are coupled to one another and held between opposing stringers to create a substantially flush walking surface through the use of first and second coupling elements, each associated with a respective one of the decking side edges. The first coupling element including a lengthwise member with a partially cylindrical outer surface, and the second coupling element including a lengthwise cradle with a partially cylindrical inner surface. Using this configuration, the lengthwise member may be hinged into the lengthwise cradle to couple. The associated pieces of decking to one another while allowing a certain degree of pivoting therebetween. In a system wherein the stringers and decking pieces are suspended using vertical poles on the outer sides of each stringer, the vertical poles being coupled to one another through a transverse member disposed beneath the decking pieces, the assembly system further includes a coupler, connector base, stackable bumper sleeves, and other articles and methods. |
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FIELD OF THE INVENTION
[0001] The present invention relates to an electrical treatment for oil based drilling or completion fluids.
BACKGROUND
[0002] In the process of rotary drilling a well, a drilling fluid or mud is circulated down the rotating drill pipe, through the bit, and up the annular space between the pipe and the formation or steel casing, to the surface. The drilling fluid performs different functions such as removal of cuttings from the bottom of the hole to the surface, to suspend cuttings and weighting material when the circulation is interrupted, control subsurface pressure, isolate the fluids from the formation by providing sufficient hydrostatic pressure to prevent the ingress of formation fluids into the wellbore, cool and lubricate the drill string and bit, maximize penetration rate etc.
[0003] The required functions can be achieved by a wide range of fluids composed of various combinations of solids, liquids and gases and classified according to the constitution of the continuous phase mainly in two groupings: aqueous drilling fluids, and oil based drilling fluids.
[0004] Aqueous fluids are the most commonly used drilling fluid type. The aqueous phase is made up of fresh water or, more often, of a brine. As discontinuous phase, they may contain gases, water-immiscible fluids such as diesel oil which form an oil-in-water emulsion, and solids including clays and weighting material such as barite. The properties are typically controlled by the addition of clay minerals, polymers and surfactants.
[0005] In drilling water-sensitive zones such as reactive shales, production formations, or where bottom hole temperature conditions are severe or where corrosion is a major problem, oil based drilling fluids are preferred. The continuous phase is typically a mineral or synthetic oil which may be alkenic, olefenic, esteric etc. Such fluids also commonly contain water or brine as discontinuous phase to form a water-in-oil or invert emulsion. Generally they furthermore contain a solid phase, which is essentially similar to that of aqueous fluids, and additives for the control of density, rheology and fluid loss. The invert emulsion is formed and stabilized with the aid of one or more specially selected emulsifiers.
[0006] Oil based drilling fluids also typically contain oil-soluble surfactants that facilitate the incorporation of water-wet clay or non-clay formation minerals, and hence enable such minerals to be transported to surface equipment for removal from circulation before the fluid returns to the drillpipe and the drillbit. The largest formation particles are rock cuttings, of size typically larger than 0.1-0.2 mm, removed by shale-shaker screens at the surface. Smaller particles, typically larger than about 5 μm, will pass through the screens, but can be removed by centrifuge.
[0007] Oil based drilling fluids have been used for many years, and their application is expected to increase, partly owing to their several advantages over water based drilling fluids, but also owing to their ability to be re-used and re-cycled, so minimizing their loss and their environmental impact.
[0008] As mentioned above, during drilling, formation particles become incorporated into the drilling fluid. Unless these are removed, they eventually move the fluid's properties, particularly the rheological parameters, out of the acceptable range. However, formation particles that are colloidal in size (less than about 5 μm) are more difficult to remove than the larger particles. A longer centrifuge run-time would be sufficient to remove the colloidal particles if the fluid were merely viscous, but the quiescent drilling fluid is usually required to behave as a gel to support cuttings in periods without circulation. Such a fluid will have a gel strength, and will behave as a non-Newtonian, shear-thinning fluid in which the viscosity at low shear rates is very large compared with the viscosity at the circulation rate.
[0009] Gel strengths typical of oil based fluids (1-10 Pa) can be shown to support particles of less than a few microns in size indefinitely against the centrifugal force typical of oilfield centrifuges, which then have no effect regardless of the time they run. Further, owing to their large specific surface area, colloidal-sized particles have a disproportionate effect on the rheology of a fluid. Moreover, as more colloidal particles become part of the fluid, the gel strength will generally increase. Thus as more colloidal particles are incorporated in the drilling fluid, the upper particle size that can be supported by the gel, and hence unremoved by the centrifuge, also increases. Increasing quantities of colloidal particles are detrimental to other aspects of a fluid's performance, particularly those engineering parameters important for efficient drilling.
[0010] Thus, in practice, the process of increasing colloidal concentration and decreasing treatment efficiency tends to continue until engineering parameters depart from their acceptable ranges. In particular, both the engineering rheology parameters PV and YP (API 1988) must be kept within bounds for efficient drilling. As drilling proceeds, and possibly also as the fluid is moved from one job to another, the driller can eventually find that PV and YP increase beyond their upper limits until the fluid becomes unusable for drilling and untreatable by centrifuge.
[0011] Typically PV should be in the range 20 to 100, and YP should lie between 15 to 55. Strictly, the PV and YP of drilling fluids are defined by the API-defined rheometer used to measure them, but they can be related to more generally used parameters by the Bingham Plastic rheology model in which the shear stress SS (in Pa) and shear rate SR (in reciprocal seconds or 1/s) are related by:
SS=BYS+BPV×SR
where BYS is the Bingham yield stress in Pa and BPV is the Bingham plastic viscosity in Pa s. The oilfield unit YP as measured by the API method is given by YP=1.96×BYS(Pa). Likewise, the oilfield unit PV=1000×BPV(Pa s).
[0012] Similar considerations apply to oil based completion fluids.
SUMMARY OF THE INVENTION
[0013] In general terms, the present invention relates to an electrical treatment for oil based drilling or completion fluids whereby the particulate structure of the fluid and/or a filter cake or sedimentary bed formed from the fluid may be altered to give advantageous fluid, cake or bed properties. The drilling or completion fluids of the present invention generally have densities of at least 1100 kg/m 3 , and more preferably 1500 kg/m or 2000 kg/m.
[0014] One effect of applying a spatially uniform field, of e.g. 100 V mm −1 , to an oil based fluid, is to cause charged colloidal particles to migrate to an electrode at which they concentrate and collect as a removable deposit. This phenomenon is well-known as electrophoresis (Delgado 2002), particularly in aqueous or highly-conductive fluids. U.S. Pat. No. 4,323,445 proposes an apparatus for electrokinetically separating water based drilling mud into liquid and solid phases. However, as far as we are aware, electrophoresis has not been exploited for the removal of colloidal or fine particles from oil based drilling or completion fluids, or any other similar non-aqueous application.
[0015] U.S. Pat. No. 5,308,586 describes an electrostatic separator for removing very dilute fine particles from oils. However, in that application (i) the oil feed was relatively clean and free from the high concentrations of the weighting agents and emulsified brine typically found in drilling fluids, and (ii) the field was applied to the feed oil amongst a bed of glass beads.
[0016] Also it is known in the petroleum industry to apply very high electric fields for coalescing dispersed water droplets dispersed in oil (Thornton 1992, Eow et al. 2001). However, in general, the field strengths we propose are less than those at which emulsion droplets in an oil based drilling or completion fluid would coalesce to form continuous and electrically-conductive chains. Such fields, giving dielectric breakdown, are routinely measured in the API Electrical Stability Test (API 1988) for oil based drilling or completion fluids as a measure of emulsion stability and sufficiency of emulsifier.
[0017] Thus a first aspect of the present invention provides a method of removing particulate solids from an oil based drilling or completion fluid, comprising:
[0018] exposing the fluid to an electric field to electrically migrate particulate solids suspended therein, and
[0019] collecting the migrated particulate solids to remove them from the fluid.
[0020] Typically, but not exclusively, the drilling or completion fluid comprises a water-in-oil emulsion. For such a fluid, the amount of water (in terms of the water to oil volume ratio) may be at least 5:95, and more preferably at least 30:70 or 50:50. The strength of the electric field is preferably lower than that required to coalesce the water droplets of the emulsion. The water generally contains a dissolved salt, i.e. the water is a brine.
[0021] Preferably, the strength of the electric field is less than 100,000 V/m, more preferably it is less than 10,000 V/m.
[0022] Preferably, the strength of the electric field is greater than 10 V/m, more preferably it is greater than 100 V/m.
[0023] In certain embodiments, the electric field is substantially uniform. However, in other embodiments the electric field is spatially non-uniform. One effect of non-uniform fields is well-known as dielectrophoresis (Pohl 1978) whereby the field induces an electric dipole moment in an uncharged particle of different electrical permittivity from the surrounding liquid. The particle is then caused by the field gradient to migrate towards the high-field region where it can be collected. An advantage of the use of a non-uniform field is, therefore, that the migrating particles are not required to possess an electrical charge.
[0024] The PV and/or YP of the drilling or completion fluid is typically reduced as a result of the collection of the particulate solids.
[0025] Generally, the fluid contains clay particles and/or weighting agent (e.g. barite) particles.
[0026] The particulate solids in the fluid may occupy at least 5 vol. % and preferably at least 15 vol. % of the total fluid.
[0027] The drilling or completion fluid may be a shear-thinning fluid which forms a gel when quiescent. Thus the method allows colloidal particles to be removed from such a fluid.
[0028] In preferred embodiment electrodes used to generate the electrical field are combined with a deposit removal system that either collects deposits from a location in the vicinity of the electrode or actively removes deposits from the surface of the electrode. The removal system may be operating continuously or as a batch process. In the latter case, it is preferred to operate the removal system during periods in which the electric field is switched off.
[0029] The method is further preferably applied such that voltage applied and current are proportional, hence that the fluid behaves as a conventional resistor following Ohm's law.
[0030] The method may further comprise heating the fluid to enhance the collection of particulate solids. Preferably the fluid is heated to a temperature of at least 25° C., more preferably at least 50° C., and even more preferably at least 75° C.
[0031] A further aspect of the invention provides a method of recycling an oil based drilling or completion fluid by performing the method of the first aspect.
[0032] The method of recycling may include the step of using a centrifuge or hydrocyclone to remove other particulate solids from the fluid. This step may be performed before or after the electrical treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The invention will now be described in more detail, with reference to the drawings in which:
[0034] FIG. 1 shows schematically a simple electrophoretic separating assembly;
[0035] FIG. 2 shows schematically an apparatus used for quantitative electrophoretic separating tests;
[0036] FIG. 3 is a graph of mass of deposit against voltage;
[0037] FIG. 4 shows a further graph of mass of deposit against voltage;
[0038] FIG. 5 shows a graph of current against voltage;
[0039] FIG. 6 shows a graph of deposit weight against rotor speed;
[0040] FIG. 7 shows a graph of deposit weight against test temperature;
[0041] FIG. 8 shows schematically a longitudinal section through a device for recycling oil based mud; and
[0042] FIGS. 9 a and b respectively show longitudinal and transverse sections of an alternative device for recycling oil based mud.
DETAILED DESCRIPTION
[0043] Tests have been performed on oil based drilling fluids in which a steady electrical field was applied to a sample of oil based mud to remove solid particles by depositing them on one electrode, leaving the drilling fluid depleted of such particles. In most cases the deposit was formed on the negative electrode, which suggests that the particles were positively-charged, but the process is equally applicable to the treatment of fluids containing negatively-charged particles.
[0000] Drilling Fluids
[0044] Initial tests were conducted with field samples in which the base oil was mineral oil. The field samples were a conventional invert emulsion based on a Versaclean™ oil based mud (OBM) formulation. These are tightly emulsified, temperature-stable, invert-emulsion, oil based drilling fluids. The following components are found in such formulations: primary and secondary emulsifiers, blends of liquid emulsifiers, wetting agents, gellants, fluid stabilizing agents, organophilic clay (amine treated bentonite), CaCl 2 brine, filtration control additives and barite as a weighting agent. The field sample drilling fluids were aged by circulation at geothermal temperatures, and contained some fine particles, typically clay, resulting from the drilling process.
[0045] Further tests were also conducted on field samples of a Versaport™ OBM system. The Versaport systems have elevated low shear rate viscosities. Versaport is either a conventional or relaxed filtrate system, the relaxed filtrate system comprising: primary emulsifier, surfactant, oil-wetting agents, lime, viscosifiers and gelling agents, organophilic clay, CaCl 2 brine and barite.
[0000] Apparatus and Tests on Versaclean
[0046] Qualitative tests were made on the field-fluid Versaclean OBM samples, using a simple electrophoretic separating assembly shown schematically in FIG. 1 . The assembly had a container 21 for two parallel stainless steel plates 22 and the sample 23 to be tested. The plates were connected to a constant DC voltage supply of about 200 V, so that one electrode was negative and the other positive, and a field strength of about 1000 V/cm was generated. After a few minutes oil appeared close to the electrodes, and after about 20 min the assembly was dismantled. The negative electrode was coated with about 0.5 mm of deposit 24 , the other remaining deposit-free but coated thinly with drilling fluid. With this arrangement of plates, the field was kept spatially-uniform by means of a guard electrode (not shown).
[0047] Thus the presence of a uniformly-thick deposit over the negative electrode was evidence that deposition resulted from electrophoresis of positive particles, rather than dielectrophoresis which requires a field gradient.
[0048] An apparatus used for quantitative tests is shown schematically in FIG. 2 . The apparatus consisted of a cylindrical epoxy conductivity cell 25 of internal diameter about 20 mm, having three axially spaced annular carbon electrodes 26 . The electrodes were connected to a constant voltage supply so that the center electrode was negatively charged and the other two were positively charged. Versaclean was poured into this cell and a constant voltage applied. A layer of oil 27 was observed to form at the surface of the mud 28 and an electro-deposit 29 collected on the negative electrode. A barite layer 30 settled at the bottom of the cell. The oil is believed to rise to the surface owing to a weakening of the gel as fine particles migrated from the center of the cell to form the deposit. The cell was weighed empty, and then after the treated drilling fluid (effluate) was poured out. The increment of weight comprised the weight of the deposit and the residual fluid unremoved by gravity that adhered to the inside of the cell. The API Theological parameters PV and YP, and the API 100 PSI fluid loss, were measured for the effluate poured from the cell.
[0049] The effect of voltage and time on the mass of the deposit is shown in FIG. 3 . Closed circles show the electrodeposit mass after 25 min. Open circles show the mass deposited after 40 minutes corrected to 25 min assuming the electrodeposit was directly proportional to the time of voltage application. The collected data show that the mass deposited was proportional to voltage and time.
[0050] A variety of different oil based drilling fluids were then investigated with the epoxy cell method, in which a voltage of 200 V was applied for a duration of 25 minutes. These fluids were two different field samples of Versaclean (Versaclean 1 and Versaclean 2), and a further sample of Versaclean 2 which has been centrifuged at 3000 rpm for 20 mn to remove barite. Measurements of the electrical stability and density of the untreated muds and of PV and YP before and after treatment are shown in Table 1.
TABLE 1 Properties of field and laboratory OBMs API Electrical Stability Density (untreated) (untreated) PV PV YP YP (V) (g/ml) (untreated) (treated) (untreated) (treated) Versaclean 1 517 1.45 78 69 37 32 Versaclean 2 435 1.455 58 52 30 25 Versaclean 2 449 1.025 39 32.5 28 27.5 Barite-free
[0051] Thus the PV and YP of all the Versaclean OBMs were reduced by the treatment.
[0052] FIG. 4 shows a graph of the mass of the electrodeposit against voltage for each of the OBMs, including the Versaport OBM. This shows that the electrodeposit mass depends on the density of the mud, suggesting that the fine particles attracted to the negative electrode tend to trap the barite. The graph also shows that high voltages do not necessarily provide a greater electrodeposit. For all the field muds the electrodeposit mass reached a maximum between 450 to 500 V. The collection process becomes less efficient as the applied voltage approached the breakdown voltage of the API Electrical Stability test (API 1988), possibly owing to a drop in the electric field experienced by the oil phase as chains of emulsion droplets begin to form prior to dielectric breakdown (Growcock et al. 1994).
[0000] Non-Ohmicity and Time-Dependence
[0053] Using the apparatus of FIG. 2 electrophoretic separation was performed on Versaclean OBM for various times and voltages and the current measured. FIG. 5 shows a graph of current against voltage. The current was observed to increase with voltage in typical ohmic behavior up to 200 V but at higher voltages there was a clear non-ohmic and time-dependent behavior. This suggests a complex conduction mechanism which corresponds with the observation that as the applied voltage approaches the breakdown voltage progressively less deposit is collected on the negative electrode. These results again suggest that the electrodeposition process is more effective at voltages less than the breakdown voltage of the API Electrical Stability test (API 1988).
[0054] In tests on Versaclean, the total solids content by weight in the deposit was found to be about 64% wt while that of the mud was 57% wt, showing that the deposit solids were more concentrated than in the drilling fluid. Similarly, the electrodeposit yield stress was about five times that of the untreated mud, suggesting that the deposit had more fine clay particles than the mud.
[0055] Measurements of the concentration by weight of metal species in the deposit and mud were made using inductively-coupled plasma metal analysis, and the results are shown in Table 2.
TABLE 2 Elemental analysis of deposit and mud Al/Ba Al/Cl Al/C Al/Ca Ba/C Mud 0.185 0.356 0.025 0.207 0.136 Deposit 0.21 0.487 0.034 0.208 0.16 Deposit/mud 15% 37% 36% 0% 18% % increase
[0056] Assuming the clay to be the only source of Al, the ratios of Al to Ba, Cl and C suggest that the deposit has gained significantly in clay. The null change in Al/Ca suggests that some Ca may be bonded to the clay, and the 18% increase in the Ba/C ratio shows that there was less oil in the deposit.
[0000] Effect of Shear on Field Mud (Versaclean)
[0057] The effect of shear on the electrodeposition process was investigated using a modified Chan 35™ oilfield rheometer in which the outside of the rotor was electrically-isolated from the rheometer body and acted as one electrode, while a brass cup of inner diameter 57 mm was inserted into a heat cup to act as the rheometer stator and also the other (earthed/grounded) electrode. In this configuration the drilling fluid could be sheared in the gap between the rotor and stator and the deposit could be collected on the outside of the rotor. The rotor gave a larger collection surface area than the annular electrode of the epoxy cell of FIG. 2 , while allowing the mud to be sheared and/or heated simultaneously with the electric field applied.
[0058] Using the Chan rotor R1 outer diameter of 40.65 mm and a brass cup inner diameter of 57.00 mm gave a laminar shear rate per unit RPM at the surface of the rotor of 0.43 s −1 /RPM. The results are shown in Table 3. Some results are also plotted on FIG. 6 , which is a graph of deposit weight against rotor speed. FIG. 6 demonstrates that the effect of shear was to reduce the amount of deposit.
TABLE 3 Effect of shear, voltage, and time on electrodeposit mass for field Versaclean OBM Rotor Applied Treatment Deposit PV YP speed voltage time weight post- post- (RPM) (V) (min) (g) treatment treatment 0 0 0 — 58 30 200 0 25 — 52 27 200 0 100 — 45.5 30 0 40 250 32.7 43 23 0 400 40 41.60 30 11 0 400 25 35.72 37 16 20 400 25 27.8 36 26 100 400 25 22.29 45 15 200 400 25 16.72 48 18 200 400 40 19.59 40 18 200 400 60 23.29 41 7
[0059] These results, together with a range of tests on samples of used field Versaclean OBM and lab Versaport OBM may be summarized as follows:
With no shear, the longer the exposure to the electrical field, the greater the amount of deposit and the lower PV and YP. The deposit weight increases with both time and voltage in both static and sheared tests. The very low voltage test over a long time (40V at 250 min) produced a similar deposit to 400 V at 25 min. PV and YP were reduced as the deposit increased. Elemental analysis after treatment of the Versaport mud indicated that the electro-deposit was enriched in Ba, Ca, Al, Na, Cl and depleted in organics (C, H, N) compared to the original mud. The reverse was found in the treated mud, confirming solids-removal from the fluid. Shear reduced the mass of electro-deposit (see FIG. 6 ) and the effect of electro-treatment on the rheology. Sheared electro-deposits were also more fluid than static electro-deposits. Combinations of static and sheared periods of electro-treatment generally increased the electro-deposit. The order of imposition of electric field and shear appears to have an effect on rheology. Reversal of the field polarity causes the deposit to detach from the electrode and slump to the bottom.
[0067] Other variations altering the sequence of electrical treatment and shear in two stages were attempted and the results are shown in Table 4. The mud was treated first for 25 min with an applied voltage of 400 V with no shear. Then the treated system was placed under a shear of 200 rpm for 25 min. The amount of deposit formed was higher and PV and YP was generally lower than that when the mud was subjected to a simultaneous electric field and shear. Reversing the order of this process resulted in a higher amount of material being deposited but also a higher PV and YP.
TABLE 4 Two phase test conditions and results of experiments investigating effect of a treatment combining shear and voltage on weight of deposit, PV and YP (Versaclean field-OBM) Rotor speed Applied Time (RPM) voltage (V) (mn) Deposit Phase Phase Phase Phase Phase Phase weight PV YP 1 2 1 2 1 2 (g) (treated) (treated) 0 200 400 0 25 25 27.27 22 20 200 0 0 400 25 25 31.58 44 21 200 200 0 400 25 25 17.49 43 20
Effect of Temperature on Field Mud (Versaclean)
[0068] FIG. 7 is a graph of deposit weight against test temperature obtained by testing the Versaclean OBM in the modified Chan rheometer. The effect of increasing the temperature, at a fixed voltage, was to usefully increase the weight of the deposit. Decreases in PV and YP, measured at laboratory temperature after treatment, are also shown in the graph.
Continuous-Flow and Batch Embodiments
[0069] The experiments described above show the utility of treating oil based drilling or completion fluids with an electric field. We now propose continuous-flow and batch embodiments that may be useful in full-scale or engineering applications. These serve to demonstrate the application of the invention but other examples are possible.
[0070] FIG. 8 shows schematically a longitudinal section through a continuous-flow device for recycling used OBM. The drilling or completion fluid 1 enters an electrically-conductive and horizontal pipe 2 , which bifurcates into pipe 3 and 4 , each branch containing a valve 5 and 6 . A series of annular electrodes 7 are held in pipe 2 and insulated from it by means of insulators 8 . Electrical contact to each annular electrode is made via leads 9 and insulating bushes 10 . Leads 11 and 12 respectively connect the electrodes and the pipe 2 to an electrical supply. In operation electrodeposit 13 forms on each of electrodes 7 .
[0071] We have found (see above) that shear tends to reduce the efficiency of the deposition process. However, FIG. 6 shows that at sufficiently low shear rates, the efficiency is largely undiminished. For example, FIG. 6 shows that 10 RPM had little effect on the deposition rate. In our modified Chan 35 oilfield rheometer, 10 RPM corresponds to about 4.3 s −1 . For a pipe of diameter D, the relation between wall shear rate (WSR), volumetric flow rate (Q) and mean axial velocity (V) is WSR=16V/(3D)=64Q/(3πD 3 ). This sets an upper limit on V and Q, in order that the deposition process is not unduly lessened. For example, for D=0.1 m and WSR=4.3 s −1 , V=0.22 m s −1 , approximately, which corresponds to about 100 l min −1 .
[0072] The device operates as follows. Deposit is collected on electrodes 7 with valve 5 open and valve 6 closed. Pipe 3 then exudes a drilling fluid with less fine particles than entered via pipe 2 . After sufficient time (to be found by experiment and corresponding to a lessening deposition rate as the deposit intrudes into the body of pipe 2 ) valve 5 is closed, valve 6 is simultaneously opened, and the voltage applied to form the deposit is reversed. This pushes deposit into the body of pipe 2 , where its greater density than the surrounding fluid causes it to be preferentially collected by pipe 4 and led into a suitable collection vessel.
[0073] An alternative continuous-flow embodiment for such a device is shown in longitudinal section in FIG. 9 a and in transverse section in FIG. 9 b . In this case the drilling or completion fluid 1 ′ enters a horizontal pipe 2 ′ which is an electrical insulator. Pipes 3 ′ and 4 ′, with valves 5 ′ and 6 ′, resemble the bifurcation and valves of the device shown in FIG. 8 . Electrodes 7 ′ and 7 ″ now run axially along pipe 2 ′, and are connected to a voltage source via leads 11 ′ and 12 ′, such that the electro-deposit 13 ′ collects along the lower electrode 7 ″ over a suitable time period and voltage, both to be determined by experiment. Pipe 3 ′ then exudes a fluid with less fine particles than entered via pipe 2 ′. After sufficient deposit is collected, the flow is stopped, valves 5 ′ and 6 ′ are closed and opened, respectively, the voltage is reversed, and the flow re-started. The re-start flow rate should be large enough to quickly remove the deposit, but not so large as to remix it with the incoming fluid. The deposit then exudes via pipe 4 ′ and led to a suitable collection vessel.
[0074] The above two examples are illustrative of a variety of possible deposit removal systems, which may also include scraper-type devices or similar apparatus.
[0075] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. For example, in batch embodiments the electrodes may be set into a stirred or a static tank. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
REFERENCES
[0076] American Petroleum Institute (1988) Recommended practice standard procedure for field testing drilling fluids. API, Recommended Practice 13B (RP 13B), 12 th Ed., Sep. 1, 1988.
[0077] Delgado A V (2002) Interfacial electrokinetics and electrophoresis. Marcel Dekker, New York.
[0078] Eow J S, Ghadiri M, Sharif A O, Williams T J (2001) Electrostatic enhancement of coalescence of water droplets in oil: a review of current understanding. Chem Eng J 84:173-192.
[0079] Growcock F B, Ellis C F, Schmidt D D (1994) Electrical stability, emulsion stability, and wettability of invert oil-based muds. SPE Drilling and Completion, March, 39-46.
[0080] Jones T B (1995) Electromechanics of particles. Cambridge University Press.
[0081] Pohl H A (1978) Dielectrophoresis. Cambridge University Press.
[0082] Thornton J D (1992) Science and practice of liquid-liquid extraction, Vol 1. Clarendon, Oxford. | A method of removing particulate solids from an oil based drilling or completion fluid ( 1 ) is disclosed. The method involves exposing the fluid to an electric field to electrically migrate particulate solids suspended therein, and collecting the migrated particulate solids to remove them from the fluid. |
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FIELD OF THE INVENTION
This invention relates-to apparatus used by hunters, photographers and naturalists to climb to elevated positions next to tree trunks or other upright objects and to sit in those elevated positions. In particular, the invention relates to the type of climbing apparatus designed to be carried by a user walking on foot to the site where he intends to erect it. Such devices are often known by hunters as "portable tree stands."
BACKGROUND OF THE INVENTION
From the perspective of a hunter, photographer or naturalist, a portable tree stand should be a light-weight device that can be easily carried for long distances over rough terrain, and easily erected and safely secured to a tree trunk or similar upright object, even in the dark. Also, the tree stand should have a seat that allows the user to sit safely and comfortably for several hours. Should the need arise, the user should be able to disassemble the stand and move it to another location quickly. For deer hunting in particular, the ability to move the stand quickly to new locations is very important and sometimes it is critical for the hunter to be able to move his stand quickly by a distance of only a few yards. Furthermore, the stand should be capable of being secured to a tree trunk in such a manner that, after it is disassembled and removed, no signs remain that would be detectable by wildlife or other persons. The portable tree stand should also be adaptable to be secured to the trunk of a tree of a wide variety of types, shapes and locations. In addition, the tree stand should be capable of being easily ascended and sat upon.
Portable tree stands fall into four general categories. One category consists of collapsible ladders, with platforms at their top ends that fasten to the tree trunk. Examples of the ladder stands are shown in U.S. Pat. Nos. 3,630,314; 4,552,247; and 5,105,908. The main disadvantage of ladder stands is that they are heavy and bulky, making them difficult to carry. They are also prone to catching on branches and other forest clutter and are noisy when they are disassembled, moved and reassembled. Furthermore, they require, for stable placement, a tree that is relatively thick, preferably 12 to 18 inches in diameter at the place where the platform at the top of the ladder is to be connected, in order to enable the ladder to resist the twisting movement of the user's weight. Alternatively, the ladder type of stand should be secured to a tree with a double trunk.
Another type of portable tree stand is the climber stand. A climber stand comprises a U-shaped arm that wraps around the tree trunk and is pivoted to platform with a wedge-shaped end that engages the trunk below the arm. The weight of the platform and, at some times, the user's weight on the platform causes the platform to press against one side of the trunk while the pivoted arm engaging the other side of the trunk prevents the end of the platform away from the trunk from falling downward. The stand can be moved by the user holding onto the trunk with either pair of limbs, either his arms or legs, while he disengages the wedged platform with his other pair of limbs and moves the stand up or down the trunk. In some cases, two stands are used, and the user moves one stand while hanging on to the other stand. Examples of climber stands are shown in U.S. Pat. Nos. 4,427,092; 4,989,766; and 5,016,733. Climber stands are generally heavy and bulky, because they have cantilevered support members that must be sturdy enough to support the users who is climb on them. They also require very straight, vertical tree trunks of 10 to 18 inches in diameter. Furthermore, the user must be strong and very athletic in order to climb quickly up and down trees using a climber stand. In addition, a climber stand tends to be noisy while the user is climbing on it and it can be dangerous if the user does not hang or sit on it properly.
Another type of tree stand is the clamp-on stand. Many of these stands are of construction similar to the climber stand. However, the clamp-on stands are secured more permanently to the tree trunk and are not designed for use in climbing the tree. Examples are shown in U.S. Pat. Nos. 4,411,335 and 5,060,756. The clamp-on stands are generally lighter in weight and less bulky than the climber stands. However, because the user must carry additional apparatus for climbing the tree, the total package is usually heavier and more bulky than a climber stand. In addition, the clamp-on stands tend to be more difficult to attach and remove from trees, making them less useful as portable devices.
The fourth type of portable tree stand is the single pole stand. This stand comprises a long upright pole with steps protruding from its sides. The top of the pole is equipped with an clamping assembly for securing it to a tree trunk. For storage purposes, the pole is divisible into sections and the steps are usually removable. Some single pole stands are climbing devices only and have no means for the user sitting on them. They are usually intended for use with a clamp-on stand, as shown in U.S. Pat. Nos. 4,411,335; 5,040,635; and 5,109,954. Others are equipped with seats, as shown in U.S. Pat. Nos. 4,257,490 and 4,592,446. All of these stands are heavy and cumbersome to carry because of the many steps that protrude from them. Those that have removable steps are less cumbersome to carry, but they are more difficult to assemble, particularly at night. The pole stands with no seats are cumbersome because additional seats must be carried with them and attached separately to the tree trunk. The stands that do have seats have heavy and cumbersome systems for securing them to the tree trunks.
In the building industry, various climbing devices are used for mounting scaffolds, such as the portable step shown in U.S. Pat. No. 4,754,841. However, such steps rely on sharp prongs for their attachment and are designed for use with wooden posts of uniform size that can withstand the biting engagement of prongs. In contrast, a portable tree stand must be designed for climbing irregular tree trunks that would be damaged by the repeated piercing of prongs.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a portable tree stand that overcomes the deficiencies of the stands described above and satisfies the user's need for a stand that is light weight, easily carried, easily and quickly assembled and disassembled, easily and safely secured to a tree trunk for extended seating by the user, does not leave behind detectable signs of its use, can be secured to trees of a wide variety of shapes, sizes and locations, and can be easily ascended and sat upon.
These and other objects are accomplished by an apparatus that comprises a pole, a clamping assembly for securing the top end of the pole to a tree trunk or other upright object, a spike at the bottom end of the pole for inserting the bottom end into the ground and upper and lower foot supports for use by the user to climb up and descend down the pole. Preferably, each foot support has a sleeve slidably mounted on the pole and a foot platform extending from one side of the sleeve. The sleeve of the upper foot support is mounted on the pole above the sleeve of the lower foot support. Each sleeve has upper and lower friction pads on its interior surface facing the pole, with the upper friction pad located on the side of the sleeve opposite from the foot platform and the lower friction pad located on the same side of the sleeve as the foot platform. The upper and lower friction pads engage the pole in response to a downward force on the foot platform. Hand straps are connected to the side of each foot support on which the foot platform is located, for pulling up on the foot support to disengage the friction pads from the pole and allow the sleeve to slide on the pole.
Preferably, the clamping assembly comprises two arms that extend outwardly from the pole and are mounted on the pole rotatably about an axis substantially parallel to the pole. A tine extends from the distal end of each arm in a direction substantially perpendicular to the pole and toward the prong on the other arm. A rope is secured at one end to one of the arms at a location between the pole and the distal end of the arm and the rope is slidably connected to the other arm at a location between its distal end and the pole. When the rope is pulled, the arms are rotated toward each other, causing their tines to come together and secure the pole to a tree trunk or other upright object located in the enclosure formed by the arms, the tines and the portion of the rope extending between the arms.
Preferably, the pole is divided into detachable sections and the arms are also rotatable about axes substantially perpendicular to the pole so that they can be rotated to positions parallel to the pole, for storage or carrying purposes.
These and other objects, features and advantages of the invention will be more apparent from the following description of the invention and attached drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a portable tree stand fully assembled and laying on its side, illustrating one embodiment of the present invention;
FIG. 2 is a view of the portable tree stand of FIG. 1 with its parts disassembled and positioned for storage or carrying purposes;
FIG. 3 is an enlarged, cross-sectional view of a portion of the tree stand of FIG. 1, taken along line 3--3 of FIG. 1;
FIG. 4 is another enlarged, cross-sectional view of a portion of the tree stand of FIG. 1, taken along line 4--4 of FIG. 1;
FIG. 5 is a perspective view of the portable tree stand of FIG. 1, being positioned next to a tree trunk by a user;
FIG. 6 is a perspective view of the portable tree stand of FIG. 1, similar to the view of FIG. 5 but showing the user securing the top of the tree stand to a tree trunk;
FIG. 7 is a top view of the portable tree stand of FIG. 1, in a postition of being secured to a tree trunk by a user;
FIG. 8 is an enlarged view of the top portion of the tree stand of FIG. 1, in a position of being secured to a tree trunk by a user;
FIG. 9 is an enlarged cross sectional view of a portion of the tree stand of FIGS. 1, 5 and 8, taken along line 9--9 of FIG. 8;
FIG. 10 is an enlarged cross sectional view of a portion of the tree stand of FIGS. 1, 5 and 8, taken along line 10--10 of FIG. 8;
FIG. 11 is an enlarged view of another portion of the tree stand of FIG. 1;
FIG. 12 is a cross sectional view of the portion of the tree stand shown in FIG. 11, taken along line 12--12 of FIG. 11;
FIGS. 13 and 14 are enlarged sectional views of yet another portion of the portable tree stand of FIGS. 1 and 2, taken along line 13--13 of FIGS. 1 and 2;
FIG. 15 is a top view of the disassembled parts of the tree stand shown in FIG. 2, arranged for carrying in a backpack; and
FIGS. 16 through 24 are views of the tree stand of FIG. 1, showing a user climbing the stand, preparing the seat at the top of the stand, and positioning himself in the seat at the top of the stand.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a portable tree stand 2 includes a pole 4 divided into a plurality of lower sections 6 (five in the illustrated embodiment) and a top section 8. Each section 6 and 8 is preferably a tube of 1.75 inches (4.5 cm.) diameter and a wall thickness of 0.065 inch (1.65 mm.). For light weight and strength, the sections 6 and 8 are preferably made of a high strength aluminum alloy of the kind used in the aircraft industry. As shown in the disassembled view of the pole 4 in FIG. 2 and the detail view of FIG. 3, each section 6 has a narrowed neck 10 at its top end and a bottom end with a preferably reamed opening 12, designed for a sliding, frictional fit with the neck 10 of another section 6. The top section 8 of the pole 4 also has a bottom end with a preferably reamed opening 12, but no narrowed neck 10 at its top end. The lengths of the pole sections 6 and 8 are preferably between 24 and 30 inches (60 to 75 cm.), so that they fit into a backpack extending from the tops of the shoulders to the bottom of the rear end of an average hunter or other user. For the purpose of this description, the user of the portable tree stand 2 will be referred to as a hunter, although the reader should appreciate the fact that this invention may be used by many others for a variety of purposes.
A pair of upper and lower foot supports 14 and 16 are slidably mounted on the pole 2 of FIG. 1. As shown in the cross-sectional drawing of FIG. 4, each of these foot supports has a plastic sleeve 18 slidably mounted on the pole 4 and an aluminum foot platform 20. The foot platform 20 is mounted on the sleeve 18 by means of aluminum blocks 22 and a thin, high tensile steel strap 24 wrapped around the sleeve 18 and attached to the upper block 22. When the hunter steps on the platform 20, the strap 24 transmits the load from the platform 20 to the sleeve 18 in a manner that prevents torsional distortion of the sleeve 18. The plastic sleeve 18 has an inside diameter slightly larger than the outside diameter of the pole 4, to permit easy sliding of the foot supports 14 and 16 on the pole 4. An upper friction pad 26 and a lower friction pad 28 are secured to pockets in the inside surface of the sleeve 18. These pads are made of a high coeficient of friction material such as urethane and fiber laminate. As shown in the detail view of FIG. 4, the upper friction pad 26 is located near the upper end of the sleeve 18 on the side of the sleeve away from the foot platform 20. The lower friction pad 28 is located near the lower end of the sleeve 18 on the same side of the sleeve 18 as the foot platform 20. When the hunter steps on the foot platform 20, the friction pads 26 and 28 engage the pole 4 and prevent the sleeve 18 from sliding on the pole 4.
As shown in FIG. 2, when the tree stand 2 is disassembled for storage or transport, the foot supports 14 and 16 are slid onto the lowest section 6 of the pole 4.
As shown in FIGS. 1, 2 and 4, a strap 30 is connected to the upper end of each sleeve 18 of the foot supports 14 and 16, on the same side of the sleeve as the foot platform 20. Each strap is approximately five feet (150 cm.) in length and is provided to allow the hunter to pull by hand upwardly on the sleeve 18 to disengage the friction pads 26 and 28, so that the foot supports 14 and 16 may be raised or lowered when the hunter is climbing or descending the pole 4. Alternatively, foot straps similar to those used on bicycle pedals may be attached to the foot platforms 20 of the supports 14 and 16, so that the hunter can raise and lower the supports with his feet rather than with his hands.
As shown in FIGS. 1, and 5 through 10, a clamping assembly 32 is attached to the top of the pole 4, for securing the top of the tree stand 2 to a tree trunk T (FIGS. 5-7). The clamping assembly 32 includes upper and lower collars 34 and 36 secured to the top section 8 of pole 4 (FIGS. 8 and 9) and arms 38. The arms 38 are rotatably held within the collars 34 and 36 by flanges 40 attached to the ends of the arms 38. The collars 34 and 36 allow the arms 38 to be rotated with about an axis substantially parallel to the pole 4. Preferably, an elastic tension band 42 (FIG. 10) is connected between the rearward ends of the flanges 40 to hold the arms 38 rotated in spread apart positions while the hunter is positioning the tree stand 2 next to a tree trunk (FIG. 5).
As shown in FIG. 8, each of the arms 38 of the clamping assembly 32 include sleeve sections 44, L-shaped inner rod sections 46, slide members 48 and outer rod sections 50 with tines 52. Preferably, these parts of the arms 38 are coated with a compressible, pliable material, such as polyurethane foam, which allows the arms 38 to grip a tree trunk more securely and also protects the surfaces of the trunk from damage. The inner rod sections 46 are held in slidable, friction fits within the sleeve sections 44, so that the arms 38 can be rotated about axes perpendicular to the pole 4 to positions parallel to the pole 4 (FIG. 2), for storage and carrying purposes. The slide members 48 are fixed to the outer rod sections 50 and have holes that engage the inner rod section in a slidable, friction fit, so that the arms 38 can be telescoped for storage or carrying purposes, as shown in FIG. 2. Preferably, the parts of the arms 38 are dimensioned so that they can be secured to tree trunks as large as 24 inches (61 cm.) in diameter. Suitable dimensions would be, for the L-shaped inner rod sections 46, a dimension W (FIG. 2) of 8 inches (20.3 cm.) and a dimension X of 27 inches (68.6 cm.) and for the outer rod sections 50, a dimension Y of 22 inches (55.9 cm.) and a dimension Z of 6 inches (15.2 cm.).
A rope 54 (FIGS. 1 and 5-7) is secured to an eyelet 56 attached to one of the arms 38, preferably at its slide member 48. The rope 54 is also passed around a pulley 58 attached to the other arm 38, preferably at its slide member 48. From the pulley 58, the rope 54 is preferably passed around a pulley 60 attached to one of the sleeve sections 44. When the hunter raises the pole 4 to the vertical position shown in FIG. 5, the rope 54 depends downwardly to the bottom of the pole 4. By pulling on the end of the rope 54, the hunter is able to rotate the arms 38 toward each other to secure them to a tree trunk, before he climbs up the pole 4. When the hunter pulls on the rope 54 to rotate the arms 38 together with the tree trunk T located in the enclosure formed by the overlapping tines 52, the outer rod sections 50 of arms 38 and the portion of the rope 54 extending between the arms 38, as shown in FIG. 6, the top of the pole 4 becomes securely attached to the tree trunk T.
To enable the hunter to secure the bottom end of the rope 54 to the pole 4, the bottom section 6 of the pole 4 is preferably equipped with a rope clamp 62, shown in FIG. 2 and in detail in FIGS. 11 and 12. As best shown in FIGS. 11 and 12, the rope 54 is passed between an eccentrically mounted cam wheel 64 and an arcuate abutment 66. When the hunter has pulled the rope 54 to the desired tension to secure the clamping assembly 32 to the tree trunk T, he rotates the handle 68 (FIG. 11) on the cam wheel 64 in a counter-clockwise direction to squeeze the rope 54 against the abutment 66 and thus hold the arms 38 firmly wrapped around the trunk T.
While the clamping assembly 32 is being secured to the tree trunk T, the bottom end of the pole 4 should be securely anchored to the ground. For that purpose, a spike 70 is attached to the free end of the bottom pole section 6, as shown in the detail drawing of FIG. 13. When the tree stand 2 is being stored or transported, the spike 70 is turned around and inserted in end of the bottom pole section 6 as shown in FIG. 14.
Preferably, so that forest wildlife and other persons will be unlikely to notice the tree stand 2 once the hunter has climbed into it, a telescopable sock 72 made of camouflage material is attached between the bottom of the sleeve 18 of the lower foot support 16 and the top of the rope clamp 62 (FIG. 2). The sock should be expandable to a length almost as long as the pole 4. As the hunter climbs up the pole 4, raising the foot supports 14 and 16 to higher positions, the top end of the sock 72 attached to the support 16 is carried up the pole 4. Thus, when the hunter has reached the top of the pole 4, the sock 72 will cover almost the entire length of the pole, hiding the naturally shiny aluminum surface of the pole. When the hunter descends, the sock 72 is telescoped back to its original storage position. While it is stored, the sock 72 tends to become very wrinkled, adding to its camouflaging properties when it is again expanded.
When the portable tree stand 2 is being stored or carried its parts are preferably carried in a backpack 74, arranged in three layers as shown in the top view of the backpack 74 in FIG. 15. The first layer, closest to the hunter's back, comprises a pocket 76 and associated velcro attachment straps 78 that hold the top section 8 of the pole 4, with its connected clamping assembly 32, collapsed as shown in FIG. 2, as well as the rope 54. Because of their shape, the pole section 8 and clamping assembly 32 act as a good frame for the backpack 74. The second layer comprises four tubular pockets 80 that hold all of the sections 6 of the pole 4, except the bottom section 6. The third layer comprises a pocket 82 and velcro attachment straps 84, which cover and hold the bottom pole section 6, the attached foot supports 14 and 16, rope clamp 62, sock 72 and spike 70. Conventional backpack straps 86 (FIG. 15) connected to the front of the backpack 74 loop over the hunter's shoulders when he is carrying the backpack. The backpack 74 is also equipped with two snap action clips 88 that are sewn to its top rear corners (FIG. 15). A loop strap 90, made of heavy cloth similar to the cloth of the other components of the backpack 74, is sewn to the outside of the rear cover 92 of the backpack, preferably in the middle of the lower portion of the cover. The clips 88 and loop strap 90 enable the backpack 74 to form a sling type seat for the hunter between the arms 38 of the clamping assembly 32, after the hunter has climbed the pole 4 and is ready to sit at the top of the tree stand 2. Eyebolts 94 (FIGS. 2 and 7) are provided on the inner rod sections 46 of the arms 38, and when the backpack 74 is used as a seat, the clips 88 are attached to the eyebolts 94. The third suspension point for the sling type seat is formed when the loop strap 90 is placed around the top of the pole 4.
To assemble the portable tree stand 2, the hunter first removes the top pole section 8 with connected clamping assembly 32 from the backpack 72. Then, he rotates the inner rod sections 46 of the arms 38 until the arms 38 are perpendicular to the pole section 8. He also slides the outer rod sections 50 to extend the arms 38 to their maximum lengths. When that is completed, he removes the other pole sections 6 from the backpack 72 and connects all the pole sections together in their proper order. Then, the spike 70 at the bottom end of the pole 4 is removed from its storage position of FIG. 13 and put back in its use position of FIG. 14. The rope 54 is checked to insure that its end is properly secured to one of the arms 38 and threaded through the pulleys 58 and 60. Then, the hunter threads the other end of the rope 54 between the cam wheel 64 and abutment 66 of the rope clamp 62. That completes the assembly of the tree stand 2.
To secure the tree stand 2 to a tree trunk T (FIG. 5), the hunter raises the pole 4 to a vertical position next to the tree and manipulates the stand 2 until the arms 38 of the clamping assembly 32 encircle the trunk T, as shown in FIG. 6. He then pulls upwardly on the end of the rope 54 that has been threaded through the rope clamp 62, to begin rotating the arms 38 together. At the same time, he pulls downwardly on the pole 4 to force the spike 70 into the ground. When the arms 38 have been secured tightly against the trunk T, he rotates the handle 68 of the rope clamp 62 to secure the rope 54 and hold the arms 38 in place. The tree stand 2 is now secured to the tree trunk T and is ready for the hunter to begin climbing the pole 4.
The hunter climbs the pole 4 using the foot supports 14 and 16. Facing the pole 4, with the pole 4 between himself and the tree, as shown in FIG. 6, he grasps the straps 30 connected to the foot supports 14 and 16, with the loops on the ends of the straps 30 extending around his hands. Then he steps onto the foot platforms 20 of the supports 14 and 16 and goes through a mounting procedure illustrated in FIGS. 16-18. Because the hunter's body is at all times on the outside of the pole 4, he creates a moment about the bottom of the pole that pulls the tines 52 of the arms 38 even more tightly against the back side of the trunk T, thus maintaining the stability of the stand 2 during the climbing and descending processes. To begin the climbing process, the hunter stands on the supports 14 and 16, as shown in FIG. 16, and then shifts his weight entirely to his left foot and raises both his right hand and right foot in a synchronous motion. The strap 30 attached to his right hand thus lifts right support 14, releasing the grip of the support's friction pads 26 and 28 on the pole 4 and maintaining the foot support in contact with the bottom of the hunter's right foot, as shown in FIG. 17. When he has raised his right foot to a comfortable height, the hunter shifts his weight from his left foot to his right foot, thereby pressing down on the foot support 14 and reapplying the grip of the supports friction pads 26 and 28 to the pole 4. Then, the hunter repeats the lifting procedure with his left hand and left foot to bring his left foot and associated foot support 16 to the position shown in FIG. 18. This procedure is continually repeated, always raising the right foot and foot support 14 first and then bringing the left foot and foot support 16 up to a position just beneath the foot support 14, until the hunter has reached the position shown in FIG. 19, with his waist at approximately the same elevation as the top of the pole 4.
When the hunter reaches the position shown in FIG. 19, he attaches additional ropes or straps to secure the clamp arms 38 to the tree trunk T, so that the clamp arms 38 will be held securely to the tree trunk T independent of any tension in the rope 54. The reason for such additional securement is to allow the rope 54 to be loosened at a later time and used for a different purpose. The hunter then leans over the arms 38 and attaches the clips 88 on the backpack 74 to the eyebolts 94 on the inner rod sections 46 of arms 38.
If the hunter has left items on the ground, such as a weapon, that he could not carry on his back during his initial climb up the pole 4, he descends the pole 4, first taking his left foot off the foot support 16 and allowing the support 16 to drop slowly while hanging on to the strap 30 connected to the support 16. When the foot support 16 has dropped a comfortable distance, the hunter steps it, allowing his weight to force the friction pads 26 and 28 of the support 16 into engagement with the pole 4. Then, he repeats this process with his right foot and the foot support 14. The hunter repeats the process with his feet and foot supports 14 and 16 until he has descended to the bottom of the pole 4.
After reaching the ground, the hunter disconnects the rope 54 from the rope clamp 62 and ties his weapon or other peraphernalia to the end of the rope. Then, he climbs back up the pole 4, using the procedure previously explained and shown in FIGS. 16-18. On this ascent, he stops with his waist six to ten inches below the top of the pole 4. Then, he crouches down as shown in FIG. 20 and swings around the pole 4 to the dotted line position shown in FIG. 21. From there, he rises up from his crouch position to the solid line position shown in FIG. 21. Then, he places the loop strap 90 over the top end of the pole 4, as shown in FIG. 22 and sits in the sling type seat formed by the backpack 74, as shown in FIG. 23. Whenever he desires, he may rise from his seat to point a weapon or a viewing instrument, as shown in FIG. 24.
When the hunter desires, he reverses the procedure shown in FIGS. 20 to 24. First, he lowers his weapon to the ground, using the rope 54. Then he climbs down the pole 4, using the procedure described above for retrieving his weapon prior to sitting in the tree stand 2. Once on the ground, he removes his weapon from the rope 54 and secures the rope to the rope clamp 62. (FIGS. 11 and 12) While securing the rope to the rope clamp, he pulls the rope tightly to insure that the arms 38 of the clamping assembly 32 are held tight against the tree trunk T. Then, the hunter climbs back up the pole 4 and unties the ropes or straps that additionally secure the arms 38 to the tree trunk T. After climbing down the pole 4 again, the hunter releases the rope 54 from the rope clamp 62, which in turn releases the arms 38 from the tree trunk T. It may be necessary for the hunter to rotate the pole 4 back and forth to cause the arms 38 to spring open.
When the arms 38 have been separated from the tree trunk T, the hunter pulls the pole 4 backwardly. If he intends to move the tree stand 2 more than a short distance, he lays it on the ground, disconnects the pole sections 6 and 8 and puts them back in the backpack 74.
The portable tree stand 2 thus embodies several novel features that provide a combination of advantages not present in previously known tree stands. First, the foot supports 14 and 16, with their friction-padded sleeves, enable the hunter or other user to climb the stand quickly, if desired, and to take whatever size steps that are comfortable for him. The process of climbing and descending the stand with these foot supports requires little more exertion than climbing a set of steps. Secondly, the clamping assembly 32, with its light-weight arms that surround and attach to a tree trunk by the simple pull of a rope, provides a tree stand attachment that is very secure when the hunter climbs on the outside of the pole 4, creating an outward moment that causes the tines 52 to grip the other side of the tree evermore tightly. Thirdly, the three-point, sling seat provided by the backpack 74 gives the hunter a secure, comfortable place to sit. In this seat, the hunter is surrounded by clamping arms 38 that act as a safety cage, arm rest and a rest for a gun or cross bow. Furthermore, this safety cage is not an add-on item that adds weight to the stand, but is an integral part of the clamping assembly of the tree stand 2. From his seated position, the hunter can twist, turn and even stand, as shown in FIG. 24. In addition, the tree stand 2 may be secured to trees having either single or double trunks of a wide variety of shapes and sizes.
While one embodiment of the present invention has been shown and described, other embodiments and modifications will be apparent to those skilled in the art, without departing from the spirit of the invention, as defined by the appended claims. | A portable tree stand is provided for use by a person to climb to and descend from an elevated position next to an upright object. The stand comprises a pole, a clamping assembly attached to the pole near its top end for securing the pole to the upright object, a device on the bottom end of the pole for anchoring it to the ground and upper and lower foot supports for use by the person to climb and descend the pole. Each foot support is slidably mounted on the pole but has a friction device that locks the foot support in a fixed position on the pole in response to a downwardly applied force. |
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BACKGROUND OF THE INVENTION
This invention relates to equipment security devices, especially ones that are adapted to rotationally secure various appliances such as a hand held television remote control module to a support surface, such as an end table in a hotel room. The device is also adaptable for use with larger appliances, such as televisions.
The prior art consists primarily of a metal holder to which the remote control unit is fixed so that it cannot be dismantled. The holder, in turn, is typically attached to a fixed base by a cylinder lock that requires a traditional machined key. The cost of these devices is undesirably high, both because of the expense of the lock itself and its assembly into a finished product. In addition, the prior art devices have an undesirably high vertical profile, which facilitates a forcible removal and is also aesthetically unpleasing.
SUMMARY OF THE INVENTION
The present invention eliminates the need for a lock cylinder and machined key. Fabrication and installation costs are concomitantly reduced. Security is not sacrificed, because a lower profile is achieved, which increases the horizontal force the device can withstand.
The present invention rotatably fastens an appliance, such as a remote control television device, to a support surface. An upper housing for holding an appliance has a stud depending from it, with the stud having a shank and a head. The stud head fits inside a lower housing mounted to the support surface with a top surface and side walls. There is a first aperture in the top surface with a wide portion large enough to permit the passage of the stud head through the top surface and a second portion narrower than the stud head but wide enough to permit sliding movement and rotation of the stud shank. This allows for the assembly and disassembly of the upper and lower housings. A second aperture in one of the side walls permits releasing of the stud head from the first aperture when the stud head is positioned within the lower housing.
The invention also includes a locking means inside the lower housing for releasably securing the stud head. A biasing means urges the locking means into a securing position so that the stud is secured in the narrow portion of the first aperture for retaining the upper housing in rotatable engagement with the lower housing. The locking means preferably includes an operatively connected parallel ledge. Instead of a machined key, a disengaging means, such as a tabbed bar, slides through the aperture in the side surface and rotates to depress the ledge, which also depresses the locking means, permitting the release of the stud head from inside the lower housing, and thus disengagement of the upper and lower housings.
Various embodiments of the invention accomplish certain desirable objectives. For example, a cover plate with a top and walls and a base plate can be fabricated together so that the base plate can be attached to a surface with a double side adhesive tape. Alternatively, screws can be placed through aligned holes in the cover plate and base plate to attach the entire structure to a surface. Once the upper housing is attached, the screw holes are covered and thus inaccessible. Interlocking nubs and depressions can secure the biasing means between the cover plate and base plate with no further fastening.
The typical purpose of this device is to prevent the ordinary hotel visitor from misappropriating a remote control device for a television. The device is not designed to deter the accomplished thief who will destroy a table top by prying screws, removing thin double coated foam tape with solvents or piano wire, or duplicating the key-like member necessary to operate the present invention. Nevertheless, the low profile makes the unauthorized removal more difficult, while the force for removing the upper housing with a specially configured bar or other actuating means is trivial.
Another embodiment of the invention can be used to rotatably support a larger device, such as a television. The low profile permits the television to fit inside a cabinet without a hotel guest being aware that the television is actually locked in place and cannot be removed. This feature is particularly appealing to higher class hotels that do not wish to offend their guests by exhibiting the mistrust implied by the visible presence of a lock.
This embodiment uses a release rod with a pointed tip to depress the ledge inside the housing.
DETAILED DESCRIPTION OF THE DRAWINGS
The novel features which are characteristic of the invention are set forth in the appended claims. The invention itself, however, together with further objects and attendant advantages thereof, will be best understood by reference to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of the base structure with the two tabbed key inserted;
FIG. 2 is an elevation view of the side of the cover plate, depicting the appliance holder, stud head, and double-side adhesive tape;
FIG. 3 is a plan view of the cover plate;
FIG. 4 is a vertical section view, 4--4, drawn through FIG. 3, depicting the biasing means securing the stud head;
FIG. 5 is a vertical section view, 5--5, drawn through FIG. 3, depicting the biasing means in a position to release the stud head;
FIG. 6 is an exploded view of a device with a different platform for holding the appliance and a different release rod for actuating the spring plate;
FIG. 7A is a vertical section view through FIG. 6 with the spring plate in a locking position behind the stud head; and
FIG. 7B is the same view as FIG. 7A except the release rod has actuated the spring plate so that the stud is free to move in the slot.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The security device, generally designated as 10, has a base section comprised of a base plate 20 and cover plate 30 that form a lower housing enclosing a locking means 50 for releasably locking a stud head 73. Typically the locking means 50 is placed inside the enclosure formed by cover plate 30, with top surface 32 and side walls 34, and base plate 20, and then the cover and base plates are spot welded together. Preferably the bottom of the biasing means possesses recesses or holes that interlock by projections or nubs 22 (FIG. 5) that can be punched out of the base plate. The locking means 50 should have enough spring force so that its bottom 52 is always forced into contact with the base plate 20, even when the biasing means is simply enclosed by the base and cover plate (or support surface) but not exposed to any other forces such as those from a releasing means that unlocks the locking means.
The locking means 50 includes an upper portion of a leaf spring 54 that is constantly urged toward the inside of cover plate 30 by a biasing portion or means 51. A means for releasing stud head 73, such as ledge 56, is preferably parallel to and non-planar with the leaf spring and is connected to leaf spring 54 by connecting member 55. A key 80 depresses ledge 56. The bottom 52 of the locking means is connected to tab 58, which extends vertically between the end of ledge 56 and side 34. Tab 58 also has a slot or aperture 59 positioned above ledge 56 and is aligned with a similarly shaped aperture 42 in one of the sides 34.
The base structure can be secured to a surface 12 in either of two ways. The first method is by the use of a double-sided adhesive foam tape 14, as shown in FIG. 2. The second method is by using screws 16 to attach base plate 20 to surface 12 (FIG. 4), whereas access to the screws can be obtained through holes 36 in cover plate 30. Once the appliance holder 70, which retains the remote control device, is secured to the base structure, access to screws 16 through holes 36 is prevented, because the holder 70 covers most or all of the top surface 32 of cover plate 30.
The appliance holder, or upper housing 70, rotatably attaches to the base section by means of a projection such as stud 72, with a head 73 and shank 74, as shown in phantom in FIG. 2. The head 73 fits through an aperture 38 in the cover plate 30 that includes a larger portion 39, preferably circular in shape. A narrower, slotted portion 40 of aperture 38 connects to the circular portion 39. The slotted portion 40 must be narrow enough so that head 73 cannot pass through it.
To secure stud head 73 within cover plate 30, the head is placed in the larger portion 39 of aperture 38 and pressed downward against leaf spring 54. When the head 73 is completely below top plate 32, as depicted in FIG. 5 (which also depicts the reverse procedure of releasing the stud head 73 by use of a key 80), stud shank 74 is slid all the way to the end of narrower slot 40. At that point the edge of head 73 should clear the edge of leaf spring 54, allowing the leaf spring to rebound upward against the inside of top 32, closing off access to the larger portion 39 by stud head 73. Thus, the shank 74 is rotatably secured in narrow slot 40 by leaf spring 54.
To release stud head 73 and thus appliance holder 70 from the base section requires the use of a disengaging means such as a bar or key 80 to move leaf spring 54. FIG. 5 depicts the preferred shape of the key, which is a flat bar, with two slots 81 and 82 and an end tab 83. The key 80 is held horizontal, as shown in phantom in FIG. 4, and inserted through aligned holes 42 and 59. Slots 81 and 82 are spaced on key 80 the same distance as holes 42 and 59, so that the narrow portion of the key, where the slots are, can rotate easily in the holes. Preferably the slots 81 and 82 and holes 42 and 59 have rounded portions that make the rotation of key 80 subject to less friction and thus easier.
As the key is rotated from the position shown in FIG. 4 to that in FIG. 5, tab 83 depresses ledge 56, actuating the release of stud head 73. This creates enough space so that stud head 73 can be slid from under narrow slot 40 to the larger opening 39. Then the stud head can be withdrawn through the top 32 so that the appliance holder 70 and the remote control device it holds can be removed.
FIGS. 6, 7A, and 7B depict another embodiment of the invention. It is presently contemplated that this embodiment will be used for larger devices, such as televisions, while the other described embodiment will be used for remote control devices. The invention is not so limited, however.
This embodiment also includes a base plate 120 and cover plate 130 secured to a surface 115 by screws 117. A platform 170 attaches to cover plate 130 by means of a projection such as stud 172. Platform 170 should be large enough so that when it rotates in the slotted portion 140 of aperture 138, screws 117 are never exposed enough to allow access by an ordinary screw driver. The preferred height of cover plate 130 is on the order of 1.5 centimeters.
Platform 170 includes screw or bolt holes 174 for securing an appliance 176 from the underneath side of the platform. Rivet 172 attached to the bottom of platform 170 fits through the large portion 139 of aperture 138. The rivet 172, aperture 138, and spring plate 154 cooperate as previously described to secure and release the rivet from cover plate 130. Nubs 122 on base plate 130 can secure the spring plate as described above.
Ledge 156 is depressed by release rod 180 to unlock rivet 172 from cover plate 130. The tip 182 of rod 180 is inserted through aperture 142 and the rod is rotated in the direction of Arrow A (FIG. 7B). This depresses spring plate 154 below the head of rivet 172 so that the rivet can slide easily within aperture 138 to a point where the rivet head 173 can be removed through the large portion 139 of aperture 138.
In the prefered embodiment, tip 182, aperture 142, and ledge 156 are especially configured to perform this function. In particular, tip 182 is pointed, so that it can slide over ledge 156. Ledge 156 and aperture 142 should be sized and aligned so that if the tip 182 is not pointed, it will abut the vertical end 157 of ledge 156 and not be able to pass above ledge 156 to unlock rivet 172 and appliance platform 170.
In the preferred embodiment, nylon plugs 190 maintain a small degree of spaced relation between platform 170 and upper housing 130 to prevent friction between those two parts. The legs of release rod 180 must be sized and configured to permit the tip 182 to fit under platform 170, as well as for the particular location of the security device, e.g., inside a cabinet.
Different configurations within the scope of the present invention can easily be imagined. For example, the distance between tab 58 and side 34 can be varied during different manufacturing runs, thus allowing the locking configuration of the key to be varied. This creates the effect of having different keys without the expense of lock cylinders and machined keys. Another example would be the use of either the key 80 or release rod 180, with the appropriate corresponding spring plate to enable release, for both a small appliance holder and a large one. In that manner, only one unlocking mechanism is necessary for a hotel room with both a secured television and remote control device. Of course, it should be understood that various changes and modifications to the preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is, therefore, intended that such changes and modifications be covered by the following claims: | A low profile security device for television remote controls, televisions, and other appliances has a lower housing that encloses a leaf spring. The control module is held by an upper housing with a stud on the bottom. The stud can be locked in an opening in the lower housing by the leaf spring. A key-like member can be inserted through a hole in the side of the lower housing and a similar hole in a tab inside the lower housing. Rotation of the key-like member depresses the leaf spring, permitting the release of the stud. Another embodiment of the release mechanism uses a rod with a tapered or pointed tip that permits the rod to pass through the side hole and over the leaft spring. |
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[0001] National stage of PCT/FR2007/001043 filed Jan. 22, 2007 which claims priority from French Application 0606199 filed Jul. 7, 2006
FIELD OF INVENTION
[0002] The invention relates to a gap lining for a rail used for guiding or rolling a railway or urban public transport vehicle by means of at least one flanged roller or railway wheel.
[0003] The top surface of the rail is generally flush with the ground or slightly above ground level.
[0004] In a particular application the invention concerns a gap lining for a guide-rail embedded in the ground with edges that form rolling tracks for an assembly that guides a vehicle on tires by means of one inclined roller or a pair of the same.
[0005] Classically, for guiding or rolling by or with one or more flanged roller(s) there must be a free space between the flange, the adjacent edge of the recess holding the rail and the rail fixture. This space is known as the “gap”, and the said gap or gaps form(s) one or two channel(s) on either side all along the rail.
BACKGROUND OF THE INVENTION
[0006] Owing to its exposure to bad weather and to the environment, it often happens that the gap is locally blocked by an accumulation of plant matter, ice, snow, pebbles or other foreign bodies or objects that can obstruct the flange(s) during the passage of the guide roller(s) or railway wheels. Such obstacles can lead to severe problems, such as damage to the rollers or wheels or, more seriously, to their derailment.
[0007] To avoid such problems, the gap all along the guide-rail or rolling rail network must be cleared regularly. However, such cleaning is time-consuming and expensive, and cannot be carried out during operation of the transport network and in particular that part of it using the rail concerned. Besides, even regular cleaning does not ensure the total cleanliness of gaps constantly exposed to bad weather, discarded garbage and attempted vandalism.
[0008] The forward protection element known as a “pebble guard” enables hard objects and ones above a certain size to be cleared from a rail and more generally a guiding or rolling track. Such protection, however, is quite useless against debris and small objects that may be present in one or other of the channels along the rail, which potentially endanger the guiding function and the vehicle's rollers or wheels.
[0009] There is thus a need for a gap that enables such objects to be passed over in total safety.
SUMMARY OF THE INVENTION
[0010] The purpose of the present invention is to provide a lining for the gap alongside a guide-rail or rolling rail positioned substantially flush with the ground.
[0011] According to the invention the gap is lined with a specific material that ensures the free passage of wheel or roller flanges, and confers upon it a self-cleaning nature realized during the passage of flanged wheels or rollers.
[0012] The urban integration of ground-level guiding means by rails flush with the surface has specific advantages and, thanks to the invention, ensures the reliability and safety of guiding and rolling even in the locations most exposed to all kinds of debris and to bad weather.
[0013] The gap lining material has compressibility properties that enable it to ensure the cleaning of objects during or after the passage of the roller(s) or wheel(s), or their obliteration or pressing down into the material during the passage.
[0014] The invention relates to every manner of obtaining the basic nature and properties of the lining material, namely its compressibility.
[0015] The technical form of the gap lining is such that it does not interfere with the dynamic engagement of the rollers. The lining material is chosen such that it never interferes with that engagement, regardless of the environmental conditions, in particular the climate conditions and the conditions in which the vehicle is used within the limits specified by the manufacturer. In particular, the filler does not swell and expands very little or not at all regardless of the conditions of its environment or use, especially under the action of temperature variations or precipitations.
[0016] Advantageously, in suitable cases the material can be designed to insulate the rail electrically from the ground.
[0017] In certain preferable embodiments of the invention the lining material can have one or more of the following properties: it can be electrically insulating, with low thermal expansion, impermeable, elastic, and/or it may not retain water internally.
[0018] When the rail not only provides a guiding function but also supports the vehicle while it is rolling, it can be imagined that the gap lining does not hold the rail in place, this being done in some other way.
[0019] In contrast, when the rail only acts to guide the vehicle, it is easy to envisage fixing the rail by means of the lining material itself while filling the gap. For example, the bottom of the recess designed to hold the rail can be covered with the lining material, the rail can then be placed on the bed so constituted while also positioning the rail with precision in the recess, and the gap or gaps bordering the length of the rail as well as any other free, unused, volume of the recess can then be topped up with the lining material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Other characteristics and advantages of the invention will emerge on reading the detailed description given below, which relates to the attached drawings showing:
[0021] FIG. 1 : Cross-section illustrating the application of the invention to a railway rolling rail;
[0022] FIG. 2 : Cross-section illustrating the application of the invention to a grooved railway rail;
[0023] FIG. 3 : Perspective view from above, of a first, flush-fitted ground-level guiding rail system with a gap lining according to the invention;
[0024] FIG. 4 : Perspective view from above, of a second, flush-fitted ground-level guiding rail system with a gap lining according to the invention;
[0025] FIG. 5 : Perspective view from above of a gap lining according to the invention, whose gap is obstructed by a solid object;
[0026] FIGS. 6 to 8 : Sectional views illustrating the function of freeing the passage carried out by the gap lining according to the invention, in the case when a solid object is obstructing a gap such as that of FIG. 3 ;
[0027] FIGS. 9 to 11 : Perspective views illustrating the function of freeing the passage carried out by the gap lining according to the invention, in the case when the gap is obstructed by snow or ice; and
[0028] FIG. 12 : Cross-section showing a guiding application for a vertical roller.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The gap lining for a guide-rail or rolling rail according to the present invention will now be described in detail with reference to FIGS. 1 to 12 . Equivalent elements in the various figures will be given the same index numbers.
[0030] The gap lining is applied to guide-rails for flanged rollers arranged vertically or inclined, but also for railway wheels, i.e. wheels with a flange that roll on a rail in the vertical or inclined position, whether alone or in pairs.
[0031] FIGS. 1 and 2 aim to illustrate the general nature of the application of the present invention, by showing the case of a railway rolling rail with a classical profile and then one with a grooved profile.
[0032] As shown, the invention relates as much to a ground rail 1 for the rolling of a railway vehicle as to a ground-level guide-rail 2 .
[0033] The rails 1 and 2 to which the invention relates are ones of the type comprising in particular a supporting base or foot 3 positioned below ground level and of the type that is mounted or held in a recess 4 formed in a solid base 5 .
[0034] Classically, such rails have a web 6 which may be longer or shorter, and a rail head 7 , technically of suitable shape with an upper, rolling surface 8 and a foot such as the supporting base 3 , which is more or less wide and, if needs be, has a groove 9 ( FIG. 2 ).
[0035] Preferably, the rails used in the invention are those of the type whose top is almost flush with the ground.
[0036] In general the base 3 of the rolling rail 1 shown as an example in FIG. 1 is surrounded by a filler material 10 that forms a filling 11 which delimits at the top at least one gap 12 which is covered or filled with a lining 13 of a compressible lining material 14 that can obliterate objects due to the compression of the material and/or expel them due to its elasticity and/or retain them embedded or encrusted during the passage of the roller(s) or wheels with flanges 15 at a level low enough for them not to impede the guiding, nor damage the rollers or wheels, especially avoiding any risk of derailment.
[0037] The same applies to a rolling rail 2 or guide-rail with a groove 9 ( FIG. 2 ). In that case it is the groove 9 of the rail which acts as the gap 12 . According to the invention, in such cases the bottom of the rail groove is lined with a suitable material such as the material 14 , while leaving above the lining a space large enough to ensure that the material never interferes with the dynamic engagement of the roller(s) or wheel(s), regardless of the environmental conditions or the vehicle's conditions of use within the limits specified by its manufacturer.
[0038] Wheels such as that indexed 16 on the same side of a railway vehicle roll on such a rail. These are classical railway wheels with a rolling crown 17 and a flange 18 , which roll on the upper, rolling surface 8 .
[0039] As will be seen below, there is a real effect of pressing down debris and obstructive objects present on the upper surface of the lining or filling, with clearance during and after the passage of the railway wheel.
[0040] Particularly in the case of rollers or wheels with flanges 15 that only have a guiding function, the lining material 14 for the gap 12 can just as well be the filler material 10 . It must at least be compressible, and therefore able to be compressed under the pressure of the object forced against it by the passage of the flange 15 , so avoiding a vertical deflection of the guide roller or railway wheel that could result in derailment. The material 14 must never interfere with the engagement of the flanged rollers or wheels in any environmental conditions or conditions of use specified by the manufacturer, and it is desirable for the material to have low thermal expansion, to be resistant to aggression by its environment, and not to retain water coming for example from precipitation so that, in the event of freezing, there will be no swelling of the lining material 14 that could interfere with the dynamic engagement of the flanges.
[0041] This at least compressible material may also have the properties of elasticity and of electrical and/or noise insulation. For example, it may be a polymer material with high physical resistance to being torn and pulled out, and lasting resistance to temperature, light and in particular ultraviolet, and environmental aggression in general.
[0042] As examples of possible suitable materials the following can be mentioned: plastic cellular materials and in particular closed-cell foams such as a polyurethane foam, polymers, elastomers, plastomers, polymer resins, composite materials, and materials containing mineral or organic fillers.
[0043] Preferably, the lining material 14 for the gap 12 is made as a closed-cell foam or a polymer resin. It can also be made of a composite material or of gum or rubber derivatives or equivalents.
[0044] As a particular but non-limiting example, the description will now be given of an assembly as illustrated in perspective in FIGS. 3 and 4 , which holds in position a guide-rail 2 thanks to filling of the channel or recess 4 formed in the solid base 5 .
[0045] The guide-rail 2 can have several different profiles without going beyond the scope of the invention.
[0046] FIGS. 4 and 5 show two examples of profiles, one with a supporting foot 3 identical in shape to that of FIG. 1 and the other with a substantially I-shaped profile 19 . The two rails illustrated have two rolling tracks 20 and 21 which are symmetrically inclined and are separated by a central upper surface 22 on which inclined guide rollers 23 and 24 with respective flanges 25 and 26 are rolling.
[0047] Of course, in this application the invention is not limited to just one type of guide-rail but concerns more specifically the partial or complete filling of the recess 4 with a single material having suitable properties or with two materials, one a filling and the other a lining material, the latter of which has the main property of compressibility required.
[0048] Nor is the invention limited to a particular guiding assembly with two inclined rollers, but on the contrary, relates to all types of guiding by means of a flush-mounted ground-level guide-rail.
[0049] The lining 13 of the gap 12 with its lining material 14 can if necessary be used to hold the guide-rail 2 in the ground, although this is not obligatory. In the case shown, namely that of rails which are not heavily loaded, i.e. rails whose function is only to guide, the lining surrounds the bottom and middle part of the rail and occupies the recess 4 made in the solid base 5 in such manner that, in a preferred embodiment, the only flush portion is the top of the guide-rail 2 and in particular the inclined lateral surfaces 27 and 28 on which the guide rollers 23 and 24 roll, which serve as rolling tracks for the latter.
[0050] At the top, the volume of the mass of material occupying the recess 4 has a V-shape with its point directed downward, opening in the middle onto the projecting part of the guide-rail 2 and delimiting along the rail two descending inclined ramps 29 and 30 each of which ends laterally close to the web of the rail, in each case with a groove 31 and 32 that serves as a gutter for the collection and run-off of liquids and fine debris. The V-shape of the upper part of the lining 13 of the gap 12 makes it possible to avoid any interference with the dynamic engagement of the guide rollers 23 and 24 .
[0051] Advantageously, if the gap lining 13 according to the invention becomes degraded local repairs can be carried out by casting in a material that polymerizes at ambient temperature. Thus, a deteriorated gap lining 13 can be repaired without having to replace it entirely.
[0052] Advantageously, the lining 13 can be produced industrially by casting, extrusion or co-extrusion, or it can be cast in on the spot, or produced by any other suitable industrial process.
[0053] It can then be bent to adapt to the contour desired for the rail network and force-fitted into the recess 4 in the solid base 5 which, itself occupies the trench in the road.
[0054] The gap lining 13 according to the present invention can also be used with rollers 33 having two flanges 34 and 35 , as illustrated in FIG. 12 . In this case the rail has a gap 12 on each side and each gap is filled with the lining material 14 as described above.
[0055] A description will now be given of the function of clearing the space required for the passage of the flange 15 , and of the behavior of objects related to the properties and shape of the lining 13 of the gap 12 according to the invention.
[0056] 1) When Solid Objects or Debris are Present in the Gap
[0057] FIGS. 5 to 8 illustrate the clearing function and the self-cleaning effect of the lining 13 of the gap 12 according to the invention, in the case of a solid object 36 or various kinds of solid debris that can obstruct the gap 12 as illustrated in perspective in FIG. 5 .
[0058] The figure shows a cross-section at the level of a solid object 36 in the form of a calibrated test cylinder, just before one of the guide rollers makes contact with it.
[0059] During the passage of the inclined guide rollers 23 and 24 , the solid object 36 is forced down against the lining material 14 of the gap 12 which, because of its compressibility, sinks down under the pressure of the roller transmitted by the object, as shown.
[0060] Thus, the object or debris is pushed out of the way by compressing the flexible material 14 of the lining 13 of the gap 12 , whether more or less temporarily or permanently, and this sufficiently to remove opposition to the passage of the roller or at least not deflect the roller vertically to the point of derailment. Thus, the roller is neither damaged nor deflected from its normal path.
[0061] Furthermore, as shown in FIG. 8 , after the passage of one of the guide rollers, for example 23 , the solid object 36 is often automatically expelled or ejected from the gap 12 by the elastic effect due to the additional characteristics of flexibility and elasticity of the material from which the lining 13 of the gap 12 is made.
[0062] 2) When Ice or Suchlike is Present in the Gap
[0063] FIGS. 9 to 11 illustrate the effect and the self-cleaning and clearing behavior of the gap lining according to the invention when a gap is obstructed by snow or ice.
[0064] In below-zero temperatures water retained in the gap can freeze and fill up the gap 12 , as shown in FIG. 9 .
[0065] It should be noted, however, that this ice can only form when the operation of the transport network using the rail is interrupted, for example during the night. In effect, the repeated passage of vehicles guided by the rail has the effect of keeping the gaps clear.
[0066] During the passage of the inclined guide rollers 23 and 24 , their flanges 25 and 26 as they move forward exert a vertical force directed downward. Under this force, either the ice moves out of the way by sinking into the flexible material 14 of the lining 13 of the gap 12 , or it sinks and breaks up due to the bend and shear stresses produced in the strip or block 37 of ice.
[0067] Since the block of ice 37 is often fragile in relation to the stresses, it fractures locally. This effect is repeated as the rollers move forward, at least whichever of the two inclined rollers is above the ice crushing the latter continuously ( FIG. 11 ) and therefore, as the ice sinks into the material, the rollers can pass without losing contact with the rolling track or, worse, becoming derailed. The rollers are neither damaged nor deflected from their normal path.
[0068] The crushed ice 38 is then cleared by the passage of the guide rollers, in accordance with the same self-cleaning process as before.
[0069] In general, the object or matter is temporarily pressed down onto or sunk into the flexible material 14 of the lining 13 of the gap 12 , and thus does not obstruct the movement of the guide roller. So the latter is neither damaged, nor deflected from its normal course.
[0070] In addition, once the rollers have passed, the debris or small solid object(s) in contact with the flange(s) is/are generally expelled or ejected out of the gap 12 by the elastic force that results from the flexibility of the material 14 of the lining 13 of the gap 12 , this action characterizing the self-cleaning nature of the lining 13 of the gap 12 for guide-rails according to the invention.
[0071] It can also be supposed that the object 36 disappears into the depth of the material 14 of the lining 13 during the passage of the flange 15 that exerts a pressure on it as it compresses the gap lining material. Then, either the said object returns to its previous position once the rollers have passed, or it is sufficiently incrusted in the flexible material so as not to interfere with the rollers during their passage and the passage of subsequent rollers. In all such cases roller passage is made possible.
[0072] Other embodiments can be imagined by those with knowledge of the field without going outside the general principle of the invention.
[0073] The material 14 of the lining 13 of the gap 12 can enclose and even hold rails of any type and shape, and may be suitable for any type of guiding and rolling by flanged roller(s).
[0074] It must also be said that the lining material 14 is generally an added material inserted in order to fill each gap 12 at least partially, but that it can just as well be the filler material 10 . In that case the material both fills the recess 4 and grips the rail. | A self-cleaning assembly employing a gap filler for a rail on the ground which guides or in which there runs rollers or wheels with lugs housed in a groove so as to lie flush with or protrude only slightly from the ground and which has a gap on the side of the rail corresponding to the passage of the lug. A filling substance is placed in the gap outside of the dynamic footprint of the lug and at least partially lines the gap, at least partially filling it. The filling material has properties of compressibility and is positioned in such a way that under all normal conditions of use or normal environmental conditions, the gap remains filled outside of the dynamic footprint of the lug. |
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a quick-change coupling for attaching work tools to an excavator boom, in which a respective coupling body part is disposed on the work tool and on the excavator boom, the two coupling body parts being mutually securable by a hook connection and a wedge lock having mutual bearing surfaces.
In a known configuration of this type, the receiving recesses of the hook connections, and the bearing surface, as well as the wedge lock, are disposed on the work tool in offset arrangement in a plane parallel to the transverse center plane, the hooks of the hook connection being provided symmetrical to the transverse center plane on the work tool and the bearing surface and the wedge lock acting essentially in the region of the transverse center plane. Such a configuration has the drawback that a plurality of different receiving members have to be provided, which, because of the lateral offset one to the other, are subjected to strong bending forces if the work tool is placed under uneven load.
SUMMARY OF THE INVENTION
According to the invention, these stated drawbacks are avoided by the fact that on the work tool, on both sides of the longitudinal center plane and parallel to the latter, there is respectively provided at least one coupling plate, which coupling plates have, congruent with each other, the receiving recesses both of the hook connection and of the wedge connection. The fact that the receiving recesses both for the hook connection and for the wedge connection are provided congruent with each other on either side of the longitudinal center plane means that the forces which arise are imparted evenly to the coupling plates, the coupling plates between the hook connection and the wedge connection being respectively subjected only to tensile load. This is because the hook connection, on the one hand, and the bearing surfaces, on the other hand, are oppositely directed and the wedge connection causes the bearing surfaces to be mutually displaced in such a way that the receiving recess of the wedge connection, in relation to the hook connection, and the bearing surfaces are forced away from each other.
Advantageously, on the excavator boom, on both sides of the plane of inflexion of the boom in the state coupled to the coupling plates, support plates can be provided, running parallel on the tool, for the counterparts which are to be hung or secured in the recesses of the coupling plates. Thus, the transfer of force to the support plates attached to the excavator boom is also realized essentially in respectively one plane, so that these support plates, too, can disperse the imparted forces within the planes of the support plate. The counterpart for the wedge lock can herein be formed by a wedge bar running transversely to the planes of the support plates, which is guided in a track rising obliquely away from the work tool. It is thus easily brought about that, when the wedge member is displaced in the support plates, these are pulled in the direction of the work tool, whereby the corresponding pressing of the bearing surfaces and thus also of the hook connection is obtained. The wedge bar can then pass through the support plates and protrude on those outer sides of the support plates which are facing away from the excavator boom, the wedge profile being provided on both sides of each of the support plates. It is thus possible, with one and the same coupling part attached to the excavator boom, to receive work tools in which the coupling plates are fitted to the work tool either within the support plates, or, indeed, outside of the plate, i.e. distanced further apart. This is achieved in identical manner for the hook connection by the fact that the counterparts for the hook connection are formed by a transverse bar which passes through the support plates and protrudes on those outer sides of the support plates which are facing away from the excavator boom. For the actuation of the wedge bar, a hydraulic piston-cylinder unit can preferably be provided, which, when the wedge lock is unlocked, is fully extended. This has the advantage that the piston area which is available in the locking of the wedge connection, because of the fitted piston rod, is less than for the release of the wedge lock, thereby preventing possible jamming of the wedge connection inasmuch as greater forces can be applied in the release operation than in the locking operation.
In order for the work tools to be able to be fitted both for low-level digging and for high-level digging, i.e. in oppositely directed arrangement, the receiving recesses of the coupling plate can be configured symmetrically in relation to the vertical center plane running transversely to the plane of the plate. Furthermore, on both sides of the longitudinal center plane two coupling plates can respectively be provided, the support plates being able to be inserted into the interspace between the adjacent coupling plates. For larger work tools, in particular, very stable coupling parts can thus be achieved on the work tool. In order to make the forces impact, as far as possible, only upon the connecting members, the hydraulic piston-cylinder unit can be supported, by its end facing away from the wedge bar, against the transverse bar belonging to the hook connection. Finally, for the support of the hydraulic piston-cylinder unit in the direction of fastening of the excavator boom, cranked links are provided, which are prevented from pivoting relative to the support plates. The effect is that the hydraulic piston-cylinder unit is aligned with its longitudinal axis directly in the motional direction of the beam having the wedge surfaces. In order to keep the reciprocally moving parts of the hydraulic piston-cylinder unit free from inadmissible forces, the connection between the hydraulic piston-cylinder unit and the wedge bar can be realized with a reserved clearance.
BRIEF DESCRIPTION OF THE DRAWINGS
Various illustrative embodiments of the subject of the invention are represented in the drawing.
FIG. 1 shows a first embodiment in diagrammatic representation in the coupled state of the two coupling parts.
FIG. 2 is a side view,
FIG. 3 a front view and
FIG. 4 a top view of the configuration according to FIG. 1 . In the representation, both the excavator boom and the work tool are in this case omitted, so as not to complicate the representation.
FIG. 5 shows the coupling part to be fitted to the excavator boom alone, without the coupling part present on the work tool, this in side view.
FIG. 6 is a top view of this coupling part,
FIG. 7 depicts a section along the line A—A of FIG. 6 , and
FIG. 8 a section along the line C—C of FIG. 6 .
FIG. 9 shows in diagrammatic representation a first embodiment of the coupling part to be fitted to the work tool.
FIG. 10 is a side view of this coupling part represented in FIG. 9 .
FIG. 11 depicts a further embodiment of the coupling part to be fitted or present on the work tool, in diagrammatic representation.
FIG. 12 is an associated side view.
With respect to the coupling part to be fitted to the work tool, it should further be noted that the coupling parts jutting away from the work tool do not necessarily need to be plurally present on each side, as depicted in FIGS. 9 and 11 , but rather it is also sufficient for certain usage variants for the vertical parts to be provided only individually on each side of the longitudinal center, in which case it is possible, according to requirement, for the corresponding vertical portions of the coupling part to be able to be disposed either on the inner sides or, indeed, on the outer sides of the coupling part, which coupling part is sunken relative to the excavator boom.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The quick-change coupling according to the invention has a coupling part 1 to be attached to the excavator boom, and a coupling part 2 to be attached to the work tool, the two coupling parts being joined together, on the one hand, by a hook connection 3 and, on the other hand, by a wedge connection 4 , both coupling parts additionally being provided with mutually interacting, oblique stop-face bearing surfaces 5 , which are pressed one against the other by the wedge connection in order to obtain a play-free fit of the two coupling parts.
The coupling part 1 to be attached to the excavator boom has eyelets 6 , 7 , through which the fastening bolts for the attachment to the excavator boom can be pushed and secured therein.
In order to obtain the hook connection 3 , a transverse bar 8 , for engagement in the hooks provided on the coupling part 2 to be attached to the work tool, is disposed on the coupling part 1 to be attached to the excavator boom. The wedge connection is formed by a bar 10 , which runs parallel to the transverse bar 8 and is truncated in a wedge shape in the region of the wedge connection, as counterfaces on the coupling part 2 stop faces 11 being provided, along which the wedge bar 10 can be moved such that the coupling part 1 is pulled into the coupling part 2 . For the mutual securement of the two coupling parts, the mutual bearing surfaces 5 are formed by the provision on the coupling part 1 of a pressure plate 12 , which can be brought to bear against corresponding opposing contact surfaces 13 on the coupling part 2 . The inclination of the pressure plate 12 roughly corresponds, in the coupled state, to the inclination of the opposing bearing surface 13 , so that, when the wedge connection is actuated, a mutual tensioning is obtained between the wedge connection and the bearing surfaces, which tensioning additionally has the effect, due to the inclination of the bearing surfaces 5 , of forcing the transverse bar 8 into the hooks 9 . For the displacement of the wedge bar 10 , a hydraulic piston-cylinder unit 15 is provided, which is arranged such that, for the insertion of the wedge bar 10 on the corresponding opposing wedge surfaces 11 , the hydraulic piston-cylinder unit is pressurized in the direction of a shortening of the same. This has the advantage that a higher pressure can be applied for opening purposes than for the insertion of the wedge connection, whereby possible jams can be prevented or such jams can be more easily resolved. For the configuration of the hook 9 , of the wedge stop face 11 and of the opposing bearing surface 13 , the coupling part 2 to be attached to the work tool is formed by coupling plates 14 , 14 ′, which are disposed symmetrically in relation to the longitudinal center plane of the work tool. These coupling plates 14 , 14 ′ stand parallel to each other and are attached to a support plate 18 . Cross connections for connecting the plates one to another are not provided.
In the case of the coupling part 1 to be attached to the excavator boom, support plates 16 are provided, which, on the one hand, support the eyelets 6 , 7 and, on the other hand, support the transverse bar 8 for hanging the coupling part 1 in the hooks 9 of the coupling part 2 , the transverse bar 8 joining together the two support plates 16 and jutting beyond these on their outer side on both sides. Furthermore, the two support plates 16 , which likewise run parallel to each other and are disposed symmetrically to the longitudinal center plane of the work tool and also to the plane of inflexion of the excavator boom, are further joined together by the pressure plate 12 .
Additionally provided between these two support plates 16 is a connecting web 17 , which is hung by a middle link 20 from the transverse bar 8 and to which, jutting away therefrom, on the side facing away from the link 12 , two mounting links 21 are fitted, between which the hydraulic piston-cylinder unit 15 is pivotably fastened. The connecting link 20 , and also the two mounting links 21 , are respectively cranked in the direction of the retaining eyelets 6 , 7 , whereby the longitudinal axis of the hydraulic piston-cylinder unit 15 comes to lie roughly in the motional direction of the wedge bar 10 . The wedge bar 10 is guided in the support plates 16 by means of slots 23 and juts over the support plates on both sides on their outer side. The wedge surfaces on the wedge bar 10 are here provided both at the regions located between and adjacent to the support plates 16 and at the regions jutting externally over the support plates 16 . The hydraulic piston-cylinder unit 15 engages centrally on the wedge bar 10 , the wedge bar 10 being guided in the axial direction by a guide plate 22 . As a result of the connection, it is possible for no moments whatsoever to be transmitted to the hydraulic piston-cylinder unit by possible wedge movements, e.g. pivoting about its longitudinal axis. Apart from the pivotable mounting of the hydraulic piston-cylinder unit, this is additionally achieved by the fact that the piston rod is connected to the wedge bar 10 with play and, to be precise, in such a way that, on the one hand, the inner diameter of the eyelet of the piston rod is greater than the outer diameter of the wedge bar 10 (approximately 1 mm difference) and that, on the other hand, the holding plates provided for the axial securement of the eye of the piston rod to the wedge bar are attached to the wedge bar at a distance (approximately 2 mm) from the eyelet. Fitted to these holding plates are the guide plates 22 . Thus, if the wedge is slightly slanted, for example, the reciprocally moving parts of the hydraulic piston-cylinder unit are not placed under inadmissible load.
The wedge bar 10 is continuously configured such that it is kept solid, i.e. circular, in the region of the fitting of the hydraulic piston-cylinder unit and is truncated to form a wedge surface on both sides of the connecting link of the hydraulic piston-cylinder unit.
In the illustrative embodiment of the coupling part 2 to be attached to the work tool, according to FIGS. 9 and 10 , this coupling part is configured symmetrically also in relation to the vertical longitudinal center plane of the work tool, i.e. on each coupling plate, a hook 9 ′, directed oppositely to the hook 9 , for the hook connection 3 , and corresponding oppositely directed counterfaces 11 ′ for the wedge connection 4 , and 13 ′ for the bearing contact of the pressure plate 12 , are provided. This is designed to allow, for example, an excavator bucket, on the one hand, for low-level operations with the opening downward or, on the other hand, for high-level operations with the opening upward, to be fitted using one and the same coupling tool. According to FIG. 2 , in addition to the coupling plates 14 , coupling plates 19 are herein provided, which are configured and disposed congruent with the coupling plates 14 , the distance between the plates 14 and 19 being dimensioned such that the support plates 16 of the coupling part 1 can engage therebetween. The support plate 14 then engages respectively in those regions of the transverse bar 8 , of the wedge bar 10 and of the support plate 12 which are located on the outer sides of the support plate 16 , the plates 19 acting upon those regions of the transverse bar 8 , of the wedge bar 10 and of the support plate 12 which are located on the inner side of the support plate 16 .
The embodiment according to FIGS. 11 and 12 is designed for simple fitting, i.e. such that the coupling part 2 is non-symmetrical in relation to the longitudinal center plane of the work tool, so that the relevant work tool can only be fitted in a certain direction. Accordingly, each coupling plate 14 of the coupling part 2 has only one hook region 9 and a wedge contact surface 11 and contact surface 13 for the pressure plate 12 . The additional hook coupling plates 19 ′ are provided only in the hook region, but not in the region of the wedge connection or pressure plate.
An essential feature of the fast-change coupling according to the invention lies in the fact that the mutual support for the individual parts of the hook connection in relation to the wedge connection runs respectively in mutually parallel planes, so that both the coupling plates 14 and 19 and the support plates 16 are respectively subjected only to tensile load, thereby preventing any bowing or curving of the plates.
Labeled 24 and 24 ′, a free space is respectively provided between the wedge stop face 11 and 11 ′ and the opposing bearing surface 13 and 13 ′, which free space is dimensioned such that the pressure plate 12 can be moved through simultaneously with the fully pushed-back wedge bar 10 in order to bring the pressure plate 12 to bear against the opposing pressure plate 13 and move the wedge bar 10 against the wedge stop face 11 .
In order to couple a tool to an excavator boom, the excavator boom with its coupling part 1 is lowered such that the transverse bar 8 engages in the hook 9 of the hook connection 3 , after which the pressure plate 12 , together with the wedge bar 10 , is then lowered, by pivoting of the coupling part 1 , through the free interspace 24 , until the pressure plate 12 comes to bear against the opposing bearing surface 13 . After this, the wedge bar 10 is moved in the direction of the wedge stop face 11 with the aid of the hydraulic piston-cylinder unit 15 , and following contact with the wedge bar 10 , is displaced on this wedge stop face 11 transversely to the longitudinal direction of the wedge bar until the pressure plate 12 bears tight against the opposing bearing surface 13 , whereupon, due to the inclination of the individual parts, the coupling part 1 is displaced along the opposing bearing surface 13 in such a way in the direction of the hook 9 that the transverse bar 8 is mounted in a play-free manner in the hook 9 . The hydraulic piston-cylinder unit is then fixed in this position and the pressure maintained until such time as decoupling is due to take place.
When the work activity is completed, the work tool is set up on the ground, after which the hydraulic piston-cylinder unit 15 is pressurized in the direction of an extension, the effect of which is that the wedge bar 10 is now moved away from the wedge stop face 11 , to be precise to the point where the wedge bar 10 ends up in the region of the free interspace 24 . After this, through pivoting of the coupling part 1 about the transverse bar 8 in the hook 9 of the hook connection 3 , the coupling part 1 can be released from the coupling part 2 in the region of the bearing surfaces 5 and of the wedge connection 4 and the transverse bar 8 can then be moved out of the hook 9 of the hook connection 3 .
If, in the illustrative embodiment according to FIGS. 9 and 10 , the work tool is intended to be coupled to the excavator boom such that it is differently directed, i.e. twisted by 180°, then the coupling is realized via the hooks 9 ′, the wedge stop faces 11 ′ and the opposing bearing surface 13 ′, in which case the hooks 9 , the wedge stop faces 11 and the opposing bearing surface 13 are redundant. | The subject of the patent is a quick-change coupling for attaching work tools to an excavator boom, in which a respective coupling body part ( 1, 2 ) is disposed on the work tool and on the excavator boom, the two coupling body parts being mutually securable by a hook connection ( 3 ) and a wedge lock ( 4 ) having mutual bearing surfaces ( 5 ), and at least one coupling plate ( 14, 14 ′) being respectively provided on the work tool, on both sides of the longitudinal center plane and parallel to the latter, which coupling plates have, congruent with each other, the receiving recesses both of the hook connection ( 3 ) and of the wedge connection ( 4 ). |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of laying floor tile, pavers, and the like. Specifically, the invention relates to devices used to assist measuring and cutting floor tile prior to installation.
[0003] 2. Description of the Prior Art
[0004] Laying floor tile is a craft that requires a great deal of trial and error to master. Tile must be cut to fit around obstacles, such as moulding, doorways, and structural features of the surface to be tiled. Cutting tiles is an inexact technique often requiring repeated attempts to nibble or wet-saw portions of a tile away until the proper shape results. Considerable waste is generated from mis-cut tiles and from tiles that break as a result of repeated manipulations with nippers or a wet saw. This iterative process is also very time-consuming and frustrating for all but the most skilled craftsmen. What is needed, but not found in the prior art, is a universal device that can be used to translate any complex cutting geometry to any size tile so that a single cutting or nibbling step can produce an accurately cut tile for that same geometry.
SUMMARY OF THE INVENTION
[0005] The present invention is a device used to measure and mark floor tile that must be cut to fit around obstructions. A key feature of the invention is that it has removable elements that make it possible to use the device with tile of any size. A second key feature is a plurality of telescoping members that can be extended to varying lengths in order to describe the perimeter geometry that must be duplicated by cutting away a portion of the tile. The invention is compatible with all tile and similar flat floor or wall coverings, such as pavers or carpet squares.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an oblique view of the present invention showing all probes extended.
[0007] FIG. 2 is an oblique view of the present invention showing all probes retracted.
[0008] FIG. 3 is an oblique view of the present invention showing how individual fingers are connected.
[0009] FIG. 4 is an oblique view of a finger of the present invention with probe fully extended.
[0010] FIG. 5 is an oblique view of a finger of the present invention with probe partially extended.
[0011] FIG. 6 is an oblique view of a finger of the present invention with probe fully retracted.
[0012] FIG. 7 is an end view of a finger of the present invention.
[0013] FIG. 8 is a side view of a finger of the present invention.
[0014] FIG. 9 is a top view of a finger of the present invention.
[0015] FIG. 10A is a section view of FIG. 9 with probe retracted.
[0016] FIG. 10B is a section view of FIG. 9 with probe extended.
[0017] FIG. 11 is a view of the present invention being used around a corner of a wall.
[0018] FIG. 12 is a view of the present invention translating the cut line from FIG. 11 to a tile.
[0019] FIG. 13 shows the tile with cut line drawn and piece to be removed is hatched.
[0020] FIG. 14 shows the tile of FIG. 13 with piece removed.
[0021] FIG. 15 shows the cut tile of FIG. 14 installed around a corner of a wall.
[0022] FIG. 16 is a view of the present invention being used around a column.
[0023] FIG. 17 is a view of the present invention translating the cut line from FIG. 16 to a tile.
[0024] FIG. 18 shows the tile with cut line drawn and piece to be removed is hatched.
[0025] FIG. 19 shows the tile of FIG. 18 with piece removed.
[0026] FIG. 20 shows the cut tile of FIG. 19 installed around a column.
DETAILED DESCRIPTION OF THE INVENTION
[0027] With reference to FIGS. 1 through 20 , marking tool 1 is comprised of one male end finger 5 , a plurality of identical intermediate fingers 3 , and a female end finger 3 . Each of fingers 3 , 4 , and 5 are in the shape of an elongated, orthogonal, rectangular block. Five surfaces of each type of finger are of particular interest: the four long surfaces comprising the barrel of the block and one short surface on a first end of the block. Features on these five surfaces differentiate the three finger types. Fingers 3 , 4 , and 5 may be manufactured from wood, plastic, metal, composites or other typical structural materials.
[0028] Male end finger 5 includes a smooth planar first elongated surface 2 , a smooth planar second elongated surface 22 , and a smooth planar third elongated surface 23 . Second surface 22 and third surface 23 are on opposite sides of male end finger 5 . A fourth elongated surface 21 includes a male dovetail 8 extending from a first end surface 24 of the finger down a portion of the length of fourth surface 21 . In the preferred embodiment, the ratio of male dovetail 8 length to fourth surface 21 length is in the range of about 50% and about 90%. In an alternate embodiment, male dovetail 8 extends down the entire length of fourth surface 21 . First end surface 24 includes a perpendicular bore 25 . Extendable probe 6 is integrally mounted inside bore 25 . Extendable probe 6 can be retracted until flush with first end surface 24 , or probe 6 may be extended in a telescoping fashion.
[0029] Female end finger 3 includes a smooth planar fourth elongated surface 21 , a smooth planar second elongated surface 22 , and a smooth planar third elongated surface 23 . Second surface 22 and third surface 23 are on opposite sides of female end finger 3 . A first elongated surface 2 includes a female dovetail groove 7 extending from a first end surface 24 of the finger down a portion of the length of first surface 2 . In the preferred embodiment, the ratio of female dovetail groove 7 length to first surface 2 length is in the range of about 50% and about 90%. In an alternate embodiment, female dovetail groove 7 extends down the entire length of first surface 2 . First end surface 24 includes a perpendicular bore 25 . Extendable probe 6 is integrally mounted inside bore 25 . Extendable probe 6 can be retracted until flush with first end surface 24 , or probe 6 may be extended in a telescoping fashion.
[0030] Intermediate finger 4 includes a smooth planar second elongated surface 22 , and a smooth planar third elongated surface 23 . Second surface 22 and third surface 23 are on opposite sides of intermediate finger 3 . A first elongated surface 2 includes a female dovetail groove 7 extending from a first end surface 24 of the finger down a portion of the length of first surface 2 . In the preferred embodiment, the ratio of female dovetail groove 7 length to first surface 2 length is in the range of about 50% and about 90%. In an alternate embodiment, female dovetail groove 7 extends down the entire length of first surface 2 . A fourth elongated surface 21 includes a male dovetail 8 extending from a first end surface 24 of the finger down a portion of the length of fourth surface 21 . In the preferred embodiment, the ratio of male dovetail 8 length to fourth surface 21 length is in the range of about 50% and about 90%. In an alternate embodiment, male dovetail 8 extends down the entire length of fourth surface 21 . First surface 2 and fourth surface 21 are on opposite sides of intermediate finger 3 . First end surface 24 includes a perpendicular bore 25 . Extendable probe 6 is integrally mounted inside bore 25 . Extendable probe 6 can be retracted until flush with first end surface 24 , or probe 6 may be extended in a telescoping fashion.
[0031] The tool is assembled for use by joining male dovetail 8 of male finger 5 with female dovetail groove 7 of an adjacent intermediate finger 4 into an integral assembly. Once firmly assembled in this manner, fourth surface 21 of male end finger 5 and first surface 2 of intermediate finger 4 are in contact with each other over their entire length. Additional intermediate fingers are added as required in the same manner by joining male dovetail 8 of one intermediate finger 5 with female dovetail groove 7 of an adjacent intermediate finger 4 . Finally, in the same manner, the female dovetail groove 7 of female end finger 3 is attached to the male dovetail 8 of the last intermediate finger 5 .
[0032] A key feature of the invention is that each parallel second surface 22 and third surface 23 on all fingers is exactly one inch in width. Thus, each time a finger is added to the assembly, the assembly grows in width by exactly one inch. The fingers must be assembled so that the overall width of the assembly is equal to the width of the tile. Thus, to accommodate a tile measuring four inches in width, the present invention must be assembled using one male end finger 5 , two intermediate fingers 4 , and one female end finger 3 . To accommodate a tile measuring twelve inches in width, the present invention must be assembled using one male end finger 5 , ten intermediate fingers 4 , and one female end finger 3 . There is no limit to the number of intermediate fingers 4 that can be added to the assembly.
[0033] Each finger includes a telescoping probe 6 . Each probe is individually extendable. A typical maximum extension distance is twenty inches, corresponding to the typical maximum tile size that is readily available. Thus, twenty assembled fingers with their twenty probes extended describe a square footprint equal to twenty by twenty inches.
[0034] FIG. 11 - FIG. 15 show a typical use of the present invention. Whole tiles 9 are installed on a floor until a permanent room feature such as wall 10 is approached. For each tile that must be cut, marking tool 1 is first placed upon the floor where the cut tile will ultimately be placed. Probes 6 are extended until they contact wall 10 or reach the maximum tile dimension. With probes 6 still extended, marking tool 1 is next placed upon a whole tile to be cut 11 . The operator 15 uses a pencil or other device 16 to mark an outline 17 of the extended probes 6 , thereby tracing the tile portion to be removed 12 . A cutting device (not shown) can then be employed to make cuts 13 along outline 17 . When the resulting cut tile 11 is placed on the floor, it fits around wall 10 .
[0035] As shown in FIG. 16 - FIG. 20 , the marking tool 1 of the present invention can also be used to place tile around more complex permanent room features such as column 14 . Ws before, whole tiles 9 are installed on a floor until a permanent room feature, such as column 14 , is approached. Marking tool 1 is placed upon the floor where the cut tile will ultimately be placed. Probes 6 are extended until they contact column 14 or reach the maximum tile dimension. With probes 6 still extended, marking tool 1 is next placed upon a whole tile to be cut 18 . The operator 15 uses a pencil or other device 16 to mark an outline 17 of the extended probes 6 , thereby tracing the tile portion to be removed 19 . A cutting device (not shown) can then be employed to make cuts 20 along outline 17 . When the resulting cut tile 18 is placed on the floor, it fits around column 14 .
[0036] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | The invention is a device used to measure and mark floor tile that must be cut to fit around obstructions. A key feature of the invention is that it has removable elements that make it possible to use the device with tile of any size. A second key feature is a plurality of telescoping members that can be extended to varying lengths in order to describe the perimeter geometry that must be duplicated by cutting away a portion of the tile. The invention is compatible with all tile and similar flat floor or wall coverings, such as pavers or carpet squares. |
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The present application claims priority on European Patent Application 01200180.6, filed on 18 Jan. 2001.
FIELD OF INVENTION
The present invention relates to determining the PVT properties of a hydrocarbon reservoir fluid, where PVT is an acronym used to refer to pressure, volume and temperature. PVT properties are gas-oil ratio, API gravity, viscosity, saturation pressure, formation volume factor, molecular weight, density and oil compressibility.
BACKGROUND OF INVENTION
In order to measure the PVT properties of a hydrocarbon reservoir fluid, a sample of the reservoir fluid is taken and analysed under reservoir pressure and temperature. A brief description of the way in which a PVT analysis is carried out is given in section 3 of the book Contributions in Petroleum Geology and Engineering, Volume 5, Properties of Oils and Natural Gases, K. S. Pederson et al, 1989. Such an analysis can be very accurate, however it takes a long time to be completed.
It is of great importance to know the PVT properties of the reservoir fluid as soon as possible, preferably directly after a well has been drilled. Knowing such information allows for the adjustment of the design of the production and surface equipment to take into account the actual PVT properties.
SUMMARY OF THE INVENTION
Applicant has found that there are empirical relations between the PVT properties and the pressure gradient (dp/dz) in the reservoir, wherein p is the fluid pressure in the reservoir and z the true vertical depth. Because the pressure gradient can be determined directly after completing drilling, the PVT properties can be obtained as early as possible.
Thereto the method of determining at least one of the in situ PVT properties of a hydrocarbon reservoir fluid that is present in a hydrocarbon-bearing formation layer traversed by a borehole according to the present invention comprises the steps of:
a) calculating along the hydrocarbon-bearing formation layer the pressure gradient; and b) determining the in situ PVT property from the pressure gradient using an empirical relation that had been obtained by fitting a curve through previously obtained data points comprising the measured PVT property as a function of the pressure gradient.
BRIEF DESCRIPTION OF DRAWINGS
The method will now be described by way of example with reference to the accompanying drawings in which the examples should not be construed to limit the scope of the invention.
FIG. 1 shows the gas-oil ratio in standard cubic feet per standard barrel on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 2 shows the API gravity in °API on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 3 shows the viscosity in centipoise (at in situ pressure and temperature) on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 4 shows the saturation pressure in psi absolute on the y-axis as a function of the pressure gradient psi per foot (at in situ pressure and temperature) on the x-axis;
FIG. 5 shows the formation volume factor, oil on the y-axis as a function of the pressure gradient in psi per foot (at in situ pressure and temperature) on the x-axis; and
FIG. 6 shows the molecular weight on the y-axis as a function of the pressure gradient psi per foot (at in situ pressure and temperature) on the x-axis.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the Figures, we will now discuss the method of determining at least one of the in situ PVT properties according to the present invention in reverse order, wherein we start with discussing how the empirical relation is obtained.
The curves shown in FIGS. 1-6 show the empirical relation, line i 1 , that fits the data points i 2 , i 3 and i 4 , where i is the number of the Figure (i=1-6) obtained from samples taken from reservoirs in the same geological area. For the sake of clarity not all data points have been referred to by a reference numeral.
A data point was obtained as follows. At first a well was drilled to the formation layer containing a hydrocarbon reservoir fluid. Then a tool was lowered to the first of a set of locations in that formation layer by means of for example a wireline. The tool comprises a central conduit having an inlet and being provided with a pressure sensor, and a fluid receptacle having an inlet opening into the central conduit. At the first location an exclusive fluid communication was made between the formation and the inlet of the central conduit by extending into the formation a probe having an outlet that is in direct fluid communication with the inlet of the central conduit. Then formation fluid was allowed to enter into the fluid receptacle and the pressure build-up was measured. The required fluid pressure is the pressure at the end of the pressure build-up for that location.
Then the tool was moved to the next location where the pressure-build up was again measured to obtain the fluid pressure for that location, and so on until all the fluid pressures at all locations had been determined. With this the pressure gradient was determined.
Further, at each location a pressure-build no test was conducted, a sample of the hydrocarbon reservoir fluid was taken, and the PVT properties of the sample were measured in a laboratory under reservoir conditions. Each measurement resulted in a data point that was plotted in FIGS. 1-6 .
To get all data points these data were collected and analysed for more wells in the same geological area.
Then for each PVT property a curve was fitted through the data, and surprisingly, the data could be fitted with a considerable accuracy, with a goodness of fit R 2 of greater than 0.9, wherein
R 2 = ( ∑ i = 1 n ( x i - x ) ( y i - y ) ) 2 ∑ i = 1 n ( x i - x ) 2 ∑ i = 1 n ( y i - y ) 2 ,
wherein n is the number of data points, (x 1 , . . . , x n ) is the set of pressure gradients, x is the mean pressure gradient, (y 1 , . . . , y n ) is the set of measurements of the PVT property and y is the mean PVT property. R 2 is the squared value of the correlation coefficient.
The below Table gives the results of the curve fitting.
PVT property
Curve
R 2
Gas oil ratio
(8.6) (dp/dz) −42
0.98
API gravity
65 − (117) (dp/dz)
0.91
Viscosity
(0.0005) exp (24 dp/dz)
0.96
Saturation pressure
(16980) exp (−3.6 dp/dz)
0.72
Formation volume factor
(0.10) (dp/dz) −23
0.97
Molecular weight
(5.2) exp (8.9 dp/dz)
0.98
The correlation can as well be obtained for other PVT properties, such as density and oil compressibility.
We now discuss how a PVT property of an unknown hydrocarbon reservoir fluid that is present in a hydrocarbon-bearing formation layer traversed by a borehole is determined in situ. Suitably, the hydrocarbon-bearing formation layer is in the same geological area.
At first a tool is lowered to the first of a set of locations in that formation layer. The tool comprises a central conduit having an inlet and being provided with a pressure sensor, and a fluid receptacle having an inlet opening into the central conduit. At the first location an exclusive fluid communication is made between the formation and the inlet of the central conduit by extending into the formation a probe having an outlet that is in direct fluid communication with the inlet of the central conduit. Then formation fluid is allowed to enter into the fluid receptacle and the pressure build-up was measured. The required fluid pressure is the pressure at the end of the pressure build-up for that location.
Then the tool is moved to the next location where the pressure-build up is again measured to obtain the fluid pressure for that location, and so on until all the fluid pressures at all locations have been determined. With this the pressure gradient is calculated.
Then the pressure gradient is used with the empirical relation to get the PVT property that is required.
This shows that with the method according to the present invention a good accuracy can be achieved.
In case the hydrocarbon reservoir fluid is a so-called heavy oil that is relatively viscous, it will be difficult to acquire a representative sample of the reservoir fluid. In order to obtain a representative sample, the step of making an exclusive fluid communication further includes activating a heating device arranged near the probe to heat the formation fluid.
Suitably, the probe is associated with a packer pad in an assembly, and the heating device is placed in the packer pad. Alternatively the heating device is arranged on the tool. The heating device may be a device generating microwaves, light waves or infrared waves. The heating device may also be an electrical heater, a chemical heater or a nuclear heater.
So far the present invention has been discussed with reference to an open hole, however, the present invention can as well be applied in a cased hole. In that case, calculating the pressure gradient along the hydrocarbon-bearing formation layer starts with making a plurality of perforation sets through the casing wall into the formation layer. Then the tool is lowered in the cased borehole to the first perforation set. The tool is further provided with an upper and a lower packer arranged at either side of the inlet of the central conduit, wherein the distance between the upper and the lower packer is larger than the height of a perforation set, and wherein the spacing between adjacent perforation sets is at least equal to the length of the longest packer. The packers are set so that the perforation set is straddled between the packers. Then formation fluid is allowed to enter into the fluid receptacle, the pressure build-up is measured, and the fluid pressure is determined. Then the tool is positioned near the next perforation set, and the fluid pressure is measured and so on, until the fluid pressures of a predetermined number of locations have been measured. From these fluid pressures and the true vertical depths of the casing sets, the pressure gradient is calculated. | A method of determining an in situ PVT property of a hydrocarbon reservoir fluid that is present in a hydrocarbon-bearing formation layer traversed by a borehole, which method involves the steps of:
a) calculating along the hydrocarbon-bearing formation layer the pressure gradient; and b) determining the in situ PVT property from the pressure gradient using an empirical relation that had been obtained by fitting a curve ( 11 ) through previously obtained data points ( 12, 13, 14 ) having the measured PVT property as a function of the pressure gradient. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 61/788,733 filed Mar. 15, 2013, reference of which is hereby made in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to flush valve actuators.
BACKGROUND OF THE INVENTION
Flush valves are well known in the art. Although many different types of flush valves are known, two types of flush valves that are commonly used rely upon an auxiliary valve to relieve a pressure chamber to allow the main valve to open for a flush. For example, see U.S. Pat. Nos. 5,881,993, 6,913,239 and 7,980,528 incorporated herein by reference. In order to initiate a flush cycle, that is, to flush the fixture, the auxiliary valve must be unseated. Typically this is accomplished by the use of a gland that extends from an auxiliary valve member. Engaging the gland, such as by striking the side of the gland, will tilt the auxiliary valve member off of the valve seat. As the flush cycle proceeds, the auxiliary valve member reseats allowing the pressure chamber to repressurize causing the main valve to close. Although typical flush valves have been designed to provide a single flush volume, dual mode flush valves have become increasingly important as a way to conserve water. Dual mode flush valves provide the user the ability to select between a higher volume flush and a lower volume flush.
In general, two types of actuation mechanisms are known in the art: manual and automatic. Manual actuation is accomplished through a user initiated process, traditionally by interaction with a mechanical handle. Automatic actuation is accomplished through the use of sensors to determine when a user is present and to actuate the flush valve without the need for direct user initiation, for example when the user has completed usage of the fixture.
There is a need to combine the water conservation of a dual mode flush valve with the reliability of a manual actuation and the ease of use and hygiene of automatic actuation.
SUMMARY OF THE INVENTION
One implementation of the invention relates to an automatic actuation assembly for a flush valve. An actuator assembly housing is provided with a mechanism assembly disposed therein. The actuator assembly housing has a receptacle for engaging with a flush valve, the receptacle comprising an outer ring disposed about a receptacle plunger passage. A retention flange is engageable with the receptacle. The flush valve further includes a plunger having a plunger head at an outer end and a shank extending there from to an inner end, the plunger head disposed within the housing and the plunger shank axially slidable in the receptacle plunger passage.
Another implementation of the invention relates to an automatic actuation assembly for a flush valve. An actuator assembly housing includes a sensor aperture. A sensor assembly is positioned adjacent the sensor aperture and has a first angled emitter and a second angled emitter and an angled receiver sensor. The first angled emitter and the second angled emitter are non-parallel and non-perpendicular to a vertical longitudinal plane of the actuator assembly housing. The sensor and at least one emitter are at an angle with respect to each other, the sensor receiver is positioned to not receive rays emitted by the at least one emitter that are specularly reflected.
Another implementation of the invention relates to an automatic flush actuation assembly comprising an actuator assembly housing and a mechanism assembly disposable therein. The housing has a housing plunger passage. The actuation assembly further comprises a plunger having a plunger head at an outer end and a shank extending there from to an inner end, the plunger head disposed within the housing and the plunger shank axially slidable disposed in the housing plunger passage. The mechanism assembly includes a mechanism frame supporting a gear train assembly. The gear train assembly includes a motor coupled to at least one gear and a roller system. The roller system includes a support gear and one or more rollers positioned a distance from the center of the support gear rotatable cam. The roller system is positioned adjacent the plunger for engagement of the plunger head. The actuation assembly further comprises a manual actuation assembly at least partially disposed within the actuator assembly housing, the manual actuation assembly including a face plate having a button coupled to a manual actuation arm, the manual actuation arm positioned adjacent the plunger and engageable with the plunger when the button is depressed.
Another implementation of the invention relates to a flush valve assembly comprising a valve body having a diaphragm assembly disposed therein with a stem extended therefrom. An actuator assembly housing is provided with a mechanism assembly disposable therein. The actuator assembly housing has a receptacle for engaging with the valve body, the receptacle comprising an outer ring disposed about a receptacle plunger passage. A retention flange engageable with the receptacle and a nut retained between the retention flange and the actuator assembly housing, the nut engageable with a handle boss of the valve body. A plunger is included having a plunger head at an outer end and a shank extending there from to an inner end, the plunger head disposed within the housing and the plunger shank axially slidable in the receptacle plunger passage. A bushing is at least partially disposed in the handle boss, the bushing having a bushing plunger passage for slidably receiving the plunger. The mechanism assembly includes a mechanism frame supporting a gear train assembly and a roller system including one or more rollers adjacent the plunger head. A manual actuation assembly is at least partially disposed within the actuator assembly housing, the manual actuation assembly including a face plate having a button coupled to a manual actuation arm, the manual actuation arm positioned adjacent the plunger and engageable with the plunger when the button is depressed. The plunger is engageable with the valve gland by rotation of the rollers to engage the plunger head for lateral movement of the plunger or actuation of the manual actuation arm to engage the plunger head for lateral movement.
Additional features, advantages, and embodiments of the present disclosure may be set forth from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the present disclosure and the following detailed description are exemplary and intended to provide further explanation without further limiting the scope of the present disclosure claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, aspects, features, and advantages of the disclosure will become more apparent and better understood by referring to the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1A is a partial section through a diaphragm valve body; FIG. 1B is a section through a piston valve body.
FIG. 2 is an exploded perspective view of a side mount actuator assembly, a dual mode bushing, and the valve body.
FIG. 3A is a left side (proximate the valve body) perspective view of a side mount actuator assembly with the retention flange and nut shown in exploded perspective;
FIG. 3B is a right side (distal the valve body) perspective view of a side mount actuator assembly with the actuating assembly housing, plunger, mechanism assembly, and battery assembly shown in exploded perspective.
FIG. 4A is a top view of a mechanism assembly; FIG. 4B is a proximate perspective view of a mechanism assembly; FIG. 4C is a side view of a mechanism assembly; FIG. 4D is an exploded distal perspective view of a mechanism assembly; FIG. 4E illustrates an implementation of an second arm of the mechanism assembly.
FIG. 5A is an exploded view of the motor gear train assembly, the mechanism assembly frame, and the support plate; FIG. 5B is an exploded view of the roller system.
FIG. 6A is an exploded view of a manual actuation assembly faceplate having one button; FIG. 6B is an exploded view of a multibutton manual actuation assembly faceplate.
FIG. 7 is an exploded view of a battery assembly.
FIG. 8A is a perspective view of a plunger in accordance with one embodiment; FIG. 8B is a cross-section view of the plunger of FIG. 8A along line 8 B- 8 B.
FIG. 9A is a schematic sectional representation of one embodiment of a bushing of the present invention, showing the plunger travel for a full flush; FIG. 9B is a schematic sectional representation of one embodiment of a bushing of the present invention, showing the handle and plunger travel for a partial or reduced volume flush with the angled illustrated as exaggerated for clarity regarding the relative movement.
FIG. 10A is a proximate end view of a side mount actuator assembly;
FIG. 10B is a horizontal cross-sectional along line 10 B- 10 B of FIG. 10A ; FIG. 10C is a vertical cross-sectional along line 10 C- 10 C of FIG. 10A .
FIG. 11 is a vertical cross-section of a side mount actuator assembly affixed to a valve body with a bushing disposed there between.
FIG. 12A is a side-view of a down-looking emitter for higher mounting installations; FIG. 12B is a side-view of an up-looking emitter for lower mounting installations;
FIG. 12C is a top-view of the sensor unit for a right hand (facing the fixture) mounting; FIG. 12D is a top-view of the sensor unit for a left hand (facing the fixture) mounting; FIG. 12E illustrates a top-view of a typical perpendicular emitted beam from a sensor unit.
FIG. 13 illustrates a typical perpendicular emitted beam from a sensor unit to a highly reflective surface, such as a shiny door.
FIG. 14A illustrates an angled emitted beam from the sensor unit to a highly reflective surface, such as a shiny door and the reflection of same; FIG. 14B illustrates an angled emitted beam from the sensor unit to a typical restroom fixture user wearing typical fabrics and the diffuse reflection of the same.
FIG. 15A illustrates an embodiment utilizing a transreflective filter; FIG. 15A illustrates an exploded view of the sensor unit; FIG. 15B illustrates a cross-section along the longitudinal axis of the sensor unit; FIG. 15C illustrates a cross-section along the lateral axis of the sensor unit, with an inset close-up of the circled region.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.
A flush valve of, or for use with certain embodiments of the present invention may be of a known type, such as, but not limited to a diaphragm valve as generally described in U.S. Pat. No. 7,980,528 incorporated herein by reference, or a piston valve as generally described in U.S. Pat. No. 5,881,993 or 6,913,239 incorporated herein by reference. With reference to FIGS. 1A and 1B , the flush valve 1 includes a valve body 10 having an inlet 12 and an outlet 14 and a main valve 16 a ( FIG. 1A ), 16 b ( FIG. 1B ) disposed there between for controlling the flow of water through the flushometer. When installed the inlet 12 is connected to a water supply [not shown] and the outlet 14 is connected to a fixture 5 ( FIG. 12A ) such as a toilet. The valve body 10 also typically includes a handle opening 15 .
The main valve 16 (typically a diaphragm assembly 16 a ( FIG. 1A ) or a piston assembly 16 b ( FIG. 1B )) comprises a valve seat 26 formed at an upper end of a barrel 28 and a valve member 18 (e.g., diaphragm 18 a or piston 18 b ). With continued reference to FIG. 1A , the barrel 28 forms a fluid conduit connecting the valve seat 26 with outlet 14 . A pressure chamber 50 is provided within the valve body 10 , above the main valve seat 26 . The pressure chamber 50 is pressurized by the line pressure from the inlet 12 and retains the valve member 18 , such as a diaphragm 18 a or piston 18 b , against the main valve seat 26 . An auxiliary or relief valve 30 , having an auxiliary valve head 31 and auxiliary valve seat 40 , is provided between the pressure chamber 50 and the outlet 14 to controllably seal the pressure chamber 50 . Opening of the auxiliary valve 30 vents the pressure chamber 50 due to the relatively higher pressure in the pressure chamber 50 compared to the outlet 14 . A bottom surface of the valve member 18 is exposed to the inlet 12 , which is pressurized, and, when the pressure chamber 50 is vented, the pressurized inlet water causes the main valve 16 to open, allowing flow of water from the inlet 12 to the outlet 14 over the main valve seat 26 . By-pass valves 54 place the pressure chamber 50 in communication with the inlet 12 , allowing repressurization of the pressure chamber 50 when the auxiliary valve 30 closes. The repressurization of the pressure chamber 50 reseats the main valve 16 , ending the flush cycle.
With reference to FIG. 1A , the auxiliary valve 30 typically includes a valve stem 32 that extends below the main valve seat 26 and is adjacent the handle opening 15 in the valve body 10 . The valve stem 32 may include a telescopically carrying movable gland 34 . It should be appreciated that the gland 34 allows the auxiliary valve 30 to close even where the flush valve is still being actuated (for example, a manual handle 17 being depressed). The valve stem 32 , or specifically, gland 34 , is positioned for contact by a plunger 36 . The plunger 36 (see FIG. 1B ) includes a plunger head 37 and a plunger shank 38 extending there from. The plunger head 37 generally has a larger perimeter than the plunger shank 38 . The plunger shank 38 opposite the plunger head 37 is configured to engage the valve stem 32 . The plunger 36 is slidably positioned in a bushing 65 , which is typically disposed within the handle opening 15 of the valve body 10 . Actuation of the plunger 36 imparts lateral movement to the plunger 36 to slide in the bushing 65 and engage the valve stem 32 . The auxiliary valve 30 is opened by engaging the valve stem 32 to tilt an auxiliary valve member 31 , typically a disk, off the auxiliary valve seat, 40 .
A typical mechanism for actuating the plunger 36 is the manual handle 17 , shown in FIGS. 1A and 1B . The handle 17 may be retained on the valve body 10 by a nut 39 , such as the embodiment illustrated in FIG. 1A wherein the nut 39 captures a handle socket 60 that retains a portion of the handle 17 and the plunger 36 . Alternatively, the socket 60 and nut 39 may be a single component as illustrated in FIG. 1B .
For diaphragm assembly valves, an embodiment of which is shown in FIG. 1A , the valve member 18 includes a diaphragm 18 a peripherally held to the valve body 10 by an inner cover 20 . The diaphragm 18 a is seated upon a shoulder 22 at the upper end of valve body 10 . The inner cover 20 may secure a peripheral edge 52 of the diaphragm 18 a in this position. An outer cover 24 is affixable to the body, such as by threading, to hold the inner cover 20 in position. The diaphragm assembly 16 a , in addition to diaphragm 18 a and the auxiliary valve 30 , may include a retaining disk 40 , a refill ring 42 and a flow control ring 44 . The underside of the retaining disk 40 is attached to a collar 46 , which in turn is attached at its exterior to a guide 48 which carries the refill ring 42 . The above described assembly of elements firmly holds the diaphragm 18 a between the upper face of the refill ring 42 and a lower facing surface of the collar 46 . Above the diaphragm assembly 16 a is a pressure chamber 50 which maintains the diaphragm assembly 16 a in a closed position when the flush valve 1 is not in use.
As is known in the art, when the handle 17 is operated, the plunger 36 will contact gland 34 , tilting the auxiliary valve 30 off its seat on the retaining disk 40 . This will permit the discharge of water within the pressure chamber 50 down through the guide 48 . Inlet pressure will then cause the diaphragm 18 a to move upwardly off the main valve seat 26 , permitting direct communication between the inlet 12 and the outlet 14 through the space between the bottom of the diaphragm assembly 16 a and the main valve seat 26 . The raising of the diaphragm 18 a also lifts the auxiliary valve gland 34 , allowing it to clear the plunger 36 even if the user has held the handle 17 in an actuated position. Once the gland 34 clears the plunger 36 the auxiliary valve 30 reseats on the auxiliary valve seat 40 , such as the diaphragm 18 a seating on the retaining disk 40 a . As soon as this operation has taken place, the pressure chamber 50 will begin to fill through the by-pass valves 54 in the diaphragm assembly 16 a . As flow continues into the pressure chamber 50 , the diaphragm 18 a will move back down toward the main valve seat 26 and when it has reached that position, the flush valve 1 will be closed.
Piston assemblies work in a generally similar manner but having a piston rather than a diaphragm for sealing the main valve 16 . One embodiment of a piston assembly is illustrated in FIG. 1B . The main valve 16 is a piston assembly 16 b and the main valve member 18 is a piston 18 b . The actuation mechanism engages the plunger 36 , which contacts the valve stem 32 of the auxiliary valve 30 . This allows the pressure chamber 50 to evacuate and the piston 18 b to unseat from the main valve seat 26 , opening the flush valve 1 .
Side Mount Actuator Assembly
In one embodiment, a side mount actuator assembly 100 is provided for removable connection to the valve body 10 . FIGS. 2, 3A, and 3B illustrate an embodiment wherein the side mount actuator assembly 100 includes an actuator assembly housing 110 configured to removably connect to the valve body 10 and having disposed therein a mechanism assembly 200 . In one embodiment, the actuator assembly housing 110 serves to support and contain one or more of an automated actuation assembly 220 ( FIG. 4C ) and a manual actuation assembly 400 ( FIG. 4D ). In one embodiment, the actuator assembly housing 110 engages directly with the valve body 10 of a flush valve mounting to the side of the valve body 10 at the handle opening 15 .
The actuator assembly 100 includes a proximate portion 111 that is generally proximate the flush valve 1 when the actuator assembly 100 is attached to a valve body 10 . The actuator assembly 100 further includes a distal portion 112 general opposite the proximate portion 111 . It should be appreciated that the proximate portion 111 and the distal portion 112 may be understood to refer to general areas of the actuator assembly 100 . In one embodiment, the structures described in greater detail herein are positioned on or within the actuator assembly housing 110 such that the actuator assembly 100 is ambidextrous with regard to the mounting side of the valve body 10 , allowing for “left hand” or “right hand” installations.
In one implementation, the bushing 65 and/or the receptacle 120 may include a bushing alignment feature 173 , such as corresponding features, to allow for alignment of the bushing 65 , for example a dual flush bushing 66 as described herein, within the receptacle 120 . That is, the dual mode bushing 66 and the receptacle 120 are “keyed” to ensure proper alignment of the dual mode feature of the bushing 66 . One embodiment includes an alignment groove 174 on an interior portion of the outer ring 121 for engaging a protrusion 173 of the dual mode bushing 66 . It should be appreciated that the protrusion 173 may be utilized with a dual mode bushing 66 as described further herein to allow orientation of the bushing 72 in relation to the actuator assembly 100 and valve body 10 to effectuation the desired dual mode flush volumes. The corresponding features may include a protrusion [not shown] on the receptacle 120 and a groove [not shown] on the bushing; 66 or such similar arrangements.
Connection Mechanism
The actuator assembly 100 is removably connectable with the valve body 10 . In one embodiment, best shown in FIGS. 2, 3A, 10A -C, and 11 , a receptacle 120 extends from the proximate portion 111 of the housing 110 for engaging with the valve body 10 . The receptacle 120 includes an outer ring 121 ( FIG. 3A ) that extends from the housing 110 . The receptacle 120 has a receptacle plunger passage 124 ( FIG. 3A ) that is configured to allow a portion of the plunger 36 to pass through the housing 110 .
In one implementation, the outer ring 121 further includes a receptacle 120 retention flange 130 , which may be a raised portion, for example having a larger outer diameter than the adjacent outer ring 121 . The retention flange 130 may be a separate component removable, preferably selectively removable via a tool, from the receptacle 120 such as a retaining ring. The retention flange 130 may serve to secure the nut 39 to the outer ring 121 , and thus to the actuator assembly 100 . In one embodiment, the outer ring 121 includes an outer ring groove 132 circumscribing the outer ring 121 . The retention flange 130 may be a component removable from the outer ring 121 and that is engageable with the outer ring 121 by being partially seated within the outer ring groove 132 . The retention flange 130 may be, but is not limited to, a rigid, such as metal, ring or clip, or a elastic gasket or such, for example having a barbed shape for allowing passage of the nut 39 in one direction but retaining the nut 39 against removal in the other direction.
In one embodiment, the nut 39 is disposable on the receptacle 120 , captured between the housing 110 and the retention flange 130 to retain the nut 39 on the actuator assembly 100 . In one embodiment, the nut 39 includes a threaded interior surface 41 that is engageable with a threaded handle boss 19 on the outer surface of the handle opening 15 . Engaging the nut 39 to the handle boss 19 secures the actuator assembly 100 to the valve body 10 . In one embodiment best illustrated in FIG. 11 , when assembled, as the nut 39 is threaded onto the handle boss 19 , the nut 39 moves toward the retention flange 130 , on the receptacle 120 , as the receptacle 120 engages the dual mode bushing 66 and secures the dual mode bushing 66 between the end of the receptacle 120 (and the entire actuator assembly 100 ) and the edge of the handle boss 19 .
In certain embodiments, the receptacle 120 is configured to engage with the dual mode bushing 66 and the valve body 10 . FIG. 11 illustrates a cross-section view of one embodiment of a valve body 10 , dual mode bushing 66 , and actuator assembly 100 assembled with the actuator assembly 100 retained on the valve body 10 and the plunger shank 38 extending from the actuator assembly 100 through the dual mode bushing 66 to adjacent the gland 34 . Specifically, in one embodiment, the dual mode bushing 66 is at least partially disposed within the handle opening 15 of the valve body 10 and the receptacle 120 engages one or more of the dual mode bushing 66 or the valve body 10 . In the embodiment illustrated in FIG. 3A , the receptacle 120 comprises an outer ring 121 and an inner ring 122 circumscribed by the outer ring 121 with a receptacle annular gap 123 there between for receiving the skirt 70 of the dual mode bushing 66 . The receptacle plunger passage 124 is provided in the inner ring 122 . The bushing 65 , such as illustrated with respect to a dual mode bushing 66 in FIGS. 9A-9B , may include an outer skirt 70 having an annular flange 71 and a bushing central sleeve 68 defining a bushing plunger passage 67 , with a bushing annular gap 69 there between. In such embodiments, the bushing 65 and receptacle 120 form a “nesting” arrangement. It should be appreciated that this arrangement aids in stabilizing and securing the connection of the actuator assembly 100 to the valve body 10 . The actuator assembly 100 and the dual mode bushing 66 /valve body 10 , in one embodiment, engage in more than a single plane.
In one implementation, when the actuator assembly 100 is affixed to a valve body 10 with dual mode bushing 66 , the bushing outer skirt 70 is partially disposed within the receptacle annular gap 123 between the outer ring 121 and inner ring 122 . The receptacle inner ring 122 is partially disposed within the bushing annular gap 69 between the bushing outer skirt 70 and the bushing central sleeve 68 . The bushing plunger passage 67 and the receptacle plunger passage 124 substantially align such that the plunger is slidably and tiltably disposed within the dual mode bushing 66 and actuator assembly 100 . The receptacle plunger passage 124 and the dual mode bushing 66 align to allow the plunger shank 38 to pass there through. In one embodiment, the plunger 36 has a longer shank 38 than typical prior art manual actuation devices to accommodate the distance from the valve stem 32 to the interior of the actuator assembly housing 110 where the plunger head 37 must be disposed.
Mechanism Assembly
The mechanism assembly 200 is disposable within the housing 110 . The mechanism assembly 200 includes the mechanism for actuating the plunger 36 . In one embodiment illustrated in FIG. 3B , the mechanism assembly 200 is removable from the distal portion 112 of the housing 110 , such as where the housing 110 includes an open side for accommodating the mechanism assembly 200 . The mechanism assembly may be fixed to the housing 110 via fasteners 190 , such as screws or bolts. A portion of the mechanism assembly 200 may form an exterior surface 447 of the actuator assembly 100 as illustrated in FIG. 2 .
Automated Actuation Assembly
One embodiment of the mechanism assembly 200 includes an automated actuation assembly 220 . FIGS. 4A-D illustrate an embodiment of the mechanism assembly 200 . An automated actuation assembly 220 includes a mechanism assembly frame 221 for supporting the structures of the automated actuation assembly 220 . The automated actuation assembly 220 further includes a printed circuit board (PCB) 230 for interconnecting various electronic components. The electronic components may include a sensor unit 300 and a motor and gear train assembly 240 . The PCB 230 may be supported by PCB supports 231 elevating the PCB 230 above the motor and gear train assembly 240 . The sensor unit 300 may be placed on the PCB 230 such that the sensor unit 300 is positioned to correspond with a sensor aperture 360 in the housing 110 .
In one embodiment, the motive force for the automated actuation assembly 220 is provided by a motor 241 as part of the motor and gear train assembly 240 , which is shown in FIGS. 4A, 4C and 4D and in greater detail in FIG. 5A . In one implementation, the motor 241 converts electrical energy to rotational energy. The motor 241 is coupled to a gear train 242 comprising of one or more gears 243 for translating the rotational energy of the motor 241 to one or more rollers 510 . The one or more gears 243 may be secured by a corresponding pin 244 , which itself may be secured to the frame 221 or the support plate 280 . Rotation of the motor 241 , such as a traditional small electric motor spinning a drive shaft, rotates a gear 243 in the gear train 242 . The gear train 242 interacts with the plunger 36 to convert the rotation motion of the motor 241 into linear motion of the plunger 36 to engage the valve stem 32 .
Sensor Unit
The sensor unit 300 may be included for embodiments utilizing an automatic actuation feature. The sensor unit 300 is configured to controllably engage the motor 241 to actuate the plunger. Because automatic flush valves are frequently placed in water closets, or the like, opposite a door, it has been observed that certain features of the door may cause poor performance of the sensor unit 300 . FIG. 13 illustrates a typical sensor unit 57 that provides a perpendicular infrared (IR) beam 58 from the sensor unit 57 to a highly reflective surface, such as a highly reflective door 56 . As can be seen, the door 56 tends to specularly reflect the IR beam 58 back. Because of the proximity of the emitter and the sensor within the sensor unit 57 , the reflected IR (in particular, the major rays) that is sensed by the sensor unit 57 travels through nearly the same space as the emitted beam.
FIG. 13 illustrates a problem with prior art sensor unit 57 , a false detection due to the presence of the door 56 and the position of the sensor unit 57 . The emitted beam 58 is reflected by the door 56 and can cause the sensor unit 57 to provide a false indication of a user being presence or, if calibrated to account for the strong reflection from the door 56 , can be too insensitive to detect the relatively weaker reflection from a user.
In one embodiment, the actuator assembly 100 includes the sensor unit 300 . The sensor unit 300 may be in communication with other components of the actuator assembly 100 so as to enable automatic actuation of the flush valve upon the detection of a certain state, such as the presence and then absence of a user. One implementation of the sensor unit 300 , an embodiment of which is illustrated in FIG. 4A , comprises an active sensor having an emitter 310 and a sensor receiver 320 . The emitter 310 of the embodiment in FIG. 4A includes a first emitter 311 and a second emitter 312 .
One embodiment, examples of which are illustrated in FIGS. 12A-D , the emitters 311 , 312 are positioned at an angle with respect to the actuator assembly 100 and valve body 10 , in one implementation at a compound angle of 2-15 degrees, preferably 5-11 degrees and more preferably 5-7 degrees in an alternative embodiment, most preferably 10 degrees from perpendicular to the normal line of the sensor unit 300 in the horizontal and 6-30 degrees, preferably 12-20 degrees, more preferably 12-15 degrees, and most preferably 15 degrees from perpendicular in the vertical. It should be understood that the position of the emitters 311 , 312 is described with respect to their emitted beams rather than the physical emitter. The two emitters 311 , 312 may be positioned such that their beams are angled in the opposite direction in the horizontal, the vertical, or both. The sensor receiver 320 is angled, 5-11 degrees from perpendicular in the horizontal. Thus, each of the emitters 311 , 312 is at a non-transverse angle with respect to the handle axis. FIGS. 12A-D illustrate various views of the field of emission for one embodiment of the sensor unit 300 . As can be seen in FIGS. 12A-D , the position of the emitters 311 , 312 results in the sensor unit's output being nontransverse with respect to the handle 17 . In one embodiment, the sensor unit 300 is positioned such that the emitters 311 , 312 are angled, in the horizontal, towards a center line of the associated fixture, such as a toilet, to provide an emitter field roughly corresponding to where a user would be positioned at the center of the fixture. In one embodiment, the emitters 311 , 312 beams are non-parallel and non-perpendicular to a vertical longitudinal plane. In one implementation, the emitters 311 , 312 beams are also non-parallel and non-perpendicular with respect to each other, preferably such that they extend at opposite angles from the actuator assembly 100 . In one implementation, the sensor receiver 320 and the at least one emitter 310 are at an angle respect to each other.
The position of the emitters 311 and 312 being angled with respect to the sensor unit 300 , such as being mounted on angled spacers, and side mount actuator assembly 100 result in the specularly reflected rays from an object such as a door 56 being reflected away from the sensor receiver 320 . FIG. 14A illustrates an embodiment of the sensor unit 300 having an angled emitter with an emitted beam 301 that is angled in the vertical with respect to the valve body 10 . The major reflected rays 370 do not reflect back to the sensor receiver 320 and, thus, significantly reduce the chances of a false indication of a user. FIG. 14B illustrates the sensor unit 300 of FIG. 14A with a user present. The emitted beam 301 is reflected by the user in a much wider field due to the typically non-planar surface of the user and the specular reflecting materials worn by most users. At least a portion of the reflected rays 380 return to the sensor receiver 320 , allowing for a detection of the user's presence.
FIG. 12E illustrates the non-angled emitted beam in the horizontal that is reflected to the sensor by a top of a lifted toilet seat and causes a false indication of a user. FIGS. 12C and 12D illustrate an embodiment of the sensor unit 300 having an angled emitter with an emitted beam 301 that is angled in the horizontal with respect to the valve body 10 . In the horizontal, the emitters 311 , 312 are angled, towards a center line of the associated fixture 5 , such as a toilet, not only to provide an emitter field roughly corresponding to where a user would be positioned at the center of the fixture, but also significantly to reduce the chances of a false indication of a user by the reflection from the lifted toilet seat because the angled beam passes through the top gap of toilet seat.
FIG. 12A is a down-looking emitter for higher mounting installations and for short users; FIG. 12B is a side-view of an up-looking emitter for lower mounting installations to avoid the reflection from the toilet bowl and seat.
FIGS. 3A and 3B illustrate a sensor aperture 360 in the housing 110 . The sensor aperture 360 allows the emitters 311 , 312 to be in communication with the environment outside of the housing 110 , i.e. for the emitted beam 301 to exit the side mount actuator assembly 100 . A sensor aperture cover 361 may be removably positioned in the sensor aperture 360 of the housing 110 to allow the emitted beam to 301 but to prevent tampering and protection from external liquids with the sensor 300 and to provide an aesthetically pleasing look. For example, the aperture cover 361 may be transparent to infrared energy but less transmitting with respect to visible light for red and green indicators. In one embodiment, the PCB support 231 positions the sensor adjacent the sensor aperture 360 . The sensor aperture 360 may be on a forward-facing portion of the housing 110 . The sensor aperture cover 361 may be parallel with the PCB 230 and the portion of the housing 110 in which the sensor aperture cover 361 is positioned, but at an angle with respect to the emitter 310 .
The sensor unit 300 may also include one or more visual indicators, such as LEDs 320 ( FIG. 15A ). For example, the LEDs 320 may provide a visual indication, through the sensor aperture, of the status or state of the side mount actuator assembly 100 .
In one embodiment, the a photocell 318 is provided. The photocell 318 is used upon manufacturing shipment, ex-factory, to extend battery life of on board installed batteries. When in packaging and at the initial power up stages of the side mount actuator assembly 100 , the photocell 318 detects darkness and causes the unit to power down and conserve battery power. When the side mount actuator assembly 100 is installed and exposed to visible light, the logic causes the photocell 318 to become nonfunctional and the unit operates as intended throughout its remaining life; even if dark bathrooms are encountered.
In certain environments, too much ambient light mixing with the I.R. signal causes interference with an I.R. receiver. Interference with the sensor receiver 320 causes to high a noise level for logic to process, causing malfunction and unanticipated detection. The malfunction can manifest itself in not properly detecting valid targets. Much of this interference comes from the lighting fixtures in a restroom. There are two mechanisms in the lighting which causes receiver interference: 1) the ballast frequency which the particular ballast operates at, 2) the ballast intensity, along with the manufacturer of the light tube and the internal coating on the inside of the bulb. Electronic ballasts determine how much energy gets input into the fluorescent light tube. Interferences can also come from light and other sources such as T.V.
In one embodiment, illustrated in FIGS. 15A-C , a transreflective filter 363 is utilized. This transreflective filter 363 decreases the background noise caused by lighting fixtures, limiting the amount of spectral interference that the sensor receiver 320 detects. In the embodiment of FIGS. 15A-C , the transreflective filter 363 is provided as a layer between the sensor 300 and the aperture cover 361 . The transreflective filter 363 acts as a light filter using graduated lensing, to become sensitive only to certain incident angles. When the transreflective filter is oriented in the proper plane relative to the sensor receiver 320 ; it is a spatial filter fitted over the sensor 300 , for example fitted over only the sensor receiver 320 not the emitters 310 , optimized to maximize the signal detection of the active I.R. emitted by the sensor 300 . The material causes the multiple interfering light sources to be cancelled out while being able to focus on the active I.R. beam reflection angle which is detecting to determine a valid target. More extreme angles of incident confusing light sources (sources that confuse the sensor unit 300 ) are filtered out causing a dramatic increase in system gain which blocks out noise sources as described above.
In an embodiment illustrated in FIG. 15A , a shroud 365 is provided that receives the emitters 311 , 312 and the shroud 365 gives a partial direction block to the emitter signals. In one implementation, the shroud 365 receives the transreflective filter 336 , which may be keyed to fit within the shroud and be secured by a small frame 364 . The incident light goes through the receiver 320 after passing through the filter 363 . Shroud 365 has blocking passages 366 , 367 for upper and lower target zone detection.
Manual Actuation Assembly
Although many flush devices are designed with an automatic actuation ability, such as certain embodiments described herein, it is beneficial to provide the ability to manually flush a fixture as well. The handle 17 , such as illustrated in FIG. 1A , cannot be mounted to the valve body 10 if an actuator assembly 100 is attached to the valve body 10 . A manual flush may be accomplished by initiation of the motor 241 without input from the sensor unit or by physical interaction with the plunger, bypassing the motor and gear train assembly 240 . One embodiment of the present invention relates to a manual actuation assembly 400 for manually actuating a flush for a flush valve having an actuator assembly 100 . FIG. 3B , FIGS. 4A-D , FIG. 6A-B , and FIG. 10B best illustrate the manual actuation assembly 400 .
One embodiment of a manual actuation assembly 400 includes a face plate 428 which serves as a portion of the exterior surface of the mechanism assembly 200 . The manual actuation assembly 400 further includes a mechanical manual actuation assembly 401 . An embodiment of the mechanical manual actuation assembly 400 includes a manual actuation arm 440 that is in communication with a button 411 disposed on the face plate 428 .
In one embodiment shown in FIG. 4B the arm 440 comprises a first arm 441 and a second arm 442 . The first arm 441 is connected with the button 411 and moves laterally when the button 411 is depressed inward, i.e. it moves in the same general direction as the button 411 . The first arm 441 may be secured to a post 412 attached to the button 411 , such as at a first end 445 of the first arm 441 . The first arm 441 is connected to the second arm 442 , such as pivotally connected at a second end 453 , opposite the first end 445 . In one embodiment, the first arm 441 serves as a linkage between the button 411 and a second arm 442 . The second arm 442 is pivotally connected to the mechanism assembly frame 221 , such as at the two brackets 448 . In one embodiment, the second arm 442 has a generally “H” shape, with two vertical members 443 a , 443 b connecting to the first arm 441 at each of the vertical member first ends 454 a , 454 b and a bracket 448 at the vertical member second ends 446 a , 446 b . The second arm 442 also includes a central stabilizing member 444 connecting the vertical members 443 . In one implementation, the second arm 442 is connected to the mechanism assembly frame 221 at a location below the plane of the first arm 441 , for example at bracket 448 of FIG. 4D , such that movement of the first arm 441 toward the second arm 442 (and, thus, the plunger 800 ) results in the second arm 442 pivoting and arm 440 engaging the plunger 800 to move the plunger 800 to engage the valve stem 32 , initiating a manual flush cycle. In one embodiment, a biasing mechanism 449 , such as a torsion spring, may be used to bias the arm 440 away from the plunger 36 , such that engagement of the button 411 is necessary to move the arm 440 to engage the plunger and release of the button 411 results in the biasing mechanism 449 returning the arm 440 to a resting state not so as not to engage the plunger 800 .
In one embodiment, the central member 444 of the second arm 442 engages secondary plunger head, such as a protrusion 819 extending from the plunger head 810 . One illustration of a plunger 800 in accordance with this embodiment is shown in FIGS. 8A-B . The protrusion 819 extends from the plunger head 810 and provides a surface for the arm 440 to engage. In one implementation, the central member 444 includes a protrusion or cam 439 for engaging the plunger head protrusion 819 . For embodiments utilizing an automated actuation assembly 220 such as having rollers 510 for engaging the lower portion 811 or the upper portion 812 of the plunger head 810 , the protrusion is positioned apart from but adjacent the portion of the plunger 800 that rollers 510 engage, allowing both the rollers 510 and the arm 440 to be capable of engaging the plunger 800 to effectuate an appropriate flush cycle.
Where the actuator assembly 100 is a dual flush actuator using a bushing such as illustrated in FIGS. 9A and 9B , the protrusion 819 extends to the side of the plunger head 810 . A plunger head 810 as described above and shown in FIGS. 8A and 8B may be utilized with the dual mode bushing 66 shown in FIGS. 9A and 9B . When the arm 440 engages the plunger head 810 , the plunger 800 travels along the lateral travel path, i.e. the plunger is not titled, resulting in the higher volume flush. It should be appreciated that where the dual mode bushing 66 is such that a lateral travel path is a reduced flush (i.e. it causes the plunger 800 to strike the valve stem 32 at a lower point than a tilted travel path), the engagement of the protrusion 819 will result in a reduced flush.
In one embodiment, such as illustrated in FIGS. 4D and 10B , a user presses the button 411 , which moves the first arm 441 substantially laterally, engaging the second arm at a first end and pivoting the second arm about a pivot point at the bracket connecting a second end of the arm to the frame 221 , such that the central stabilizing member 444 of the second arm 442 engages the protrusion 819 of the plunger 800 .
FIG. 6A illustrates an embodiment of the face plate 428 having an outer cover 450 and an inner face plate frame 460 . The outer cover 450 includes a button opening 452 and a outer cover battery opening 451 . The inner face plate frame 460 includes a inner face plate frame battery opening 461 and a button frame 462 which supports a button 411 that extends through the button opening 452 . The button 411 may include a peripheral portion 419 secured between the outer cover 450 and inner face plate frame 460 . Outer cover openings 457 correspond to inner face plate frame openings 467 to receive the fastener 190 (illustrated as an embodiment having two fasteners and corresponding openings 457 , 467 ) to secure the mechanism assembly 200 the housing 110 . In one embodiment, battery fastener outer cover openings 456 correspond to battery fastener inner face plate frame openings 466 to receive the fastener 195 to secure the battery assembly 700 to the mechanism assembly 200 , with the battery assembly 700 being inserted through the battery openings 451 , 461 . The button 411 may include a post 412 for engaging the plunger 800 via mechanical interaction, such as through the use of arm 440 .
In one embodiment, the manual actuation assembly 400 includes, either alone or in combination with the mechanical manual actuation assembly 401 , a manually initiated motorized actuation assembly 402 , such as the embodiment illustrated in FIG. 6B . Thus, manual actuation can be accomplished, in various embodiments, through a mechanical actuation of the plunger, i.e. bypassing the motor 241 , or through a manual actuation of the motor 241 , i.e. without use of the sensor unit 300 . In addition to a button 411 for engaging the plunger 36 through mechanical interaction, a second button 430 may be provided to manually initiate the motor and gear train assembly 240 to start a flush cycle (a reduced or full flush, depending on the structure). The second button 430 may be similarly disposed in the button opening 452 of the outer cover 450 and have a corresponding second button post 431 and supported by a portion of the frame 462 and peripheral portion 419 . The buttons 411 , 430 may utilize a return spring 433 ( FIG. 6B ).
In one implementation, the second button 430 includes a magnet 432 ( FIG. 6B ) at an end of the second button post 431 . The magnet is positioned to interact with a Hall Effect sensor 235 (shown in FIG. 4A ) positioned on the PCB 230 when the second button 430 is depressed. The electronic components can be programmed in various ways to respond to the Hall Effect sensor 235 , for example it may actuate the motor in one direction so the rollers rotate in a first rotation corresponding with a reduced flush or a second motor direction causing the rollers to rotate in a second rotation corresponding to a full flush. Thus, the second button 430 provides a mechanism, other than the sensor unit 300 , for initiating the motor 241 and the rollers 510 , including the possibility of a reduced flush, while the first button 411 provides a mechanical linkage mechanism for by-passing the motor and gear train assembly 240 to directly interact with the plunger 800 via the arm 440 to initiate a flush, such as a full flush. In one embodiment, the button 411 effectuates a flush for one flush volume of a dual mode flush valve and the second button 430 effectuates a flush for a second flush volume, such as a reduced flush volume, of a dual mode flush valve. It should be appreciated that the mechanical manual actuation assembly 401 and the manually initiated motorized actuation assembly 402 may both initiate the same flush volume, whether a regular flush or a reduced flush, or one may initiate a reduced flush and the other a standard volume flush.
Dual Mode Flush Valves
One group of flush valves are dual mode flush valves, i.e. flush valves that provide the ability to deliver two discrete flush volumes, typically one sufficient for solid waste evacuation and a lesser flush volume still sufficient for liquid and light paper waste evacuation. One mechanism for providing different flush volumes is to alter the height at which the plunger 36 / 800 contacts the gland 34 . A higher point of contact will result in a longer time for the auxiliary valve 30 to clear the plunger 36 / 800 . The auxiliary valve 30 will remain open until it has cleared the plunger 36 / 800 . In particular, one type of dual mode flush valve is taught by U.S. Pat. No. 7,607,635, which utilizes a dual mode bushing 66 providing two different plunger travel axes that each contact the valve stem 32 at a different vertical location.
As illustrated in FIGS. 9A and 9B , the bushing 65 may be a dual mode bushing 66 , such as that of the '635 patent, may be utilized for enabling dual flush modes. As previously described, the dual mode bushing 66 is typically disposed or partially disposed within the handle opening 15 . Certain implementations may utilize a general bushing 65 , while dual flush embodiments described herein may utilize a dual mode bushing 66 . The dual mode bushing 66 includes a bushing plunger passage 67 adapted to receive the plunger 36 and for guiding the plunger to the gland 34 . The dual mode bushing 66 also serves to prevent water from exiting the valve body 10 though the handle opening 15 . FIG. 2 illustrates a gasket 80 that may be used to provide a water-tight seal between the dual mode bushing 66 and the valve body 10 . A plunger gasket 81 provides a water-tight seal at the end of the bushing passage adjacent the valve stem 32 ( FIG. 1B ).
The dual mode bushing 66 allows the plunger to tilt within the dual mode bushing 66 such that the plunger 36 will strike the gland 34 at different vertical heights. In one embodiment, the dual mode bushing 66 has an enlarged opening adjacent the valve stem and includes two paths “A” and “B” of plunger travel, which allow the plunger 36 to strike the valve stem 32 at two different vertical locations depending on the path of travel. As explained in the '635 patent, the vertical location on the gland 34 that the plunger 36 strikes impacts the flush volume, with a high strike point being correlated with larger flush volumes. As set forth in the '635 patent, the tilting of the handle 17 allows for engagement of a peripheral portion of the plunger head resulting in a moment. In the dual mode bushing 66 , an enlarged portion of the bushing plunger passage 67 allows the plunger 36 to tilt, when aligned vertically to lay in the vertical plane, depending where the peripheral portion of the plunger head 37 is engaged. It will be understood that the bushing plunger passage 67 will not allow the plunger to tilt in any direction, but only when actuated in line with the enlarged portion to allow tilting. In one embodiment, the dual mode bushing 66 includes an outer skirt 70 and a bushing central sleeve 68 , connected via a wall 72 . The central sleeve 68 further defines the bushing plunger passage 67 of the dual mode bushing 66 for receiving the plunger 36 . The plunger 36 described above moves laterally through the dual mode bushing 66 to contact the valve stem 32 . The mechanism of actuating the flush valve 1 must provide a motive force to move the plunger 36 .
In one embodiment, the present invention relates to a side mount actuator assembly 100 for selectively engaging a plunger 36 guided by the dual mode bushing 66 to effectuate one of two flush modes: a high volume sufficient for solid waste or a lower volume for conserving water, but sufficient for liquid and light paper waste, such as a 30% reduction from a “standard” flush (higher relative volume). The actuator assembly 100 engages the plunger 800 to move along either the first plunger travel path “A” or the second plunger travel path “B” to effectuate the desired flush volume. The actuator assembly 100 may be utilized in place of a manual handle 17 .
With respect to FIGS. 8A and 8B , one implementation of a plunger 800 is illustrated for use with a manual actuation assembly 400 . It should be appreciated that a plunger 36 may be used with various implementations and that plunger 800 may be used with, for example, the described embodiments having the manual actuation assembly 400 . The plunger 800 comprises a plunger head 810 and a plunger shank 820 connected thereto. The plunger head 810 is positioned at a first (outer, with respect to the valve body 10 ) end 802 of the plunger 800 . The plunger shank 820 extends from the plunger head 810 to the second (inner, with respect to the valve body 10 ) end 803 of the plunger 800 , adjacent the valve stem 32 . At a first side opposite the plunger shank 820 , the plunger head 810 tapers from a center to the perimeter. The plunger head 810 includes a lower portion 811 and an upper portion 812 In one embodiment, the plunger head 810 at least two angled surfaces, corresponding to lower portion 811 and upper portion 812 , respectfully, that provide a follower surface for interaction with the automated actuation assembly 220 as further described below. In one embodiment, the lower portion and upper portion are not in the same plane, with the lower portion 811 and upper portion 812 each comprising one or more faces of a polyhedron. In an alternative implementation, the plunger head comprises a curved surface, such as forming a frustum, semi-ellipsoid, semi-paraboloid, semi-spheroid or semisphere, with the lower portion 811 and the upper portion 812 each corresponding to an opposite portion of the curved surface.
The automated actuation assembly 220 for use with a dual flush mode flush device is best illustrated in FIGS. 4A-D . In addition to the components described above, one embodiment of the automated actuation assembly 220 includes as part of the gear train 242 a roller system 500 . Rotation of the motor 241 , such as a traditional small electric motor spinning a drive shaft, rotates a gear 243 in the gear train 242 . Rotation of the gear train 242 engages the plunger 800 .
In one embodiment, illustrated in FIG. 5B , one or more rollers 510 are positioned on a rotating platform, such as a roller support gear 501 . One or more rollers 510 are connected to the roller support gear 501 , wherein the one or more rollers 510 are spaced from the center of the roller support gear 501 such that the one or more rollers 510 travel a path about the center when the roller support gear 501 is rotated. The one or more rollers 510 are configured to engage the plunger head 810 as a cam. For example, as illustrated in FIG. 11 , the rollers 510 may be positioned to rotate generally in the vertical plane such the that plunger is engaged with an upward curving rotation or a downward curving rotation of the rollers 510 . In one implementation, the one or more rollers 510 are rotatable in a clockwise or counterclockwise direction. For example, when the motor 241 is run “forward” the one or more rollers 510 rotate in one direction and when the motor 241 is run in “reverse” the one or more rollers 510 rotate in the opposite direction. In one implementation, rotation in a clockwise direction results in at least one of the rollers 510 engaging the lower portion 811 of the plunger 800 and rotation in a counterclockwise direction results in at least one of the rollers 510 engaging the upper portion 812 of the plunger 800 . FIG. 11 and FIG. 10C best illustrate the spatial arrangement of the components, including the positioning of the rollers 510 relative to the plunger head 810 .
In one embodiment program logic is utilized to control the motor. For side mount actuator assemblies having dual mode flush capabilities, such as utilizing a dual mode bushing 66 , the program logic, in one embodiment, utilizes input from the sensor unit 300 and applies logical instructions, such as computer program code, to determine if a reduced flush or a normal volume flush should be utilized. For example, where rotation of the motor in a clockwise direction achieves a reduced flush, the program logic will initiate a clockwise rotation of the motor when the sensor unit indicates only a short direction presence indicative of a liquid waste event. In contrast, upon detection of a longer presence, the program logic initiates rotation of the motor in a counter clockwise direction to effectuate a normal flush as the sensor unit's input is indicative of a solid waste event.
It should be appreciated that the actuator assembly 100 may be mounted in a “left hand” or “right hand” position with respect to the valve body 10 . A single actuator assembly 100 may be useable in either position by allowing an installer to select the orientation of installation. The actuator assembly 100 is right-side up in one orientation and upside down, respectively, in the other. Therefore, in one implementation, the direction of rotation of the motor 241 , and thus the one or more rollers 510 , associated with a particular flush volume is reversed between the left-handed installation and the right-handed installation. A switch (not shown) may be provided on the PCB 230 to accomplish the change in relationship between the motor rotation and the flush volume. A tilt sensor (not shown) may be provided on the PCB 230 to provide an indication of orientation of the actuator assembly 100 , and thus the type of installation, i.e. left hand or right hand, where the actuator assembly 100 is right-side up for one of a left hand or right hand installation and upside down in the other installation. In one embodiment, the dual mode bushing 66 is keyed to match the receptacle 120 as described previously and the keying is such to accommodate either a left-hand or right-hand position. In one embodiment, the bushing 65 (including if a dual mode bushing 66 is utilized) is a separate and distinct component from the side mount actuator assembly 100 . Thus, the bushing 65 may be rotated separately for a left-hand or right-hand installation as necessary, particularly if a dual mode bushing 66 is utilized to ensure proper location of the dual mode bushing 66 for achieving a reduced flush.
In one embodiment illustrated in FIGS. 5A and 5B , the one or more rollers 510 are connected to the roller support gear 501 by pins 511 that engage gear pin holes 521 and pin holes 513 in a top plate 512 that is secured to the roller support gear 501 such as by protrusion 522 that mates with an opening 514 in the top plate 512 . A support shaft 530 may pass through the top plate opening 514 and an protrusion opening 523 to support the roller system 500 .
The use of the dual mode bushing 66 allows the plunger 800 to tilt where the action of the rollers 510 or manual action (discussed below) creates a sufficient moment with a specific vector to tilt the plunger 800 in the dual mode bushing 66 . The plunger 36 is aligned within the dual mode bushing 66 such that the upper portion 812 corresponds with the top of the dual mode bushing 66 , which has an angled portion to allow the plunger 800 to tilt the end adjacent the valve stem 32 downward. This downward tilt of the plunger end results in a lower flush volume as described in U.S. Pat. No. 7,607,635. Rotation of the rollers 510 in a first direction, engaging the upper portion 812 , results in lateral movement of the plunger to engage the flush valve stem at a first location and a “normal” flush volume sufficient for solid waste. Rotation of the rollers 510 in a second direction, engaging the lower portion 811 , results in a tilting of the plunger 800 and lateral movement of the plunger 800 to engage the flush valve stem 32 at a location below the first location effectuating a “reduced” flush volume that remains sufficient for liquid—but not intended for solid waste. The reduction may be from a normal flush volume of about 1.6 gpf to a reduced 1.3 gbf. In one embodiment, the reduction may be 30% from a “normal” flush.
Battery Tray
In one embodiment portable energy sources are utilized, such as batteries 701 . A battery assembly 700 may be provided. The battery assembly 700 may be as shown in FIG. 7 . The battery assembly 700 is configured to be disposed within the housing 110 .
In one embodiment, the battery assembly 700 includes batteries 701 insertable into a tray 710 having at one end a first linked pair of electrodes 704 wherein one of the pair is a positive electrode (e.g., 704 a ) and the other a negative (e.g., negative electrode 704 b ) and at a second, opposite, end a set of unlinked electrodes 705 , 706 (such as a positive electrode 705 opposite negative electrode 704 b and a negative electrode 706 opposite positive electrode 704 a ). Each electrode 704 a , 704 b , 705 , 706 is conductively connected to the support plate 280 . The blade electrodes 781 , 782 are configured to receive a corresponding blade 281 , 282 , respectively. The blades 281 , 282 are connected to the mechanism assembly frame 221 . The assembly frame 221 is in conductive communication with the PCB 230 to provide electricity to the electrical components.
A spring contact 740 may be provided in one embodiment within the housing 110 to assist in removal of the battery assembly 700 . In one embodiment, the battery assembly 700 includes a battery assembly cover 720 covering outer cover openings 456 and fasteners 195 to provide a more aesthetic look and to hinder tampering with the actuator assembly 100 . The battery assembly 700 may be affixed to the mechanism assembly 200 by a battery assembly fastener 195 , such as a screw, that engages a battery assembly hole 795 in the cover 720 and the battery fastener outer cover opening 456 in the face plate 428 .
One embodiment of the invention relates to a complete flushometer valve assembly, such as either a diaphragm valve or a piston valve, with the bushing being a dual flush mode bushing and the actuator assembly being a side mount automatic actuator, such as for new construction installation. An alternative embodiment comprises only the actuator assembly, such as for converting existing installed dual mode valve bodies to automatic flush systems. Alternatively, one embodiment relates to the actuator assembly and a dual flush mode bushing, such as for converting existing single mode flush valves to automatic dual mode flush valves.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable sub combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub combination or variation of a sub combination. Furthermore, headings are provided as a visual aid and should not be construed to limit the scope of the invention.
It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated”, “coupled” or “connected” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components.
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least”). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include, but not be limited to, systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
Thus, particular implementations of the invention have been described. Other implementations are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. | A flush actuator for engaging a flush valve. The flush actuator provides a mechanism assembly for automatically flushing the flush valve. A sensor provides a presence detection to trigger the automatic flushing. Redundant manual activation is provided. |
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The present application is a continuation of application Ser. No. 10/417,594 filed Apr. 17, 2003 which is incorporated herein by reference in its entirety.
BACKGROUND
The present invention relates to barrier movement operators and particularly to such operators which include a timer-to-close feature.
Barrier movement operators are known which include a motor for moving a barrier between open and closed positions and a controller for selectively energizing the motor to move the barrier. Gate operators and garage door operators are examples of the wide range of such barrier movement operators. The controller of a barrier operator may be responsive to stimulus signals to perform various barrier movements with safety. For example, the barrier operator may include a control switch which, when pressed, reverses the direction of travel of the barrier or starts the barrier moving toward the open or closed position.
Most door movement has, for safety concerns, been under the control of a human operator. That is the barrier was opened or closed only when a human was present to provide a movement initiating stimulus. The human, being aware of the environment was a significant part of safely moving the barrier. Humans, however, are not infallible and occasionally the barrier is left open when it should be closed. Doing so may be energy inefficient by allowing heat or cool to escape from a space which should be a closed interior or it may be unwise because unauthorized persons may enter the area to be protected by the barrier.
In order to combat the problem of a left-open barrier, some systems include a timer-to-close feature. This feature generally includes a timer which is enabled when the barrier is in the open position. When the timer indicates that the barrier has remained open for a predetermined period of time, the barrier operator motor is energized to move the barrier to the closed position. A barrier movement operator with a timer-to-close feature is generally equipped with special safety equipment like an alerting light and/or audible signal which are activated prior to moving the barrier to the closed position.
It may be desirable for a user to pause the timer-to-close feature for reasons such as airing out the interior space of which a human user is in control. Known systems with a timer-to-close feature generally provide no user controlled ability to pause the feature without shutting the feature off, requiring at least a complete recycle of the barrier or even a reprogramming of the parameters of the feature. A need exists for a more convenient arrangement for pausing a timer-to-close feature.
Further, known operators having a timer-to-close feature move the barrier directly from the open to the closed position. Such may not always be desirable either for reasons of safety or for reasons predicted by a human operator. A need also exists for a human controlled capability to move the barrier first to a mid-travel stopping point, then to the closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a barrier movement operator;
FIG. 2 is a block diagram of a controller of the barrier movement operator and apparatus which interacts with the controller;
FIG. 3 represents apparatus for defining particular points of barrier travel;
FIG. 4 is a flow diagram of the inhibiting of a timer-to-close feature;
FIG. 5 is a flow diagram of barrier movement with a mid-travel point defined; and
FIG. 6 is a view of a wall control unit for signaling the controller.
DESCRIPTION
FIG. 1 is a view of a barrier movement operator embodying the present invention. FIG. 1 shows a jack shaft balanced, powered jack shaft moved residential garage door movement operator. It will be understood from the following that the improvements described and claimed herein apply to other types of barrier movement systems such as commercial door operators, rolling gate operators, swinging gate operators, other types of balancing such as tension spring, and other types of movement such as high lift and powered rail and trolley.
In the embodiment of FIG. 1 , a panel door 112 is raised and lowered in a pair of side tracks 114 and 116 . Door 112 is connected by cables 105 and 107 to a pair of drums 104 and 108 disposed on a jack shaft 106 and rotated under the power of a motor 150 contained by a head end 102 . The motor is selectively energized by a controller 208 and associated apparatus ( FIG. 2 ) to move the door 112 between a closed position, as shown in FIG. 1 , and an open position. The controller 208 , which includes a programmed microprocessor, responds to user input signals from a wall control 124 and an rf transmitter 118 to initiate door movement. Obstructions to door movement may be detected by an optical transmitter 138 and receiver 142 which “watch” the door opening to detect when an obstruction is beneath the door. Similarly, an optional door edge sensor (not shown) may be attached to the bottom of the door to detect physical contact with an obstruction.
When the barrier movement system is installed, the controller 208 is taught the open and closed positions of the door by known means so that the motor 150 is energized only long enough to move the door between those limit positions. Such limit positions may be learned in the software and data of controller 208 , they may consist of physical door detectors mounted to the rails, the garage, or the door, or they may be physical switches within head end 102 which sense the movement of representations of the door position. FIG. 3 represents one apparatus internal to the head end for setting limits of door travel.
The limit setting arrangement of FIG. 3 comprises a first limit switch 145 , a second limit switch 146 , and a third limit switch 147 . Each limit switch includes an actuator lever, e.g., 148 , which responds to contact by causing its associated switch to change from an open to a closed electrical state. The state of all switches is reported to controller 208 via a communication path 232 . Also included is a threaded shaft 149 which is connected to the output shaft of motor 150 to rotate therewith. In FIG. 3 , the shaft is connected to motor 150 by means of a pulley 155 and belt 156 . Threaded onto shaft 149 are three switching cogs 152 , 153 , and 154 which are kept from rotating during normal operation by a guide rail (not shown) attached to a mounting plate 151 .
The open and closed limits are set by cogs 152 and 154 . They are set by lowering the door to the closed position, displacing mounting plate 151 so that the cogs are free to rotate, and rotating cog 152 until switch 145 changes state. Similarly, the open limit is set by moving the door to the open position and adjusting cog 154 until switch 146 changes state. After setting open and closed limits, controller 208 can accurately control barrier movement.
After the barrier operator is installed, a user may press the command button 134 of wall control which signals controller 208 via a path 126 . Controller assesses the present state of the barrier based on various inputs discussed and sends a signal on a communication path 220 to control relays 222 which apply power to motor 150 . For example, when the barrier 112 is at the open limit and push button 134 is pressed, controller 208 energizes relays 222 to energize motor 150 to move the barrier toward the closed limit. During such movement the optical sensors 138 and 142 , and other safety equipment, are surveyed to assure safe movement of the door. A user can also initiate barrier movement by rf transmitting an appropriate security code from a transmitter 118 in a manner well known in the art. Such an rf transmission is received by a receiver 207 via an antenna 120 and the resultant received signal is sent on to controller 208 . A non-volatile memory 212 stores previously learned security codes and when a match exists between a previously learned code and a received code, the controller operates the door in the same manner as if button 134 of wall control 124 had been pressed.
The present embodiment includes a timer-to-close feature which is in part implemented with routines to be performed by controller 208 . The timer-to-close feature automatically moves the barrier toward the closed position when the barrier has been in the open position for a predetermined period of time. The predetermined period of time may be preset and stored in controller 208 at the time of manufacture or it may be established by known user controlled methods during installation. The present embodiment adds to the timer-to-close feature by permitting the user to conveniently inhibit operation of this feature. A switch 132 of wall control 134 is used to enable and disable the timer-to-close feature.
FIG. 4 is a flow diagram of an embodiment of the timer-to-close feature. The flow begins at block 161 which is entered whenever the door achieves the open position. In block 161 the timer-to-close timer is started. Flow proceeds to block 163 in which when a determination is made as to whether the timer is active. When the timer is active, flow proceeds to blocks 165 and 167 where switch 132 is checked to see if it has been pressed by a user. If not, flow proceeds to block 169 to determine whether the timer has reached the predetermined time out value. If it has not, flow returns to block 165 . As long as the switch 132 is not pressed, the loop of blocks 165 , 167 , and 169 continues until time out is detected in block 169 , and flow proceeds to block 171 where a timer-to-close flag is set indicating that door closing movement was begun by the timer-to-close time out. The motor 150 is then energized in block 173 to move the door toward the closed position. When the door reaches the closed position, the timer-to-close flag is reset.
Should a user press button 132 while the loop of blocks 165 , 167 , and 169 is being executed, flow proceeds from block 167 to block 175 where the timer is turned off, which in the present embodiment includes resetting the timer. From block 175 flow returns to block 163 and on to blocks 177 and 179 where the state of switch 132 is again checked. When there has been no change, flow returns to block 163 and a loop consisting of blocks 163 , 177 and 179 is repeatedly executed. Whenever block 179 detects a press of button 132 , flow proceeds to block 161 where the timer is again started and flow continues as previously described. Optionally the wall control 124 may include an LED 133 which is energized by controller 208 when the timer-to-close is being inhibited and is not energized when timer-to-close is in the normal mode.
As discussed with regard to FIG. 3 , the barrier movement operator described herein includes a limit switch 147 and corresponding limit cog 153 which may be adjusted to identify to controller 208 a position of the barrier intermediate to the positions identified by switches 145 and 146 . The point at which switch 147 changes state is adjusted in the manner described previously with regard to switches 145 and 146 . With such adjustment, the controller 208 will be informed each time the door passes the intermediate position while moving between open and closed positions. In the present embodiment, the passage of the intermediate position while the door is traveling upwardly toward the open position is ignored by controller. FIG. 5 is a flow diagram representing downward or closing movement of the barrier during which the intermediate position is responded to.
The routine of FIG. 5 is performed each time the motor 150 is energized to move the barrier from the open position toward the closed position. The routine begins with the energization of motor 150 for downward motion in block 181 . A block 183 is performed throughout downward door movement to assure door movement safety. A decision block 185 is next performed to identify if the timer-to-close flag has been set. It will be remembered that the timer-to-close flag is set in block 171 ( FIG. 4 ) when the downward motion is initiated by time out of the timer-to-close timer. When block 185 determines that the timer-to-close flag is set, flow proceeds to block 187 where a loop is performed until the mid-travel position set by switch 147 is detected. When the mid-travel position is reached, flow proceeds to block 189 and the motor is stopped to await a mid-travel time out in block 191 , at which point the motor is re-energized in block 193 and finally closed in block 195 . When block 185 determines that the barrier is moving toward the closed position for reasons other than the timer-to-close (such as in response to a user command), flow proceeds from block 185 to continue its closing the barrier without regard for the mid-travel position.
In the embodiments discussed above, the barrier waits at mid-travel until a timer re-initiates door movement as represented in blocks 191 and 193 . Alternatively, blocks 191 and 193 could be replaced with a single block 197 (shown in dotted line on FIG. 5 ) in which a user command is awaited to re-energize the motor.
Motor 150 can be energized to rotate either clockwise or counter-clockwise by power provided from an up and down motor control relay unit 223 of relays 222 . Whenever the barrier is to be moved, controller 208 transmits to the motor control relay unit 223 an appropriate set of signals to control relays 223 to rotate the motor in either the clockwise or counter-clockwise. The choice of clockwise, counter-clockwise rotation is made by controller 208 operating under pre-programmed parameters which are set using assumptions about the installation of the operator. It is possible that, because of decisions made during installation a control signal which causes the motor to rotate counter-clockwise will move the barrier toward the wrong limit. That is, the controller 208 may send a signal to relays 223 which is intended to raise a barrier and the result is that the barrier is lowered.
Wall control unit 124 includes a two position switch in which one position indicates normal barrier travel and the other position indicates the reverse barrier travel. Whenever the barrier motor is to be energized, the controller 208 consults the switch 130 to determine whether the motor is to be energized normally i.e., in accordance with pre-programmed parameters, or in the reverse. For example, by pre-programming, controller 208 may direct the motor to rotate clockwise to move a barrier from open to closed position, and the installed gearing of the motor results in clockwise, rotation which moves the barrier from closed to open position. Such reversal may also happen due to placement of head end on the left of the doorway rather than on the right as shown in FIG. 1 . When a user determines that the barrier is moving in the opposite direction to that expected the user changes the position of switch 130 . At the next command to energize the motor, controller 208 detects the changed setting of switch 130 and directs relays 223 to energize motor 150 for rotation opposite to the energization before the change of switch position. Additionally, controller 208 reverses the sense of the limit switches e.g., 145 and 146 so that proper door operation will result.
The preceding embodiments operate with a timer-to-close timer, the value of which may be set in any manner. The following discusses two examples for setting the timer-to-close timer to a particular value. A first example begins when a user presses the timer learn button 187 for a momentary contact to which controller 208 responds by entering a button oriented learn mode. The button oriented learn mode operates with an optional wall control 124 ′ which is shown in FIG. 6 . Wall control 124 ′ replaces wall control 124 for the present example.
In the button oriented learn mode, controller 208 responds to each press of an open button 135 by adding five seconds to the timer count, to each press of a close button 136 by adding one minute to the timer count and responds to a press of a stop button by clearing the timer count. Accordingly, when the button oriented learn mode is operational a user presses a combination of buttons 135 and 136 to total the desired timer value. The absence of button presses for a predetermined period of time e.g., 20 seconds, allows the controller to leave the learn mode and revert to the operating mode.
A second method of setting the time out period of the timer-to-close timer is a time based learn mode which is entered by holding the timer learn button 187 closed for more than five seconds. In the time based learn mode the barrier should be at the open position when button 187 is pressed or the first act after entering the time based learn mode should be to move the barrier to the open position. Controller 208 then counts the time that the barrier is in the open position. When the appropriate time has passed e.g., five minutes, the user presses either the close button 136 ( FIG. 6 ) or the timer-to-close button. The time base for the timer-to-close timer then becomes the time that the barrier was in the open position. | Methods and apparatus for controlling a barrier movement operator having a timer-to-close feature are disclosed. The methods and apparatus include arrangements for conveniently inhibiting and re-activating the timer-to-close feature and for providing a mid-stop position during movement toward the closed position. Additionally, the embodiments include methods and apparatus for reversing barrier operation. |
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This Application is a National Phase application of PCT/EP2005/052636 entitled, “VEHICLE COMPONENT AND METHOD FOR SECURING A PIVOTABLE COMPONENT AGAINST OPENING IN THE EVENT OF A CRASH” filed on Jun. 8, 2005 which published under PCT Article 21(2)2 on Jun. 22, 2006 as WO 2006/063871 A1 in the German language, which claims priority to German patent application DE102004028846.1 filed Jun. 16, 2004, the entire disclosures of which, including the specification and drawings, are expressly incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to a vehicle component, preferably a backrest of a seat, which includes a pivotable component, preferably a through-load hatch with a lock.
[0003] To increase the loading volume, the passenger compartment and the luggage compartment in vehicles are frequently separated by pivotable walls, seats or by through-load hatches, so that the passenger compartment may be used at least partially as a luggage compartment. Through-load hatches, in particular, have the advantage that long objects such as skis may be loaded into a passenger vehicle without a seat having to be folded down. To help ensure that, in the event of an accident, at least when walls, seats or through-load hatches are folded up, no luggage penetrates the passenger compartment or the through-load hatch does not spring open, it is best to ensure that the through-load hatches do not open by means of the forces acting on the walls, seats or the through-load hatch.
[0004] Thus, it would be desirable to provide an inexpensive vehicle component which may be easily produced and assembled, which does not open in the event of an accident.
SUMMARY
[0005] In one embodiment, a vehicle component includes a pivotable component with a lock, the lock comprising a detent hook which, when operational, may be rotated about a first rotational axis from a locked position into an unlocked position, the unlocked pivotable component being able to be folded about a second rotational axis in an opening direction from a substantially vertical resting position into a substantially horizontal loading position, the first rotational axis being displaced in relation to the pivotable component and/or the detent hook being displaced in relation to the first rotational axis from an operating position into a crash position, when the pivotable component is in the locked resting position and by means of a force acting in the opening direction of the pivotable component, so that the detent hook preferably cooperates in a reversible manner with the pivotable component such that said component may not be unlocked.
[0006] The displacement of the rotational axis, according to one exemplary embodiment, in relation to the pivotable component and/or the displacement of the detent hook in relation to the rotational axis, ensures that the pivotable component may not be unlocked and therefore no luggage is able to penetrate the passenger compartment by means of the pivotable component, when the pivotable component is located in the locked resting position. In one embodiment, the detent hook cooperates in a reversible manner with the pivotable component in the event of an unintended incident such that the component is not able to be unlocked, which allows the vehicle component to be reused without repair costs, if the vehicle component has not been damaged during the incident.
[0007] According to one embodiment, the first rotational axis may be displaced in relation to the pivotable component, and/or the detent hook may be displaced in relation to the first rotational axis, from an operating position into a crash position. Preferably, one of the pivotable component and the detent hook may comprise a recess, preferably a slot, particularly preferably an elongated hole, by means of which the first rotational axis may be displaced in a controlled manner in relation to the pivotable component and/or the detent hook may be displaced in a controlled manner in relation to the first rotational axis. The recess guides the rotational axis and/or the detent hook in the event of a crash into the preferred crash position, so that it is no longer possible to unlock the pivotable component.
[0008] In one exemplary embodiment, the lock comprises a locking part which is fixedly connected to the vehicle component, the detent hook, when operational and in the resting position of the pivotable component, cooperating with the locking part and preventing folding of the pivotable component and the pivotable component being able to be unlocked by rotating the detent hook about the first rotational axis and about the locking part. The cooperation of the locking part with the detent hook locks the pivotable component, when operational, in a simple and secure manner.
[0009] Preferably, in the event of an unintended incident, and in the locked resting position of the pivotable component, the detent hook acts non-positively between the locking part and the pivotable component and transmits the force acting in the event of a crash in the opening direction of the pivotable component onto the locking part. Due to the non-positive connection of the detent hook with the locking part and the pivotable component and the arrangement between the locking part and the pivotable component, the forces occurring in the event of a crash are directed into the structure of the vehicle component and thus do not act on the vehicle passengers, at least not fully.
[0010] In one exemplary embodiment, the detent hook comprises a detent means, preferably a nose, which cooperates with the pivotable component and, in the event of a crash and in the locked resting position of the pivotable component, prevents the unlocking of the detent hook. A detent is any means which secures the position of a component and prevents an alteration of the position. The detent means secures against the unlocking of the pivotable component by preventing, in the event of an unintended incident, the alteration of the position of the detent hook. The detent means may, in the event of an incident, plastically and/or elastically deform and therefore also possibly act in a locking manner.
[0011] In a one embodiment, the lock comprises an unlocking lever which, when operational, may be rotated about the first rotational axis and by the rotation of which the detent hook may be rotated from the locked position into the unlocked position. Easy operation of the pivotable component is possible using the unlocking lever.
[0012] In one embodiment, the lock comprises a spring or biasing means, preferably a spring, which holds the first rotational axis and/or the detent hook in the operating position and preferably, after the incident, transfers the first rotational axis and/or the detent hook into the operating position again. The spring means increases the operational reliability of the lock and by the preferred transfer of the detent hook from the crash position into the operating position after a crash, preferably due to the return force of the spring, allows the first rotational axis and/or the detent hook to be transferred again into the operating position, so that the reuse of the vehicle component is possible without repair costs, if the vehicle component has not been damaged during the crash. The spring means may additionally serve always to return the unlocking lever into its locked position. Preferably, in the event of a crash, the first rotational axis is displaced in relation to the pivotable component and/or the detent hook is displaced in relation to the first rotational axis against the force of the spring means. It is thereby ensured that the pivotable component has not already been prevented from being unlocked by forces occurring when operational, but that a minimum force is required therefor, which preferably does not occur when operational. The spring means may also be a means which is plastically deformed in the event of a crash.
[0013] Preferably, in one embodiment, at least the unlocking lever and the detent hook of the lock are produced in one piece. As a result, the number of components is small and the lock may be produced and assembled inexpensively and easily. Preferably, the pivotable component and/or the lock are produced from plastic which is inexpensive and, as a result of which, the vehicle component has a low weight.
[0014] The vehicle component ensures that, in the event of a crash, no luggage is able to penetrate from the luggage compartment into the passenger compartment, by means of a pivotable component of the vehicle component, if the pivotable component is in the locked resting state before the crash. The lock of the pivotable component may be produced and assembled easily and inexpensively and the vehicle component has a low weight. Preferably, the pivotable component may be reused without repair costs, after a crash, if the vehicle component has not been damaged during the crash. The pivotable component is able to be easily operated by a passenger.
[0015] In one exemplary embodiment, a method for securing a pivotable component against opening in the event of a crash, which may be locked by means of a lock which comprises a detent hook which, when operational, may be rotated about a first rotational axis from a locked position into an unlocked position, the unlocked pivotable component being able to be folded about a second rotational axis in an opening direction from a substantially vertical resting position into a substantially horizontal loading position, the first rotational axis, in the event of an unintended incident in the locked resting position of the pivotable component, being displaced in a reversible manner by a force acting in the opening direction of the pivotable component, preferably such that the pivotable component may not be unlocked. The method may be carried out in a simple manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A vehicle component is explained below by reference to FIGS. 1-6 b . The explanations are merely exemplary.
[0017] FIG. 1 shows a vertical cross-section through a vehicle component, in this case through a backrest of a seat.
[0018] FIG. 2 shows a vertical cross-section of a lock of a pivotable component, in this case of a through-load hatch, of the vehicle component of FIG. 1 .
[0019] FIG. 3 shows the lock of FIG. 2 in a locked position when operational.
[0020] FIG. 4 shows the lock of FIG. 2 in a unlocked position when operational.
[0021] FIG. 5 shows the lock of FIG. 2 in the locked position in the event of a crash.
[0022] FIG. 6 a shows the pivotable component with the lock of FIG. 2 in a horizontal cross-section in the locked position, when operational.
[0023] FIG. 6 b shows the pivotable component 2 with the lock of FIG. 2 in a horizontal cross-section in the locked position in the event of a crash.
DETAILED DESCRIPTION
[0024] Referring to FIGS. 1-6 b and, in particular to FIG. 1 , a vehicle component 1 , in this case a backrest of a seat is shown. The term “backrest” is, therefore, used hereinafter for the vehicle component 1 . The backrest 1 separates a passenger compartment 4 from a luggage compartment 20 and comprises a pivotable component 2 , in this case a through-load hatch, for example, for skis and other lengthy items. The term “hatch” is, therefore, used hereinafter for the pivotable component 2 . When operational, the hatch 2 is able to be folded in a reversible manner from a substantially vertical resting position, shown in FIG. 1 , to a substantially horizontal loading position about a second rotational axis 5 in an opening direction, which is shown by the arrow 3 . The through-load hatch 2 may be locked in a reversible manner to the backrest 1 , by means of a lock 8 , in the resting position. The locking and/or unlocking of the lock 8 is carried out by the unlocking lever 6 which, when operational, may be rotated about a first rotational axis 11 which is shown in FIG. 2 , whereby the hatch 2 may be unlocked into an unlocked position. In the sense of the explanations, the term, “when operational” means the normal use situation of the vehicle in contrast to an unintended incident, accident or crash situation. For easier handling of the unlocking lever 6 the hatch comprises a recessed grip 7 .
[0025] FIG. 2 shows the lock 8 of the through-load hatch 2 of FIG. 1 in a vertical cross-section. The hatch 2 , which comprises the recessed grip 7 for easier handling of the unlocking lever 6 , is shown. The unlocking lever 6 may be rotated about a first rotational axis 11 . FIG. 2 shows the lock 8 when operational in the locked position. The first rotational axis 11 is in the operating position 18 . A recess 12 is also visible, in this case an elongated hole, in which, in the event of a crash, in the embodiment shown in FIG. 2 , the first rotational axis 11 is displaced in relation to the hatch 2 into a crash position 19 . The first rotational axis 11 is formed in this case by a pin 13 . When rotating the unlocking lever 6 about the first rotational axis 11 , the detent hook 17 which, in this embodiment of the vehicle component 1 , is integral with the unlocking lever 6 , is rotated about the first rotational axis 11 and about a locking part 9 . The locking part 9 is arranged in a receiver 10 for the locking part 9 . The detent hook 17 is arranged in the locked position between the locking part 9 and the hatch 2 and is rotated, when rotating about the first rotational axis 11 , about the locking part 9 , so that the hatch 2 is unlocked. For securing in the event of a crash, the detent hook 17 comprises a detent means 16 , in this case a nose.
[0026] FIG. 3 shows the lock 8 of FIG. 2 in the locked position when operational. The detent hook 17 and/or the first rotational axis 11 and/or the pin 13 , which in this embodiment forms the first rotational axis 11 , are held in the operating position 18 by a spring or biasing means 14 , in this case a spring. The term “spring” is used hereinafter for the biasing means 14 . Additionally, the unlocking lever 6 is held by the spring 14 in the locked position shown.
[0027] FIG. 4 shows the lock 8 of FIG. 2 in the unlocked position when operational. By rotating the unlocking lever 6 against the force of the spring 14 and, as a result, the detent hook 17 about the first rotational axis 11 and/or the pin 13 , the hatch 2 is unlocked, the pin 13 remaining in the operating position 18 . As the rotational axis 11 is in the operating position, the detent nose may be rotated past the hatch 2 . The spring 14 is tensioned during the unlocking and preferably moves the detent hook 17 into the locked position.
[0028] FIG. 5 shows the lock 8 of FIG. 2 in the locked position in the event of a crash. By means of a force 15 in the opening direction 3 of the hatch 2 , in this embodiment the first rotational axis 11 and/or the pin 13 is displaced to the right in the recess 12 in relation to the hatch 2 into the crash position 19 . As a result, the detent hook 17 may no longer rotate past the hatch 2 into the unlocked position. The detent hook 17 acts non-positively between the fixedly arranged locking part 9 and the hatch 2 , and directs the occurring forces into the structure of the seat. Additionally, the detent hook 17 comprises a detent means 16 , in this case a nose which, in the event of a crash, at least partially bears against the hatch 2 and prevents the unlocking of the detent hook 17 . The first rotational axis 11 is displaced against the force of the spring 14 and, after the crash, is transferred into the operating position 18 again, due to the return force of the spring 14 .
[0029] FIG. 6 a shows the hatch 2 with the lock 8 of FIG. 2 in a horizontal cross-section in the locked position when operational. The unlocking lever 6 and the detent hook 17 are integral with the detent means 16 and may be rotated about the pin 13 which forms the first rotational axis 11 . The pin 13 is held in two recesses 12 of the hatch 2 in the operating position 18 by two springs 14 . The locking part 9 is arranged in the receiver 10 for the locking part 9 , so that the detent hook 17 is arranged between the locking part 9 and the hatch 2 and the hatch 2 is locked.
[0030] FIG. 6 b shows the hatch 2 with the lock 8 of FIG. 2 in a horizontal cross-section in the locked position in the event of a crash. By means of a force 15 acting on the hatch 2 in the opening direction 3 of the hatch 2 , the pin 13 is displaced in the recesses 12 against the force of the springs 14 into the crash position 19 . In this position, the detent hook 17 is arranged non-positively between the locking means 9 and the hatch 2 and the detent nose 16 prevents the unlocking of the detent hook 17 . | A pivotable vehicle component is usable as a load or pass-through in a vehicle seat and include a pivotable latch which prevents the pivotable component from being unlatched from a force being applied by luggage (or other objects) during rapid decelerations such as in a crash. |
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This application is a continuation of application Ser. No. 08/271,0465 filed on Jul. 6, 1994 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to flag/banner display systems and, more particularly, to a pivotal flag/banner/sign display assembly which is permitted to move in response to wind loading.
2. History of the Prior Art
The display of flags, ribbons, signs, banners and the like dates back into ancient times. For centuries, banners have been simply supported from walls, ceilings and rigid poles for a variety of decorative and aesthetic reasons. Today, banners, signs and flags are supported from a myriad of structures for, likewise, a variety of purposes. Flags, banners and signs are used today for commercial advertisement and, thus, the economic importance of effective flag/banner displays has increased. Sign/flag/banner structures are now specifically designed for the most prominent, convenient and aesthetically pleasing presentation to the purchasing public.
The widespread use of flags/banners/billboards and related creative signage for commercial advertising has necessitated structural innovation. The size, shape and orientation of the flag/banner/sign is extremely important to the advertiser because the flag/banner sign assemblies are sold for the purpose of gaining the public's attention and often valued at their effectiveness. The display area itself must then maintain the appropriate orientation for display to the public, and it must withstand the forces of nature. In this regard, it is often advantageous to maintain the flag/banner/sign in a taut condition, properly oriented to the eyes of the viewing public. Problems occur when wind and other natural forces cause the flag/banner/sign to become rumpled, wrinkled, disoriented, and otherwise unattractively displayed about its support structure. Wind is, of course, a constant force with regard to a flag/banner or similar flaccid sign systems.
The present invention overcomes certain problems of prior art flag/banner display structures by providing a system adapted for maintaining appropriate support for the flag/banner thereon with an assembly that is both economical to fabricate and easy to install. In addition, it would be an advantage to provide a lightweight, inexpensive flag/banner/sign display that would move, or pivot, relative to wind loading to thereby maintain an orientation that is less likely to wrinkle or become dislodged in high winds.
SUMMARY OF THE INVENTION
The present invention relates to flag/banner display systems of the type incorporating a rigid, cantilever mounting upon which is secured a flag/banner strut array for suspending a banner (which term includes any of a variety of rigid or flaccid signs and advertising membranes) therefrom. More particularly, one aspect of the present invention comprises an improved, pivotal flag/banner support structure of the type wherein a banner (which term includes any indicia bearing membrane such as a flag, pennant, sign, or marker) is supported from an upstanding support pole for display therefrom. The improvement comprises a base pole adapted for extending outwardly from the support pole. Means are provided for rigidly securing the base pole to the support pole for pivotal support of the flag/banner therefrom. A first upstanding strut is provided for pivotal mounting to the base pole for upward extension therefrom and rotation relative thereto. A top strut is provided for securement to an upper end of the upstanding strut for engagement of a top portion of the flag/banner. Securement means permit the first upstanding strut to pivot relative to the base pole whereby the flag/banner and the strut assembled thereto may assume the position of least resistance in response to wind blowing thereagainst.
In another aspect, the present invention includes an improved flag/banner support structure of the type wherein a flag/banner is supported in the presence of blowing wind from an upstanding support pole for display therefrom. The improvement comprises a base pole adapted for extending outwardly from the support pole, a means for securing the base pole to the support pole for support of the flag/banner therefrom, a first upstanding strut adapted for pivotal mounting to the base pole for upward extension therefrom, a top strut adapted for securement to an upper end of the upstanding strut for engagement of a top portion of the flag/banner, means for mounting the flag/banner to the struts, and means for mounting the first upstanding strut to the base pole and permitting the first upstanding strut and flag/banner mounted thereto to pivot relative to the base pole. In this manner the flag/banner and the struts assembled thereto may assume a position of least resistance in response to wind blowing thereagainst.
The above described invention may, in another aspect, include securement means for the base pole comprising a generally C-shaped bracket adapted for placement against the support pole and at least one band for securing the bracket to the support pole. The bracket may be formed with first and second sidewall portions constructed in generally parallel spaced relationship, with the sidewall portions having at least one aperture formed therein and in registry one with the other and adapted for receipt of the band therethrough. The sidewall portions are each formed with an enlarged aperture therein, each in registry with the other, and formed of a generally rectangular configuration adapted for matingly receiving a generally rectangular base pole therethrough. The apertures for the bands may include at least four elongated, slotted portions adapted for receiving first and second bands therethrough. The bands each comprise an adjustable filament formed of metal or synthetic fibers, and the like, capable of being tightened around the support pole for the securement of the bracket thereagainst. The first upstanding strut comprises a hollow tube adapted for receiving a shaft in either end thereof. The means for mounting the first upstanding strut to the base pole comprises a shaft adapted for securement to the base pole and upstanding therefrom with the tubular upstanding strut placed thereover in rotational relationship therewith. The top strut comprises a hollow tube adapted for receiving a shaft in at least one end thereof and further including an angulated shaft adapted for receipt within the top end of the hollow, upstanding strut for extension therefrom and receipt of the hollow, top strut thereon for permitting the assembly of the top strut to an upper end of the upstanding strut and the suspension of the flag/banner therefrom. The above described struts may be made of metal, synthetic material, or the like. The flag/banner is generally rectangular in shape, having an angulated top portion adapted for conforming to the angle of the top strut relative to the upstanding strut. The flag/banner may be made of any material and clamping means may be provided for securing a lower portion of the flag/banner to a lower portion of the upstanding strut for securement of the flag/banner to the support structure.
In another aspect, the invention includes an improved method of supporting a flag/banner against blowing wind of the type wherein the flag/banner is supported from an upstanding support pole for display therefrom. The improvement comprises the steps of providing a base pole adapted for extending outwardly from the support pole, securing the base pole to the support pole for support of the flag/banner therefrom, and providing a first upstanding strut adapted for pivotal mounting to the base pole for upward extension therefrom. A top strut is provided for securement to an upward end of the upstanding strut for engagement of the top portion of the flag/banner therefrom. The flag/banner is mounted to the struts for securement therewith. The first upstanding strut and flag/banner are then allowed to pivot relative to the base pole, whereby the flag/banner and the struts assembled thereto may assume a position of least resistance in response to wind blowing thereagainst.
In another aspect of the invention, the above described method includes the step of securing the base pole to the support pole, including the step of providing a generally C-shaped bracket adapted for securement against the support pole and providing at least one band for securing the bracket to the support pole.
The method of this aspect of the invention further includes the step of forming the bracket with first and second sidewall portions having at least one aperture formed in each sidewall portion and in registry one with another for receipt of the band therethrough. The method further includes the step of forming the side wall portions of the bracket with an enlarged rectangular aperture in each sidewall portion in registry with each other and matingly receiving a generally rectangular base pole therethrough. The method further includes the step of forming at least four elongated, slotted portions within the side wall portions, the slots each being adapted for receiving one of the bands therethrough, at least one of the bands comprising an adjustable filament capable of securing the bracket to the pole.
In yet another aspect, the present invention includes an improved method of supporting a flag/banner against blowing wind of the type wherein the flag/banner is supported from an upstanding support pole for display therefrom. The improvement comprises the steps of providing a base pole adapted for extending outwardly from the support pole, securing the base pole to the support pole for support of the flag/banner therefrom, providing a first upstanding strut adapted for pivotal mounting to the base pole for upward extension therefrom, providing a top strut adapted for securement to an upward end of the upstanding strut for engagement of the top portion of the flag/banner therefrom, mounting the flag/banner to the struts for securement therewith, and allowing the first upstanding strut and flag/banner to pivot relative to the base pole. In this manner, the flag/banner and the struts assembled thereto may assume a position of least resistance in response to wind blowing thereagainst.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference may now be had to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a flag/banner display system constructed in accordance with the principles of the present invention; and
FIG. 2 is an enlarged, perspective, exploded view of the system of FIG. 1.
DETAILED DESCRIPTION
Referring first to FIG. 1 there is shown a perspective view of a flag/banner assembly 10 structured in accordance with the principles of the present invention. The assembly 10 comprises a base strut 12 mounted in a cantilever fashion from a support pole 14 by a generally C-shaped mounting bracket 16 (described in more detail below). An upstanding, hollow, strut 18 supports a flag/banner, or sign, 20 thereon. A hollow strut 22 is connected to upstanding strut 18 by an angulated shaft 66 for supporting a top region 24 of the flag/banner 20.
As used herein, the term "flag" or "flag/banner" 20 includes any membrane, with or without indicia printed thereon, such as plain material, and being adapted for support by the strut assembly described herein. The flag/banner 20 may have information or other printing thereon for display from the flag/banner assembly 10. In no respect does the term "flag/banner" or "flag" or "banner" alone as used herein, or in the claims, limit the type of display membrane that may be secured to, and exhibited from, the struts 18 and 20 as hereinafter described.
Still referring to FIG. 1, the flag/banner 20 is shown to be constructed in a generally rectangular configuration. The term "rectangular" includes the flag/banner shape of the type shown in FIG. 1 wherein a curved, angled or straight upper membrane portion may form the top region 24. In this particular embodiment, the top region 24 is formed with a straight seamed sleeve 26 extending at an angle on the order of 120° from the side 68. The sleeve 26 forms a closed end tubular region constructed for receipt of the strut 22 therethrough. The end of strut 22 preferably includes a cap 30 to prevent the wearing of material by a bare, rough end of said strut. The cap 30 is sufficiently small to pass within the sleeve 26. A seam 23 forms the sleeve 26 for receiving the strut 22 therein and defines the section of the flag/banner 20 adapted for securement to the upper strut 22. The strut 22 is shown in phantom in this view since it is enclosed in the sleeve 26.
Referring still to FIG. 1, the base strut 12 is constructed of a generally rectangular (including square) body portion 35 having an end cap 36 formed on the distal end thereof. A second end cap 37 is formed on the end 39 of strut 12 adjacent the bracket 16 secured to support pole 14. Cap 37 is formed for press fit engagement of the end 39 and thus has a mating shape to strut body portion 35. As shown herein, support pole 14 upstands from a base or ground region 40. Base or ground region 40 may also include the top of a building or other structure adapted for securement of a support pole 14 therefrom. Fasteners such as cotter pins 41 are used to secure the position of the strut 12 relative to the bracket 16. Additionally, the cotter pins 41 are easily removed to permit the strut 12 to slide toward the pole 14 for servicing and installation of the flag banner 20.
Referring still to FIG. 1, the assembled flag/banner 20 is permitted to move in response to wind loading in the direction of arrows 42 and 44 with unsupported edges 46 and 179 depending from the angulated strut 22 and terminating above the base strut 12. The generally rectangular body of base strut 12 further provides structural support of the assembly 10 by eliminating rotation thereof relative to the bracket 16. As shown here, the bracket 16 contains generally rectangular, aligned apertures 50 in opposite sidewalls 52 and 54 thereof. The apertures slidably receive the base strut 12 therethrough during assembly. A clamp 60 is shown positioned upon upstanding strut 18 for securing a lower corner 62 of the flag/banner 20 to the strut 18 for securement. The upstanding strut 18 is further supported from the base strut 12 by a shaft assembly 64 described in more detail below. An upper angulated shaft 66 connects the upstanding strut 18 and angulated strut 22 for support of the flag/banner 20 therefrom. Additional flag/banner attachments may be provided along the edge 68 of flag/banner 20 for connection to the upstanding strut 18. These connecting elements could be clamps, tethers, wires or the like. A single clamp 60 is shown in this particular embodiment and in FIG. 2 for purposes of illustration.
Referring now to FIG. 2, there is shown an enlarged, exploded, perspective view of the assembly 10 of FIG. 1. In this particular view, the bracket 16 is shown to be constructed with the generally rectangular slots 50 formed in opposite sides 52 and 54 of the bracket 16. A second slot 50 shown in phantom is formed in side 54 in a position for receipt of the base strut 12 therethrough. The slots 50 are formed in registry with one another for receiving the base strut 12 therethrough for support of the assembly 10. Cap 37 is, of course, shown in position for receiving the end 39 of support strut 12 therein after passing through the apertures 50 of the bracket 16. The cotter pins 41 described above are received within the apertures 43 which are drilled through opposite sides of the body portion 35 of strut 12. The cotter pins 41 are easily installed and removed and, once in place, minimize relative movement between the bracket 16 and the strut 12.
Referring still to FIG. 2, the bracket 16 includes a series of angulated slots 70, 71, 72, and 73 (shown in phantom) for receiving the fastener straps 80 and 82 therethrough. Fastener straps 80 and 82 are adapted for mounting the bracket 16 against the pole 14 (shown in FIG. 1) in secured engagement therewith. A gasket 83 mode of rubber, or the like, may be used as a mounting pad that improves the fractional engagement of the pole 14 (shown in FIG. 1) by the bracket 16. A gasket 83 is shown in FIGS. 1 and 2 as an optional feature. Strap locking elements 84 are provided on the ends of the fastener straps 80 and 82 for securing engagement thereof. The fastener straps 80 and 82 maybe formed of metal, synthetic material (such as plastic) or the like and may be of a quality which is conventionally used for securement of brackets to poles for the suspension of flag/banners therefrom. In that regard, a generally C-shaped bracket similar to that shown as bracket 16 but formed with a round hold in place of the generally rectangular hole 50 has been used in the prior art for receipt of a round rod or pole therethrough and the suspension of flags, pennants and/or banners therefrom. Such a pole can obviously rotate from wind loading or the like. In the present invention, the bracket 16 comprises a rectangular hole specifically configured for the receipt and mating engagement of a generally rectangular pole base strut 12 therethrough to prevent the base strut from rotating under the influence of wind loading thereabove. The construction of the fastener straps 80 and 82 as well as the bracket 16 may be of conventional materials such as steel, aluminum and synthetics. The present invention overcomes the disadvantages of prior art systems by utilizing a configuration permitting the upstanding display of a flag/banner 20, of the type shown in FIG. 1, in a position allowing the pivotal movement thereof in a lightweight, economical assembly.
Referring still to FIG. 2, the extension of the base strut 12 from the bracket 16 secured to pole 14 (shown in FIG. 1) provides the basic cantilever support of the upstanding strut 18. The upstanding strut 18 is formed of a generally hollow tube adapted for receiving the shaft assembly 64 therein. Shaft assembly 64 includes an elongate shaft 100, preferably made of solid metal, or the like having a threaded section 102 formed on its lower end 103. The utilization of a first washer 104, nut 106, second washer 108, third washer 110, and lock nut 114 provide securement of the shaft 100 in the aperture 116 formed in the end 117 of base strut 12. Cap 36 is secured adjacent to the shaft assembly 64. The receipt of the hollow strut 18 over the shaft 100 positions the strut 18 to sit on washer 104 and facilitates the rotation of the upstanding strut 18 relative thereto and the pivotal action of the flag/banner 20 shown in FIG. 1.
Referring still to FIG. 2, the angulated shaft 66 is shown constructed with a lower region 120 and an upper region 122 adapted for receipt within upper hollow section 123 of upstanding strut 18 and lower region 125 of strut 22, respectively. The strut 22 is likewise preferably formed of a hollow configuration so that it may be received upon the region 122 of angulated shaft 66. End cap 30 is also illustrated for receipt on the end 129 of strut 22 as shown in FIG. 1 for restricting wear of the sleeve 26 of the flag/banner therefrom (as shown in FIG. 1).
Referring now to FIGS. 1 and 2 in combination, the generally C-shaped bracket 16 is fabricated from aluminum, steel, synthetics, or the like for receipt of a rectangular base strut 12 found of aluminum, steel or the like as well as receipt of at least one fastener strap 80 and preferably two fastener straps 80 and 82 therethrough. The fastener straps 80 and 82 are tightened about the pole 14 to press the bracket 16 thereagainst in the configuration preventing any relative movement between the bracket 16 and the pole 14. With the introduction of the base strut 12 therein and the placement of the cap 37 thereover, the base strut 12 is in a position for supporting the flag/banner 20 upstanding therefrom. The threaded mounting of the shaft 100 by the threaded elements described above afford an economical unit that is easily assembled in the field. Any variety of flag/banners may be suspended from the struts 18 and 22 as described herein and other angles maybe afforded by changing the angle of the angulated shaft 66 described above. A rectangular flag/banner may, for example, be provided by providing angle shaft 66 in a right angle configuration. When natural forces engage the flag/banner 20, such as rain, wind, or the like, the flag/banner 20 acts much like a boat sail that is not tied down and is able to freely pivot to a position of least resistance to the force.
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. While the method and apparatus shown or described has been characterized as being preferred it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined in the following claims. | A flag/banner display system comprising a generally horizontal, cantilever mounting of a first base strut from which is mounted a pivotal strut array adapted for supporting a flag/banner therefrom. The pivotal strut array is formed in angulated fashion that pivotally moves about the end of the cantilevered base strut to thereby permit economical and aesthetically pleasing flag/banner/signage mountings capable of moving in response to wind loading and facilitating the use of interchangeable flag/banners thereon. |
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FIELD OF THE INVENTION
This invention relates to drilling devices and processes. More specifically, the invention is concerned with the control of fluid pressure within a wellbore while drilling.
BACKGROUND OF THE INVENTION
When rotary drilling an underground wellbore from the surface, a drilling fluid in the wellbore is typically used to prevent wellbore wall caving and prevent the intrusion of formation fluid, such as unwanted oil, gas, and water. Another important function of the drilling fluid (typically a "drilling mud" mixture) is to entrain drilled cuttings and circulate them to the surface and out of the borehole. The drilling fluid typically also cools and lubricates the moving drill string components and strikes the drilling face of the underground formation with an impact force that may further assist in drilling.
Although density, viscosity, and surface pressures on the drilling fluid are controlled, the density of the drilling fluid is the most important to control in order to provide a hydrostatic pressure in excess of formation pore pressure along the wellbore. This "overbalanced" pressure strengthens the wellbore (helping to avert wall cavings) and prevents a formation fluid influx or "kick" into the wellbore. However, the overbalanced pressure also strengthens the formation face being drilled similar to the strengthening of the walls of the drilled well. This now "harder" drilling face drills at a lower rate of penetration, increasing drilling time and cost.
Reducing the normally overbalanced pressure to minimize rotary drilling cost increases the risk of wellbore caving damage and well control problems. Thus, a drilling operator has to consider the conflicting fluid pressure needs of maintaining the integrity of the bore and economically drilling the formation face.
SUMMARY OF THE INVENTION
Such conflicting pressure needs are avoided in the present invention by controlling and isolating the pressure at the drill face from the pressure in the rest of the wellbore. This is accomplished by adding a jet pump to the drilling tool and a flow restricting housing to form an underbalanced pressure cavity at the drilling face. A first portion of the pressurized drilling fluid is introduced into the cavity and circulates to entrain cuttings at underbalanced pressure. The drilling fluid also serves as the power fluid of the jet pump which pressurizes the underbalance-pressure fluid and entrained cuttings back to the surface at overbalanced pressures. At the surface, the cuttings are separated (by conventional equipment such as shale shakers) and the drilling fluid is pressurized (typically by mud pumps) to be recycled back as the power fluid. The recycled drilling fluid can be introduced into the underbalanced pressure cavity formed by the housing as a plurality of streams for improved circulation, cooling, and lubrication.
One embodiment includes a cutting separator located in the jet pump housing near the jet pump diffuser outlet. A portion of the overbalanced-pressure fluid mixture continues to entrain the cuttings while a remaining portion (substantially free of cuttings) is diverted to the drilling face (and/or drill bit) within the cavity.
The invention uses the inherent fluid restriction of the drilling tool (including drill bit and shoe) combined with a housing which contains a jet pump. The housing and drilling tool restriction combined with the jet pump produce different (overbalanced and underbalanced) pressures above and below the drilling tool. The jet pump must not only handle the injected streams, but also fluid leakage past the around the drilling tool and any formation fluids produced across the drilling face. In addition to restricting or channeling flow, the shoe or outside lip of the drilling tool tends to support the wellbore at the overbalanced/underbalanced pressure transition zone.
The preferred process for drilling an underground borehole from a surface places the housed drilling tool and jet pump at or near the formation face to be drilled. Power fluid actuates the jet pump to maintain an underbalanced drilling fluid pressure while the drill bit is rotating and cutting into the formation face. The power fluid driven jet pump draws in the underbalanced-pressure drilling fluid and entrained cuttings mixture and discharges a majority of the mixture upwards towards the surface. A portion of the pump actuating fluid is diverted to supply drilling fluids to the rotary drill as jets to assist drilling and entrain cuttings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic cross-section of a rotary drilling tool and a jet pump housing;
FIG. 2 shows sectional with 1--1, as shown in FIG. 1;
FIG. 3 shows sectional view 2--2 as shown in FIG. 1;
FIG. 4 shows alternative drill bit as viewed as a sectional from line 2--2, as shown in FIG. 1;
FIG. 5 shows an alternative jet pump embodiment; and
FIG. 6 shows a process flow schematic.
In these Figures, it is to be understood that like reference numerals refer to like elements or features.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic cross-section of a bottom hole assembly or rotary drilling tool 2 embodiment of the invention in an underground wellbore 8. A housing 3 partially covers a rotary drill bit 4 and a cavity 12 which nearly encloses a jet pump jacket 5. The housing 3 extends from a drill pipe connection 6 to a shoe or outer lip 7. The drill pipe connector 6 is typically threadably connected to a drill pipe or other fluid conductor extending up to-the surface (not shown). The outer diameter of the shoe 7 is typically proximate to or substantially in contact with wellbore 8 when drilling. The housing 3 (and reinforcing ring 18) supports the drill bit 4 and jet pump jacket 5 within the drilling tool 2, and forms an inverted cup-like enclosure of the drilling face 9.
The formation at the drilling face 9 is typically cut into by forcing (typically by a weight on bit) the drill bit against the drilling face 9 and rotating the attached drill pipe from the surface. The drill pipe rotation rotates the drilling tool 2 through attached connector 6 and housing 3. Alternatively, the rotation of the drilling tool 2 can be accomplished by means of a downhole mud motor. The rotation of the drill bit 4 (supported by substrate 18a) within the housing 3 (and reinforced by ring 18) cuts into or abrades the underground formation at drilling face 9. Cuttings, as illustrated by one particle 10 shown in FIG. 1 near the drilling face, are generated by the rotating drill bit 4 and must be carried out of the wellbore to the surface if the drilling is to continue.
Drilling fluid is supplied from nozzles 11 in the jet pump jacket 5 (fluid flow is shown in FIG. 1 by arrows) to the drill bit 4 and drilling face 9. The drilling jets of fluid emanating from the nozzles 11 can be directed to lubricate and cool the drill bit 4 as well as provide sufficient flow to the drilling face 9 to entrain cuttings 10. Although the number of nozzles 11 is theoretically infinitely variable, for a nominal "shoe" and housing outside diameter of 81/2 inches (21.59 cm), the number of nozzles 11 is expected to range from no less than about 1 to no more than about 27, more typically ranging from about 3 to 5. Typical nozzle 11 shape is essentially a constant diameter hole or orifice, but contracting and/or expanding nozzle shapes (from a minimum throat dimension) are also possible. Typical orifice or minimum nozzle diameters for a nominal housing outside diameter of 81/2 inches (21.59 cm) having 3 nozzles 11 in jet pump jacket 5 may range from as small as about 1/32 inch (0.0794 cm) to as large as about 1/2 inch (1.27 cm), but diameters are more typically expected to range from about 1/16 to 3/16 inch (0.159 to 0.476 cm).
Each nozzle 11 is sized to produce a drilling jet in the fluid-filled cavity 12 which will impact a target. The target may be a portion of the drill bit 4 (e.g., for cooling and/or lubrication) or a portion of the drilling face 9, e.g., directed between drill bit elements (as shown in FIGS. 2 and 3) to entrain cuttings. If the target is a portion of the drill bit, the nozzle stream may also be required to carry past the drill bit 4 and onto the drilling face 9 to serve multiple purposes.
The number and size of nozzles 11, when combined with the pressure performance of the jet pump within jacket 5 and other sources of fluid into the cavity 12, produce a sufficient number of jet streams to create a flow of drilling fluid to entrain drilling cuttings 10. This flowrate is expected to be comparable to the circulation rate for comparable drilling tool diameters less an amount similar to the leakage flow (around the outside diameter) and formation fluid influx (at the drilling face).
The total fluid flow through nozzles 11, plus any influx of formation fluids at drilling face 9, cuttings, and leakage of fluid between the housing 3 and wellbore 8, forms a post-drilling fluid stream (at underbalanced pressure) which is drawn to suction ports 13 of the jet pump. The underbalanced-pressure stream flow is shown by generally upward pointing arrows in cavity 12 until suction ports 13 are reached. The nozzles 11 must also be sized to produce drilling jets which will overcome the underbalanced-pressure stream flow and reach the targets of the drilling jets.
The underbalanced-pressure stream must have a sufficient flowrate and velocity to entrain cuttings 10 and lift them to a suction port 13. For a nominal 81/2 inch (21.59 cm) outside diameter drill tool, upward fluid velocity in the cavity 12 is expected to range from about 80 to 300 feet/sec (24.38 to 91.44 meters/sec), preferably no less than about 120 feet/sec (36.58 meters/sec).
The desired (underbalanced) pressure in cavity 12 and at the drilling face 9 is a function of the formation pore pressure at the drilling face. The underbalanced pressure in cavity 12 depends upon several other factors, including jet pump performance, power fluid pressure in drill pipe connector 6, and the cutting speed (i.e., the volume of cuttings 10 generated). Cutting speed and source fluid pressure are typically controlled by a drilling operator to attain the desired underbalanced pressure.
The underbalanced pressure in cavity 12 allows drilling to proceed economically. Pressure near the drilling face 9 is generally expected to be at least about 30 psi (2.0 atmospheres) less than the formation pore pressure at drilling face 9, more typically ranging from 100 to 1000 psi (6.8 to 68 atmospheres) less than the formation pore pressure at drilling face 9. At times, the average pressure in cavity 12 may be more than formation pore pressure (e.g., during transients or drilling into highly fractured formations), but an underbalanced pressure is expected to assist in economic rotary drilling most formations and therefore be underbalanced most of the time during drilling.
Once the upward flowing underbalanced-pressure stream (with entrained cuttings) in cavity 12 reaches the suction throats of ports 13 within housing 3, the stream is induced into the jet pump jacket 5. The energy to increase the pressure of the underbalance pressure stream is supplied by a power fluid flowing from the surface through the drill pipe and drill pipe connector 6 to jet pump nozzle 14. The jet pump nozzle 14 size and power fluid flowrate and pressure are selected to produce a high speed, venturi-like low pressure zone extending across the suction ports 13. This low pressure zone induces and accelerates the flow of underbalanced fluid and cuttings along with the high speed power fluid from jet pump nozzle 14 prior to entry into the diffuser section 15 housed in jacket 5.
Although a single jet pump nozzle 14 is shown directed into the diffuser cavity 15, a plurality of jet pump nozzles 14 may be also used. Some of the nozzles may be used to help divert or otherwise protect the diffuser throat from the erosive effects of the accelerated cuttings. The diffuser throat may also be composed of hard or hardened materials, such as tungsten carbide, to further resist erosion.
The high speed mixed power fluid and induced flows (including cuttings) enter a diffuser cavity 15 to convert the kinetic energy into increase pressure. The downwardly enlarging cross-sectional area of the diffuser cavity 15 slows the mixed power fluid speed and induced (fluid and cuttings) flows and increases the pressure (to an overbalanced pressure). This increased or overbalance pressure in diffuser cavity 15 is again controlled by the drilling operator primarily by the selection of power fluid pressure and flows at the surface. Although the overbalanced pressure can theoretically vary over a much wider range, the overbalanced pressure in diffuser cavity 15 is typically at least 100 psi (6.8 atmospheres) above formation pore pressure at drilling face 9, more typically ranging from about 200 to 500 psi (13.6 to 34.0 atmospheres) above formation pore pressure at drilling face 9.
After slowing in the diffuser cavity 15, the overbalanced pressure fluid then encounters a partial cuttings separator 16. In this embodiment, the separator 16 is a fixed, helically-shaped baffle swirling the mixed fluid and cuttings stream around the centerline of the drilling tool 2. The density differences between the swirling cuttings 10 and the swirling mixed fluids in separator 16 force the normally heavier cuttings outward towards discharge ports 17 along with a portion of the fluid flow. However, a portion of the (lighter-than-drill-cuttings) fluid stream separates from the entrained cuttings (nearer the centerline of the diffuser) to become the source for the drilling jet streams from nozzles 11.
The overbalanced-pressure, entrained mixture discharged from discharge ports 17 then flows up the wellbore 8 in the annulus between the walls of the wellbore 8 and the drill pipe towards the surface (not shown), as shown by generally upward pointing arrows proximate to the walls of wellbore 8. The overbalanced pressure in the wellbore 8 substantially prevents the influx of formation fluids into the wellbore (except proximate to the drilling face) as the fluid rises to the surface. For a typical discharge stream in the wellbore 8, a minimum fluid velocity of 80 ft/sec (24.38 meters/sec) is expected, preferably at least 120 ft/sec (36.58 meters/sec).
At the surface, the mixed discharge stream is recycled. The entrained cuttings in the mixed stream are substantially fully separated by conventional means, such as cyclones, shakers, screens, and/or a setting basin (not shown). The cuttings-removed stream is then recycled by treating as necessary, pressurizing the stream in a conventional mud pump at the surface (not shown), and returning the pressurized stream downhole through the drill pipe as the power fluid supplied to the drill pipe connector 6. Treating can include further fluid monitoring and processing at the surface, such as monitoring density and adding muds to compensate for any influx of unwanted formation fluids.
The power fluid is expected to be a drilling mud entrained in water or other fluids, similar to other drilling fluids since the power fluid must also function as a drilling fluid as well as the means for operating the jet pump. This added jet pump requirement can require slightly different properties than that required for a drilling fluid only application. For example, the power fluid viscosity is expected to be slightly less than a similar drilling-fluid-only application.
Other possible uses for the power fluid/drilling fluid mixture emanating as a drilling jet stream from nozzles 11 include cooling and lubricating the drill bit 4. Drill bit 4 is shown schematically in FIGS. 1 and 3 as a segmented face type, e.g, diamonds or other hard inserts embedded in a segmented substrate. These types of drill bits are expected to require minimal lubrication and cooling other than that supplied by leakage around the shoe and formation fluids influx at the drilling face 9. But other types of drill bits can also be used which may require greater attention to separate jet streams for cooling and/or lubrication. This includes conventional cone-type rolling cutter bits which may require greater lubrication, but less cooling. (See FIG. 4.)
In addition to any cooling and lubrication provided by the drilling jet streams from nozzles 11 shown in FIG. 1, entrainment, lubrication and cooling flows to the drill bit 4 (and formation face 9) may also be provided by a conduit or passageway from the drill pipe connector 6 through housing 3 to near the drill bit 4 (shown dotted as an option for clarity). A separate fluid source instead of the power fluid may also be provided, such as lubricating fluid string. The conduits or passageways would transmit the power (or other) fluid to the drill bit, such as a roller axis, or impinge the drilling face 9. The separate conduit could further supplement or replace the cooling and lubrication provided by the drilling jet streams from nozzles 11. If the conduit replaces the nozzles 11, the separator 16 could be eliminated.
Instead of leakage, channels in the outside diameter of the shoe of housing 3 (not shown) are another alternative that can provide additional or bypass flows of entrainment, lubrication, and/or cooling fluids to near the drill bit 4. Increased amounts of fluid would flow through the channels from the overbalanced pressure wellbore 8 to the underbalanced pressure cavity. Although cuttings and sediment may tend to accumulate at this lowest point of the overbalanced-pressure wellbore cavity, the rotation of the housing 3 and the continuous jet pump suction is expected to keep these channels free flowing.
FIG. 2 is the sectioned view 1--1, as shown on FIG. 1. Eight drill stream nozzles 11 around a central nozzle 11 are shown in diffuser jacket 5, but other nozzle numbers and geometries are possible.
The preferred drilling jet stream nozzles 11 not only direct the jet streams downward and outward (as shown in FIG. 1), but circumferentially as shown by the arrows in FIG. 2 emanating from the nozzles 11. This circumferential component of the jet stream directs the drilling jet streams onto the side of a segment of drill bit 4 and (from there) onto the drill face 9 (also see FIGS. 1 and 3). Other configurations can have some of the drilling jet streams from nozzles 11 directed between the drill bit segments (see FIG. 3) to directly impinge the drill face (see FIG. 1).
In addition to providing discharge conduits through the cavity 12 to the outer annulus 8a between the upper portion of the housing 3 and the wellbore 8 (see FIG. 1), the discharge ports 17 shown on FIG. 2 further serve to laterally support and stabilize the jet pump jacket 5 with respect to the drill tool housing 3. If additional lateral and/or axial support of the jacket 5 is needed, jacket-to-housing struts (not shown) or added discharge ports 17 approximately 90 degrees from those shown may be provided.
FIG. 3 is the sectioned view 2--2, as shown on FIG. 1. Eight radial or spoke-like drill bit segments 19 (only one identified for clarity) of drill bit 4 are spaced around the cutting face enclosed by housing 3. In addition to the structural rigidity provided by housing 3 and the radially oriented substrates 18a (see FIG. 1) which form the drill bit segments 19 shown in FIG. 3, the inner ring 18 reinforces the drill bit segments 19 and provides additional strength. Depending upon contact and pressures between the lip 7 of housing 3 (see FIG. 1), the reinforced housing also stress relieves the formation just above the drilling face.
The inner ring 18 may also tend to segregate drilling fluid circulation patterns as shown by the arcuate arrow near the drilling face 9 as shown on FIG. 1. The segregated circulation patterns can prevent hot spots and/or areas where cuttings are not fully entrained.
Within the spoke-like drill bit segments 19 in FIG. 3 are channel spaces 20 for fluid flow. The channels 20 (in the substrate 18a as shown in FIG. 1) shown in FIG. 3 are provided between hardened cutting faces 21 to allow cuttings and fluid flow across a drill bit segment 19 as well as around it. Cutting faces 21 are shown embedded in the substrate 18a or otherwise fixed in position relative to the housing 3, but cutting faces 21 may also be rotatable around an axis parallel or nearly parallel to the length of the drill bit segment 19 they are mounted on.
FIG. 4 shows an alternative roller drill bit 22 as it would be viewed at Section 2--2, as shown in FIG. 1, similar to the view of drill bit 4 shown in FIG. 3. Each of the three roller cones 23 shown in FIG. 4 has alternative hardened cutting protrusions 24 (identified only on one roller cone for clarity) embedded in a roller cone substrate.
The roller cones 23 rotate around individual centerline axis (only one shown for clarity) which is typically doubly offset. It is offset slightly from the (housing) radial direction and slightly out a plane parallel to section 2--2, (as shown in FIG. 1). The slight centerline offsets produce a scraping action as the roller cones 23 rotate as the entire roller drill bit 22 rotates, facilitating the cutting action. The roller cones 23 can be freely rotating as shown, geared to rotate together, driven to rotate (for example by a mud motor), or assisted in rotating by an offset impingement of a drilling jet stream.
Drilling jet streams from nozzles 11 (see FIGS. 1 and 2) could directly or offset impinge on the roller cones 23 shown in FIG. 4, but could also be directed towards the drilling face 9 (see FIG. 1) between the roller cones in spaces 25. The drilling fluid mixture and entrained cuttings would return through the spaces 25 to a cavity similar to cavity 12 shown in FIG. 1 and be drawn into a jet pump as previously discussed.
FIG. 5 is a cross-sectional schematic of an alternative and preferred embodiment which deletes the need for the partial downhole separator 16 (shown in FIG. 1). A power fluid (typically pressurized using a surface mounted pump in conjunction with the hydraulic head developed at the underground location), similar to that previously discussed, is conducted down an alternative drill pipe or other conduit connector 6a. Portions of the power fluid (shown as arrows) exit as alternative drilling jet streams through alternative drilling jet nozzles 11a and the remainder serves as to actuate the alternative jet pumps 5a. The drilling fluid and entrained cuttings in alternative cavity 12a (with flow shown as arrows) are drawn into alternative suction ports (similar to ports 13 shown in FIG. 1) to be increased to overbalanced pressure and directed back towards the surface through the annulus proximate to the wellbore 8. It will be understood by those skilled in the art that still other alternative suction ports locations and drilling jet nozzle configurations and orientations can be made, e.g., when improved erosion resistance or proximity of the suction ports to the drilling face is required.
The alternative discharge parts 17a are shown arched to discharge in a slightly upward direction toward the surface proximate to where they are attached to the alternative housing 3a, but many other directions are also possible. The arced embodiment tends to throw cutting to the outside surface of the arc, allowing takeoff (not shown) of relatively cuttings-free fluids from the inside surface of the arc, if required. Alternative discharge ports 17a may be nearly straight and oriented in a nearly vertical direction (discharging fluid near the top of the alternative housing 3a) or further curved to form a nearly 90 degree turn from a nearly horizontal orientation near the alternative suction ports (similar to ports 13 shown in FIG. 1) to discharge into annulus 8a near the alternative housing 3a. Still further, the structure forming the alternative discharge ports 17a can also be part of the drill bit substrate 18a, supporting the combined functions of the jet pumping and rotary drilling.
FIG. 6 shows a process flow schematic. A recycled source of fluid at the surface (from pump V) supplies power fluid source I, along with additives, makeup fluids, data, and controls as required. Controls may be operated manually by a drilling rig operator or may be computer controlled by a programmable controller to which data signals, such as rotational speed, are transmitted. The power fluid source I is typically mounted at the surface near the wellbore being drilled.
The pressurized (and controlled flowrate of) power fluid is transmitted downhole, typically via rotating drill pipe, to a jet pump II, such as that shown in FIG. 1. The jet pump II creates a suction which draws in drilling fluids and entrained cuttings from the drilling face.
The mixture of power fluid, drilling fluid, and entrained cuttings is discharged to a partial separator III in the preferred embodiment. The partial separator III concentrates the cuttings in a first portion of the power fluid and drilling fluid mixture, which is directed back up towards the surface to a surface separator IV. The remaining second portion can form a primary source of the drilling fluid, which is throttled to a lower pressure, sprayed towards the formation face being drilled, and drawn back into the jet pump II (possibly along with formation fluids and leakage and/or channeled bypass flows as previously discussed).
The surface separator IV removes most of the cuttings, along with some (excess) fluids, producing a fluid relatively free of large cut particles. The fluid is then directed to a pump V where it is recycled back to the power fluid source I for treatment and/or controls. Alternatively, the locations of pump V and power fluid source I can be interchanged.
The process of using the alternative embodiment shown in FIG. 5 is the same as shown in FIG. 6 except the first and second portions are produced at the jet pump II intake, shown as a dotted line. This allows the elimination or bypassing of the partial separator III.
Still other alternative embodiments are possible. These include: a variable throat jet pump nozzle 14, e.g., a moveable conical plug place at the throat of the jet pump nozzle; a variable diffuser throat, e.g. a moveable throat to allow for erosion; a plurality of jet pumps, at least one of which does not supply drilling jet nozzles and at least one which does; and inverting the orientation of the jet pump within the jacket 5, placing the suction ports 13 closer to the drilling face 9.
While the preferred embodiment of the invention has been shown and described, and some alternative embodiments also shown and/or described, changes and modifications may be made thereto without departing from the invention. Accordingly, it is intended to embrace within the invention all such changes, modifications and alternative embodiments as fall within the spirit and scope of the appended claims. | A method for rotary drilling and removing cuttings provides a underbalanced drilling fluid pressure at the drilling face but overbalanced pressure in the wellbore. The preferred method uses a rotary drill within a housing which also encloses a jet pump which draws and pressurizes the cuttings and drilling fluid, a separator of the cuttings and a portion of the pressurized drilling fluid, and a nozzles to supply separated and reduced pressure drilling fluid back to drilling face while the cuttings and remaining pressurized drilling fluid flows up towards the surface. The method avoids overpressure strengthening of the drill face and underpressure damage to the wellbore. |
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TECHNICAL FIELD
[0001] This patent of invention application relates to a device to be used in mechanically enlarge of caisson bases, so that form a semi-spherical cavity at the base of caisson performed.
[0002] Currently, every soil excavating process for carrying out of base for caissons é performed manually, consisting of carrying out the same with a operator going down in the shank of caisson for enlarging the base, which process impose risks to the executor, incurring the possibility of soil landslip.
[0003] In this patent of invention application, the developed process has the purpose to remove the human figure of the process, avoiding burial risks and speeding up the base enlarging process, which is efficient in terms of reduction of execution time in the order of 80% or more.
[0004] Some features of purpose of invention are:
possibility of change in knives, which allows a opening of bases with different diameters; creation of a collector system facilitating the removal of excavated soil, besides take the easy of coupling in consideration.
SUMMARY DESCRIPTION OF INVENTION
[0007] The present invention relates to a device to be used in mechanically enlarge of caisson bases.
[0008] Device for enlarging caisson bases comprises:
an engine shaft; a socket of engine shaft; a fixation pin of engine shaft; a moveable column; a guide ring bound to moveable column; a rotary joint, a stationary column; two side arms and two knives fixed to arms, which are part of soil excavating mechanism; a collector vessel of excavated soil bound to stationary column; and pivotable caps at vessel.
[0018] The device is a mechanism comprising, at upper extremity, the socket of engine shaft of machine carrying out the mechanical excavating of caisson (the fixation of shaft in socket is made through cylindrical pin), being, at the side arms, the knives carrying out the enlarging and, at lower extremity, a collector vessel of excavated soil.
[0019] The engine shaft rotates and presses the device against the bottom of orifice. The side arms of device open and the knives perform the excavation of soil, which is lodge at collector vessel, as the excavation proceeds.
[0020] The collector vessel, at the base of mechanism, is bound to its, through rotary joint, so that, while the mechanism rotates, the collector vessel could not rotate.
[0021] After the end of operation, a collector pan can already rotate, removing the soil from the bottom of caisson which is irregular due to excavation process of shank, providing a compact surface at the base of same.
[0022] To better understanding, the following schematic figures of particular embodiments of invention will be shown, the dimensions and ratios of which are not real necessarily, because the figures has the only purpose for didactically show the preferred applications, the protection scope of which is determined by the scope of appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0023] This invention will be better understood by means of figures, which illustrate schematically the following:
[0024] FIG. 1 —perspective view of device in general feature;
[0025] FIG. 2 —front view of device during the performance of enlarging of caisson base;
[0026] FIG. 3 —view of device at initial position, about to initiate the enlarging of caisson base;
[0027] FIG. 4 —view of device at final position of enlarging operation;
[0028] FIG. 5 —view of device already out of caisson, with pivotable caps at position for eliminating excavated soil;
[0029] FIG. 6 —view of shank of accomplished caisson ( 6 a ) and view of caisson base enlarged by device ( 6 b );
[0030] FIG. 7 —view of stationary and moveable columns, separated by rotary joint, in details; and
[0031] FIG. 8 —schematic view of fixation of knife in the side arm.
DETAILED DESCRIPTION OF INVENTION
[0032] According to FIG. 1 , it is possible to note the general feature of device for enlarging caissons, said device comprising, at upper extremity thereof, a socket ( 11 ) of engine shaft ( 1 ), a guide ring ( 2 ), a soil excavating mechanism ( 3 ), and a collector vessel for excavated soil ( 4 ).
[0033] Said soil excavating mechanism ( 3 ) and collector vessel of excavated soil ( 4 ) has cylindrical shape, which fits to diameter of caisson to be enlarged.
[0034] FIG. 2 shows the device in details, during the performance phase of enlarging a caisson base, wherein said device comprises, at upper extremity thereof, the socket ( 11 ) of engine shaft ( 1 ) of machine carrying out the mechanical excavating of caisson, wherein a fixation of shaft ( 1 ) in the socket ( 11 ) is made through a cylindrical fixation pin ( 12 ), said device comprises, at side arms ( 6 ) thereof, knives ( 7 ) which perform the enlarging of caisson base, and said device further comprises a collector vessel ( 4 ) of excavated soil at lower extremity thereof.
[0035] During the enlargement performance, engine shaft ( 1 ) rotates and presses the device against the bottom of caisson, thus, side arms ( 6 ) open and knives ( 7 ), fixed to arms ( 6 ), perform excavation of soil, which will be lodge in the collector vessel ( 4 ). Said collector vessel ( 4 ) is bound to said mechanism ( 3 ), at base thereof, through a rotary joint ( 8 ), such that, while mechanism ( 3 ) rotates, the vessel ( 4 ) could not rotate.
[0036] Said side arms ( 6 ) are fixed in the excavating mechanism ( 3 ) through horizontal bars ( 62 ) and pivotable bars ( 61 ), moving in accordance with motion of moveable column ( 5 ), as said moveable column ( 5 ) is pressed against the caisson, thus allowing the arms ( 6 ) to leave of initial position thereof, and moving to the final position of enlarging process. Said bars ( 61 , 62 ) and arms ( 6 ) are hinged through pins ( 63 ).
[0037] FIGS. 3 and 4 show, respectively, device at the initial position, about to initiate the enlarging operation of caisson base, and the device at the final position of operation, wherein the soil excavated by knives ( 7 ) is lodged in the collector vessel ( 4 ). Device is shown at FIG. 5 , already out of caisson after operation, with pivotable caps ( 41 ) at position for eliminating excavated soil, arranged at lower portion of collector vessel ( 4 ). Said pivotable caps ( 41 ) have a semi-circular shape, matching with collector vessel ( 4 ).
[0038] FIGS. 6 a and 6 b show the shank of accomplished caisson, before and after the base enlarging by said device, respectively.
[0039] In accordance with FIG. 7 , it can be seen the columns, called stationary ( 9 ) and moveable ( 5 ), separated by rotary joint ( 8 ) of device for enlarging.
[0040] Said stationary ( 9 ) and moveable ( 5 ) columns have cylindrical shape, and further, said moveable column ( 5 ), according to motion thereof, works at the device like a shaft.
[0041] At the beginning of enlarging operation, pin ( 81 ) crosses the lock ( 82 ), and lateral portion ( 85 ) of rotary joint ( 8 ), such that two columns stand alone. This allows the rotate of collector pan ( 4 ), removing the soil from the bottom of caisson, which is irregular due to excavation process of shank, and providing a compact surface at the base of caisson.
[0042] A lower portion ( 84 ) is a stand-alone stationary column ( 9 ), and together with upper portion ( 83 ), through bolt ( 87 ), they make a coupling of rotary joint ( 8 ), which allows motion at the same longitudinal axis of engine shaft ( 1 ), and moveable column ( 5 ) with the stationary column ( 9 ). This alignment is obtained in operation both with and without the lock pin ( 81 ).
[0043] Rotary joint ( 8 ) further comprises abutment joints ( 86 ) disc-shaped, to eliminate the friction between metallic parts in the excavation operation of soil, wherein, at this moment, only the moveable column ( 5 ) rotates.
[0044] At following step, lock pin ( 81 ) is removed, and only the moveable column ( 5 ) rotates, causing the knives ( 7 ) starts the soil removal process.
[0045] Said knives ( 7 ) are fixed to side arms ( 6 ) through three bolts ( 64 ), as shown at FIG. 8 , providing a risk-proof fixation.
[0046] In addition, device allows utilization of knives with different sizes, so as to provide different diameters of base for the same diameter as the shank of caisson. Said knives ( 7 ) have an L-shape, and at upper portions thereof, a portion of knife ( 71 ) is tilted, so as remove the soil easier.
[0047] The scope of this patent of invention, therefore, should not be limited to illustrated applications, but, instead, only to terms defined at claims and equivalents thereof. | The present invention relates to a device used to mechanically enlarge the base de caissons, so as to form a semi-spherical cavity in the base de the caisson formed, in which said device includes a socket in the upper extremity thereof for the engine shaft, a guide ring, a soil excavating mechanism and a recipient for collecting the excavated soil. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation patent application of United States patent application Ser. No. 13/595,834 filed on Aug. 27, 2012, which is a continuation patent application of United States patent application Ser. No. 12/357,274 filed on Jan. 21, 2009, the entire contents of which are incorporated herein by reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not Applicable
BACKGROUND
The present invention relates generally to concrete products, and more particularly, to a method of imprinting a visual and textural decorative pattern upon a concrete surface.
As is well known in the building and construction trade, concrete is extensively utilized as a building material for industrial, commercial and residential applications. Due to its durability, water resistance, and cost economy, concrete has gained wide spread use in flooring applications. As a result of wide spread use and popularity, the market is currently demanding concrete surfaces that have an improved aesthetic appeal with limited imperfections and irregularities. Common imperfections include blowholes, or minor lines and cracks that may form while the concrete is cured.
In order to meet this demand, the concrete trade has developed various coloring and surface finishing techniques designed to enhance the aesthetic appeal of concrete surfaces while masking imperfections and irregularities that may exist in the exposed surface areas. An example of such a finishing technique includes push broom finishes. Familiar push brooms such as are commonly used in sweeping floors are pulled across the drying concrete surface, leaving a pattern formed by the bristles as they pass across. Such brooms will ordinarily be found to possess threaded apertures into which a handle with perhaps one or more extensions may be fitted. The resultant bristled appearance provides a generic broom pattern across the concrete surface and serves to hide irregularities and imperfections that may exist thereupon. However, the bristled appearance left by the push brooms is often undesirable as it is not aesthetically pleasing and fails to provide any variations in depth, size, or diameter within the contours of the texture. Additionally, a push broom is increasingly unwieldly and it being the general experience that a push broom is unable to provide a consistent uniform finish across the surface.
Another known method of providing visual and textural effects to a concrete surface is the exposed aggregate method. The exposed aggregate method may be used to diminish the appearance of imperfections within a concrete surface while creating an aesthetically appealing application of concrete. Applicant has conducted extensive research and has developed a variety of methods improving upon the exposed aggregate method, including a variety of surface seeded exposed aggregate products and methods. In particular, several of these methods and products are described in Applicant's U.S. Pat. Nos. 4,748,788, 6,016,635, 6,033,146, and U.S. Patent Publication No. US 2007/02346, the contents of which are incorporated herein by reference.
In a particular surface seeded exposed method, subsequent to pouring the concrete, rock or gravel aggregate is scattered (i.e. broadcasted or seeded) over the top surface of the concrete and subsequently troweled into the same. As the concrete cures, the aggregate becomes adhered to the top surface of the concrete and is thus exposed. Although various sizes of aggregate can be broadcast over the top surface of the concrete in this method, such aggregate is normally of about three-eighths inch diameter or greater in size, and has sheared or jagged edges. The size and shape of the aggregate allows it to be worked into the top surface of the concrete and adequately adhered thereto. Applicant's techniques as described in the above-mentioned patents overcame many of the deficiencies of the prior art and produced improved surface finishes on surface seeded exposed aggregate concrete. In particular, the concrete resultant from practice of the above-mentioned patents exhibits an extremely flat exposed aggregate surface suitable for extremely high traffic flooring applications.
A requisite feature of surface seeded exposed aggregate is the addition of aggregates to the concrete surface. Therefore, there is a need in the art for applying a visual and textural decorative pattern upon a concrete surface capable of concealing imperfections or irregularities thereupon.
BRIEF SUMMARY
According to a preferred embodiment of the present invention, a method of imprinting a visual and textural decorative pattern to an uncured concrete surface is provided. Implementations of the present invention include a concrete product having a surface that models the fine, medium, and/or coarse grain textures of wood, lightly finished cut or honed stone, and the like. Further implementations of the present invention include a concrete product having a surface that incorporates a design pattern featuring any visual or textural pattern in accordance with a pattern imprinted upon a decorative finishing tool. Thus, implementations of the present invention may provide a concrete surface that precisely assimilates the characteristics and colors of wood or stone, including graining, fractures, and/or rock texture properties common in cut or honed stone implemented by utilizing a single finishing tool. Additionally, the unique design pattern serves to shield imperfections and irregularities existing on the concrete surface.
The method generally commences by preparing the concrete surface so that the decorative pattern may be implemented. In this regard, the initial step requires pouring a concrete mixture over the subgrade, with the concrete mixture defining an upper exposed surface when poured. Prior to the concrete mixture being poured thereover, the subgrade is preferably prepared to a desired grade. Such preparation preferably comprises compacting the subgrade to approximately 90% compaction. The compaction of the subgrade may be followed by the placement of a layer of sand thereupon, and the subsequent placement of reinforcement members (e.g., rebar) upon the layer of sand. When the layer of sand and reinforcement members are provided with the prepared subgrade, the concrete mixture is poured over the layer of sand and the reinforcement members such that the reinforcement members are encapsulated therewithin.
After the concrete mixture has been poured, the same is preferably screeded to a desired grade, which is followed by the step of finishing the exposed surface of the concrete mixture with a finishing tool, such as a vibrating metal bull float, to dispose a quantity of cement/fines paste derived from the concrete mixture at the exposed surface thereof. The finishing of the exposed surface via the vibrating metal bull float in this particular step also seals the exposed surface. It is contemplated that this initial finishing step may be completed through the use of either a vibrating magnesium bull float or a vibrating aluminum bull float. The Lievers Holland Company sells a preferred metal bull float under the trademark HAL 200.
It is contemplated that the decorative pattern may be implemented upon all types of concrete surfaces including surface seeded exposed aggregate. If the concrete surface is a surface seeded exposed aggregate then subsequent to the completion of the initial finishing step, a quantity of aggregate is broadcast upon the exposed surface of the concrete mixture. The aggregate may comprise silica sand, glass bead, coarse sand (e.g., Monterey Aquarium coarse sand), organic materials (e.g., sea shells), metals, or composite materials. The aggregate may comprise of particular materials specifically needed to create the sought after pattern. The quantity of aggregate is preferably broadcast over the exposed surface of the concrete mixture at an approximate rate of one pound per square foot of the concrete mixture. It is contemplated that the aggregate selected should carry certain requisite design features sought in the decorative patterns, such as size, color, or reflective qualities.
After being broadcast about the exposed surface of the concrete mixture, the quantity of aggregate is then preferably mixed into the quantity of cement/fines paste through the use of the vibrating metal bull float. As indicated above, the vibrating metal bull float used in the mixing step may comprise either a vibrating magnesium bull float or a vibrating aluminum bull float. Importantly, this mixing step is used to fully embed the quantity of aggregate into the quantity of cement/fines paste.
Subsequent to the initial preparation of the concrete surface, the exposed surface of the concrete mixture is finished with a decorative finishing tool thereby imprinting a decorative pattern on the exposed surface. In this regard, the predetermined pattern may be any visual or textural pattern such as wood grain, or light ground finishes found in cut or honed stone. A decorative finishing tool includes a blade having an impression of the decorative pattern formed thereupon. The blade is then troweled over the exposed surface of the concrete mixture to imprint the decorative pattern upon the exposed surface. The blade may have a custom designed template having protrusions such as rods, or indentations to uniquely form the decorative pattern. It is contemplated that protrusions, such as rods, may be rigidly attached to the blade through conventional means known in the art such as adhesives, welding, or fitting into grooves. It will be appreciated that the decorative pattern may have variations in depth, length, or size while still being formed by a single decorative finishing tool. Thereby, permitting a user to create such an aesthetically pleasing surface without the need for additional manpower.
Upon the implementation of the decorative pattern, the concrete surface is cured. In this regard, it is contemplated that a variety of finishing techniques may be employed specific to the type of concrete being utilized. Resultantly, a concrete surface having an aesthetically appealing visual and textural decorative pattern formed thereupon is provided. It will be appreciated that such a surface may be utilized in high traffic applications and retains the stability and durability features of concrete.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:
FIG. 1 is a perspective view illustrating stages of preparation of a decorative concrete product produced in accordance with an embodiment of the present invention;
FIG. 2 is a perspective view of a decorative finishing tool having a blade configured with a plurality of grooves for attaching the rods therein.
FIG. 2 a is a section view of the decorative finishing tool illustrating the grooves formed in the blade.
FIG. 3 is a perspective view of the rods configured to attach in the grooves of the blade of the decorative finishing tool; when attached the rods contact the exposed surface and imprint the visual and textural design pattern thereupon.
FIG. 4 is a perspective view of the rods rigidly attached to the grooves of the blade of the decorative finishing tool.
FIG. 5 is schematic diagram illustrating steps of a method for producing the concrete product in accordance with the present invention
DETAILED DESCRIPTION
Referring now to FIGS. 1-5 , pictorially and schematically illustrating the method transferring a visual and textural design to an uncured concrete surface of a concrete mixture utilizing a decorative finishing tool. The preferred method utilizes a decorative finishing tool to implement a pattern on the exposed surface of the concrete. As a result, the concrete is given an aesthetically pleasing appearance having various depths, sizes, diameters, and length within the contours of the texture thereby resembling natural patterns such as wood grain, or lightly finished cut or honed stone. Additionally, such contours and designs conceal imperfections and irregularities from the concrete surface.
The preferred method commences by preparing the concrete surface. In this regard, the initial step comprises preparing the subgrade 10 to a desired elevation and grade. The subgrade 10 layer of a pavement is, essentially, the native material underneath the pavement. It is also known as the “formation level”, which can be defined as the level at which excavation ceases and construction starts, therefore it is the lowest point of the pavement structure. Generally, a subgrade 10 requires some basic preparation for adaptation for construction purposes, this process is known as ‘subgrade formation’ or ‘reducing to level’. Such preparation preferably comprises compacting the subgrade 10 to approximately 90% compaction. Subsequent to being compacted, the subgrade 10 is preferably covered with a layer of clean, moist fill sand 12 which is preferably maintained at a minimum four inch thickness. Although the fill sand 12 is not absolutely necessary for the method of producing the decorative concrete surface of the present invention, it is highly desirable to control the hydration process of the concrete. In order to increase the resultant strength of the concrete and reduce subsequent cracking of the same, reinforcement members 14 such as wire mesh or rebar is/are positioned upon the layer of fill sand 12 .
With the reinforcement members 14 in place, a concrete mix or mixture 16 is poured over the layer of fill sand 12 and the reinforcement members 14 such that the reinforcement members 14 are encapsulated therewithin. The concrete mixture 16 is poured to approximately a three and one-half to four inch thickness. Although variations in the concrete mixture 16 are clearly contemplated, a preferred concrete mixture 16 comprises 70% sand and 30% three-eighth inch mean diameter aggregate combined with six sack cement (two thousand pounds per square inch) or seven sack cement (three thousand pounds per square inch). Dependent upon individual desires, various color mixtures can be added to the concrete mixture 16 . The color of the concrete mixture 16 may be specifically selected to complement the overall design being implemented in the decorative pattern. It is contemplated that a variety of colors to enhance the effects of the decorative pattern 24 may be employed by the present invention. In the present embodiment of the invention, the decorative pattern 24 implemented on the concrete structure is similar to wood grain. Therefore, the color of the cement mixture 16 may be reflective of wood, taking the color of brown or dark brown or a mixture of colors complementing the desired aesthetic appeal of the decorative pattern 24 . It is further contemplated that numerous colors may be employed at various stages of concrete preparation process to obtain varying shades of color if so desired.
After the concrete mixture 16 has been poured, the same is preferably screeded to a desired level plane or grade. Screeding is leveling and smoothing the top layer of the concrete mixture 16 , so the mixture 16 is the same height as the forms, or guides, that surround it. The screeding of the concrete mixture 16 results in the same defining a generally level or planar upper exposed surface 18 . Therefore in order to facilitate the implementation of the decorative pattern, subsequent to screeding, the exposed surface 18 of the concrete mixture 16 is surfaced or finished with a conventional finishing tool to dispose a quantity of cement/fines paste derived from the concrete mixture 16 at the exposed surface 18 thereof.
In the preferred embodiment, a vibrating metal bull float is utilized as the finishing tool. Such vibrating metal bull floats are known in the art and are characterized by possessing an extremely smooth or polished surface which, in addition to bringing up the appropriate amount of cement/fines paste for the subsequent manipulative steps of the present invention, also tends to seal the exposed surface 18 of the concrete mixture 16 . It is contemplated that this initial finishing step may be completed through the use of a conventional bull float. A bull float consists of a trowel blade produced from a specially designed hollow section alloy extrusion with a convex profiled sole. Typically, the blade angle is easily controlled to facilitate forward and backward movement by a blade pitch control. A bull float generally provides very accurate levels without the need for guiding rails. In the present embodiment, it is preferred that either a vibrating magnesium bull float or a vibrating aluminum bull float is utilized. A preferred metal bull float is sold under the trademark HAL 200 by the Lievers Holland company.
According to one aspect of the present invention, when the exposed surface is in the plastic state, fine sand 20 may be broadcast over the exposed surface 18 . The fine sand 20 may be of any given color or texture, as required by the decorative pattern 24 . Further, it is contemplated that various combinations of color, texture, or other characteristics of the fine sand 20 may be selected in order to complement the decorative pattern 24 .
It is contemplated that the present invention may be implemented upon a variety of concrete surfaces, including surface seeded exposed aggregate. Therefore, in an exemplary embodiment of the present invention, a quantity of aggregate 22 may also be broadcast upon the exposed surface 18 of the concrete mixture 16 . When the exposed surface 18 of the concrete mixture 16 is still plastic, small size exposed aggregate 22 is broadcast over the exposed surface 18 . It is preferred that aggregates 22 be clean, hard, strong particles free of absorbed chemicals or coatings of clay and other fine materials that could cause the deterioration of concrete. The selection of aggregates 22 may impact the aesthetic appearance of the decorative pattern. In this regard, the aggregates 22 are selected to complement the overall visual and textural characteristics of the design pattern.
As a result, a variety of techniques may be employed such that the aggregates 22 carry the desired visual and textural characteristics as required by the decorative pattern 24 . In an exemplary embodiment of the present invention, a benefaction process such as jigging or heavy media separation can be used to upgrade the quality of the aggregates 22 . In this regard, once processed, the aggregates 22 are handled and stored in a way that minimizes segregation and degradation and prevents contamination. Aggregates 22 not only impact the aesthetic characteristics of concrete but also influence freshly mixed and hardened properties, mixture proportions, and economy of the concrete.
It is preferred that the aggregate 22 comprise silica sand, glass bead, coarse sand (e.g., Monterey Aquarium coarse sand), organic materials (e.g., sea shells), metals, or composite materials. Additionally, it is preferred that any aggregate 22 employed in the present invention be characterized by having a mean average diameter size of approximately one-eighth inch diameter, and further be characterized by possessing a generally rounded external surface configuration. Such small size aggregate 22 is a substantial departure over prior art surface seeded exposed aggregates which typically comprise rock or gravel aggregate having average mean diameters of three-eighths of an inch or greater and are characterized by rough, jagged exterior surfaces. Typically, the aggregate 22 is broadcast over the exposed surface 18 of the concrete mixture 16 by use of square point shovels and is applied at a preferred rate of approximately one pound per square foot of the exposed surface 18 of the concrete mixture 16 . It is preferred that the aggregate 22 should not initially depress below the exposed surface 18 of the concrete mixture 16 , but rather should be broadcast solely to cover the same.
After being broadcast upon the exposed surface 18 of the concrete mixture 16 , the aggregate 22 is mixed or worked into the exposed surface 18 of the concrete mixture 16 , and more particularly is mixed into the quantity of cement/fines paste at the exposed surface 18 through the use of the above-described vibrating metal bull float. As indicated above, this vibrating metal bull float may comprise either a vibrating magnesium bull float or a vibrating aluminum bull float. This mixing of the aggregate 22 with the cement/fines paste at the exposed surface 18 derived during the previous vibrating metal bull float step is critical to the process of the present invention and insures that the aggregate 22 is fully embedded into the cement/fines paste, and thus thoroughly adhered or bonded to the exposed surface 18 of the concrete mixture 16 upon resultant curing. In order to maintain the design pattern, it is critical that the aggregate 22 is thoroughly bonded to the exposed surface 18 so that individual pieces of aggregate 22 are not dislodged and impacting the visual and textural effect of the decorative pattern.
Subsequent to the mixing of the aggregate 22 into the cement/fines paste at the exposed surface 18 of the concrete mixture 16 , the exposed surface 18 is finished with a decorative finishing tool 26 to implement the decorative pattern 24 upon the exposed surface 18 . A decorative finishing tool 26 is a concrete finishing tool that imprints a visual and textural decorative pattern 24 upon the exposed surface 18 of the concrete mixture 16 . It is contemplated that the decorative finishing tool 26 may be utilized upon any concrete surface. The decorative finishing tool 26 includes a blade 28 having first and second opposing sides 28 a , 28 b . The first opposing side 28 a is adapted to have a handle 30 or the like so that a user may easily navigate the decorative finishing tool 26 about the exposed surface 18 . It is contemplated that the first opposing side 28 a may carry an insert for employing conventional attachments known in the art such as broom handles and the like. It is further contemplated that the decorative finishing tool 26 may be adapted to work with existing trowels, floats, vibrating floats, and the like.
The second opposing side 28 b is smoothed or troweled over the exposed surface 18 and imprints the design pattern 24 thereupon. The second opposing side 28 b is adapted in accordance with the parameters of the design pattern 24 so that the when the decorative finishing tool 26 is troweled over the exposed surface 18 , the blade 28 creates the visual and textural design impressions upon the exposed surface 18 . It is contemplated that a predetermined template of the design pattern 24 may be formed upon the second opposing side 28 b . In a preferred embodiment, the second opposing side 28 b includes a plurality of rods 32 disposed about the second opposing side. The rods 32 are positioned in accordance to the decorative pattern 24 and configured to create the pattern 24 in the exposed surface 18 .
In the present embodiment, the decorative pattern 24 is that of wood grain. Generally, natural wood grain finishes include the alignment, texture and appearance of wood fibers. The appearance of natural wood grain varies depending on the sought after look. For example, one wood finish may include grains which runs in a single direction along the cut wood, a product of a straight growing tree. In a second example, a spiral wood grain where grain which develops as the trunk of the tree twists in development may be the sought after look. In order to capture these varying looks, the rods 32 may be constructed so that each rod 32 is varying in linearity, depth, length, and diameter to provide a naturally looking finish. As further illustrated by FIGS. 3 and 4 , the rods 32 may be positioned so that there are varying spaces 32 between them which further creates natural finishes found in wood grains.
It is contemplated that the rods 32 are rigidly affixed to the second opposing side 28 b so that the construction of the decorative finishing tool 26 can withstand the rigor of imprinting the decorative pattern 24 upon the exposed surface 18 . In this regard, the rods 32 may be affixed to the second opposing side 32 through conventional welding techniques or through the use of adhesives such as epoxy or the like. It is preferred that the second side 28 b is configured with grooves 34 that are adapted to rigidly clasp the rods 32 , as illustrated in FIGS. 2 , 2 a , and 4 . Therefore, as with the rods 32 , each groove 34 may be configured to have a varying length, size, depth, or width to capture the intended design. It is contemplated that conventional concrete-finishing tools such as floats or trowels may be adapted so that a decorative pattern 24 is formed upon conventional blades and configured to implement the decorative pattern 24 upon the exposed surface 18 . Prior art finishing tools do not provide such a capability and such a pattern would require utilizing numerous tools to create variations in depth, diameter, size and texture within the concrete. As such, the decorative finishing tool 26 provides the appearance of a multi troweled finish. Additionally, the decorative finishing tool 24 advantageously provides a consistent pattern 24 throughout its application over the entire exposed surface 18 .
Once the decorative pattern 24 has been troweled on the exposed surface 18 the concrete may be cured or finished. In certain concrete surfaces a variety of finishing techniques are employed to enhance the stability and durability of the surface. It is contemplated, that the implemented design retains its appearance during the employment of a finishing technique. A common finishing technique utilized with exposed aggregate concrete is the application of a chemical surface retarder. A chemical surface retarder is sprayed upon the exposed surface 18 to uniformly cover the same. The chemical retarder slows down the hydration process of the concrete mixture 16 . The chemical retarder does not affect the visual or textural appeal of the decorative pattern 24 . The application of the surface retarder to the exposed surface 18 is followed by the step of finishing the exposed surface 18 of the concrete mixture 16 with a conventional finishing tool or a spray to massage the surface retarder into the cement/fines paste having the aggregate 22 mixed therein. This finishing step preferably results in the penetration of the surface retarder into the cement/fines paste a distance of at least approximately three-eighths of an inch which, due to the relatively small size the aggregate 22 therein, is below the maximum depth of the aggregate 22 . The chemical retarder slows down the hydration process of the concrete mixture 16 . Advantageously, this particular finishing step conducted subsequent to the application of the surface retarder to the exposed surface 18 of the concrete mixture 16 eliminates hard spots in the resultant concrete by facilitating a full mix of the retarder and cement/fines paste.
Subsequent to the surface retarder being massaged into the cement/fines paste, a vapor barrier is preferably formed on the exposed surface 18 of the concrete mixture 16 . In the preferred embodiment, the formation of the vapor barrier is facilitated by the application of a liquid chemical evaporation reducer to the exposed surface 18 of the concrete mixture 16 . A preferred evaporation reducer is sold under the trademark CONFILM by the Concrete Tie company of Compton, Calif. An alternative vapor barrier may be formed by covering the exposed surface 18 with four or six mill visqueen. The vapor barrier is maintained upon the exposed surface 18 of the concrete mixture 16 for a prescribed period of time, which may range from approximately two to twenty-four hours. The vapor barrier does not affect the visual or textural characteristics of the decorative pattern 24 upon the exposed surface 18 .
After the vapor barrier has remained upon the exposed surface 18 for a prescribed period of time, the exposed surface 18 of the concrete mixture 16 is washed with water to remove any surface films therefrom. In this washing procedure, it is additionally preferable to lightly bristle brush the exposed surface 18 wherein preferably no more than about 5% of the aggregate 22 is dislodged and removed therefrom. The extremely low percentage (i.e., less than 5%) removal of the aggregate 22 from the exposed surface 18 evidences the extremely strong adherence of the aggregate 22 to the exposed surface 18 of the concrete mixture 16 . It is preferred that brushing the exposed surface 18 is done in a manner to minimize any deviation from the intended visual appeal of the decorative pattern 24 .
As a result of the washing step, the full mixture of the retarder and cement/fines paste accomplished through the use of a conventional finishing tool known in the art, such as a trowel or float, subsequent to the application of the surface retarder to the exposed surface 18 of the concrete mixture 16 significantly aides in the elimination of perimeter wear-down and excessive dislodgement and loss of the aggregate 22 during this initial washing step. Which resultantly facilitates the preservation of the decorative pattern 24 upon the exposed surface 18 . Additionally, the application of the liquid evaporation reducer to the exposed surface 18 which prevents hydration of the concrete mixture 16 and reduces the rate of evaporation of moisture therefrom increases the ease at which excess cement/fines paste and residual surface retarder are washed from the exposed surface 18 during this initial washing step. In this regard, the aggregate 22 embedded within the decorative pattern 24 is minimally affected.
Subsequent to washing, the concrete mixture 16 is cured with water only as opposed to chemical curing agents to avoid any staining of the same or interference with the visual or textural aesthetics of the design pattern, with such water curing typically being facilitated through the use of a conventional fogger or soaker hose. After a prescribed period of time (e.g., 30 days after initiating the curing process) any surface residue present on the exposed surface 18 is removed by conventional power washing with a 90% steam and 10% muriatic acid mixture which is applied by a power washer via a high pressure nozzle. It is contemplated that conventional power washing of the concrete does not detract from the decorative pattern 24 formed upon the exposed surface 18 .
The resultant concrete exhibits an aesthetically appealing surface that conceals imperfections upon the surface and is advantageously suitable for high pedestrian traffic flooring applications. Additionally, the surface color and texture may be such that it approximates conventional flooring surfaces such as stone or wood. This resemblance can further be accentuated by saw cutting the concrete surface into rectangular grids to give the appearance that the individual rectangular squares of the grid were laid in a manner analogous to stone or wood flooring. Thus, the present invention comprises a significant improvement in the art by providing a surface seeded exposed aggregate concrete having a decorative pattern formed thereupon and possesses a surface texture and color having improved aesthetics over the prior art.
Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. Thus, the particular combination of parts and steps described and illustrated herein is intended to represent only one embodiment of the present invention, and is not intended to serve as limitations of alternative devices and methods within the spirit and scope of the invention. | A decorative concrete product and method of making the same is provided. The concrete surface carries a unique textural and visual decorative pattern that is troweled over the uncured surface. The decorative pattern strategically conceals any imperfections in the concrete surface. A decorative finishing tool is utilized to create a unique and consistent pattern throughout the exposed surface of the concrete. Unique visual patterns may include any aesthetic design including wood grain, or lightly finished honed or cut stone. The decorative finishing tool may be configured so that varying textures and contours may consistently be imprinted throughout the concrete. Advantageously, the cured concrete retains the durability of a concrete surface while carrying a visually and texturally appealing appearance. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/461,262 filed Jan. 15, 2011 under 35 U.S.C. Section 1.119(e) hereby specifically incorporated by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to apparatus and method to distribute liquid to solid waste disposal sites for compacting and collecting solid waste.
BACKGROUND OF THE INVENTION
In the solid waste industry typically permitted active landfills are used for the disposal of solid waste. The portion of the landfill where waste is actually being unloaded, placed, and compacted is called the “working face” of the landfill. This working face is where waste is placed and compacted by vehicles. Generally these vehicles are track or cleated/chopper wheel driven. These vehicles not only position the waste for efficient air space utilization of land fill capacity but most importantly compact the waste for maximum utilization of the permitted volume. Sub-portions of this permitted volume are most frequently called a “cell” by field personnel.
One of the side effects of this disposal and compacting process is the generation of “leachate”. Leachate is the liquid that is hauled in with the waste or rainwater that has fallen on the site, that has come in contact with solid waste. By regulation most landfills are required to collect, treat, and/or dispose of this liquid. This is an added expense to landfill operations. One very effective means to dispose of this liquid is to redistribute leachate on the working face with the new incoming waste stream. Experience has shown that the compaction rate is improved if the incoming waste stream is damp or moist. This dampness will increase the compaction of waste into a smaller volume, thus using less volume of the cell per ton of waste. Furthermore, with this added moisture a greater waste compaction is achieved with less vehicle time, thus requiring fewer passes of the compaction equipment back and forth across the working face. This translates to greater productivity of these vehicles and the use of less fuel per ton of waste compacted.
Landfill leachate is created when precipitation percolates down through the waste deposited at a landfill. Landfill leachate is very high in organics, nitrogen, metals and other toxic materials and is a significant environmental and health concern if released into the environment untreated.
Prior art techniques for leachate disposal on the working face have generally been confined to the use of spray nozzles and portable pumps. This technique frequently requires the presence of assigned personnel to control and direct the leachate distribution. Prior art also uses a pressured nozzle (much like a garden or small fire hose) that shoots the liquid leachate into the air in order to get it to the waste being compacted on the working face. Because of the nozzle and pressure pump there is a fairly solid stream of liquid being propelled from it, and the nozzle also causes some of the liquid (leachate) to be turned into a vapor or mist which potentially could be carried by a breeze where it can settle on nearby earth or vegetation. Furthermore, this mist could cause potential health hazard to personnel working nearby.
Prior art techniques limit the area that can be covered by the sprayed leachate to that reached by the spraying radius of the nozzle. This will cause an uneven distribution of the leachate over the working face waste leaving dry areas and over saturated areas. This would obviously make the compaction uneven and sporadic.
The intended purpose of the present invention is to provide a means to spread a relatively even distribution of liquid (typically site collected leachate) over the entire working face of a solid waste disposal site to improve compaction as well as other benefits.
The present invention would substantially minimize or almost eliminate the misting of the leachate and cause the leachate to be much more evenly distributed over the work surface. It will also add additional weight to the working face vehicle which enhances the compaction rate. In addition, keeping the compactor wheels and cleats as well as the tracks of the dozer damp or wet with leachate will greatly reduce clogging and improve the effectiveness of the compacting process.
Another benefit of the present invention is to minimize fire hazards on the working face waste. The present invention will also minimize the spread rate of any fire if it should occur. Moist or damp waste will obviously not burn as rapidly as dry waste.
An additional benefit of the present invention is the accelerated rate of decomposition of the compacted waste. This will lead to a more rapid generation of methane gas which could be used as a potential energy source.
SUMMARY OF THE INVENTION
This invention provides an apparatus for distributing waste treatment liquid over the working face of a solid waste disposal site. This apparatus includes: an inflow conduit to receive inflow liquid; a storage tank for the liquid received from the inflow conduit; an outflow conduit for the liquid to flow out of the said storage tank; a control valve that contains a remote-valve control, a manifold inlet conduit attached to the control valve to allow liquid to flow through when the control valve opens, and a manifold to allow the liquid received from the manifold inlet conduit to be distributed over the working face of a solid waste disposal site.
This apparatus is used to apply waste treatment liquid to a solid waste disposal site by providing a vehicle for solid waste compacting with a connected liquid storage tank; filling the storage tank with waste treatment liquid; and releasing the waste treatment liquid from the tank to a portion of the site in need of moisture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an apparatus of the present invention.
FIG. 2 is a perspective view of an apparatus of the present invention showing attachment means.
FIG. 3 is a perspective view of an system of the present invention.
FIG. 4 is a perspective view of a system of the present invention installed in various positions of a track driven machine.
FIG. 5 is a perspective view of the system of the present invention including a wheel driven vehicle that has three positions on which the apparatus can be installed.
DETAILED DESCRIPTION OF THE INVENTION
The present invention may be understood more readily by reference to the following detailed description of the invention. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes one particular value and/or the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
Unless defined otherwise, all technical terms used herein have the same meaning as commonly understood by one ordinarily skilled in the art to which this invention belongs.
Referring now to the drawings, a preferred embodiment of an apparatus 101 for distributing waste treatment liquid over the working face of a solid waste disposal site includes an inflow conduit 11 and/or a vent tube 11 - 1 on top of a storage tank 12 . Liquid flows into the storage tank 12 through inflow conduit 11 and air could flow out through vent tube 11 - 1 during the storage tank 12 filling. An outflow conduit 13 , a remote valve control 14 , a control valve 15 , a manifold inlet conduit 16 , a manifold 17 , and a plurality of liquid discharge openings 18 are shown in FIG. 1 .
The storage tank 12 typically receives the liquid from an inflow conduit 11 at an inlet end 20 and is sized in relation to the various locations of the installation areas as shown in FIGS. 3-5 . On the side of the storage tank 12 , located substantially near the bottom, an outlet opening 22 is positioned to allow liquid, such as leachate, to gravity feed through an outflow conduit 13 . The outflow conduit 13 is attached to a remote valve control 14 which is controlled by a control valve 15 to regulate the outflow of liquid, such as leachate, to a manifold 17 through a manifold inlet conduit 16 . The remote valve control 14 can be operated from inside the cab of a vehicle for solid waste compacting or it can be remotely controlled by an infrared sensor 41 coupled to the remote valve control 14 . When the control valve 15 is switched on, a liquid, such as leachate, can travel past the valve 15 and is carried by a manifold inlet conduit 16 to a manifold 17 . The manifold 17 , in one embodiment, is located on the bottom or back side of the storage tank 12 .
Next, the liquid flows from the manifold inlet conduit 16 to a distribution head 23 . The distribution head 23 distributes the liquid over the solid waste working face 51 through the liquid discharge openings 18 . The manifold 17 has liquid discharge openings 18 that allow the leachate to be discharged along the length of the manifold 17 . In a preferred embodiment, the manifold liquid discharge openings 18 are configured such that when the control valve 15 is opened the leachate will flow by gravity into the manifold 17 and drain out through the discharge openings 18 . In an alternative embodiment, a pump (not shown) can be used in place of gravity feed to move liquid thought the apparatus 101 . The storage tank 12 could be equipped with a pump 42 that could be used to pressurize the manifold 17 . Alternatively, storage tank 12 could be pressurized using a compressed gas to force the liquid such as leachate into manifold 17 for distribution.
In another preferred embodiment of the invention, the liquid discharge openings 18 are placed such that leachate is distributed over the length of the manifold 17 . In a preferred embodiment of the invention, the liquid is applied intermittently and repeatedly. In one embodiment, the manifold 17 is built to the approximate width of the vehicle for solid waste compacting as shown on FIGS. 3-5 .
FIG. 2 shows an apparatus 101 that can be connected to a working face vehicle. This embodiment functions, for example, as the blade of a bulldozer 202 and 301 as shown on FIG. 3 and FIG. 4 , respectively. The apparatus 101 can be directly attached to different vehicles through a plurality of connectors 25 , such as a lift cylinder connector positioned on the back side surface 26 of storage tank 12 . The front side surface 27 as shown on FIG. 5 of storage tank 12 is configured to form a blade that can be curved at the lower edge. The vehicles 202 and 301 include a plurality of attachment. means 35 to reversibly connect with the connector 25 . An example of an attachment means 35 is a push bar 31 .
The apparatus 101 is connected to a working face vehicle in the followings ways. The apparatus 101 can be made as an integral part of the working face vehicle, connected by attachment means, or mounted on a trailer and connected to the working face vehicle by a hitch or other means.
In one preferred embodiment of the invention, as illustrated in FIG. 3 , a apparatus 101 is located on the back end of a working face vehicle, such as a track driven vehicle 202 i.e. dozer. The track driven vehicle 202 is connected by connectors 43 to the side surface 26 of storage tank 12 of apparatus 101 and the attachment means which are counter weight attachment points (not shown). Alternatively, as shown above, an apparatus 101 is located on the front end of the working face vehicle 202 and the apparatus 101 is attached to the vehicle through attachment means 35 .
In another embodiment of the invention, FIG. 4 shows the apparatus 101 installed on various locations of a dozer 301 . The apparatus 101 is installed in the front 302 and back 303 of a dozer 301 .
In yet another embodiment of the invention, FIG. 5 shows the apparatus 101 on various locations of a wheel driven vehicle 401 . The apparatus 101 is installed in the front 405 , middle 402 , and back 403 of track driven vehicle 401 .
Once the present invention is connected on a working face vehicle, the method of distributing waste treatment liquid over solid waste disposal site and compacting solid waste in a landfill may be followed by the steps below.
Step One: fill the storage tank 12 with liquid such as leachate from an inflow conduit 11 located on the top of the storage tank 12 through an inlet end 20 . This could be handled by pumping a liquid, such as leachate, into the storage tank 12 or filling the storage tank 12 from an elevated source of liquid (like a dust control tank).
Step Two: once the storage tank 12 is full then the vehicle, such as compactor 301 or track driven vehicle 401 , would move out into the working face area 51 . The vehicle operator will determine what area of the working face is in need of more moisture for a number of different reasons.
Step Three: after the operator determines an area that needs the moisture, he will move the vehicle over the area. Then he would use the control valve 15 through a control system 14 that is able to be operated from inside the cab of the vehicle to release liquid, such as leachate, from manifold 17 to moisturize the solid waste. The rate of discharge will be controlled by the operator as needed.
Step Four: once the working area needing moisture is as saturated as determined by the operator, the operator would be able to close the control valve 15 through a control system 14 and hold the remaining liquid in storage tank 12 .
Step Five: the operator(s) will continue to add layers of waste and then go back to Step Three.
Step Six: once the on storage tank 12 is empty, the operator will return to the loading location and start back at Step One.
This process would be repeated several times throughout the working shift/day. On days of heavy rain or extreme cold weather it would be sufficient to just complete Step One and leave the on storage tank 12 loaded for the extra weight on the compaction vehicles as needed.
It is anticipated that the increased compaction rates obtainable with this invention will yield extra revenues in the same air space. The amount of increased compaction and savings can be seen in Table 1 to Table 6.
The following tables incorporate a couple of different variables of landfill airspace utilization (tons per day and a possible change in pounds per cubic yard compaction) and shows the financial effect on the landfill with small improvements in the compaction ratios that this invention might provide. In describing the present invention some terms referred in the tables are defined as follows:
Depletion: In the landfill industry this is considered the recognition of the cost of landfill development and construction. It is generally based on a per ton rate, which means if a landfill is considered to hold 500 tons of waste and the development and construction cost was $1,000 then the depletion rate would be $2.00 per ton.
Closure/Post Closure: In the landfill industry this is considered to be the setting aside a determined amount of funds to properly close the landfill once it is full and to take care of the landfill facility for a term of approx. 30 years after it is closed. Meaning if it is determined that the closure will cost $1 million and 30 years of care will cost $500,000 then the total fund needed would be $1.5 million. Now if it is determined that the landfill would hold a grand total of 750,000 tons then the landfill company would be required to set aside $2.00 from every ton to cover these expenses.
Gate Rate: In the landfill industry this is considered the publicly published rate for disposal. It could be by the ton, by the cubic yard, or by the load.
EBITDA: In the landfill industry this means “Earnings Before Interest Taxes Depletion Amortization.”
Airspace: In the landfill industry this is a term that is used to describe useable volumetric capacity of landfill space for the disposal of waste.
TABLE 1
Assumptions
1,400
Pounds per cubic yard currently
$4.00
Per ton for Depletion and Closure/Post Closure
$15.00
Per ton gate rate for revenue
1,000
Tons per day Monday through Friday
260,000
Tons per year
50
Pounds per cubic yard: Increased compaction using
present invention
1,450
Pounds per cubic yard New Compaction Rate
371,429
Current cubic yards consumed per year
358,621
New cubic yards consumed per year
12,808
Cubic yards saved per year
9,286
Extra Tons available in the same airspace.
$37,143
Depletion and Closure/Post Closure savings per year
$139,286
Extra Revenue in the Same Airspace
50%
Average EBITDA of Landfill Airspace
$69,642.86
EBITDA Savings per year
$50,000.00
Assumed cost of present invention
8.7
Pay Back Rate in months
TABLE 2
Assumptions
1,400
Pounds per cubic yard currently
$4.00
Per ton for Depletion and Closure/Post Closure
$15.00
Per ton gate rate for revenue
1,000
Tons per day Monday through Friday
260,000
Tons per year
100
Pounds per cubic yard: Increased compaction using
present invention
1,500
Pounds per cubic yard New Compaction Rate
371,429
Current cubic yards consumed per year
346,667
New cubic yards consumed per year
24,762
Cubic yards saved per year
18,571
Extra Tons available in the same airspace.
$74,286
Depletion and Closure/Post Closure savings per year
$278,571
Extra Revenue in the Same Airspace
50%
Average EBITDA of Landfill Airspace
$139,286
EBITDA Savings per year
$50,000
Assumed cost of present invention
4.4
Pay Back Rate in months
TABLE 3
Assumptions
1,400
Pounds per cubic yard currently
$4.00
Per ton for Depletion and Closure/Post Closure
$15.00
Per ton gate rate for revenue
1,000
Tons per day Monday through Friday
260,000
Tons per year
150
Pounds per cubic yard: Increased compaction using
present invention
1,550
Pounds per cubic yard New Compaction Rate
371,429
Current cubic yards consumed per year
335,484
New cubic yards consumed per year
35,945
Cubic yards saved per year
27,857
Extra Tons available in the same airspace.
$111,429
Depletion and Closure/Post Closure savings per year
$417,857
Extra Revenue in the Same Airspace
50%
Average EBITDA of Landfill Airspace
$208,929
EBITDA Savings per year
$50,000
Assumed cost of present invention
2.9
Pay Back Rate in months
TABLE 4
Assumptions
1,400
Pounds per cubic yard currently
$4.00
Per ton for Depletion and Closure/Post Closure
$15.00
Per ton gate rate for revenue
1,500
Tons per day Monday through Friday
390,000
Tons per year
50
Pounds per cubic yard: Increased compaction using
present invention
1,450
Pounds per cubic yard New Compaction Rate
557,143
Current cubic yards consumed per year
537,931
New cubic yards consumed per year
19,212
Cubic yards saved per year
13,929
Extra Tons available in the same airspace.
$55,714
Depletion and Closure/Post Closure savings per year
$208,929
Extra Revenue in the Same Airspace
50.00%
Average EBITDA of Landfill Airspace
$104,464
EBITDA Savings per year
$50,000
Assumed cost of present invention
5.8
Pay Back Rate in months
TABLE 5
Assumptions
1,400
Pounds per cubic yard currently
$4.00
Per ton for Depletion and Closure/Post Closure
$15.00
Per ton gate rate for revenue
1,500
Tons per day Monday through Friday
390,000
Tons per year
100
Pounds per cubic yard: Increased compaction using
present invention
1,500
Pounds per cubic yard New Compaction Rate
557,143
Current cubic yards consumed per year
520,000
New cubic yards consumed per year
37,143
Cubic yards saved per year
27,857
Extra Tons available in the same airspace.
$111,429
Depletion and Closure/Post Closure savings per year
$417,857
Extra Revenue in the Same Airspace
50.00%
Average EBITDA of Landfill Airspace
$208,929
EBITDA Savings per year
$50,000
Assumed cost of present invention
2.9
Pay Back Rate in months
TABLE 6
Assumptions
1,400
Pounds per cubic yard currently
$4.00
Per ton for depletion and closure/post closure
$15.00
Per ton gate rate for revenue
1,500
Tons per day Monday through Friday
390,000
Tons per year
150
Pounds per cubic yard: Increased compaction using
present invention
1,550
Pounds per cubic yard New Compaction Rate
557,143
Current cubic yards consumed per year
503,226
New cubic yards consumed per year
53,917
Cubic yards saved per year
41,786
Extra Tons available in the same airspace.
$167,143
Depletion and Closure/Post Closure savings per year
$626,786
Extra Revenue in the Same Airspace
50.00%
Average EBITDA of Landfill Airspace
$313,393
EBITDA Savings per year
$50,000
Assumed cost of present invention
1.9
Pay Back Rate in months
It is intended that the foregoing description is only illustrative of the present invention and that the present invention be limited only by the hereinafter appended claims. | This invention relates to a method to apply waste treatment liquid to a solid waste disposal site by filing a storage tank with waste treatment liquid, connecting the liquid storage tank with a vehicle for solid waste compacting and releasing the waste treatment liquid to a portion of solid waste site in need of moisture. This invention further provided an apparatus for distributing waste treatment liquid over the working face of a solid waste disposal site includes an inflow conduit, a storage tank, an outflow conduit, a control valve that contains a remote-valve control; manifold inlet conduit attached to the control valve, and a manifold to allow the liquid received from the manifold inlet conduit to be distributed evenly over the working face. |
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FIELD OF THE INVENTION
This invention is directed to an apparatus and method of establishing cast-in-place and on-ground-surface foundations. A bottom portion of a building support pier or stanchion is partially embedded in a cementitious material that has been poured into a flexible fabric or geo-textile container. The inosculated assembly is intended to provide a ground surface foundation primarily, although not exclusively, to mobile homes or modular dwellings.
BACKGROUND OF THE INVENTION
The use of flexible fabric for foundation forms renders it possible to produce and maintain a very level building foundation, and to produce such a foundation on sloping and/or underlying terrain. The flexible forms permit a foundation to conform to the underlying surface contour of ground matter, when such ground matter is somewhat irregular.
The use of flexible fabric forms are known in the building construction art as disclosed by R. Fearn in U.S. Pat. No. 5,224,321. The patentee sets forth a method of preparing a sub-wall foundation using a pair of separate rigid forms connected at their bottom end by a fabric sling. A concrete is used to fill the combined fabric and rigid form to the extent that, when hardened, a building structure is readied with a sub-wall foundation situated on ground surface. The patent further discloses the use of a vertical reinforcement rod partially situated in the fabric form and surrounded by concrete.
In one embodiment to the R. Fearn patent, a concrete foundation is seen to extend from ground surface upward to abut a floor assembly, thus, producing an exterior or perimeter sub-wall. However, the patented devices are not revealing or suggestive of an assembly wherein a metal support pier, tubular stanchion, or seismic cradle upright is partially embedded in a fabric container and held with a binder or cementitious material.
Cognizant of the significant need in the building construction industry for a reliably sturdy, relatively inexpensive, and quickly assembled ground surface foundation, the inventors have now discovered a new and improved apparatus that achieves such purposes.
As is well known in the art, mobile homes and modular housing units contain longitudinal support beams or joists as part of their undercarriage structure. By means of support piers, such buildings are typically levelled on site by diversely raising or lowering the support piers. The assembly of the fabric container, hardened cementitious material, and selected upright support of the present invention, is adapted as a ground surface foundation that completely maintains the supporting beams in a levelled position after the original and temporary support piers have been removed.
Accordingly, it is a general object of this invention to provide a new and improved apparatus and method for casting cementitious or concrete foundations by using a flexible fabric container, also referred to as a geo-textile bag, to hold and form the cementitious slurry wherein the bottom part of a support pier, tubular stanchion, or upright to a seismic cradle is embedded in the slurry while the top part of the pier, tubular stanchion, or upright is engaged with the floor beam of the dwelling's underside structure.
Another object of this invention is to provide a new and improved apparatus and method, as set forth in the preceding general object, wherein multiple support piers, tubular stanchions, or seismic cradle uprights may be arranged in series within a single fabric container.
In yet another object of the present invention to provide a new and improved apparatus and method, as set forth in the two preceding objects, wherein the flexible fabric container, itself, is recessed from three to six inches below ground surface.
It is a further object of the present invention to provide a new and improved apparatus and method of setting cast-in-place building foundations that exhibit high structural integrity, is relatively inexpensive to perform, and display a high degree of resistance to ground tremors and heavy winds.
Several preferred embodiments of the invention are shown by way of example in the accompanying drawings and are described in detail without attempting to show all of the various forms and modifications in which the invention might be embodied. Other objects and advantages of the invention will be reflected in the drawings and concomitant written description.
SUMMARY OF THE INVENTION
The present invention provides a new and improved apparatus and method of producing cast-in-place and, generally, on-ground-level building foundations. The objects of this invention are achieved when vertical supports such as construction piers, tubular stanchions, or the vertical support portions of seismic cradles, are engaged at their top end, to a mobile dwelling or modular housing undercarriage support structure. At this juncture, the pier base, stanchion, or seismic cradle vertical support bottom end is suspended several inches above ground surface. A cementitious slurry is poured into the fabric container located on ground surface and directly beneath a selected vertical support, to the extent that the bottom end of the vertical support is embedded within the slurry. Hence, upon hardening of the cementitious material, there is accomplished a cast-in-place foundation comprising a cementitious material and the selected vertical support. The invention contemplates further comprising the fabric container.
Preferred embodiments, along with related embodiments of the present invention, are illustrated by way of examples in the accompanying drawings. Each example is described in detail without attempting to express all of the various forms and modifications in which the invention may be embodied; the invention being measured by the appended claims and not by the details of the specification.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partially in section, illustrating a footing foundation in accordance with the present invention and its method of use with a support pier and ground anchoring means;
FIG. 2 is a side elevational view, of the general structure to FIG. 1, showing the foundation assembly slightly recessed within ground matter;
FIG. 3 is a side elevational view of a second embodiment to this invention where a single fabric container is seen to accommodate two support piers for a building structure;
FIG. 4 is a schematic illustration to an example of another embodiment, in accordance with this invention, where multiple support piers are suitably lodged in a single fabric container;
FIG. 5 is a side elevational view of still another related embodiment to this invention, partly in section, showing a cementitiously filled container co-operating with a tubular stanchion in support of a building structure;
FIG. 6 is a side elevational view of one other related embodiment to this invention, partially in section, and illustrating one upright to a seismic or earthquake cradle embedded in a small fabric bag, and
FIG. 7 is a front elevational view to the inventive embodiment shown in FIG. 6, wherein the seismic or earthquake cradle is seen to have each upright partially embedded in an oblong fabric container into which cementitious material has been introduced.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a ground surface cast-in-place foundation assembly adapted to vertically engage an underside support beam of a dwelling comprising a pier assembly that includes a pier having an upper and lower end, a base fixedly connected to the lower end of the pier, and means for connecting the upper end of the pier to the support beam; and a flowable and settable foundation material which envelops at least a portion of the assembly, wherein the foundation material conforms to the shape of a porous fabric container into which it is poured, and it sets with the enveloped portion of the pier assembly embedded therein. For purposes of this invention "pier" means any vertical member used to support the undercarriage beams of dwellings and includes piers with one or more legs and the vertical supports of seismic or earthquake cradles. For purposes of this invention "beam connection means" includes welds, clamps, fasteners, bolts, and clips. For purposes of this invention "flowable and settable foundation material" means any material utilized for stabilizing vertical support members including cement, mortar and slurries which contain such materials.
In a preferred embodiment to the invention, the foundation assembly further comprises the container into which the flowable and settable foundation material is poured, the container comprising a porous fabric unibody defining an entrance and having an inner and outer surface, a portion of the outer surface in contact with the ground surface; and means for securing the container to the pier, wherein the base and the foundation material are introduced into the container through the entrance so the foundation material contacts the inner surface of the container while enveloping the base when it is poured through the entrance, whereby the ground, container, and container securing means restrains the foundation material from flowing after it is poured into the container. For purposes of this invention, means for securing the container to the pier may be on the pier, the container, or both and includes bolts, screws, hook and loop configurations, and drawstrings. In another preferred embodiment to the invention, the foundation assembly further comprises means for anchoring the foundation assembly, wherein the anchoring means is fixedly connected to the foundation material. For purposes of this invention "means for anchoring" includes steel plates to which the foundation material is bolted or screwed to, as well as, bolts and rebars embedded in the ground and secured to the foundation material.
In yet another preferred embodiment of the invention, the beam connection means comprises a beam clamp; a vertical member having an upper and lower end, the upper end being fixedly attached to the beam clamp; and means for fixedly attaching the lower end of the vertical member to the pier. For purposes of this invention "beam clamp" means any beam clamp which fixes itself to the beam and includes multi-piece clamps and clamps which do or do not require the beam to be compromised by drilling holes therein.
In another preferred embodiment of the invention, the container is elongated in construction and defines at least two entrances situated on the same side of the container, each entrance disposed to receive a pier assembly and foundation material.
The present invention also provides a ground surface cast-in-place foundation assembly adapted to vertically engage a perimeter beam of a dwelling comprising means for seating the perimeter beam; a tubular stanchion having an aperture, the seating means fixedly attached to the stanchion above the aperture; and a flowable and settable foundation material, wherein the foundation material is introduced into the tubular stanchion through the aperture and flows into a porous fabric container whose entrance is securely fitted around the stanchion below the aperture so that the lower portion of the stanchion is embedded into the foundation material which resides in the container after being introduced therein. In a preferred embodiment of the invention, the foundation assembly further comprises the porous fabric container. In another preferred embodiment of the invention, the foundation assembly further comprises a rotatively detachable spout having a first and second end, the first end positioned above a horizontal plane that the beam seating means is on, and the second end rotatively connected to the wall of the stanchion which defines the aperture.
The present invention provides a ground surface cast-in-place foundation assembly adapted to vertically engage a support beam of a dwelling comprising; a vertical member having an upper and lower end; means for connecting the upper end of the vertical member to the support beam; a flowable and settable foundation material into which the lower end of the vertical member is embedded; and a container into which the foundation material is poured, the container comprising a porous fabric unibody and means for securing the container to the vertical member, the ground and container means restraining the foundation material from flowing after it is poured into the container. In a preferred embodiment of the invention the means for securing the container is a drawstring.
The present invention provides a method for installing a ground surface cast-in-place foundation assembly adapted for engaging beams of a dwelling comprising securing a vertical support assembly to a beam wherein the bottom portion of such assembly hovers above the ground surface; pouring a flowable and settable foundation material into a suitable fabric container which resides on the ground surface; positioning the vertical support assembly inside the fabric container; and securing the fabric container to an intermediate portion of the vertical support assembly wherein the lower portion of the assembly is embedded in the foundation material in the container.
The present invention provides a method for installing a ground surface cast-in-place foundation assembly adapted for engaging beams to the underside of a dwelling comprising securing a vertical support assembly to a beam such that a bottom portion of the assembly hovers above the ground surface; securing a fabric container around and to the vertical support assembly, wherein the secured container defines an aperture higher than the horizontal plane on which the lowest portion of the assembly hovers and its bottom contacts the ground surface; and pouring an amount of a flowable and settable material through the aperture suitable to embed the lower portion of the assembly into the foundation material in the container.
The present invention provides a container for receiving flowable and settable foundation material and one or more vertical members comprising a porous fabric material defining an entrance for receiving the vertical member and the foundation material; and means for securing the container to the vertical member wherein the container and container securing means restrains the foundation material from flowing after it is poured into the container. In a preferred embodiment of the invention, the means for securing the container is a drawstring.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance to the invention, a mobile home or modular dwelling is delivered to a selected construction site and levelled above ground surface by strategically placing construction piers throughout the undercarriage support beams. The cast-in-place and generally on ground foundations that more securely support the levelled building, and which incorporate the concepts of the present invention, are designated by the numerals 10, 20, 30, 40, 50, and 60 in the attached drawings.
In a preferred embodiment depicted in FIG. 1, the novel and improved foundation 10 is comprised of a two-part clamp 9 contiguous at the apex of an adjustable pier 8. Clamp 9 is secured to an undercarriage beam 11 such that the base portion of pier 8 is suspended several inches above ground surface 13. Fabric container 1 is temporarily placed immediately beneath pier 8 in order to assess and mark an optimal position at which plate 3 will be located for anchoring container 1. After removing container 1, the worker is able to dig a hole 12, on the mark, that is approximately five inches in diameter and ten to fifteen inches in depth. Plate 3, designed to help anchor container 1, is positioned onto surface 13 to the degree that an aperture (not shown) occurring at one end of plate 3, is centered over hole 12. At the opposite end of plate 3, bolt 4 is disposed in an upright position to surface 13. Container 1 is relocated beneath pier 8 and appropriately punctured by bolt 4. A concrete slurry 6 is poured into container 1 to about one-third the capacity thereof. One or more rods or rebars 7 are horizontally arranged on top of slurry 6 for their well known reinforcement purposes. The upper end or entrance to container 1 is pulled up and over the base portion of pier 8 and secured in a chosen position about the legs of pier 8 with a drawstring 2. Slurry 6 is further introduced into container 1 until it is about one inch below the level of drawstring 2. Plate 3, at this juncture, can be move laterally, and is thus, swiveled away from hole 12 to permit the filling of hole 12 with other of slurry 6. Plate 3 is relocated over hole 12 followed by the vertical insertion of rebar 5 through the aperture and into slurry 6.
Plate 3 and rebar 5 unite to securely anchor foundation 10 against movement on surface 13 during the occasion of heavy winds and/or ground vibrations, such as earthquakes or nearby heavy construction efforts, such as blasting, pile-driving, and the like.
In accordance to this invention, an alternate arrangement, from that expressed in FIG. 1, is illustrated in FIG. 2, where foundation 10 is identical in construction but functions without plate 3 and rebar 5, while using ground matter itself as the anchoring feature to foundation 10. Foundation 10, of FIG. 2, is cast-in-place within a shallow hole 29 that is about three to five inches below ground surface 13. In lieu of anchor plate 3 and rebar 5 being wedded to hole 12 as shown in FIG. 1, hole 29 of FIG. 2 serves to inhibit the movement of foundation 10 on the occurrence of heavy winds and/or ground tremors.
Referring now to FIG. 3, wherein a related embodiment to the present invention is illustrated as having a foundation 20, integrally supporting a floor assembly 23 and building walls 24. Foundation 20 is comprised of an oblong/fabric container 21, having identical protruding entrances 25a, 25b, for receiving vertical supports, binder material, and reinforcement rods, disposed on the same side of container 21 but at opposite ends to one another. For the moment, container 21 is placed on surface 13, with its entrances 25a, 25b immediately beneath the base portion of piers 8. Two-part clamps 9, located at the apex of piers 8, tightly engage the bottom flanges of parallel beams 11. A slurried binder or cementitious material, such as slurry 6, is poured into each entrance 25a and 25b until container 21 ia about one third filled. Several rebars 7 are inserted through entrances 25a, 25b and are horizontally positioned on top of concrete slurry 6. After rebars 7 are in position, entrances 25a and 25b are drawn up the legs of each pier 8, to a position several inches above the base portion of each pier 8 and held in place by tying each of drawstrings 2 around the legs to piers 8. Slurry 6 is poured into entrances 25a, 25b until slurry 6 is about one inch below the level of each drawstring 22.
Another embodiment to this invention is shown in FIG. 4, wherein a footing foundation 30 is comprised of an elongated fabric container 31 having protruding entrances 35a and 35d situated on the same side of container 31, but at opposite ends thereof, while entrances 35b and 35c are intermediately disposed relative to entrances 35a and 35d. Operationally, foundation 30 is assembled in the same fashion as that of foundation 20. In its assembled state, foundation 30 is supportive to floor assembly 33 and building 34.
Each of the foundations represented by FIGS. 1 to 4 and designated by the numerals 10, 20, and 30 have been determined to be useful as support foundations for beams or joists that extend out from and beneath the flooring assemblies 23 and 33. Such extensionsbeams or joists are typically found interposed between the perimeter joists that are an integral part of flooring assemblies 23 and 33. Thus, it has been assessed that the two-part clamp 9 feature of pier 8 is a somewhat undersirable fastener for the perimeter joists themselves, since foundation integrity is more easily compromised in comparison to, here discovered, a new and improved foundation arrangement.
In the latter regard, the related embodiment illustrated in FIG. 5 as foundation 40 functions admirably well in support of perimeter joists or beams, while foundations 10, 20, and 30 are more suitable in their support of undercarriage and interiorly positioned beams. Foundation 40 is comprised of a fabric container 1 housing slurry 6 that partially embeds a tubular stanchion 14, disposed with a lateral and rotatively detachable spout 15 and further equipped with an affixed L-shaped bracket 16. As earlier stated and now repeated for emphasis, the method of this invention is practiced after a mobile home or modular dwelling has been levelled on site. In operation then, the cast-in-place installation of foundation 40 requires measuring the distance between surface 13 and joist 23. That distance minus three to six inches, is equal to the optimal adjusted length of stanchion 14. The use of a tube-cutter may be necessary to produce the optional of stanchion 14, should the initial length be too long. A selected length of stanchion 14 is attached, at its upper end, by attaching bolt 17 through an aperture located in the vertical flange of L-shaped bracket 16, thus, suspending stanchion 14 three to six inches above ground surface 13. While the bottom end of container 1 resides on ground surface 13, the entrance to container 1 is suitably tied around stanchion 14 by means of drawstring 2. A concrete slurry 6 is poured through the spout 15, that is disposed at a forty-five degree angle relative to tube 14, until both container 1 and tube 14 are completely filled. A worker is able to determine when container 1 and stanchion tube 14 are full by observing the refusal of spout 15 to accept any more of slurry 6 after some prodding thereof, as with a small straight object. Since the entrance to spout 15 exists on a horizontal plane that is slightly higher than the bottom flange of bracket 16, the appearance of slurry 6 at the entrance of spout 15 signals that stanchion 14 is completely and sufficiently full to the bottom of L-bracket 16 and within stanchion tube 14. Spout 15 may be rotatively detached from stanchion 14 for cleaning and its subsequent use in the construction of yet another foundation 40. As elsewhere described, container 1, of this embodiment may also be optionally equipped with one or several rebars 7.
An additionally related embodiment to this invention is shown in FIG. 7, wherein a cast-in-place foundation 60 entails the use of a seismic or earthquake cradle 51 and a fabric container 21 filled with the concrete slurry 6 (not shown). The seismic cradle 51 functions as an auxiliary support system as disclosed in U.S. Pat. No. 5,146,724 and issuing to Arthur Angelo on Sep. 15, 1992. By way of reference to its purpose, the seismic cradle 51 disclosure in the '724 patent is deemed coordinate to this discourse and is incorporated in this disclosure. Through use of C-clamps or the like, the top flange to I-beam 53 is temporarily and abuttingly engaged to the lower flange of I-beam 11 such that each stanchion 51 hovers three to six inches above ground surface 13. With container 21 residing on surface 13 and entrances 25a, 25b positioned immediately beneath each upright to stanchion 51, slurry 6 poured into each entrance 25a, 25b until container 21 is about one-third filled. A selected number of rebars 7 are inserted through entrances 25a, 25b and are horizontally disposed on top of slurry 6. Incremental slurry 6 is poured into entrances 25a, 25b until slurry 6 is about one inch below the level of each drawstring 22. The C-clamp fasteners may be removed after slurry 6 has properly hardened.
Owe to terrain conditions availability of fabric containers at job-site, and other considerations the construction engineer may determine it more desirable to use a separate flexible container 1 at the base of each stanchion 51 as illustrated in FIG. 6. Thus, a cast-in-place foundation 50 is installed in a similar manner to the installation of foundation 60 of FIG. 7, the sole dissimilarity between foundations 50 and 60 residing in the use of smaller and separate containers 1 for foundation 50 while foundation 60 is comprised of an elongated unibody.
One skilled in the art is able to appreciate that after slurry 6 has sufficiently hardened in each of foundations 10 to 60, all temporary leveling piers are retrieved from the undercarriage structure. Piers 8, stanchions 14, and seismic cradle 51 uprights, as unified members to foundations 10 to 60, function to maintain a levelled mobile or modular building after the temporary piers are removed. It is envisaged that foundations 10, 20, 30, 50, and 60 may be interchangeably disseminated throughout the interiorly arranged undercarriage beams, while foundation 40 is preferably assigned to the building's perimeter beams.
In conformance to current technology, it is appreciated that plate 3, bolt 4, rebars 5, 7, and piers 8, of this invention be constructed of iron, steel, or other formidable material. Fabric containers 1, 21, and 31 are composed of any one of many geo-textile materials well known in the art. It is further contemplated that stanchion 14, spout 15, and L-bracket 16 be constructed of iron, steel, cast aluminum or other appropriately rigid metal, while any or all elements to the seismic cradle be constructed from iron, steel, or similar formidable material.
In view of the foregoing it is apparent that the present invention provides a new and improved apparatus and method of forming cast-in-place, yet ground surface foundations. Moreover, the invention for ground surface foundations has been set forth in language more or less specific in accounting for structural, functional, and component features. Comprehension of the foregoing description is now believed to move an artisan to the appraisal that this invention is not closed to the specific features shown but that means and construction herein disclosed comprise a preferred mode of executing the invention, while numerous modifications of the several embodiments will undoubtedly occur to others of skill and interest in the art, such modifications are deemed pertinent to the spirit of the invention. Thus, the scope of the invention is to be limited solely in light of the appended claims. | There is disclosed a new and improved apparatus and method for forming a cast-in-place and on-the-ground support system. The support system is especially useful in maintaining a levelled and secure undercarriage structure for dwellings. The support system consists of unitized foundation assemblies. A given assembly is comprised of a flexible fabric container, disposed to ground surface, that contains a cementitious material or binder having a pier partly embedded within the cementitious material. There is further disclosed a new and useful foundation assembly for a perimeter beam which is comprised of a flexible fabric container, situated on ground surface, that is furnished with a cementitious material having a stanchion partially embedded within the cementitious material. |
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RELATED APPLICATIONS
[0001] A Provisional Application was submitted on Jun. 2 nd , 2002, with a granted filing dated given of Jun, 4, 2002, by the United States Patent and Trademark Office, confirmation number 6794 under application No. 60/385,951.
BACKGROUND OF THE INVENTION
[0002] This invention relates to an improvement to the External Insulation And Finish System (EIFS), especially the non-combustible variation to the External Insulated And Finish System, which is mandated, when a non-combustible high impact resistant wall panel is required per municipal building code or architect preference, especially in hurricane or tornado areas of the United States.
[0003] EIFS, which is a type of cladding for exterior building walls, is defined per ASTM E631-91b as a “a non-loading outdoor wall finish system consisting of a thermal insulation board, an attachment system, a reinforced base coat, exterior joint sealant, and a compatible finish”.
[0004] The development of EIFS occurred after World War II and was introduced to North America in the late 1960s or early 1970s as an EIFS called Dryvit™. While there are slight differences in the EIFS between the European and North American methods for the “System”, there are mandatory components for the EIFS wall cladding in both cases.
[0005] As described in detain later herein, the mandatory components of a typical prior art EIFS (see FIG. 1), are: a stud 3 and sheathing substrate system 4 , which the EIFS is attached, such as wood sheathing, mineral boards, an exterior grade or glass fiber-faced gypsum board, or cement board insulation made of expandable polystyrene 6 ; attachment means for attaching the insulation to the substrate; a base coat adhesive 7 with reinforcing mesh 8 embedded in the adhesive located over the outside face of the EPS insulation board; and the finish 9 , which is basically an esthetic part of the EIFS and is the visible portion of the wall system. This finish coat is typically made from an acrylic resin, which is either troweled or sprayed on, and a joint sealant system of which there are several types. Items 7, 8 and 9 are collectively referred to as the EIFS' “lamina”.
[0006] The EIFS cladding is typically comprised of at least those components as described above. Each component has its own specification(s) with several manufacturers supplying any one component. A critical component of the system is the Expandable Polystyrene (EPS) insulation board. Expandable Polystyrene comes to the molding facility looking very much like a grain of sand, with a weight per cubic foot of about 64 pounds. The polystyrene beads included a thin outer layer of polystyrene and a hollow interior that includes a blowing agent, such as pentane. In pre-expanding, the beads are expanded by applying heat through hot air or steam, which causes the blowing agent to vaporize and expand the bead, to the desired density required for the second step, which is to mold the beads, through heat, steam, pressure and cooling, into the desired construct, for example; a panel, packaging material or helmet. Each construct has its own desired density requirements. In the EIFS industry the EPS beads are pre-expanded to its desired weight, which is from 0.9 to 1.1 pound(s) per cubic foot. This weight is about at the lowest limit EPS it can be pre-expanded to and molded.
[0007] In the EIFS industry this EPS board is required to have very specific characteristics, such as, it can be no less than ¾ of an inch thick, nor more than 4 inches thick, and needs to be pre-expanded to and molded at a density of one pound per cubic foot, plus or minus ten percent. EPS at one-pound density acts as a buffer or type of “shock” absorber, between the substrate and the “lamina”, which is the base coat, mesh and finish or esthetic coat, as described as items 7, 8, and 9 above. The ability of the EPS to flex as the substrate moves, or the lamina expand and contracts, allows the EPS to absorb the energy of a shearing movement and to minimize the energy or stop the shearing energy from passing through the EPS to the lamina, which could cause it to crack and/or deform. EPS at a density of more than 1 pound per cubic foot is stiffer and has been found to not give the EPS board the elasticity, which helps to prevent deforming or cracking in the lamina. Accordingly, with EPS board made at higher densities the greater the tendency to transfer any build up of forces from the substrate to the lamina, that might otherwise cause deforming or cracking. In fact, EIFS manufacturers will not warrant their systems if the EPS insulation board is of the wrong density. By not using EPS and by instead applying the lamina directly to a substrate, any build up of forces in the substrate may be passed directly through it and could cause cracking in the lamina. The above describes the components, which are the integral parts of the External Insulated and Finish System (EIFS), and outlines why the EPS panels have a requirement by the EIFS manufacturers that the EPS board by made at 0.9 to 1-pound density.
[0008] It is known in the art that the EIFS cladding, when used in hurricane or tornado parts of the United States, are modified to include at least two more layers of mesh, in order to withstand the high impact of a foreign object as might occur during a hurricane or tornado. As later described in detail, FIG. 2 depicts a prior art cladding construct modified to withstand heavy impacts. These extra layers of mesh are required because EPS at one-pound density while flexible, is very fragile and can be crushed or punctured rather easily, when it is made with the industry standard base coat, fiberglass mesh and finish material, as depicted in FIG. 1 and noted as numbers 7,8 and 9. Building codes, such as those in Miami-Dade County Florida, have adopted a Hurricane Protocol. A component of the testing protocol is PA 201, the “Large Missile Impact Test”, which is becoming the standard for building codes in hurricane and tornado regions of this country. There are several elements to the testing protocol, but of major concern in the EIFS industry is passing the large missile impact test. In this test, a 2×4 wood framing stud, about 9 feet long, is propelled from a “canon” at a speed of about 42 miles an hour at the surface of the object that is to be tested. The missile must not penetrate through the object tested to the inside of said object, or a test failure will occur. In the case of a wall panel, the missile must not crack or puncture the substrate so that light may be visible from the inside of the exterior wall cavity to an outside light source.
[0009] Improvements in the construction, with substantial cost savings of the above described External Insulated and Finish System, EIFS, are provided in accordance with this invention to achieve the same high impact non-combustible resistant panel system by providing a panel construct where the use of a high density expandable polystyrene panel, as is described in the teaching by Cutler in U.S. Pat. No. 5,718,968, is used in place of a layer of heavy weight fiberglass mesh. By using a high density EPS panel in place of a layer of fiberglass mesh, a savings in time and cost is achieved by doing away with the cost of the fiberglass mesh, the application of the adhesive, and the time and labor involved with embedding the fiberglass into the adhesive, with the attendant “down time” because of the need to allow the adhesive to dry and “set up”.
[0010] By simply attaching, through screwing, gluing or nailing, the high density panel to the stud or its backing, a rather inexpensive alternative to the prior art EIFS has been accomplished. This high density panel at about 2 foot by 4 foot in dimension can be attached simply and quickly, especially when working on scaffolding many floors off of the ground since it is reasonably light in weight yet offers the impact resistance that is currently required in the EIFS construct by building codes in certain hurricane and tornado areas of the country.
[0011] The present invention provides an exceptionally strong non-combustible Expandable Polystyrene And Fixed System construct at a substantial cost savings over typical EIFS prior art systems, as are outlined in FIGS. 1 and 2.
[0012] Saving is achieved without sacrifice in impact resistance by employing a high density Expandable Polystyrene (EPS) panel/board in place of a layer of high impact reinforcing as shown in FIG. 3, a single layer of high impact reinforcing mesh is then attached to the high density board, and then a layer of conventional 1-pound EPS board with a light weight mesh embedded in an adhesive; a finish material, such as a stucco material or acrylic based finish coat, is then applied.
[0013] In accordance with the foregoing objective, a high impact resistant EIFS construct is achieved by using the high density EPS panel in lieu of a layer of fiberglass mesh, having the advantage of a time saving method with low cost, and ease of construction, over the standard EIFS claddings as are furnished by the various EIFS manufacturers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a Cross-Sectional drawing of an EIFS construct according to the prior art, as is typically used in the industry.
[0015] [0015]FIG. 2 is a Cross-Sectional drawing of an EIFS construct according to the prior art, as is typically used when a non-combustible high impact EIFS system is required, either by building code or architect preference.
[0016] [0016]FIG. 3 is a Cross-Sectional drawing of an EIFS construct provided in accordance with the present invention.
DETAILED DESCRIPTION
[0017] Prior Art
[0018] An EIFS construct can be formed by the conventional EIFS method of applying the mandatory components as shown in FIG. 1. These are: A substrate system 4 (the surface to which the EIFS is attached), such as wood sheathing, mineral boards, exterior grade or glass fiber-faced gypsum board, or cement boards, which is attached to a wood or metal framing stud 3 ; Insulation board 6 , which shall be by steam expansion of polystyrene resin beads, to a minimum weight of 0.9 to 1.1 pounds per cubic foot, and at a thickness of at least ¾ of an inch 6; Attachment systems: base coat 5 A for attaching the insulation to the substrate, the attachment base coat adhesive, such as that used by the Dryvit Systems, Inc of West Warwick Rhode Island, consisting of a “Primus” mixed by weight with Portland Cement and water based primus, which is a 100 percent polymer based product, or 5 B, a mechanical fastener, such as a screw or nail. To the base coat adhesive 7 is embedded, over the outside face of the EPS insulation board 6 , for example, a Dryvit standard plus reinforcing mesh 8 , typically of a weight between 4 to 5 ounces per square yard. The finish coating 9 is basically an esthetic part of the EIFS, which is the visible portion of the wall system, and is typically made from an acrylic resin, or stucco product, which is either troweled or sprayed on.
[0019] To the mandatory components of the construct as shown in FIG. 1 are added layers of reinforcing mesh, as shown in FIG. 2, which are used when an EIFS is required to pass certain building codes, in for example hurricane and tornado areas of the country. The first layer of reinforcing mesh 7 is typically made of a glass woven fiber, with a weight of between 6 to 11 ounces per square yard. It is adhered to the substrate 4 with a base coat 5 consisting typically of Portland Cement with a setting additive, which is typically a 100 percent polymer based product. To this layer is added the EPS 9 by an attachment system 6 A or 6 B, of either a mechanical means or an adhesive, which is typically a 100 percent polymer based product mix, which may be mixed with an 100 percent acrylic based product and with water and Portland Cement. To the outside of the installed EPS board 9 is embedded, into a base coat 10 a very heavy high impact fiberglass reinforcing mesh 11 , typically of a weight of between 15 to 22 ounces per square yard. Added to this layer of mesh is the standard base coat and reinforcing mesh 12 , which is typically of between 4 to 6 ounces per square yard in weight. To this last layer is added the finish coat 13 , which is mainly used for esthetic purposes and consists typically of a 100 percent acrylic based product. The added layers 7 & 11 , of the heavy weight high impact reinforcing mesh are the integral components to the standard EIFS construct, and are a requirement in order to pass the Hurricane Testing Protocol, especially the Large Scale Missile Impact, PA 201 as is required in the Miami-Dade County South Florida Building Code.
[0020] The Present Invention
[0021] The present invention does away with one of the required layers of mesh and its attachment system that are shown in FIG. 2. FIG. 3 illustrates a construct according to the present invention. This variation to the EIFS System in its use of a high density EPS board 6 in place of the high impact fiberglass layer 7 , as described above, and as depicted in FIG. 2.
[0022] Koch's 1955 U.S. Pat. No. 3,445,406 discussed the making of a high-density Expandable Polystyrene, EPS board. A refined process for producing a high-density EPS board is outlined by Cutler in his 1998 U.S. Pat. No. 5,718,968. In it he describes the making of a high-density EPS construct through a two-step molding process. Cutler uses a compression molding technique or process, which “gives” the construct more of an energy-absorbing “memory”, and structural strength, without an increase in embrittlement, than what could be offered by a regularly molded high-density board. The “memory” allows for the board to withstand higher impacts, that is, when impacted the construct does not deform to the degree a regularly molded high-density construct would. In this invention a high-density board, with a density of between 11 pounds per cubic foot and 15 pounds per cubic foot is used. In regular EPS molding an EPS construct can be made up to densities of about 8 pounds per cubic foot. Regular EPS molding at such high densities is difficult and at times leaves the molded construct brittle, which is not the case when a construct is made per the process as described by Cutler. The present invention employs that process to produce the unique component of the present invention, the EPS board identified by reference numeral 6 in FIG. 3.
[0023] In the present invention as shown in FIG. 3 a newly developed non-combustible EIFS construct is detailed. This non-combustible EIFS construct is attached to a suitable wall stud, typically a land ⅝ inch, at least, 16 gauge, metal stud 3 , spaced at about 16 inch on centers. The construct includes a substrate of at least ¼ inch exterior or water proof grade gypsum board or other “non-combustible” sheathing material 4 , which is attached either by an adhesive, screws or nails to the metal stud 3 . To the sheathing substrate is attached, either through nailing, screwing 5 A or an adhesive 5 B or a combination thereof, the high density board 6 . To the high-density board 6 is affixed a layer of high impact reinforcing fiberglass mesh 7 of at least about 11 ounces per square yard to about 20 ounces per square yard, which is embedded in a standard base coat 8 of Portland Cement and an adhesive additive, which is typically a 100 percent polymer based product. To the high impact reinforcing fiberglass mesh 7 is attached an Expandable Polystyrene (EPS) board 9 of at least ¾ inch thick with a density from between 0.9 to 1.1 pound per cubic foot. The EPS board is affixed by the use of an adhesive base coat 10 A or mechanical means, such as with nails or screws 10 B. Attached to the outside portion of the EPS is a standard reinforcing mesh 11 of about 4 to 5 ounces per square yard, which is embedded into a standard base coat 12 and adhesive, as is typically used in the industry. To this last layer is added the finish coat 13 , which is mainly used for esthetic purposes and consists typically of a 100 percent acrylic based product.
[0024] While I have described a preferred embodiment of my invention as having the various layers in a certain order, it will be apparent to those skilled in the art that other orders may be employed. For example, the high impact mesh 7 may be the layer immediately adjacent the substrate 4 , or it may be the layer immediately adjacent the mesh 11 . Moreover, in some cases, it may not be necessary to include the substrate at all. The important aspect of the invention is the inclusion of both the high-density board 6 and the lower density board 9 in the construct. | An External Insulated And Fixed System (EIFS) and method for making the same. The method provides a cost effective procedure for constructing an EIFS that can meet current hurricane high impact test protocol, especially for non-combustible EIFS “Systems”. A reinforcing high impact layer of fiber glass mesh is eliminated, and a high density compression molded expandable polystyrene board is provided that yields significantly improved impact resistance |
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This invention relates to building structures, and more particularly, to residential housing in a terraced arrangement
It has been common practice to construct multi-story apartment buildings in order to obtain maximum utilization of land, particularly at locations where the view of the surrounding terrain enhances the value of the property. The disadvantage of multi-story apartment buildings is that the occupants of the upper floors are far removed from the surface of the ground, and access to the outside is provided only by narrow balconies at the level of the occupant's apartment. Because the occupants of such a building share many common areas, such as hallways, elevators, parking lots and a common entrance and exit, there is very little sense of privacy and individuality among the occupants of the building.
In other areas, the terrain is relatively flat. Multi-story apartment buildings which are commonly built in such areas tend to project upward from the ground, so that many of such buildings give an impression of conjestion and crowded living conditions which are unpleasant for the inhabitants. Prior attempts to blend the housing into the flat terrain have had the disadvantage of reducing the density of population so that each dwelling unit becomes excessively expensive, or greatly expands the area required so that the buildings are spread apart and create traffic congestion with many dwellings located far from the most desirable location.
There are also many sites that are suitable, and highly desirable for housing, but unacceptable because of poor soils, or because the terrain is too steep for the construction of economical housing.
I have previously developed a system for constructing retaining walls and other structures, as described in my U.S. Pat. Nos. 3,421,326 and 3,686,873. Furthermore, I have suggested that my technique can be utilized to construct terraces on several levels, and to build dwelling units on the horizontal surface of each terrace. This concept is disclosed, for example, in my French Pat. No. 72.01591 and in Annales De L'Institut Technique Du Batiment Et Des Trauvaux Publics Supp. No. 299 November 1972. Neither my prior patents nor my publications, however, have disclosed a practical arrangement for a multi-dwelling structure in a hill formed at least partially of non-cohesive earth.
SUMMARY OF THE INVENTION
This invention relates to a multi-dwelling structure in which the dwellings are arranged in terraces. Preferably, the multi-dwelling structure of this invention is arranged in a community with terraces formed by portions of the wall of each dwelling and earth is superimposed on the roof of the dwelling in the next lower terrace. The exposed side of the dwelling includes an entrance and windows, and the earth covering the roof of the dwelling on the next lower terrace level serves as a patio in front of the exposed wall of the upper dwelling. Plants and trees are arranged in the earth around the dwellings to screen one from another, and the terraces provide a visual and physical separation between the dwellings, both vertically and laterally.
A retaining wall for the next higher terrace level serves as an interior wall of the dwelling. Preferably, the interior wall includes a plurality of rigid panels extending substantially upright and arranged side-by-side. The panels extend continuously from adjacent the floor to adjacent the roof of the structure. On the rear side of the wall, a plurality of reinforcing members extend outwardly into the earth that is retained behind the wall. The reinforcing members are spaced apart vertically and horizontally and extend generally perpendicular to the face of the wall. The earth which is of a particulate material, is interspersed and compacted between and around the reinforcing members through substantially the entire height of the walls panels. The roof of the structure rests directly on the top of the panels and is supported thereby.
Instead of constructing the retaining walls with the panels, as described above, the walls may be formed of concrete cast in situ. The terraces may be constructed with earth fill on existing sloping terrain, including steep hillsides, or the terraces may be constructed on relatively flat terrain by using earth fill to build a large mound.
DESCRIPTION OF PREFERRED EMBODIMENT
A preferred embodiment of this invention is illustrated in the accompanying drawing in which:
FIG. 1 is a top plan view, partially schematic, of a housing community incorporating the building structures of this invention;
FIG. 2 is a cross-sectional view of the community along the line 2--2 in FIG. 1;
FIG. 3 is an enlarged cross-sectional view of the building structure along the line 3--3 in FIG. 1;
FIG. 4 is a front elevational view, partially in cross-section, along the line 4--4 in FIG. 3;
FIG. 5 is a cross-sectional view of the structure in a reduced scale along the line 5--5 in FIG. 3;
FIG. 6 is a cross-sectional view of the rear wall of the dwelling along the line 6--6 in FIG. 3;
FIG. 7 is a cross-sectional view of the rear wall along the line 7--7 in FIG. 6;
FIG. 8 is a detail view of the joint at the top of the rear wall;
FIG. 9 is a detail view of the rear wall base;
FIG. 10 is a cross-sectional view as in FIG. 5, but showing a modified form of the invention;
FIG. 11 is a perspective view of a modified panel block of FIG. 10;
FIG. 12 is a cross-sectional view of the modified wall along the line 12--12 in FIG. 10;
FIG. 13 is an enlarged cross-sectional view of the modified panels and blocks as in FIG. 10; and
FIG. 14 is a cross-sectional view of the community as in FIG. 3, but showing a second modified form of the invention.
A typical community constructed in accordance with this invention is shown in FIGS. 1 and 2. The dwelling units 2 are arranged on terraces as shown in FIG. 2. The dwellings 2 may be arranged in a single row as shown at the right and left ends in FIG. 1, or may be arranged side-by-side on the various levels of the terraces as shown in the middle of FIG. 1. The community arrangement in FIG. 1 is designed to allow the dwellings to overlook the terrain on two sides of the community. The other two sides, at the top of FIG. 1 do not contain dwelling units, but provide roadways 4 for access to the dwellings. Of course, the community can be designed to permit dwellings to be positioned on all sides of the community, if desired.
An important feature of this method of construction is that the community can be constructed economically on relatively level terrain. For example, the natural surface of the ground prior to construction is shown schematically at 5 in FIG. 2. Earth fill 38 is brought to the site and deposited on the ground to form an earth mass which serves as a base for the elevated community, including dwellings 2, roadways 4 and terraces 6. The earth fill 38 is a substantially particulate material having good drainage and load supporting properties. If the natural ground surface is sloping, it is nevertheless preferable to superimpose earth fill 38 on the surface of the ground to construct the dwellings without requiring excavating.
As shown in FIGS. 2 and 3, the dwellings 2 are arranged on the horizontal areas which form the terraces 6. Each dwelling 2 includes a rear wall 8, a floor 10 and a roof 12. The rear wall 8 may extend around the interior of the dwelling along the sides and join with the front wall structure 14. A typical front wall 14 is shown in FIG. 4, and may include doors 16 and windows 18 with louvers or blinds 20.
The rear wall 8, according to one embodiment, includes a plurality of rigid concrete panels 22, as shown in FIG. 6. The rear wall 8 and the front wall 14 preferably are arcuate, and the side walls 9 are straight. The panels 22 are supported at the base by concrete blocks 24. Each of the blocks has an upright alignment pin 26 which is cast in the block. Each of the panels 22 has a corresponding socket, preferably with a ferrule in the socket to receive the pin 26 so that the pin prevents lateral displacement of the panel from the blocks 24. As shown in FIGS. 5 and 7, the panels 22 are preferably arranged in angular relation to each other to provide a curvature to the wall 8. Similarly, the blocks 24 are set at an angle to each other to accomodate the curvature.
At the top of the panels 22, adjacent panels are secured together in a predetermined angular relation by a key 28 (FIG. 8) which is received in corresponding slots 30 in the panels 22. The key 28 is bent approximately midway of its length to correspond to the predetermined angle between adjacent panels. The joint between the panels may be sealed with suitable filler materials such as tar or polystyrene, and preferably a wide tape 32 is applied over the joint at the rear side of the wall. The arrangement for the straight walls 9 is essentially the same as that of the curved wall 8, except that the keys 28 are straight and the panels 22 and blocks 24 are aligned.
As shown in FIGS. 3 and 7, a plurality of reinforcing members 34 are secured to the rear side of the panels 22 by means of brackets 36 which are cast in the panels. These reinforcing members 34 are in the form of thin, flexible strips capable of sustaining tension, as defined in greater detail in my U.S. Pat. No. 3,421,326. Earth particles 38 fill the space between the reinforcing members throughout substantially the entire height of the panels 22, as described in my patent. As a result of the frictional engagement between the earth particles and the reinforcing members, the earth behind the rear wall 8 is stabilized and provides support for the next higher terrace 6. The rear wall 8 serves as a cladding for retaining the earth particles adjacent the rear face of the wall.
The floor of the dwelling is preferably formed of a concrete slab which is poured after the wall 8 is constructed so that the edge of the slab abuts against the curved wall surface formed by the panels 22. A conventional joint seal is preferably provided between the face of the panel and the floor slab 10. The earth 38 under the slab 10 preferably is of a particulate nature and extends continuously under the floor 10 and throughout the area surrounding the reinforcing members 34 behind the wall 8. The depth of the particulate earth 38 placed under the slab is preferably one meter. Also, the earth 38 under the slab 10 and between the reinforcing members 34 should be uniformly compacted to avoid settling.
The roof 12 preferably is formed by a concrete slab which rests directly on the top edge of the panels 22. The roof 12 may also be partially supported by a front wall 14. The weight of the roof is supported directly by the panels 22 and by the blocks 24. The earth under the blocks 24 is sufficiently compacted to avoid vertical movement of the panels 22. In accordance with conventional practice, the roof 12 may be precast in a thin slab with the remainder of the slab being poured at the site after the roof is in position.
At the front of the dwelling 2, directly over the wall 14, a plurality of precast blocks are superimposed on the roof 12. These blocks cooperate with an upright wall 42 to form a planter 44. The blocks 40 also extend over the wall 14 to deflect rain away from the wall. The planter 44 screens the upper terrace level 6 from the terrace of the next lower level.
The shape of the dwellings 2 may be varied by changing the curvature of the wall 8 and the orientation of the front wall 14 relative to the ground. As shown in FIG. 1, a variety of arrangements of the dwellings 2 may be provided according to the requirements of the community.
The community is quickly and efficiently constructed by depositing a mass of the particulate material 38 on the natural ground surface 5 (FIG. 2). The mass is contoured by conventional grading techniques to provide a plurality of substantially horizontal areas 6 which are spaced apart both vertically and horizontally from each other. The wall 8 is constructed by placing the footing block 24 on the material 38 after compacting the material. The panels 22 are then installed as shown in FIGS. 6 and 7, with the material 38 being filled and compacted in layers alternating with the reinforcing members 34. The floor 10 is applied over the material, and is preferable in the form of a slab of concrete. The front wall structure 14 is installed at the front of the slab. The roof 14 is then placed on the top of the wall 8, as previously explained, and covered by the material 38 to form a terrace above the roof 14 and in front of the front wall structure of the next higher area 6.
A modified form of the walls 8 and 9 is shown in FIGS. 10-12. In this form of the invention, the panels 22' are of substantially the same configuration as the panels 22 shown in FIGS. 6,7. Each of the panels 22' has reinforcing members 34' secured to the rear side of the panels to consolidate the earth fill 38'. The panels 22' are supported on precast blocks 46 which have a longitudinal slot 48 to receive the panels. The rear side 50 of the slot 48 slopes rearwardly (FIGS. 11 and 12) to provide a groove in which a moisture sealing material 52 is applied. Each panel 22' rests on a single block 46, and extends slightly beyond the end of the block to abut against the adjacent panel 22'. A suitable sealant is applied to the rear side of the joint.
Another alternative is illustrated in FIG. 14. In this form of the invention, the wall 8" is concrete that is cast in situ. The natural ground surface 5" is shown to slope, although it may also be more level, as in FIG. 2. The mass of particulate material 38" is superimposed on the surface 5", as previously described, and contoured to form horizontal areas 6". The dwelling 2" include the wall 8" at the rear edge portion of the areas 6". A footing 54 is placed on the compacted material 38" and may be precast, or cast, in situ. The floor slab 10" is also applied over the compacted material 38". Preferably, the rear edge of the slab 10" is also supported on the footing. The roof 12" rests on the wall 8" and on the front wall structure 14" of the dwelling, and is covered with material 38" to form a terrace in front of the front structure 14" of the next higher area 6".
In accordance with conventional practice, the concrete in the wall 8" should be reinforced adequately to withstand the loads bearing on the wall. Of course, the wall 8" may be formed of any other suitable wall construction, provided that the wall is sufficiently rigid to support the roof without substantial deflection.
While this invention has been illustrated and described in relation to a preferred embodiment, it is recognized that variations and changes may be made therein without departing from the invention as set forth in the claims. | A multi-dwelling structure is disclosed in which dwellings are arranged on terraces. The structure may be constructed on steep hill sides, or a hill may be built up from earth brought to the site. Preferably, one of the walls of the dwellings is formed of rigid upright panels with pliable reinforcing members secured to the panels and extending rearwardly into the earth to consolidate the earth particles. In the alternative, one of the walls of the dwellings may be formed of concrete cast in situ. The arrangement of the dwellings in the structure provides privacy and extensive areas for growing plants and trees. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] The invention relates to building construction and, in particular, to suspended ceilings.
PRIOR ART
[0002] Building areas such as corridors or hallways and small rooms typically have short spans between opposing walls. Frequently, the space above such areas is utilized for air ducts and other utilities. It can be desirable or mandatory that a suspended ceiling be provided with removable panels to allow ready access to the space or plenum above a ceiling. The existence of primary air ductwork and other objects in the overhead space often makes hanging conventional suspension wires difficult or prohibitive. Any solution for constructing a suspended ceiling should avoid the need for extensive and/or specialized labor and, ideally, will actually reduce the labor and skill requirements.
SUMMARY OF THE INVENTION
[0003] The invention resides in a short span suspended ceiling system with a unique grid runner and wall angle attachment. The attachment is made by permanent magnets carried on the ends of the grid runners that extend perpendicularly to the wall angles. The magnets are arranged to be strongly attached to the horizontal leg of a steel wall angle. The wall angles are of sufficient strength to support the grid runners and the ceiling tiles carried on the grid runners. The invention can be embodied with the type of grid runner that has a box section with an open slot on its bottom face. In this case, a magnet is inserted in the box section at each end of the grid runner. The grid runners are cut to a length such that their ends and the associated magnets overlie the horizontal legs of oppositely facing wall angles.
[0004] The invention is useful with the more common style of grid runner or tee with flat flanges at their lower sides. In such a case, the ends of the tees can be modified by displacing material from a web above the flange for reception of a magnet.
[0005] With the invention there is no need to index the spacing of a runner along the length of the wall angles. The position of the runners, for example, can be determined by the width of the ceiling tiles or panels as they are being installed or by lengths of short cross runners if the latter are used. The grid runners of the invention can be used in trapped modules where the grid runner ends are supported on elements that, like the wall angles, cannot be deflected or rotated laterally to receive or release a connector designed to extend through such an element, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a fragmentary isometric view of a short span suspended ceiling system constructed in accordance with the invention;
[0007] FIG. 2 is a fragmentary isometric view of a grid runner constructed in accordance with the invention shown in relation to supporting wall angles; and
[0008] FIG. 3 is a fragmentary isometric view, similar to FIG. 2 , showing an alternative grid runner profile.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] A short span suspended ceiling is represented at 10 . The ceiling 10 and walls 11 can represent, for example, a corridor or hallway that typically is of a length substantially greater than its width. However, the invention can be used for the ceiling of a small room. The ceiling 10 comprises a plurality of spaced parallel grid runners 12 , extending transversely to the length of the corridor, and rectangular ceiling panels or tiles 13 carried by the grid runners 12 .
[0010] On the walls 11 , at ceiling height is a pair of opposed, elongated wall angles 14 . The wall angles 14 are made of sheet steel which may be hot dipped galvanized and painted. Each wall angle 14 has a horizontal leg 16 and a vertical leg 17 .
[0011] The illustrated style of grid runner in FIGS. 1 and 2 is of a known style, disclosed for example in U.S. Pat. No. 4,535,580. This style of grid runner has a hollow box-like structure 21 at its lower side. The profile of the grid runner 12 includes an upper hollow reinforcing bulb 22 , a vertical web 23 , and two inwardly facing C-shaped flanges 24 that mutually form the box section or structure 21 . The flanges 24 are at the lowermost part of the runner 12 and are spaced from one another to leave a gap or slot 26 . Typically, the grid runner 12 is roll-formed of sheet steel that can be hot dipped galvanized and painted.
[0012] The invention is particularly useful in arrangements where the grid spans a distance of between about 5′ to about 9′. At the longer spans within this range, the grid runner can be made of relatively heavy gauge stock and/or can be reinforced by adding layers of sheet steel to the reinforcing bulb 22 and/or can be increased in height to make it stronger. The length of a grid runner 12 is cut to provide moderate clearance with the inside surfaces of the vertical legs 17 of the opposed wall angles 14 .
[0013] A permanent magnet 27 is assembled at each end of a grid runner 12 into the flange formed box 21 . The magnet 27 will tend to hold itself in position in the flange box 21 at which it is placed. An adhesive, indicated at 28 , can be used to secure a magnet in position, if desired.
[0014] The ceiling tiles 13 can be standard commercially available units typically with nominal rectangular face dimensions of 2′×2′, 2′×4′, or 2-½′×5′, or metric equivalents thereof. The ceiling 10 can be constructed by initially installing the wall angles 14 on opposite walls 11 at the desired height. Wall angles, not shown, can be similarly installed at the end or ends of the corridor. Alternatively, a grid runner or runners 12 can be used for starting and ending at the beginning or end of a hallway. Starting at one end of a corridor or hallway, the walls 11 or wall angles 14 can be marked to indicate the desired centers for the grid runners 12 . Normally, the runners will be arranged perpendicularly to the walls. Typically, the grid runners 12 will be positioned on 2′ centers. The magnets 27 , being disposed directly over the horizontal legs 16 of the wall angles 14 , will releasably hold the grid runners 12 in the positions at which they are manually set. The tiles 13 can be laid on the grid runners 12 in a conventional manner by manipulating them through the plane of the grid runners 12 . If desired, the steps of laying out the centers of the grid runners along the respective walls angles 14 can be omitted and the grid runners 12 can be roughly positioned on the wall angles. Thereafter, successive grid runners 12 can be more precisely positioned using a row of installed tiles 13 as a gauge. From the foregoing, it will be understood that the position of a grid runner 12 along a wall angle 14 is not dictated by locating features on the wall angle. The magnets 27 will hold their respective grid runner ends firmly, but releasably, in place on the wall angles 14 . The grid runners are installed in a so-called “trapped module” where there is no horizontal freedom available for the wall angles 14 .
[0015] The broken lines 31 in FIG. 1 represent abutting edges of panels 13 or locations of cross runners aligned with the walls 11 . As is conventional, the panels or tiles 13 can be cut to fit the width of the corridor. If desired, the grid runners 12 can be provided with regularly spaced slots along their lengths. Such slots, in a conventional manner, can receive connectors on the ends of the cross runners as is known in the art and shown, for example, in aforementioned U.S. Pat. No. 4,535,580.
[0016] It will be understood that the ceiling components comprising the wall angles 14 , grid runners 12 , and tiles 13 , can be installed in locations where there is little or essentially no overhead clearance available in the space above the ceiling 10 . Moreover, a high level of access is afforded to the space above the ceiling 10 since an installed grid runner 12 can be moved out of position by simply lifting the tiles 13 it supports and shifting it along the wall angles 14 . A grid runner 12 can be completely removed from the ceiling 10 with intuitive motion, not requiring special technique and not requiring any movement of the supporting wall angles 14 . Temporary removal of one or more grid runners 12 , as well as associated ceiling tiles 13 afforded by the invention, gives full unobstructed access to the plenum above the ceiling. The risk of damaging these displaced ceiling parts is reduced where work is being conducted through the plane of the ceiling.
[0017] FIG. 3 illustrates the invention applied to a common form of grid runner that has the general shape of an inverted tee. The grid runner or tee 36 , as is typical, is roll formed of sheet steel and includes a hollow upper reinforcing bulb 37 , a vertical web 38 , and a lower flat flange 39 , extending on opposite sides of the web. The web 38 is notched at each end of the grid runner 36 to receive a respective permanent magnet 27 . To supplement the attractive force on the grid runner 36 , the magnet can be adhesively secured to the runner and/or the notch, designated 41 , can be configured to mechanically hold the magnet in position. The grid runner or tee 36 can be used in the manner described above in connection with the grid runner 12 .
[0018] It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. | An elongated metal grid runner for a suspended ceiling, the grid runner having a cross-section with an upper hollow reinforcing bulb, a vertical web extending below the bulb, and lower flange elements extending laterally from opposite sides of the web, the length of the grid runner being less than about 9′, a permanent magnet disposed on each end of the grid runner at its flange elements, the magnet being adapted to overlie and be attracted to a horizontal leg of a steel wall angle to thereby releasably retain the grid runner in position on the wall angle. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to offshore modular and floatable gravity structures which are normally supported on the sea bed in shallow water and which, in deeper water include a steel gravity platform is supported by a concrete base resting on the ocean floor; with steel gravity structure being adapted to support an oil and/or gas exploration or production platform. More particularly, the invention is adapted for use in an arctic environment wherein the structural system is subjected to significant horizontal and tipping moments generated by impinging ice sheets, ice packs, and iceridges or floes.
2. Discussion of the Prior Art
Heretofore, a number of varied solutions to the problems encountered in protecting offshore oil and gas drilling structures from damage caused by ice sheets, ice packs, and iceridges or floes have been suggested in the prior art. This technology has developed as the offshore exploration and production of oil and gas has extended into arctic regions consisting of oceans, inlets and bays wherein the waters are frequently covered by vast sheets of ice during the winter months, and extremely large ice floes in the magnitudes ranging up to a mile across and even larger during and other seasons.
Pierce et al. U.S. Pat. No. 4,245,929 discloses an offshore structure which is able to withstand ice forces generated by impinging ice sheets, ice packs, or iceridges, and wherein the lower portion of the support structure of the offshore platform includes upper and lower differently sloped conical exterior wall portions to form an inclination relative to the horizontal. The inclined conical wall portions are designed to deflect ice masses coming into contact with the platform support structure. The particular structural selection of the conical wall structure is designed to cause the ice to tilt upwardly upon impinging against the support structure and fragment the ice by converting the horizontal load to vertical tensile stresses. In contrast therewith, the invention improves upon the structure disclosed in Pierce et al. in at least two major respects. Firstly, the inventive structure is modular and floatable to allow for repositioning of the structure when the system is used for exploratory oil and gas well drilling. Secondly, the structure is designed to generate extremely high gravitational shear forces which will withstand the horizontal and vertical forces normally generated by ice sheets and dense ice packs. Additionally, the gravity mass of the inventive structure is sufficient to withstand ocean waves of maximum amplitude for the depth of water in which the structure is intended to operate.
Howard U.S. Pat. No. 3,766,737 discloses an offshore platform which is encompassed, at a radial distance from the platform, by a circumferentially movable ice trenching machine. This machine circulates about the platform so as to fragment and remove ice in a circular path at a rate approximately equal to the rate of movement of the ice sheet.
Oshima et al. U.S. Pat. No. 4,230,423 discloses a rotary ice breaking member having spiral rotary blades attached to the main structure thereof for use in icy waters. The rotary blades raise the ice sheet or dense ice pack and cause it to shear or break in a flexural mode as the ice is raised.
Challine et al. U.S. Pat. No. 4,142,819 discloses an offshore platform in which the platform is of the gravity displacement type. This prior art structure includes a base member resting on the marine floor, and has an annular steel shell affording rigidity in the upwardly extending direction, and incorporates a circular wall and diaphragm extending about the base portion of the platform so as to constitute a reinforcement for the base structure. While Challine et al. disclose a portable drilling platform for use on the ocean floor, it is not particularly intended for use in the arctic environment, nor does it disclose any structure for protecting the device from the horizontal forces generated by sheet ice and dense ice packs.
Galloway U.S. Pat. No. 3,881,318 discloses a method and an apparatus for creating an artificial ice ridge to protect the work platforms from encroaching ice sheets, pressure ridges, ice floes and the like.
SUMMARY OF THE INVENTION
Accordingly, the present invention contemplates the provision of a novel modular arctic structural system for supporting an oil or gas exploration or drilling platform, and wherein the structure derives its stability and ability to resist large horizontal shear loads by virtue of a massive gravity base which is floated to the exploration or production cite and then submerged to the seabed through a unique and novel ballasting method.
The inventive structure is intended for use in relatively shallow waters; in effect, waters of about 20 to 100 ft in depth. The base structure is provided in a modular form, and is normally ballasted down into a predredged hole or cavity formed in the seabed to provide a support structure for the platform which is at a predetermined distance below the mean water level. As contemplated, the inventive base provides a stable support structure having an extremely high resistance to horizontal shear loads encountered 30 feet below the mean water plane. In addition, a platform arrangement for supporting an oil and/or gas exploration or drilling rig is equipped with a novel ice impacting structure capable of withstanding 1200 lbs/in 2 pressure over a relatively large circumferential area. Moreover, the outer periphery of the platform is heated and sloped so as to be able to convert any horizontal shear loads exerted by the ice into tensile stresses which will tend to fracture the ice rather than forming a resistance along the compression line of the ice sheet. As such, the lower base portion of the novel platform configuration concurrently serves as an ice deflector, an ice breaker and an ice shield.
The modular system of the present invention is designed to be reusable. Each component of the system is separately floatable and equipped with ballasting means for raising and lowering the structure to its gravity base position. Thus, a base may be fitted for an exploration site and an exploration platform floated in over the site and thereafter ballasted into position on the seabed. Upon completion of the exploration, if it is desired to provide a production platform for the oil or gas reserve discovered during the exploration process, the exploration platform may be deballasted and floated off the base, and a production platform floated in for oil or gas production. The base may remain in place, or if the oil and gas exploration data indicates the site is not economically viable for a production platform, the base may be refloated and moved to a new exploration site.
Thus, it is an object of the present invention to provide a floatable and reusable modular offshore exploration and production platform system which is particularly adapted for use in arctic environments, wherein the platform is subjected to large lateral shear forces from ice sheets, ice ridges, ice packs, ice floes and other ice formations. The present invention uses a floatable base member that is designed to be towed to an exploration or production site and which is equipped with novel ballasting means for lowering the base member below the water plane to a predredged ocean cavity. After it is ballasted with seawater or sand, the base member then defines a massive base structure for supporting an offshore exploration or production platform and provides a high lateral load resistance therefor. The system also comprises an offshore exploration or production platform wherein the platform itself is designed to be towed to an exploration or production site. The platform comprises a steel gravity structure having a conically or sloped surface at the mean water plane and a large massive base structure that cooperates with the first base member to define an ice deflector, an ice breaker and ice shield when used in an arctic environment. The platform also incorporates a ballasting arrangement for raising and lowering the platform from and onto the first base member. The base member defines a moon pool in the center thereof which is slightly larger in diameter than the moon pool furnished with the exploration or drilling platform wherein up to 20 holes may be drilled at each exploration or production site. After use, the platform and the base member may be separately reballasted at the end of the exploration or production cycle and refloated to a new exploration or production site.
It is another object of the present invention to provide a novel method for lowering a large massive concrete structure below the water plane while maintaining it in a stable lateral position. The method essentially comprises at least two steps, such as a first step of attaching a plurality of removable buoyancy caissons around the outer perimeter of the base; and secondly, filling a large interior annular cavity with sea water to define an interior lake level with the existing water plane and separated therefrom by a large annular rim surrounding the base member. The interior lake and the caissons provide the stability needed to prevent the structure from slipping sideways or tipping as it is lowered below the water plane by the ballasting means.
It is another object of the present invention to provide a high shear gripping means between the massive base member, and the exploration or drilling platform, by providing a sand bed therebetween, and in which the sand bed is confined by the annular rim extending upwardly around the perimeter of the base.
It is a further object of the present invention to provide a novel method of ensuring that the conical ice deflecting and breaking structure for the exploration and drilling platform is placed at its optimum operating level by predredging a cavity in the ocean floor, and using one or more of a plurality of modular bases to define a stable support base approximately thirty feet below the mean water plane.
Moreover, a still further object of the present invention is to provide a novel arrangement for pumping a sand slurry into one or more cavities defined between the ocean bottom and the base member so as to produce an ocean floor base interface which will present a high resistance to horizontal shear forces.
Yet another object of the present invention is to construct both an oil exploration platform and an oil production platform with an hourglass profile having a plurality of inclined or sloped surfaces thereon which will convert horizontal compressive forces exerted by the ice sheet into vertical shear forces so as to assist in breaking the ice into fragments as the horizontal shear load components are converted into vertical tensile forces.
It is a more specific object of the present invention to provide a structure as described which incorporates a heated ice deflector surface which will prevent adfreeze of the ice sheet during periods of the winter months when the ice sheet is relatively stationary.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference may now be had to the following detailed description of preferred embodiments of the invention, taken in conjunction with the accompanying drawings; in which:
FIG. 1 is a partially sectioned plan view of an exploration platform and base member installed in an arctic environment in about 50 ft of water;
FIG. 2 is a partially sectioned plan view of a production platform and base member installed in about 100 ft of water;
FIG. 3 is a diagrammatic plan view of the base member of the present invention;
FIG. 4 is a diagrammatic view of the ballasting means used to initially lower the base member into its desired location;
FIG. 5a is a sectional plan view of the first step in the novel method of ballasting the base member into its desired location;
FIG. 5b illustrates the second step in the novel method of ballasting the base member into its desired location;
FIG. 5c illustrates the third step in the novel method of ballasting the base member into its desired location;
FIG. 5d illustrates the base member installed in its final position;
FIG. 6 is a sectional view illustrating a a modular base member and arrangement for filling the base member with a suitable ballast;
FIG. 7 is a partial plan view of the method of floating a production platform over a base member according to the method of the present invention;
FIG. 8 is a diagrammatic plan view of a portion of the exploration or drilling platform illustrating the ballasting arrangement used for ballasting a platform into position;
FIG. 9 is a diagrammatic elevation view of the lower portion of an exploration or production platform illustrating the ballasting and venting arrangement therefore;
FIG. 10 is a diagrammatic view of a heating arrangement used to prevent the ballast from freezing and to prevent adfreeze of the ice sheet to the platform hull; and
FIG. 11 is a diagrammatic view of the heat scavenger system used to supply the heating arrangement illustrated in FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As illustrated in FIG. 1, the modular arctic structural system is installed in 50 ft of water in an arctic environment. The ocean floor 11 has been dredged 20 ft as indicated at 12 to provide a mean support level 13, 30 ft below the mean water plane.
The structures illustrated in FIGS. 1 and 2 are particularly adapted for use in the arctic environment, although they would provide great utility in any shallow water irrespective of the climactic environment. In addition to providing great lateral resistance to ice sheets or ice floes, they also provide great lateral resistance with respect to waves 30 and 40 ft high which may be encountered in other seas or oceanic regions having a shallow water depth and wherein frequent storms are encountered.
As illustrated in FIG. 1, an exploration platform has been mounted on a 40 ft high concrete base in 50 ft of water. As illustrated in FIG. 2, a production platform has been mounted on a 70 ft concrete base in 100 ft of water. Both the exploration platform illustrated in FIG. 1, and the production platform illustrated in FIG. 2 define an hourglass profile along the ice and wave engaging surfaces thereof. As illustrated in FIG. 1, the exploration platform defines a massive base member 14 having a conically sloped surface 14a below the mean water level located at 15 and a second steeper cross-sectional profile 16 above the mean water plane level located at 15. In addition, a reduced cross-sectional diameter portion 17 is provided before the platform again widens outwardly at the first level as indicated by 18 to provide support means for the operating equipment used in the exploration platform.
As illustrated in FIG. 1, an ice sheet 19 has engaged the conical surface 14, and as the horizontal load generated by the ice sheet impinges against the massive base member 14, the horizontal compressive forces are deflected into vertical tensile forces by the sloping conical surface 14a below the mean water level defined at 15. Ice may be characterized as having a significant structural strength in the compressive mode, but as being relatively frangible and fracturable in the tensile mode. Thus, as the forces encountered by the ice sheet are transmitted to the vertical shear mode, the ice sheet is fragmented and broken away from the main ice sheet 19 in the form of blocks 20.
The arctic waters in which the present structures are intended to operate are covered with ice eight to ten months of the year, with the ice sheet reaching an average thickness of six to nine feet. Pressure ridges are formed when two separate sheets of ice move towards each other and collide by the over thrusting in crushing of the two interacting ice sheets. As illustrated in FIG. 1, a pressure ridge has been formed as the ice sheet encounters the modular arctic structure constructed in accordance with the present invention. At times the pressure ridges will grow so large as to contact the ocean floor. The pressure loads generated by these ice sheets, and the pressure loads generated by waves of up to 40 feet in height is discussed hereinbelow in greater detail.
In addition to the pressure generated by the continuous ice sheets which "creep" or move slowly in response to climactic conditions during the winter months, large ice flows are encountered during the summer months, ice floes having a mean depth of seven or eight feet and ranging in diameter from 1/2 mile to a mile may impact the structure at speeds of up to 1 or 2 ft/sec when mobilized by a strong wind. The kinetic energy carried by an ice floe of this magnitude is significant and requires a massive base structure, together with the sloping hourglass configuration defined in FIGS. 1 and 2 to withstand the horizontal loads impinging upon the exploration or production platforms.
Referring to FIGS. 1 and 2, two structures have been illustrated, with two separate types of ballast. In FIG. 1, there is shown a water ballast, while in FIG. 2 there is shown sand fill ballast. A combination of water and sand could also be used to provide the gravity mass necessary to secure the base to the ocean floor. In some instances in which the ocean floor is of a particularly silty nature, it is desirable to remove the silt to a firm base, and to backfill the cavity with sand to the desired operating level prior to installation of the concrete base.
As contemplated by the present invention, the base units are constructed of concrete, and are embedded in the sea floor so that any horizontal loads transmitted to the base structure are dissipated by shear forces at the concrete soil interface through the classical gravity structure mode. It is contemplated that a friction angle of at least 35° can be achieved by preliminary dredging and overlaying the ocean floor with a sand layer prior to the installation of the concrete base. In addition, if the ocean floor at the desired site was constituted of a significant clay component, it may be desirable to deposit a layer of sand over the clay before installation to the concrete base inasmuch as the clay would tend to adhere to the undersurface of the structure, and possibly increase the effective weight of the structure to the point so that refloating and movement of the base at some future date could prove to be impossible.
A summary of the horizontal loads impinging upon the structure is presented in the following tables wherein Table 1 is representative of the ice load conditions and wave loading conditions for an exploratory platform with a 40 ft concrete base and a 70 ft concrete base. Table II is representative of the horizontal load impinging upon a production platform placed on both the 40 ft concrete base and the 70 ft concrete base.
TABLE I______________________________________EXPLORATION PLATFORM Horizontal Net Lateral Load Weight Resistance (kips) (kips) (kips)______________________________________Ice Load ConditionExploration Platform 40,000 75,600 63,400 (R1)(Minimum Weight)Exploration Platform 40,000 93,600 78,500 (R1)(Maximum Weight)Exploration Platform + 40,000 182,600 127,900 (R2)40 ft CBExploration Platform + 45,000 267,600 187,400 (R2)70 ft CB30 ft Wave Load ConditionExploration Platform 6,300 64,800 54,400 (R1)(Minimum Weight)Exploration Platform 6,300 82,800 69,500 (R1)(Maximum Weight)Exploration Platform + 9,600 161,400 113,000 (R2)40 ft CBExploration Platform + 18,700 242,000 169,500 (R2)70 ft CB______________________________________
TABLE II______________________________________PRODUCTION PLATFORM Horizontal Net Lateral Load Weight Resistance (kips) (kips) (kips)______________________________________Ice Load ConditionProduction Platform 78,000 106,400 89,300 (R1)(Minimum Weight)Production Platform 78,000 127,600 107,100 (R1)(Maximum Weight)Production Platform - 67,000 339,400 237,000 (R2)40 ft CBProduction Platform - 170,000 541,200 379,000 (R2)70 ft CBWave Load ConditionProduction Platform 8,400 92,000 77,200 (R1)(Minimum Weight)Production Platform 8,400 113,200 95,000 (R1)(Maximum Weight)Production Platform - 12,800 311,100 217,800 (R2)40 ft CBProduction Platform - 24,900 507,000 355,000 (R2)70 ft CB______________________________________
The horizontal loads, the net weight and resistance R1 and R2 are illustrated in FIG. 2. These tables are set forth by way of examples of values that were calculated for two separate sizes of base members, a typical exploration structure, and a typical production platform structure. In computing these numbers, the design water depth ranged from 20 to 100 feet. The sea state was assumed to have a maximum wave height of 40 feet, a wave period of 10 seconds, and a sustained wind speed of 120 knots. The cummulative tide, encompassing both astronomical tide and storm tide, was assumed to be 10 feet, and the surface current was assumed to be 4 knots.
In computing the ice loading, the maximum sheet ice thickness was considered to be 7 ft, the multiyear ice thickness was considered to be 15 ft, and the multiyear ridge height was assumed to be water depth. The angle of friction for soil cohesion was assumed to be 35° between the concrete base and the ocean bottom and 40° between the exploration or production platform and the concrete base.
As was previously indicated, the modular arctic systems are intended to be moved by floatation from the side of origin to the installation site. The ballasting of the concrete base and of the massive support base for the platform provide the necessary mass to resist the lateral shear loads imposed thereon by the ice sheets. By way of example, the total weight of the 40 foot base illustrated as 21a in FIG. 1 was computed to be 65,600 ST or 131,200 kips. The displacement of the 40 foot concrete base was 130,800 ST or 261,600 kips. The draft, computed for the above weight and displacement, was 22 feet.
The concrete base illustrated at 21b in FIG. 2 was computed to be 145,100 ST or 290,100 kips, its displacement was 253,600 ST or 507,200 kips and its draft transit was 37 feet. Inasmuch as many portions of the shallow waters of the arctic ocean and bays in which the device is intended to be used may prohibit the use of a device with a 37 foot draft, it is contemplated by the invention that the concrete base may also be constructed in modular form as illustrated in FIG. 6 and towed to the exploration or production site for assembly in situ.
As illustrated in FIGS. 1 and 2, the exploration and production platforms have a substantial proportion of their structure above the mean water level. Nevertheless, the major portion of the weight and displacement, when installed, is below the mean water level. The weight of the exploration platform illustrated in FIG. 1 was computed to be 51,400 kips, or 25,700 ST. Of this, 39,200 kips was located in the ice shield the double bottom, and the bulkheads of the hull structure which are at or below the mean water level for the structure. Thus, 76% of the total weight, before ballasting, is located below the mean water line for the hull. In transit, the displacement of the exploration hull structure will draw a 17 foot draft.
The production platform, which is somewhat larger than the exploration platform was calculated to have a weight of 42,100 ST or 84,200 kips. Of this, 38% of the weight was involved in the production platform, equipment, and quarters for the crew, and the remaining 62% in the hull structure and ice shield. The production platform had a total transit displacement which drew a 23 foot draft before ballasting.
It should be understood that once the structures are towed to their on site location, and ballasted into position, a substantial amount of gravity mass is added not only by the ballasting, but by the liquids stored in the platforms. Thus the minimum weight for the production platform was calculated to be 42,100 ST while the total weight with liquids was computed to be 50,300 ST. The production platform is capable of holding 54,400 ST of ballast, and when positioned on a concrete base extending to 30 feet below the mean water level, the displacement is 51,500 ST. Thus, the total minimum weight of the production platform is 53,200 ST or 106,400 kips. Its maximum weight, when filled with producing liquids, drilling liquids and consumables, drill water and fuel oil totals 60,900 ST plus 54,400 ST of ballast. The displacement of 51,500 remains the same, or total maximum weight of 63,800 ST or 127,600 kips.
The total gravity mass of the modular system is calculated in the following two tabular examples as being representative of the total mass generated by the base member, the structural member, and the respective ballasting added to each member with a compensating displacement lift subtracted therefrom. Table III is for the structure illustrated in FIG. 1, while Table IV is for the structure illustrated in FIG. 2.
TABLE III______________________________________Net Founding Weights (ST)Exploration Platform + 40 ft Concrete Base______________________________________Concrete Structure 61,100Appurtenances 3,500Installation and Tow Appurtenances 1,000Total Transit 65,600 STDraft: 22 ftMaximum Weight:Total Transit Displacement 65,600Maximum Weight Exploration SGS 46,800Interface System (Sand) 9,000Ballast 105,200Total Maximum 226,600Displacement (130,800)Maximum Net Weight 95,800 STMinimum Net Weight 86,800 ST______________________________________
TABLE IV______________________________________Net Founding Weights (ST)Production Platform + 70 ft Concrete Base______________________________________Concrete Structure 139,900Appurtenances 4,500Installation and Tow Appurtenances 1,000Total Transit 145,400 STDraft: 37 ftMaximum Weight:Total Transit Displacement (70 ft CB) 145,400Maximum Net Founding Weight Production SGS 63,800Interface System (Sand) 9,000Ballast 311,300Total Maximum 529,100Displacement (70 ft CB) (253,600)Maximum Net Weight 275,900 STMinimum Net Weight 265,300 ST______________________________________
As can be ascertained from the foregoing values, the computed weights and displacements values for each of the components of the modular arctic system provide floatable bases and platforms which may be ballasted into position over an exploration or development site.
The ballasting of the concrete base into position is difficult inasmuch as the concrete base loses its water plane once it slips beneath the surface of the ocean. In addition, it is impractical to maintain the center of buoyancy at a significant distance above the center of gravity for the concrete vessel. The combined effects of the loss of water plane and the differential between the center of buoyancy and the center of gravity would cause the vessel to submerge out of control once it drops beneath the water surface.
FIGS. 3 to 5 illustrate a novel method for submerging a concrete base of the present invention while maintaining a level keel with respect to the ocean floor.
As illustrated in FIG. 3, the concrete base structure is formed of modular segments 31-37, wherein two of these segments 31 and 35 include valve rooms which provide the initial ballasting of the vessel. A schematic of the one of the valve rooms is illustrated in FIG. 4. Two 20-inch supply mains 38 and 39 open into the moon pool 40 formed in the center of the concrete base. Valve members 40 and 41 provide flooding of the various compartments within the concrete base member by headers 41-44 and a plurality of lateral feed conduits generally identified by the numeral 45. In addition, circumferential headers 46 and 47 are provided to route the incoming sea water to each of the segments in the concrete device. For example, the valve room 31a illustrated in FIG. 3 is adapted to control ballasting for segments 30, 31, 32 and 33, while the valve room 35a illustrated in segment 35 is adapted to control the flooding of the chambers and compartments in segments 34, 35, 36 and 37.
The above is meant to be merely representative, and it is to be understood by one skilled in the art that various configurations of the concrete base member would result in various sizes and shapes of compartments in order to achieve maximum structural integrity for the structure. As such, the piping illustrated in FIGS. 3 and 4 is meant to be a representation, of one possible arrangement of ballasting a base member.
The novel method for submerging the concrete base is illustrated in FIGS. 5a-5d. As illustrated in FIG. 5a, a 40 foot concrete base member 21c is floated to its desired location. A plurality of buoyancy caissons represented generally in FIGS. 5a-5d as 50 and 51 are attached to the upper outer periphery of the concrete base member. For the 40 foot base illustrated in FIG. 5a, six 30-foot diameter caissons are attached to the upper outer periphery of concrete base member 21c. A cavity 11b is dredged in the ocean floor and provided with a relatively thin sand layer 11c. The sand layer is used to provide final adjustment of the depth of the cavity below the mean water plane 15. While the designs of the exploration and production vessels illustrated in FIGS. 1, 2 could be altered to any specific dimension, the chosen design dimension provides that the top of the base support member 21c should be 30 feet below mean water level 15 when the base member is fully submerged and in place. The sand layer 11c is used to even out any irregularities in the dredged cavity, and to provide a consistent and predictable lateral angle of cohesion for the concrete base member 21c.
For purposes of clarity, valve rooms 31a and 35a illustrated in FIGS. 3 and 5a have been omitted from FIGS. 5b-5d, as have the supply conduits and headers 41 and 41a illustrated in FIG. 5a. In addition FIG. 5a illustrates vertical risers 41b-41e which are provided for flooding the upper and lower compartments of the multi-compartmented concrete base member.
After the cavity has been prepared, and the base member 21c floated to the location illustrated in FIG. 5b, the concrete base member is ballasted to approximately 3 feet of freeboard. This is done by opening valves 40 and 41 in valve room 31 and corresponding valves in valve room 35a (not shown). As illustrated in FIGS. 1, 2, 5, 6 and 7, the concrete base member defines an upstanding annular rim 60 which extends around the perimeter of the concrete base member. As will be hereinafter illustrated with respect to FIG. 7, the elevation of the upstanding aim or parapet wall may vary depending on its location on the concrete base. However, for the base member illustrated in FIGS. 5a-5d the upstanding rim or parapet wall extends from 5 to 8 foot above the upper surface 21f of the concrete base member 21c. In addition, an interior annular rim 61 is installed around moon pool 40 by means of sand bags or other removable water-impervious members.
Once the concrete base member is positioned and ballasted to approximately 3 foot of freeboard, sea water is pumped into the upper annular space defined between the parapet wall 60 and inner temporary rim 61 to define an upper annular lake 62. The lake on top of the surface of the base is used as a balancing device to level the structure. The procedure is sensitive enough to accurately bring the center of gravity to normal alignment with the plane of the concrete base, and directly in line with the center of buoyancy. Once the lake levels the structure as illustrated in FIG. 5c, the concrete base can be submerged using the gravity ballast method by reopening valves 40 and 41 in valve room 31a, and the corresponding valves (not shown) in valve room 35a. As the concrete parapet is submerged, the six caissons are used to maintain a sufficient medacentric height above the mean water plane 15 to prevent any tipping or tilting as the base descends the final 10 to 20 feet to the cavity 11b. It should be noted that when the concrete base 21c is installed as illustrated in FIG. 5d, the ballasting compartments are filled with sea water, the caissons are then partially flooded and removed prior to the installation of the exploration or drilling rig. In actual use, the base member may be installed as much as a year prior to the shipment and delivery of the exploration or development platform.
As illustrated in FIGS. 3 and 6 the concrete base may be formed of a modular construction. The modular construction may be both vertical (FIG. 3) and horizontal (FIG. 6). The diameter of the concrete base member, for large installations may approach 400 feet. When the concrete base is that large, it may be divided as illustrated in FIG. 3 along axis a-a' constructed in two halves, port and starboard, to limit the size of the dry or graving dock required. While it would be possible to construct a graving dock to accommodate a 400 foot diameter structure, it is considered more economical to build concrete bases in halves and mate them together in a protected location. The halves will be mated while they are floating by using prestress steel that is added to the first interior bulkheads. In addition, where water passages will not permit the passage of a 70 foot high concrete base with a 37 foot transit draft, it may be desirable to fabricate the concrete base in vertical modular components as illustrated in FIG. 6.
The concrete base member illustrated in FIG. 6 is formed of two vertical components 21d and 21e which are stacked above one another. In addition, FIG. 6 illustrates the novel method of filling the ballast tanks generally indicated as 60 and 60a with sand or a mixture of sea water and sand in a slurry form. As schematically illustrated in FIG. 6, each of the compartments is equipped with a fill opening 61 and a vent opening 62. The fill and vent pipes 61 and 62 are a series of short run pipe tubes that penetrate the top of the slab of the concrete base and communicate with the ballast chambers 60 and 60a. The top of each spout has a flange to which a flexible pipe from pumps or sand hoppers on a service barge can be attached. Two pipe spouts 61 and 62 are provided for each compartment so that a more level top surface of said fill can be attained, and so that water can escape as fill is placed in the other spout. While vent and fill openings 61 and 62 have been illustrated for ballast chambers 60 and 60a in FIG. 6 it is to be understood each of the ballast chambers 60 and 60a contain separate and distinct fill and vent lines. The fill and vent tubes are intended to be a representation of one type of filling and venting method that could be employed to fill the cavity 60 and 60a with a sand or sand/seawater slurry ballast. The fill pipes 61 may be as much as 24 inches in diameter to provide for rapid and efficient ballasting of the compartments 60 and 60a with water or sand.
Each of the concrete base members 21e and 21d also includes a slurry grouting system 65 which includes an upstanding vertical fill tube 65a and a plurality of horizontal headers indicated by 65b that terminate in a plurality of downwardly extending openings generally indicated at 65c. As illustrated in FIG. 6, the downwardly extending grout tubes may be as much as 24 inches in diameter, with the radially outwardly extending headers 65 being 12 to 14 inches in diameter. Each of the downwardly extending spouts 65c is approximately 6 inches in diameter.
The slurry grouting system below the base is composed of a system of 6 inch pipes which distribute sand slurry to subdivided 2,500 sq/ft areas under the concrete base. Sand builds up in one area and works its way back along the internal piping until the first 2,500 sq/ft area is filled. The slurry flow will then allow a second consecutive area to be filled and so on. The slurry pipe network can also be used for a water jet before lift off when it is 5 desired to refloat the base. Refloating the base is accomplished by installing air hoses from barge mounted air compressors to the fill tube openings 61. A vertical water vent extending downwardly to the floor of compartments 60 and 60a is then installed in the vent openings 62. The air pressure generated by the compressors will then deballast the compartments. The grouting system illustrated in FIG. 6 is used when the concrete base member 21e is installed on the ocean floor without the sand layer 11c previously illustrated in FIG. 5a. In addition, when a pair of modular units are stacked vertically, a sand slurry may be pumped between the concrete base units as illustrated by sand pillow 70 in FIG. 6. Sand pillow 70 enables the selection of a sand material having a shear angle of at least 40° to maximize the gravity shear resistance imparted from base member 21e to the secondary member 21d.
After installation of the base member, the exploration or drilling platform illustrated in FIGS. 1 and 2 are floated into position as illustrated in FIG. 7. When installating the modular system the relatively shallow water, the respective draft of the platform to be used and the height of the concrete base must be very carefully calculated to ensure that the upper surface of the concrete base member 21b is 30 feet below the mean water level. Inasmuch as the production platform is designed with a 23-foot draft, a 7-foot clearance will be maintained between the installed height, and the draft drawn by the floating platform. The upstanding rim or parapet wall 60 illustrated in FIG. 7 is illustrated as having two separate heights. The seaward parapet wall is 8 foot high, while the shoreward parapet wall is 5 foot high. The floating platform is brought in from the shoreward side of the concrete base structure to provide a 3-foot minimum clearance between the draft of the floating platform and the parapet wall on the shoreward side of the concrete base member 21b. As illustrated in FIG. 7, the lower tanks 14b of the platform clear the shoreward parapet by 3 foot as the platform is positioned over the concrete base member. The ice shield also covers the lower tanks 14b of the production platform.
As was previously illustrated with respect to FIG. 6, a sand layer or sand pillow 70a is provided between the upper surface of the concrete base member and a lower surface 14b of the production platform. Again, the sand layer 70a is used to provide a high angle of cohesion between the steel surface of the production platform, and the concrete base member 21b. The specified 40° angle results in a significant safety factor of 1.59 between the platform and the concrete base. A 30° angle would be equivalent to a friction factor of 0.58, well above the factor of 0.30 that could be expected from a pure steel-soil interface. The 30° angle of friction characterizes a poorly graded said or silt with a relative density less than 50%. The sand layer 70 and 70a is provided from a service barge mounted above the assembly area to provide a sand grout having a 40° angle of friction to maximize the shear factors between these structures.
Both the exploration and production platform contain ballasting systems for lowering the platform into place once it has been positioned. While it is essential that the system for the exploration platform provide for deballasting, the production platform need not contain a deballasting system if its production life is intended to be approximately equal to the service life of the production site.
The platform structures are submerged during installation from their 17 or 23-foot draft to their founded condition in 30 foot of water as illustrated in FIGS. 1 and 2. The ballast systems are designed with contingency systems and backup system. The ballast systems are also available for refloatation at any time to enable the structure to be relocated in the event that adverse ice conditions are encountered which exceed the design capabilities of the platform.
Pump or valve flooding is used to provide a controlled descent and landing as illustrated in FIGS. 8 and 9. Water is pumped onboard through sea chest 80 on the outer periphery of the ice shield at the level of the double bottom within 7-feet of the bottom of the hull. Water is distributed via a valve manifold system in a valve and pump room 81 as illustrated in FIGS. 8 and 9. Ballasting of the platforms may be accomplished by valving sea water into the ballast tanks 82, 83 and 84 and 85 as illustrated in FIG. 9, and as illustrated at 82a and 85a in FIG. 8. The ballast tanks 82-85 are vented to 85 feet above the surface by means of vent lines 86-90. Alternately, pumps 92 and 93 illustrated in FIG. 8 may be used for controlled descent by pumping the incoming sea water from sea chest 80 into a series of manifolds generally indicated by 92 and 93 and a plurality of radially outwardly extending headers generally indicated at 94, 95.
The outwardly extending radial headers 94 and 95 are also used for deballasting when it is desired to refloat the platform. Pumps 92 and 93 then draw water from the ballast tanks 82-85 and eject it upwardly via discharge line 91 to an elevation 85 foot above sea level. This is done to prevent clogging of the outlets due to surface ice or ice ridges that may have built up on the surface of the ice shield. The reversal of the pumping action by pumps 92 and 93 may be accomplished by pipe manifolding, or by closing valves 97-99 and reversing the action of the pumps to pump the seawater from the ballast tanks through conduit 91.
The vent system illustrated at 86-90 is designed to backup the ballasting system to provide yet another way to ballast and deballast the ballast tanks. The nominal purpose, however, of the vent system is to vent the tanks and to provide sounding tubes for a level indicator system. The most efficient network of vent piping provides vertical runs directly to the weather deck from each compartment. Manifolds are used to minimize the number of termination areas. Groups of vent pipes therefore share a common control area. The vent pipes are also terminated at an elevation of 85 feet above the mean water plane to prevent clogging with ice at the outlet, to provide maintenance convenience, and to maintain hull integrity to that elevation. Each compartment has more than one vent outlet placed at the extreme end of the tanks so the pressure can be released in the case the outlets are blocked because of the inclination of the structure, because of icing, or because of some other obstruction.
It is apparent that the actual manifolding and piping configuration are dependent upon the tank and bulkhead structures actually employed in the construction of the platform. Inasmuch as these will vary depending upon the size and nature of the platform, the piping diagram set forth in FIG. 8 and FIG. 9 is meant to be a representation of one layout. Many other piping layouts could be used to accomplish the same function. It should be noted that pipe diameters are relatively large with 18 inch manifolds extending outwardly to the seachest openings 80, and 12 inch distribution headers being used to flood the various ballast compartments 82-85. The vent lines 86-90 are sized at 8 inches to prevent the build up of back pressure during the filling of the ballast tanks 82-85. The design capacity of pumps 92 and 93 is 40,000 gallons per minute and two such pump rooms are contemplated for each of the platforms. Thus, the design of the system enables complete deballasting of the platform within 12 hours.
It should be noted that the steel platform structures and the concrete base structures are framed with double walls around the circumference. This means that at least two bulkheads must be penetrated by any ice floes before significant structural damage will occur. The highest stresses occur when the bulkheads are subjected to a large vertical load at their intersection with the outer ice shield. This is the point at which the large lateral loads are applied by the ice and transmitted to vertical shear forces by the slanted surface of ice shield 14a. The design ice pressure for ice shield 14 is 1,200 lbs/in 2 .
The modular arctic structure also includes a heating arrangement as illustrated in FIGS. 10 and 11. The hull heating is principally intended to prevent freezing of the ballast water. It is also intended to prevent ice sheets from freezing to the structure and inducing extreme loads when the ice begins to move because of environmental conditions.
The waste heat from the prime mover engines 101, 102, 103 is dissipated to the outer hull as illustrated in FIG. 10 by means of heat exchangers 104, 105 and 106 which are continually pumped by means of pump 107 to the hull heat exchangers generally indicated by 108 in FIGS. 9 and 10. Manifold piping generally indicated 109 provides a continuous loop between the heat exchanger 104, 105 and 106 and the hull heat exchangers 108. In addition, a supplemental heat exchanger 111 is provided to dissipate heat to the arctic sea through sea chests 112 and 113 by means of pump 114. If the heat load generated by the prime mover engines 101-103 exceeds the demand of the hull heat exchangers 108, the valve members 115 and 116 are opened to allow the excess heat to be dissipated into the arctic ocean. In the event the engines 101-103 are not dissipating enough heat, oil-fired boilers generally indicated at 117 can be used to provide supplemental heat through heat exchanger 118.
An economical arrangement results if the hull is divided into eight 45° segments, with a heating coil type network as illustrated in FIG. 10 being provided for each segment. Most of the heat is lost through the steel plates above the water surface. The air zone dissipates 520 btu per hour per square foot while the ice sheet dissipates 44 btu per hour per square foot. The water zone dissipates only 4 btu per hour per square foot. These values are based on internal bath water temperatures of 50°-60° F. Based on these figures, each 45° segment of the hull structure would normally dissipate 1.4 million btu per hour. The three engines 101-103 at full capacity would be able to supply as waste heat 18.9 million btu per hour. Thus each segment of the hull could be heated if desired, although it would appear that only those segments oriented towards the advancing ice flow would need to be heated.
While there has been shown and described what is considered to be a preferred embodiment of the invention, it will of course be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact form and detail herein shown and described, nor to anything less than the whole of the invention herein disclosed as hereinafter claimed. | A modular and floatable offshore exploration and production platform system for use in shallow arctic waters is disclosed. A concrete base member is floated to the exploration or production site, and ballated into a predredged cavity. The cavity and base are sized to provide a stable horizontal base 30 feet below the mean water/ice plane. An exploration or production platform having a massive steel base is floated to the site and ballasted into position on the base. Together, the platform, base and ballast provide a massive gravity structure that is capable of resisting large ice and wave forces that impinge on the structure. The steel platform has a sloping hourglass profile to deflect horizontal ice loads vertically, and convert the horizontal load to a vertical tensile stress, which assists in breaking the ice as it advances toward the structure. |
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This is a continuation of application Ser. No. 08,661,695, filed Jun. 11, 1996, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a support post system, and, particularly, to a support post system for use in construction of fences and walls for various purposes.
BACKGROUND OF THE INVENTION
Post-supported fences and walls have been used in numerous settings for hundreds of years. In such fences or walls, substantially horizontal rails are supported by substantially vertical posts. Generally, the supporting posts of such fences are buried into the ground.
The posts for early post-supported fences and walls were fabricated largely if not entirely from wood. Unfortunately, wood is adversely affected by environmental conditions over a relatively short period of time, especially when buried in the ground. Recently, therefore, wooden posts have been replaced in many instances by concrete or metallic posts better suited to withstand the extremes of temperature and moisture required of an outdoor system.
In the past it also has been very difficult to construct post-supported fences and walls and to replace damaged rails in post-supported fences or walls. In many cases it was necessary to remove the post adjacent a damaged rail from the ground to repair or replace the damaged rail. In an attempt to facilitate the construction of fences and walls and to facilitate the repair thereof, a number of modular fencing systems have been proposed.
Nonetheless, the modular systems currently available suffer from a number of significant drawbacks. For example, such systems are often difficult to assemble. Moreover, it is often difficult to lay out such modular systems in a desired geometric arrangement. Still further, many such modular systems are not sturdy enough for use in many settings.
It is, therefore, desirable to develop a support post and support post system that minimizes or eliminates these and other drawbacks associated with current posts and support post systems.
SUMMARY OF THE INVENTION
The present invention provides generally a support post system comprising a support member having at least one recess in a surface of the support member for receiving and seating a rail member. The support member further comprises at least one attachment member which extends outwardly substantially perpendicular to the longitudinal axis of the support member. The attachment member extends through the recess and preferably beyond the surface of the support member. In one embodiment, the attachment member passes through a corresponding passage in the rail member when the rail member is seated in the recess. The rail may be seated in the recess without the attachment member passing through the rail member, however. The support post system further comprises a finish plate for placement over the rail member after the rail member is seated in the recess. The finish plate has a passage formed therein to allow passage of the attachment member therethrough. The support post system also comprises means for removably securing the finish plate to the attachment means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a front view of an embodiment of a support post system under the present invention.
FIG. 2 illustrates a side view of the embodiment of FIG. 1 .
FIG. 3 illustrates a front view of an embodiment of reinforcement members for use in the support members of the present invention.
FIG. 4 illustrates a side view of the reinforcement member of FIG. 3 .
FIG. 5A illustrates a front view of an embodiment of a fence system of the present invention.
FIG. 5B illustrates a side perspective view of an embodiment of a fence system of the present invention.
FIG. 5C illustrates a front view of an embodiment of a fence system of the present invention.
FIG. 6A illustrates an embodiment of a fence system of the present invention have an angled connection plate.
FIG. 6B illustrates an embodiment of a support member having recesses in more than one side thereof for creating an angle in a fence system.
FIG. 7A illustrates an embodiment of a cross rail fence system of the present invention.
FIG. 7B illustrates an embodiment of a privacy fence system of the present invention.
FIG. 7C illustrates and embodiment of a landscaping or retention wall incorporating an embodiment of a support member of the present invention
DETAILED DESCRIPTION OF THE INVENTION
As illustrated in FIGS. 1 and 2, support post system 10 preferably comprises a support member 20 having at least one recess 30 therein. In the embodiment illustrated in FIGS. 1 and 2, support member 20 has a substantially rectangular cross-sectional shape and comprises three recesses 30 on one of its four sides. For maximum strength and facility of construction, recesses 30 are preferably rectangular grooves of an appropriate width and depth to seat a rail member 40 of rectangular cross section (see FIGS. 1 and 2) therein. As clear to one skilled in the art, however, support member 40 can have any of a number of cross-sectional shapes. Likewise, recesses 40 can be of substantially any cross-sectional shape corresponding to the cross-sectional shape of rail member 40 to be seated therein.
Each recess 30 includes at least one attachment member 50 extending therethrough, which may, for example, comprise a bolt. Preferably, at least two attachment members 50 are included in each recess. Support member 20 is preferably fabricated from a strong and durable material such as steel reinforced concrete or fiberglass. Most preferably, support member 20 is fabricated from steel reinforced concrete. As best illustrated in FIGS. 2 through 4, support member 20 may, for example, comprise one or more steel reinforcement rods 100 longitudinally oriented within the interior of support member 20 . Reinforcement rods 100 may be placed within concrete support member 20 using well known concrete molding techniques. Preferably, at least two reinforcement rods 100 are included. To increase the strength of attachment of rail members 40 to support members 20 , attachment members 50 are preferably attached to enforcement rods 100 . Attachment members 50 comprising metallic bolts, for example, may be welded to reinforcement rods 100 before support member 20 is molded.
As best illustrated in FIG. 5A, support members 20 are preferably anchored at desired positions by, for example, being buried in the ground. Rail members 40 are then seated in recesses 30 with each rail member 40 preferably being supported by at least one support member 20 . At the position where a rail member 40 is seated in a recess 30 , one or more passages 45 may be formed in rail member 40 through which attachment members 50 may pass. Alternatively, the ends of rail members 40 may simply be seated in recesses 30 without attachment member 40 passing therethrough (see FIG. 5 C).
After rail member 40 is seated in recess 30 of support member 20 , a finish plate 60 is placed over rail member 40 and secured to support member 20 as best illustrated in FIG. 5 A. Preferably, finish plate 60 is shaped to conform to the surface of rail member 40 . In the case of a rectangular rail member, for example, finish plate is preferably substantially flat. Likewise, finish plate 60 may be curved if the surface or rail member 40 is curved. Finish plate 60 includes means for removably attaching finish plate 60 to attachment member 50 . Preferably, finish plate 60 includes one or more passages 65 therethrough to allow attachment means 50 to pass through passages 65 . In the case of threaded bolts used for attachment means 50 , a nut 70 (see FIG. 5B) as known in the art may be used to secure finish plate 60 (and thereby rail member 40 ) to support member 20 . Preferably, finish plate 60 is fabricated from a strong, durable material such as steel and acts to securely maintain rail member 40 within recess 30 .
As best illustrated in FIGS. 5A and 6A, the installation of a hinged gate or creation of an angle in a fence or wall is very simple with the present system. In that regard, FIG. 5A illustrates a hinge plate 80 that is (for durability) preferably placed in recess 30 of support member 20 before rail member 40 is placed therein. Hinge plate 80 preferably has one or more passages 85 to allow attachment members 50 to pass therethrough. After hinge plate 80 is set in place in recess 30 , rail member 40 is then set in place within recess 30 over hinge plate 80 . A finish plate 60 is then placed over rail member 40 and secured to support member 20 via attachment means 50 . Hinge plate 80 includes a hinged portion 90 attached to hinge plate 80 via a hinge 87 . A swinging gate may be attached to hinge portion 90 as known in the art. A hinged portion may alternatively be attached to finish plate 60 for supporting a hinged gate or door.
Similarly, an angle θ may easily be created in a fence or wall under the present invention with used of an angled plate 110 . In the case that rail members 40 are of a rectangular cross-section, angled plate 110 preferably comprises a first substantially flat surface 110 A and a second substantially flat surface 110 B. Surfaces 110 A and 110 B form angle θ therebetween. Surface 110 A is preferably provided with one or more passages 105 and seated in recess 30 . Attachment member(s) 50 pass through passages 105 . After surface 110 A of angled plate 110 is set in place within recess 30 , rail member 40 is placed thereover. Second surface 110 B acts as a support for a further rail member 40 , which, when attached to second surface 110 B through any means known in the art (for example, bolts and nuts) forms approximately an angle θ with respect to first surface 110 A and the rail member attached thereto. To provide strength to the angled attachment, an angled finish plate 60 ′ is preferably set in place last to secure the angled attachment. As clear to one of ordinary skill in the art, an angled connection can also be made in the present system with use of angled finish plate 60 ′ without the use of angled plate 110 . Moreover, angled plate and angled finish plate are easily formed to any angle θ (for example, by bending metallic plates).
FIG. 6B illustrates another manner in which an angle in a fence system of the present invention can be made. In the fence system illustrated in FIG. 6B, rails members 40 are placed in recesses 30 and 30 ′ which are formed in the exterior sides of support member 20 ′. Recesses 30 and 30 ′ form an angle φ therebetween, thereby forming the angle φ in the fence system. As clear to one of skill in the art, support member 20 ′ may easily be constructed to form a wide range of angles φ.
FIGS. 7A through 7C provide a number of examples of the aesthetic and utilitarian versatility of the present system. FIG. 7A illustrates a cross rail design in which cross rails 40 ″ have been attached to support members 20 ″ as have been rail members 40 ′. As illustrated in FIG. 7A, recesses 30 ″ are appropriately shaped to accommodate the ends of rail members 40 ′ and of cross rail members 40 ″. Finish plate 60 ′ is placed over recess 30 ″ to secure rail members 40 ′ and cross rail members 40 ″ within recess 30 ″. In the embodiment of FIG. 7A, attachment members 50 are shown to pass through rail members 40 ′ and cross rail members 40 ″. As illustrated in FIG. 5C, however, rail members 40 ′ and cross rail members 40 ″ may be seated in recesses 30 ″ in a manner such that the one or more attachment member passing through recesses 30 ″ do not pass through rail members 40 ′ or cross rail members 40 ″.
FIG. 7B illustrates a privacy wall or fence in which vertical planks 150 have been attached to rail members 40 . FIG. 7C illustrates a landscaping wall 170 in which blocks 200 have been inserted between rail members 40 . As clear to one skilled in the art, the dimensions of support members 20 and rail members 40 are easily adjustable to fit any situation. In the case that a large load must be supported by a fence or wall under the present invention, recesses 30 of support members 20 preferably face the direction from which the most force will be applied. In the case of a landscaping retaining wall, for example, recesses 30 preferably face the ground or soil to be retained. In the case of a livestock fence, for example, recesses 30 preferably face the interior of the fenced portion wherein the livestock is to be retained.
The fence systems of the present invention are also easily adaptable to an electric fence system for retention of livestock. In that regard, insulators (not shown) for supporting electrified wire (as well known in the art) are easily attached to support members 20 using methods well known in the art.
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. | The present invention provides generally a support post system comprising a support member. The support member comprises at least one recess in a surface of the support member for receiving a rail member. The support post further comprises at least one attachment member which extends outwardly substantially perpendicular to the longitudinal axis of the support member. The attachment member extends through the recess. The support post system further comprises a finish plate for being placed over the rail member when after the rail member is seated in the recess. The finish plate has a passage formed therein to allow passage of the attachment member therethrough. The support post system also comprises a mechanism for removably securing the finish plate to the attachment member. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a divisional application of U.S. application Ser. No. 13/541,249, filed Jul. 3, 2012 (pending). U.S. application Ser. No. 13/541,249 is a divisional application of U.S. application Ser. No. 12/597,370, filed Jun. 23, 2010 (now U.S. Pat. No. 8,236,738). U.S. Pat. No. 8,236,738 was filed as a national stage application under 35 U.S.C. §371 of International Application No. PCT/CA08/00786, filed Apr. 25, 2008. International Application No. PCT/CA08/00786 cites the priority of Provisional U.S. Application No. 60/924,006, filed Apr. 26, 2007.
FIELD
This invention relates to fluid compositions and their use in controlling proppant flowback after a hydraulic fracturing treatment and in reducing formation sand production along with fluids in poorly consolidated formations.
BACKGROUND
Hydraulic fracturing operations are used extensively in the petroleum industry to enhance oil and gas production. In a hydraulic fracturing operation, a fracturing fluid is injected through a wellbore into a subterranean formation at a pressure sufficient to initiate fractures to increase oil and gas production.
Frequently, particulates, called proppants, are suspended in the fracturing fluid and transported into the fractures as a slurry. Proppants include sand, ceramic particles, glass spheres, bauxite (aluminum oxide), resin coated proppants, synthetic polymeric beads, and the like. Among them, sand is by far the most commonly used proppant.
Fracturing fluids in common use include aqueous and non-aqueous ones including hydrocarbon, methanol and liquid carbon dioxide fluids. The most commonly used fracturing fluids are aqueous fluids including water, brines, water containing polymers or viscoelastic surfactants and foam fluids.
At the last stage of a fracturing treatment, fracturing fluid is flowed back to the surface and proppants are left in the fractures to prevent them from closing back after the hydraulic fracturing pressure is released. The proppant filled fractures provide high conductive channels that allow oil and/or gas to seep through to the wellbore more efficiently. The conductivity of the proppant packs formed after proppant settles in the fractures plays a dominant role in increasing oil and gas production.
However, it is not unusual for a significant amount of proppant to be carried out of the fractures and into the well bore along with the fluids being flowed back out the well. This process is known as proppant flowback. Proppant flowback is highly undesirable since it not only reduces the amount of proppants remaining in the fractures resulting in less conductive channels, but also causes significant operational difficulties. It has long plagued the petroleum industry because of its adverse effect on well productivity and equipment.
Numerous methods have been attempted in an effort to find a solution to the problem of proppant flowback. The commonly used method is the use of so-called “resin-coated proppants”. The outer surfaces of the resin-coated proppants have an adherent resin coating so that the proppant grains are bonded to each other under suitable conditions forming a permeable barrier and reducing the proppant flowback.
The substrate materials for the resin-coated proppants include sand, glass beads and organic materials such as shells or seeds. The resins used include epoxy, urea aldehyde, phenol-aldehyde, furfural alcohol and furfural. The resin-coated proppants can be either pre-cured or can be cured by an over-flush of a chemical binding agent, commonly known as activator, once the proppants are in place.
Different binding agents have been used. U.S. Pat. Nos. 3,492,147 and 3,935,339 disclose compositions and methods of coating solid particulates with different resins. The particulates to be coated include sand, nut shells, glass beads, and aluminum pellets. The resins used include urea-aldehyde resins, phenol-aldehyde resins, epoxy resins, furfuryl alcohol resins, and polyester or alkyl resins. The resins can be in pure form or mixtures containing curing agents, coupling agents or other additives. Other examples of resins and resin mixtures for proppants are described, for example, in U.S. Pat. Nos. 5,643,669; 5,916,933; 6,059,034 and 6,328,105.
However, there are significant limitations to the use of resin-coated proppants. For example, resin-coated proppants are much more expensive than normal sands, especially considering that a fracturing treatment usually employs tons of proppants in a single well. Normally, when the formation temperature is below 60° C., activators are required to make the resin-coated proppants bind together. This increases the cost.
Thus, the use of resin-coated proppants is limited by their high cost to only certain types of wells, or to use in only the final stages of a fracturing treatment, also known as the “tail-in” of proppants, where the last few tons of proppants are pumped into the fracture. For less economically viable wells, application of resin-coated proppants often becomes cost prohibitive.
During hydrocarbon production, especially from poorly consolidated formations, small particulates, typically of sand, often flow into the wellbore along with produced fluids. This is because the formation sands in poorly consolidated formations are bonded together with insufficient bond strength to withstand the forces exerted by the fluids flowing through and are readily entrained by the produced fluids flowing out of the well.
The produced sand erodes surface and subterranean equipment, and requires a removal process before the hydrocarbon can be processed. Different methods have been tried in an effort to reduce formation sand production. One approach employed is to filter the produced fluids through a gravel pack retained by a screen in the wellbore, where the particulates are trapped by the gravel pack. This technique is known as gravel packing. However, this technique is relatively time consuming and expensive. The gravel and the screen can be plugged and eroded by the sand within a relatively short period of time.
Another method that has been employed in some instances is to inject various resins into a formation to strengthen the binding of formation sands. Such an approach, however, results in uncertainty and sometimes creates undesirable results. For example, due to the uncertainty in controlling the chemical reaction, the resin may set in the well bore itself rather than in the poorly consolidated producing zone. Another problem encountered in the use of resin compositions is that the resins normally have short shelf lives. For example, it can lead to costly waste if the operation using the resin is postponed after the resin is mixed.
Thus, it is highly desirable to have a cost effective composition and a method that can control proppant flowback after fracturing treatment. It is also highly desirable to have a composition and a method of reducing formation sand production from the poorly consolidated formation.
SUMMARY
The present invention in one embodiment relates to an aqueous slurry composition having water, particulates, a chemical compound for rendering the surface of the particulates hydrophobic and an oil.
The present invention in another embodiment relates to a method of controlling sand in a hydrocarbon producing formation comprising the steps of mixing water, particulates and a chemical compound for rendering the surface of the particulates hydrophobic, pumping the mixture into the formation.
DETAILED DESCRIPTION OF THE INVENTION
Aggregation phenomena induced by hydrophobic interaction in water are observed everywhere, in nature, industrial practice, as well as in daily life. In general, and without being bound by theory, the hydrophobic interaction refers to the attractive forces between two or more apolar particles in water. When the hydrophobic interaction becomes sufficiently strong, the hydrophobic particles come together to further reduce the surface energy, essentially bridging the particles together and resulting in the formation of particle aggregations, known as hydrophobic aggregations. It is also known that micro-bubbles attached to hydrophobic particle surfaces also tend to bridge the particles together.
In this invention the concept of hydrophobic aggregation is applied to develop compositions and methods to control proppant flowback as well as to reduce formation sand production during well production. Unlike in conventional approaches, where attention is focused on making proppants or sand particles sticky through formation of chemical bonds between resins coated on the particle surfaces, in the present invention the attention is focused on making particle aggregations by bridging the particles through strong hydrophobic force or micro-bubbles. Moreover, the hydrophobic surfaces of the particles induced by the present compositions reduce the friction between the particles and water making them harder to be entrained by fluids flowing out of the well.
In general, only a limited amount of agents is required in the present invention, and the field operational is simple.
There are different ways of carrying out the invention. For example, during a fracturing operation, a proppant, for example, sand, which is naturally hydrophilic and can be easily water wetted, is mixed with a fluid containing a chemical agent, referred as hydrophobizing agent, which makes the sand surface hydrophobic. The hydrophobizing agent can be simply added into a sand slurry comprising sand and fracturing fluid which is pumped down the well. Depending on the hydrophobizing agent used and the application conditions, different fracturing fluids (aqueous or non-aqueous fluids) can be used. Aqueous fluid is normally preferred. Of particular interest as a fracturing fluid, is water, or brine or water containing a small amount of a friction reducing agent, also known as slick-water.
The hydrophobizing agent can be applied throughout the proppant stage or during a portion of the proppant stage such as the last portion of the proppant stage, i.e., tail-in. Alternatively, sand can be hydrophobized first and dried and then used to make a slurry and pumped into fracture.
It has been discovered that when a small amount of an oil, including hydrocarbon oil and silicone oil, is mixed into the aqueous slurry containing the hydrophobized sands, the hydrophobic aggregation is enhanced significantly. The possible explanation for this is that the concentration of oil among the hydrophobic sands may further enhance the bridge between sand grains.
The present invention can be used in a number of ways. For example, in a fracture operation, proppant such as sand is mixed with a hydrophobizing agent in water based slurry and pumped into the fractures, and then followed by over flush with oil or water containing a small amount of oil to strengthen the bridge between the sand grains. Similarly, the same operation can be applied in the tail-in stage. Alternatively the slurry containing a hydrophobizing agent can be pumped into the fracture forming the proppant pack, which can be further consolidated by oil or condensate contained in the formation. Or the pre-hydrophobized sand is used as proppant and then followed by flushing with water, containing small amount of oil. Or the pre-hydrophobized sand is used as proppant which can be further consolidated by oil or condensate contained in the formation. Or the pre-hydrophobized sand is tailed in and followed by flushing with water containing small amount of oil. In all such operations, a gas such as nitrogen, carbon dioxide or air can be mixed into the fluid.
There are different ways of pre-treating the solid surface hydrophobic. For example, one may thoroughly mix the proppants, preferable sands, with a fluid containing the appropriate hydrophobizing agent for certain period of time. After the proppant grains are dried, they can be used in fracturing operations. Different fluids can be used. Different hydrophobizing agents may need different conditions to interact with the solid surface. When an aqueous fluid is used, the pH of the fluid may also play a role.
Besides controlling proppant flowback in hydraulic fracturing treatments, the present invention is also useful in reducing formation sand production during well production. In the majority of cases, sand production increases substantially when wells begin to produce water. The formation sand is normally hydrophilic, or water-wet, and therefore is easily entrained by a flowing water phase. Depending on the hydrophobizing agent used and the operational conditions, different carrying fluids, aqueous or non-aqueous, can be used. There are different methods, according to the present invention, to treat a formation to reduce formation sand production. For example, a fluid, preferably an aqueous fluid, containing an appropriate amount of hydrophobizing agent can be injected into the poorly consolidated formation. After the sand grains become hydrophobic they tend to aggregate together. The hydrophobic surfaces also reduce the dragging force exerted by the aqueous fluid making them more difficult to be entrained by the formation fluid. If the water phase contains certain amount of oil, the hydrophobic aggregation between sand grains can be further enhanced. Alternatively, the fluid contain the hydrophobizing agent can be first injected into the poorly consolidated formation, and then followed by injecting small volume of oil or a fluid containing oil. In all these applications, a gas such as nitrogen, carbon dioxide or air can be mixed into the fluid.
Also, the compositions and methods of the present invention can be used in gravel pack operations, where the slurry containing hydrophobised sands are added in the well bore to remediate sand production.
There are various types of hydrophobizing agents for sand, which can be used in the present invention. For example, it is known that many organosilicon compounds including organosiloxane, organosilane, fluoroorganosiloxane and fluoro-organosilane compounds are commonly used to render various surfaces hydrophobic. For example, see U.S. Pat. Nos. 4,537,595; 5,240,760; 5,798,144; 6,323,268; 6,403,163; 6,524,597 and 6,830,811 which are incorporated herein by reference for such teachings.
Organosilanes are compounds containing silicon to carbon bonds. Organosiloxanes are compounds containing Si—O—Si bonds. Polysiloxanes are compounds in which the elements silicon and oxygen alternate in the molecular skeleton, i.e., Si—O—Si bonds are repeated. The simplest polysiloxanes are polydimethylsiloxanes.
Polysiloxane compounds can be modified by various organic substitutes having different numbers of carbons, which may contain N, S, or P moieties that impart desired characteristics. For example, cationic polysiloxanes are compounds in which organic cationic groups are attached to the polysiloxane chain, either at the middle or the end. Normally the organic cationic group may contain a hydroxyl group or other functional groups containing N or O. The most common organic cationic groups are alkyl amine derivatives including secondary, tertiary and quaternary amines (for example, quaternary polysiloxanes including, quaternary polysiloxanes including mono- as well as, di-quaternary polysiloxanes, amido quaternary polysiloxanes, imidazoline quaternary polysiloxanes and carboxy quaternary polysiloxanes.
Similarly, the polysiloxane can be modified by organic amphoteric groups, where one or more organic amphoteric groups are attached to the polysiloxane chain, either at the middle or the end, and include betaine polysiloxancs and phosphobetaine polysiloxanes.
Similarly, the polysiloxane can be modified by organic anionic groups, where one or more organic anionic groups are attached to the polysiloxane chain, either at the middle or the end, including sulfate polysiloxanes, phosphate polysiloxanes, carboxylate polysiloxanes, sulfonate polysiloxanes, thiosulfate polysiloxanes. The organosiloxane compounds also include alkylsiloxanes including hexamethylcydotrisiloxane, octamethylcyclotetrasiloxane, decamethylcydopentasiloxane, hexamethyldisiloxane, hexaethyldisiloxane, 1,3-divinyl-1,1,3,3-tetramethyldisiloxane, octamethyltrisiloxane, decamethyltetrasiloxane.
The organosilane compounds include alkylchlorosilane, for example methyltrichlorosilane, dimethylchlorosilane, trimethylchlorosilane, octadecyltrichlorosilane; alkyl-alkoxysilane compounds, for example methyl-, propyl-, isobutyl- and octyltrialkoxysilanes, and fluoro-organosilane compounds, for example, 2-(n-perfluoro-octyl)-ethyltriethoxysilane, and perfluorooctyldimethyl chlorosilane.
Other types of chemical compounds, which are not organosilicon compounds, which can be used to render particulate surface hydrophobic are certain fluoro-substituted compounds, for example certain fluoro-organic compounds including cationic fluoro-organic compounds.
Further information regarding organosilicon compounds can be found in Silicone Surfactants (Randal M. Hill, 1999) and the references therein, and in U.S. Pat. Nos. 4,046,795; 4,537,595; 4,564,456; 4,689,085; 4,960,845; 5,098,979; 5,149,765; 5,209,775; 5,240,760; 5,256,805; 5,359,104; 6,132,638 and 6,830,811 and Canadian Patent No. 2,213,168 which are incorporated herein by reference for such teachings.
Organosilanes can be represented by the formula
R n SiX (4-n) (I)
wherein R is an organic radical having 1-50 carbon atoms that may possess functionality containing N, S, or P moieties that imparts desired characteristics, X is a halogen, alkoxy, acyloxy or amine and n has a value of 0-3. Examples of organosilanes include:
CH 3 SiCl 3 , CH 3 CH 2 SiCl 3 , (CH 3 ) 2 SiCl 2 , (CH 3 CH 2 ) 2 SiCl 2 , (C 6 H 5 ) 2 SiCl 2 , (C 6 H 5 )SiCl 3 , (CH 3 ) 3 SiCl, CH 3 HSiCl 2 , (CH 3 ) 2 HSiCl, CH 3 SiBr 3 , (C 6 H 5 )SiBr 3 , (CH 3 ) 2 SiBr 2 , (CH 3 CH 2 ) 2 SiBr 2 , (C 6 H 5 ) 2 SiBr 2 , (CH 3 ) 3 SiBr, CH 3 HSiBr 2 , (CH 3 )HSiBr, Si(OCH 3 ) 4 , CH 3 Si(OCH 3 ) 3 , CH 3 Si(OCH 2 CH 3 ) 3 , CH 3 Si(OCH 2 CH 2 CH 3 ) 3 , CH 3 Si[O(CH 2 ) 3 CH 3 ] 3 , CH 3 CH 2 Si(OCH 2 CH 3 ) 3 , C 6 H 5 Si(OCH 3 ) 2 , C 6 H 5 CH 2 Si(OCH 3 ) 3 , C 6 H 5 Si(OCH 2 CH 3 ) 3 , CH 2 ═CHCH 2 Si(OCH 3 ) 3 , (CH 3 ) 2 Si(OCH 3 ) 2 , (CH 2 ═CH)Si(CH 3 ) 2 Cl, (CH 3 ) 2 Si(OCH 2 CH 3 ) 2 , (CH 3 ) 2 Si(OCH 2 CH 2 CH 3 ) 2 , (CH 3 ) 2 Si[O(CH 2 ) 3 CH 3 ] 2 , (CH 3 CH 2 ) 2 Si(OCH 2 CH 3 ) 2 , (C 6 H 5 ) 2 Si(OCH 3 ) 2 , (C 6 H 5 CH 2 ) 2 Si(OCH 3 ) 2 , (C 6 H 5 ) 2 Si(OCH 2 CH 3 ) 2 , (CH 2 ═CH) 2 Si(OCH 3 ) 2 , (CH 2 ═CHCH 2 ) 2 Si(OCH 3 ) 2 , (CH 3 ) 3 SiOCH 3 , CH 3 HSi(OCH 3 ) 2 , (CH 3 ) 2 HSi(OCH 3 ), CH 3 Si(OCH 2 CH 2 CH 3 ) 3 , (CH 2 ═CHCH 2 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (CH 2 ═CHCH 2 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (C 6 H 5 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (CH 3 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , CH 2 ═CH) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (CH 2 ═CHCH 2 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , (C 6 H 3 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 , CH 3 Si(CH 3 COO) 3 , 3-aminotriethoxysilane, methyldiethylchlorosilane, butyltrichlorosilane, diphenyldichlorosilane, vinyltrichlorosilane, methyltrimethoxysilane, vinyltriethoxysilane, vinyltris(methoxyethoxy)silane, methacryloxypropyltrimethoxysilane, glycidoxypropyltrimethoxysilane, aminopropyltriethoxysilane, divinyldi-2-methoxysilane, ethyltributoxysilane, isobutyltrimethoxysilane, hexyltrimethoxysilane, n-octyltriethoxysilane, dihexyldimethoxysilane, octadecyltrichiorosilane, octadecyltrimethoxysilane, octadecyldimethylchlorosilane, octadecyldimethylmethoxysilane and quaternary ammonium silanes including 3-(trimethoxysilyl)propyldimethyloctadecyl ammonium chloride, 3-(trimethoxysilyl)propyldimethyloctadecyl ammonium bromide, 3-(trimethylethoxysilylpropyl)didecylmethyl ammonium chloride, triethoxysilyl soyapropyl dimonium chloride, 3-(trimethylethoxysilylpropyl)didecylmethyl ammonium bromide, 3-(trimethylethoxysilylpropyl)didecylmethyl ammonium bromide, triethoxysilyl soyapropyl dimonium bromide, (CH 3 O) 3 Si(CH 2 ) 3 P + (C 6 H 5 ) 3 Cl—, (CH 3 O) 3 Si(CH 2 ) 3 P + (C 6 H 5 ) 3 Br—, (CH 3 O) 3 Si(CH 2 ) 3 P + (CH 3 ) 3 Cl—, (CH 3 O) 3 Si(CH 2 ) 3 P + (C 6 H 13 ) 3 Cl—, (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 C 4 H 9 Cl, (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 CH 2 C 6 H 5 Cl—, (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 CH 2 CH 2 OHCl—, (CH 3 O) 3 Si(CH 2 ) 3 N + (C 2 H 5 ) 3 Cl—, (C 2 H 5 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 C 18 H 37 Cl—.
Among different organosiloxane compounds which are useful for the present invention, polysiloxanes modified with organic amphoteric or cationic groups including organic betaine polysiloxanes and organic quaternary polysiloxanes are examples. One type of betaine polysiloxane or quaternary polysiloxane is represented by the formula
wherein each of the groups R 1 to R 6 , and R 8 to R 10 represents an alkyl containing 1-6 carbon atoms, typically a methyl group, R 7 represents an organic betaine group for betaine polysiloxane, or an organic quaternary group for quaternary polysiloxane, and have different numbers of carbon atoms, and may contain a hydroxyl group or other functional groups containing N, P or S, and m and n are from 1 to 200. For example, one type of quaternary polysiloxanes is when R 7 is represented by the group
wherein R 1 , R 2 , R 3 are alkyl groups with 1 to 22 carbon atoms or alkenyl groups with 2 to 22 carbon atoms. R 4 , R 5 , R 7 are alkyl groups with 1 to 22 carbon atoms or alkenyl groups with 2 to 22 carbon atoms; R 6 is —O— or the NR 8 group, R 8 being an alkyl or hydroxyalkyl group with 1 to 4 carbon atoms or a hydrogen group; Z is a bivalent hydrocarbon group with at least 4 carbon atoms, which may have a hydroxyl group and may be interrupted by an oxygen atom, an amino group or an amide group; x is 2 to 4; The R 1 , R 2 , R 3 , R 4 , R 5 , R 7 may be the same or the different, and X— is an inorganic or organic anion including Cl″ and CH 3 COO—.
Examples of organic quaternary groups include [R—N + (CH3) 2 -CH 2 CH(OH)CH2-O—(CH 2 ) 3 —](CH3COO—), wherein R is an alkyl group containing from 1-22 carbons or an benzyl radical and CH3COO— an anion. Examples of organic betaine include —(CH 2 ) 3 —O—CH 2 CH(OH)(CH 2 )—N + (CH3) 2 CH 2 COO—. Such compounds are commercial available. Betaine polysiloxane copolyol is one of examples. It should be understood that cationic polysiloxanes include compounds represented by formula (II), wherein R 7 represents other organic amine derivatives including organic primary, secondary and tertiary amines.
Other examples of organo-modified polysiloxanes include di-betaine polysiloxanes and di-quaternary polysiloxanes, where two betain or quaternary groups are attached to the siloxane chain. One type of the di-betaine polysiloxane and di-quaternary polysiloxane can be represented by the formula
wherein the groups R 12 to R 17 each represents an alkyl containing 1-6 carbon atoms, typically a methyl group, both R 11 and R 18 group represent an organic betaine group for di-betaine polysiloxanes or an organic quaternary group for di-quaternary, and have different numbers of carbon atoms and may contain a hydroxyl group or other functional groups containing N, P or S, and m is from 1 to 200. For example, one type of di-quaternary polysiloxanes is when R 11 and R 18 are represented by the group
wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , Z, X— and x are the same as defined above. Such compounds are commercially available. Quaternium 80 (INCI) is one of the commercial examples.
It will be appreciated by those skilled in the art that cationic polysiloxanes include compounds represented by formula (III), wherein R 11 and R 18 represents other organic amine derivatives including organic primary, secondary and tertiary amines. It will be apparent to those skilled in the art that there are different mona- and di-quatemary polysiloxanes, mono- and di-betaine polysiloxanes and other organo-modified polysiloxane compounds which can be used to render the solid surfaces hydrophobic and are useful in the present invention. These compounds are widely used in personal care and other products, for example as discussed in U.S. Pat. Nos. 4,054,161; 4,654,161; 4,891,166; 4,898,957; 4,933,327; 5,166,297; 5,235,082; 5,306,434; 5,474,835; 5,616,758; 5,798,144; 6,277,361; 6,482,969; 6,323,268 and 6,696,052 which are incorporated herein by reference for such teachings.
Another example of organosilicon compounds which can be used in the composition of the present invention are fluoro-organosilane or fluroorganosiloxane compounds in which at least part of the organic radicals in the silane or siloxane compounds are fluorinated. Suitable examples are fluorinated chlorosilanes or fluorinated alkoxysilanes including 2(n-perfluorooctyl)ethyltriethoxysilane, perfluoro-octyldimethylchlorosilane,
(CF 3 CH 2 CH 2 ) 2 Si(OCH 3 ) 2 , CF 3 CH 2 CH 2 Si(OCH 3 ) 3 , (CF 3 CH 2 CH 2 ) 2 Si(OCH 2 CH 2 OCH 3 ) 2 and CF 3 CH 2 CH 2 Si(OCH 2 CH 2 OCH 3 ) 3 and (CH 3 O) 3 Si(CH 2 ) 3 N + (CH 3 ) 2 (CH 2 ) 3 NHC(O)(CF 2 ) 6 CF 3 Cl—.
Other compounds which can be used, but less preferable, are fluoro-substituted compounds, which are not organic silicon compounds, for example, certain fluoro-organic compounds.
The following provides several non-limiting examples of compositions and methods according to the present invention.
Example 1
300 g of 20/40 US mesh frac sand was added into 1000 ml of water containing 2 ml of a solution containing 20 vol % Tegopren 6924, a di-quaternary polydimethylsiloxane from Degussa Corp., and 80 vol % of ethylene glycol mono-butyl ether, and 1 ml of TEGO Betaine 810, capryl/capramidopropyl betaine, an amphoteric hydrocarbon surfactant from Degussa Corp. The slurry was shaken up and then let stand to allow sands settle down. When tilted slowly, the settled sand tended to move as cohesive masses. After 10 ml of silicon oil, where its viscosity is 200 cp, was mixed into the shiny and shaken up sand grains were visually observed to clump together forming strong bridge among each other.
The solution was decanted, and the sand was dried overnight at the room temperature for further tests.
Example 2
200 g of pre-treated sand according to Example 1 was placed in a fluid 1055 chamber to form a sand pack and wetted with water. Afterward, 300 ml of water was allowed to filter from the top through the sand pack. The time was stopped when water drops slowed to less than one every five seconds. Same test using untreated sand was carried out as the reference. The average filter time over 6 runs for the pre-treated sand was 2 minutes and 5 seconds, while it was 5 minutes for the untreated sand.
Example 3
200 g of pre-treated sand according to Example 1 was placed in a fluid loss chamber to form a sand pack and wetted with kerosene. Afterward, 300 ml of kerosene was allowed to filter from the top through the sand pack. The time was stopped when kerosene drops slowed to less than one every five seconds. Same test using untreated sand was carried out as the reference. The average filter time over 5 runs for the pre-treated sand was 3 minutes and 2 seconds, while it was 3 minutes and 28 seconds for the untreated sand.
Example 4
100 ml of water and 25 grams of 30/50 US mesh fracturing sands were added into each of two glass bottles (200 ml). The first sample was used as the reference. In the second sample, 2 ml of a solution containing 20% Tegopren 6924 and 80% of ethylene glycol mono-butyl ether, and 0.5 ml of kerosene were added. The slurry was shaken up and then let stand to allow sands settle down. When tilted slowly, the settled sand tended to move as cohesive masses. Sand grains were visually observed to clump together forming strong bridge among each others.
Example 5
100 ml of water and 25 grains of 30/50 US mesh fracturing sands were added into each of two glass bottles (200 ml). The first sample was used as the reference. In the second sample, 2 ml of a solution containing 20% Tegopren 6924 and 80% of ethylene glycol mono-butyl ether, and 0.5 ml of frac oil were added. The slurry was shaken up and then let stand to allow sands settle down. When tilted slowly, the settled sand tended to move as cohesive masses. Sand grains were visually observed to clump together forming strong bridge among each others. | An aqueous slurry composition for use in industries such as petroleum and pipeline industries that includes: a particulate, an aqueous carrier fluid, a chemical compound that renders the particulate surface hydrophobic, and a small amount of an oil. The slurry is produced by rendering the surface of the particulate hydrophobic during or before the making of the slurry. The addition of the oil greatly enhances the aggregation potential of the hydrophobically modified particulates once placed in the well bore. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of an earlier filing date from U.S. Provisional Application No. 60/059,852 filed Sep. 24, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a computer controlled intelligent downhole safety valve system. More particularly, the invention relates to a preferably electrically but possibly hydraulically, mechanically, electromechanically, electrohydraulically or pneumatically actuated and operated system comprising a safety valve and a plurality of sensors delivering information to and receiving instructions from a processor whether located locally or remotely from the valve.
2. Prior Art
Safety valves have been in existence for some time and have consistently been important to the safety of the environment and hydrocarbon drilling and production personnel.
Traditionally, safety valves have been hydraulically actuated and were operated from the surface based upon information gleaned from the production fluid or based upon dangerous conditions at the surface.
Hydraulically actuated safety valves commonly employ a flapper valve and a flow tube movable axially relative to the flapper valve. Thus, when the tube moves downhole the flapper is pushed open and the tube connects with more production tube downhole. As long as the flow tube remains in this downhole position the flapper stays open. The flow tube is biased however to an uphole position by a relatively high rate coil spring, the urging of which is overcome by hydraulic fluid pressure exerted from a reservoir, usually located at the surface. Necessarily there is a high pressure hydraulic fluid line extending from the reservoir to the valve which may be, for example, six thousand feet below the surface. Due to the large volume of hydraulic fluid that must be moved uphole in this fluid line, closing of the flapper is not as speedy as might be desired. Moreover, safety valves of this type, as stated above, are actuated only when conditions requiring a shut-in are perceptible at the surface.
More recently some work has been done to employ electric power to actuate and control safety valves. U.S. Pat. No. 5,070,944 to Hopper discloses a downhole electrically operated safety valve comprising an electric motor which drives a gear assembly having a drive gear and an operating gear, said gears providing a ratio of 30:1. The gears are operatively connected to a two-part drive sleeve the parts of which rotate together but are capable of relative axial movement. An actuating sleeve is also employed and a solenoid operated releasable lock prevents relative axial movement between the two parts of the drive sleeve.
Even with what may be considered more advanced electrically actuated downhole safety valves, the decision making is made at the surface depending upon information obtained at the surface. This limits the effectiveness of the safety valve because whatever condition indicates to the operator, from evaluation of production fluids, that the valve should close is a condition occurring through perhaps six thousand feet of pipe before the valve is shut. Therefore, there is a significant need for a system capable of obtaining information and rendering decisions downhole as well as being capable of communicating with other downhole tools, the surface and other wells. An example of a computer controlled safety valve and production well control system is disclosed in application Ser. No. 08/599,324 filed Feb. 9, 1996, all of the contents of which are incorporated herein by reference thereto.
SUMMARY OF THE INVENTION
The above-discussed and other drawbacks and deficiencies of the prior art are overcome or alleviated by the several methods and apparatus for providing computerized (“intelligent”) systems for operating, monitoring, controlling and diagnosing various parameters of downhole safety valve systems whether hydraulically actuated, hydraulically/electrically actuated or electrically actuated, electrically actuated systems being preferred. The systems disclosed provide the ability for the valve assembly to sense itself, sense its surrounding environment, make decisions and communicate with other downhole systems and surface systems on the same platform or on different platforms. Communication can even be provided between safety valves in different wells.
In order to provide an overview of the computer controlled intelligent systems contemplated in the present invention and their relation to the overall system for advanced hydrocarbon production, attention is directed to FIG. 1 of the application. FIG. 1 illustrates a pelagic situation having three platforms each with multiple lateralated wells and a communication system to provide a real time link between all of the wells. The system illustrated also embodies a number of downhole control systems that communicate downhole information to the surface and can receive information or instructions from the surface and from remote locations in communication with the surface.
In accordance with the present invention, a plurality of sensors are connected to processing units located downhole, uphole or both to provide sufficient input for the processors to carry out previously installed instructions or to develop databases of information collected over time. These data and processing units allow the safety valves of the invention to alter their own operational parameters to account for such time and environmental changes as the buildup of paraffin, scaling, sand etc., in the valve which might otherwise prevent its operation. The invention includes a downhole operated heater to melt and disperse paraffin as well as a current supplying device to remove scaling. These devices greatly enhance and improve longevity and operation of safety valves which, in turn, improves the safety of hydrocarbon production.
Other sensors and sensing arrangements allow intelligent systems to monitor potential problems requiring the alteration of other downhole tools. For example, water in the production fluid can be detected at the safety valve or even therebelow by sensors and therefore allow corrective action taken before the entire production tube to the surface is filled with contaminated production fluid. This enables a faster response and less down time. An example is a system that senses water and communicates with a sliding sleeve in a lateral well further downhole. This communication will trigger other intelligent operations which result in a particular sleeve closing or a group of sleeves closing to shut-in the offending reservoir. Moreover, the safety valve may need to close while the sleeves are moving and then reopen when the sliding sleeves are closed.
Moreover, the intelligent systems at or about the safety valve will more quickly shut-in that valve upon detection of an irregularity that could not have been detected at the surface for a significant period of time depending upon the distance of the tube above the valve. For some situations this will prevent a catastrophic disaster by shutting-in all wells on a platform or in an area by communication from valve to valve, if conditions warrant. Alternatively, the intelligent system of the invention can also understand the severity of any potential problem and communicate to other wells to increase production to make up for the shut-in well. This ability avoids loss of production and revenue.
Examples of sensory perception the safety valves of the invention will have regarding itself include: sensing the flow tube position and/or orientation, sensing the flapper position, sensing the amount of friction during movement of the flow tube or flapper valve and relatively the amount of power required to move these parts (this information is mapped to predict further movement parameters and future failure of the tool) and sensing a control signal (i.e., to ensure that the signal at the valve equals the signal initiated at the surface).
Examples of sensory perception afforded the safety valve of the invention relative to its environment include: Temperature at the valve, differential pressure across the valve, annulus pressure or temperature, leakage across the valve, tension and torque on valve components, bending moment on the valve, contamination of the production fluid by water, etc.
Based upon the information gathered through the sensors utilized in the control system of the invention, downhole or surface processors render decisions about opening or closing valves and setting or actuating other tools. These decisions are based upon preprogrammed operational parameters or upon accumulated sensory information (built databases) and projections made therefrom. The accumulated information also provides information for use in product failure analysis, i.e., was failure due to manufacturing workmanship or due to extreme conditions downhole not known previously.
Decisions made and executed by the system are communicated to many places, as desired, including: sliding sleeves, surface safety systems, E.S.P. systems, gaslift systems, annulus safety valves, etc. whether in the well in which the information is collected or in other wells if necessary.
The computer controller or controllers employed in the system is/are preferably microprocessor type components which are capable of performing all desired tasks without subsequent human intervention or monitoring. It is, of course, possible to provide an associated display device at the surface for manned monitoring, if desired. Where manned monitoring is desired, a keyboard or other similar input device is also available to direct or override decisions made downhole.
The above-discussed and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several FIGS.:
FIG. 1 illustrates communication pathways to other platforms and wells;
FIG. 2 is an illustration of a prior art safety valve;
FIG. 3 is a schematic representation of a safety valve of the invention in the downhole environment;
FIG. 4 is a schematic flowchart representation of the safety valve with sensors, controllers and routing illustrated by arrows; and
FIG. 5 is a schematic representation of a particular embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 2, the general operative components of a flapper and flow tube type safety valve are retained in this invention. FIG. 2, therefore, provides a point of reference for the invention, which is preferably of electronic actuation but could be hydraulic or a combination. FIG. 2 is also the basis for building the intelligent system of the invention.
Referring to FIG. 4, one of skill in the art will appreciate the schematic representation indicating communication pathways between various components of the invention. The safety valve assembly is schematically illustrated as 30 , the internal sensors being shown therewithin and identified by numeral 32 . The invention further includes external or environmental sensors 34 illustrated outside schematic 30 but with communication pathways to internal sensors 32 and to a downhole processor 36 or surface processor 38 . Communication capability is also supplied and is indicated by 40 . Data storage 42 may be provided either locally or remotely, even over telephone lines or via satellite link.
Referring to FIG. 3, a schematic illustration of the invention is provided in order to aid in understanding the general layout of the invention. Numeral 30 identifies the safety valve housing. 32 and 34 identify internal and external sensors, respectively. The downhole controller 36 is illustrated uphole of the valve 30 , however, it should be understood that the controller 36 can be located above, below, alongside or even around the valve housing as desired. Surface controller 38 is at the surface of the well. Numeral 31 designates the downhole heater employed to melt and disperse paraffin that builds up over time. One of ordinary skill in the art will recognize casing 50 , borehole 52 and production pipe 54 .
Employing the intelligent system of the invention, real time information is obtained about conditions of the downhole environment and tools. These include conditions which require closing or opening of the valve and additionally, conditions which indicate anticipated life before failure. Moreover, sensors that accumulate information and communicate that information to a processor also provide information about paraffin, sand, etc., that might accumulate in the safety valve and which potentially can prevent or hinder proper operation thereof. Because of the intelligence in the immediate area of the valve, corrective measures are undertaken without even a direction from the surface operator. Measures such as heating to melt and disperse paraffin or cleaning to remove sand or other solid or viscous build up are actuatable in response to downhole decision making processor(s).
The safety valves of the invention are also failsafe in that they require an impetus from either electrical or hydraulic systems to open against the urging of a spring. Upon loss of power or pressure the spring will close the valve. Such a loss in power or pressure can be due to accident or by design. In the invention, a redundant electrical system for closure of the valve is also provided, preferably, powered by a capacitor or other electrical storage devices. This system will close the valve in the event the spring has scaled and will not operate. In general, a solenoid will be actuated by the capacitor to force the flapper closed.
Internal sensor 32 range in number from one to many and sense flow tube position, flapper position, friction of movement of the flow tube and power required to move it, valve orientation etc. Additionally, sensors obtain information about strength of signal from the electric or hydraulic actuation line. This is compared to the signal placed on that line at the surface to determine whether trouble exists on the line. These sensors provide confirmation of the proper operation of the safety valve and, moreover, allow operators to keep track of the breakdown thereof over time. This provides benefits both to the well operator and to the manufacturer. With respect to the operator, analyzing trends of the valve can help avoid a failure thereof and provide advance warning of a potential failure so that remedial measures can be undertaken before a catastrophic occurrence. From the standpoint of the manufacturer who may have warranted the valve or may be liable for damages caused by a failure, the sensors provide a log of information indicating whether or not the operator was negligent in the control of the valve, the maintenance thereof or in replacement of the same.
Environmental sensors, indicted in FIGS. 3 and 4 at 34 , are preferably, a multiplicity of sensors designed to obtain information regarding temperature at the valve, differential pressure across the valve(sense pressure above and below valve and calculate differential), leakage across the valve, annulus pressure, tension and torque at the valve, bending moment on the valve, water contamination, seismic activity etc. A very important aspect of the invention is adaptability of the system in response to information obtained by the sensors and without intervention by an operator. In other words, the intelligent controller analyzes all information collected and is capable of issuing commands to other tools or to safety valve components to change one or more operating parameters to optimize performance of the valve even if time or use had reduced its normal operating capacity. Altered operating parameters can regain lost efficiency in particular conditions. More specifically, where parameters are set for particular conditions and the conditions later change, the ability of the system to compensate is extremely valuable to the well operator.
Information obtained via internal and environmental sensors is used not only for adaptability of the system but is added to a database having preprogrammed information and other periodic additions. The log created hereby assists in trend analysis and also can be employed to help design new tools.
Another important aspect of the invention is the capability of communication between and among sensors, a data storage unit, the surface, other wells or even other platforms. Communicated information from one well to others can help prevent catastrophic occurrences and can avoid unnecessary shut-in of other wells if the reason for shut-in is containable in one well. This intelligent determination and instructions in real time from one well to another is very important to the industry. As one of skill in the art will appreciate, a shut-in well may indicate a serious problem, however, the interests of the operator are to avoid a reduction in production. Therefore, the interests are to increase production from other wells when a shut-in well is detected. This is sometimes appropriate and sometimes dangerous. With the system of the invention, decision making about which actions to take is based upon real time conditions and the communication capability allows the system to alter other wells according to preprogrammed responses so that either a dangerous situation is controlled or production rate is maintained as appropriate. The system also can be overridden from an input device such as a keyboard at the surface, if necessary, so that optimum operation can always be maintained.
The communication system of the invention also provides significant control of other downhole tools based upon real time data as opposed to discovering a problem such as in flow of water at the surface when the entire production tube is contaminated. More specifically, the safety valve through which all fluid entering the system downhole thereof must flow, will detect any such contamination and will communicate with a downhole tool such as, for example, a sliding sleeve in the offending zone and signal a closure of that sleeve. Communication possible with the system of the invention in real time include: the number of times a tool has been actuated; time to actuate each tool and any of the sensory information discussed hereinabove. All of the information will also be stored in memory for comparison purposes.
The entire system of the invention operates in conjunction with a surface safety system which monitors, through communications, all of the processes downhole and provides the capability of the operator to alter actions taken downhole. The communication system is most preferably a single wire with multiplexing extending to the surface. In another embodiment, a pair of communication conduits running to the valve housing are employable. Particular embodiments of the invention follow hereinbelow.
Referring to FIG. 5, a subsurface safety valve position and pressure monitoring system is shown generally at 100 . System 100 includes a valve housing 102 which houses a downhole valve such as a shut-in valve 104 . Various pressure and positioning parameters of shut-in valve 104 are determined through the interaction of five sensors which are preferably tied to a single electrical single or multi conductor line (e.g. the aforementioned TEC cable). These five sensors remotely monitor the critical pressures and valve positions relative to safe, reliable remotely controlled subsurface safety valve operations. The downhole sensors include four pressure sensors 106 , 108 , 110 and 112 and one proximity sensor 114 . Pressure sensor or transducer 106 is positioned to sense tubing pressure downstream of shut-in valve 104 . Pressure transducer or electrical sensor 108 is positioned to sense the hydraulic controlling pressure from hydraulic control-line 116 or electrical signal of the valve is electrically actuated. Pressure transducer 110 is positioned to sense the annulus pressure at a given depth while pressure transducer 112 is positioned to sense the tubing pressure upstream of valve 104 . Proximity sensor 114 may be positioned internal or external to the valve or closure member 104 depending upon the type of sensor and the parameters to be measured as well as the specific geometries and methods of operation of the various sensors employed. The sensors function to enable confirmation of the position of the valve 104 . Encoded signals from each of the sensors 106 through 114 are fed back to the surface system 24 or to a downhole module 22 through a power supply/data cable 118 connected to the surface system 24 or downhole module 22 . Alternatively, the encoded signals may be transmitted by a wireless mechanism. Preferably cable 118 comprises tubing encapsulated single or multiconductor line (e.g. the aforementioned TEC cable) which is run external to the tubing string downhole and services as a data path between the sensors and the surface control system.
A downhole module 22 may automatically or upon control signals sent from the surface, actuate a downhole control device to open or shut valve 104 based on input from the downhole sensors 104 through 114 .
The foregoing subsurface valve position and pressure monitoring system provides many features and advantages relative to prior art devices. For example, the present invention provides a means for absolute remote confirmation of valve position downhole. This is crucial for confident through tubing operations with wireline or other conveyance means and is also crucial for accurate diagnosis of any valve system malfunctions. In addition, the use of the subsurface safety valve position and pressure monitoring system of this invention provides real time surface confirmation of proper pressure conditions for fail-safe operation in all modes. Also, this system provides a means for determination of changes in downhole conditions which could render the safety system inoperative under adverse or disaster conditions and the present invention provides a means for surface confirmation of proper valve equalization prior to reopening after downhole valve closure.
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 ben described by way of illustration and not limitation. | A subsurface safety device positioning and monitoring system includes a controller and at least one downhole sensor that senses and records conditions of the well near the valve and of the valve itself. Conditions include temperature, pressure, flow rate, degree of closure of valve, structural condition of valve, water cut of produced fluids, etc. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of co-pending (and now allowed) application Ser. No. 10/325,451 filed on Dec. 20, 2002 entitled PANEL FORMING SYSTEM AND COMPONENTS, with projected U.S. Pat. No. of 7,047,700 and issue date of May 23, 2006. This application is related to co-pending application Ser. No. 10/290,118, entitled PANEL FORMING SYSTEM AND COMPONENTS, filed Nov. 7, 2002.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to forms and form supports used for creating cured pre-cast structures. More specifically, the present invention relates to configurations of pre-cast panel forming systems and various components of such systems.
[0003] Many residential and commercial construction methods involve the use pre-cast structures. Pre-cast panels, for example, are integral to the tilt-up construction process. In the tilt-up approach, concrete forms are arranged on a flat casting surface in the shape and dimension of the desired tilt-up panel, then filled with concrete. When the concrete cures, the panel and the form are separated and the panel is tilted up into a preferred, typically vertical, orientation, where it can be joined to structural frames or other panels. The present inventors have recognized a need for improvements in pre-cast panel forming systems and in various components of the panel forming systems. The improvements introduced by the present invention have applicability in the tilt-up construction process and in other pre-cast construction processes.
BRIEF SUMMARY OF THE INVENTION
[0004] This need is met by the present invention wherein improvements in pre-cast panel forming systems and in various components of the panel forming systems are introduced. In accordance with one embodiment of the present invention, a bulkhead is disclosed. The bulkhead includes an upstanding form and a base clip. The upstanding form is used to constrain the flow of uncured material that is introduced adjacent the longitudinal dimension of the upstanding form. The base clip comprises a plurality of attachment members, including a first configured to secure the base clip to the upstanding form, and a second configured to secure the base clip to the panel-forming surface. The second attachment portion includes a laterally-disposed arm such that it increases a base clip footprint formed on the panel-forming surface relative to that formed by a connection between the first attachment portion and the upstanding form.
[0005] Optionally, the base portion and upstanding form together define a unitary, monolithic structure. In addition, the second attachment portion can be substantially planar to more easily engage the panel-forming surface. In the present context, the term “substantially” is utilized represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. As such, it refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may, in practice embody something slightly less than exact. The term also represents the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. The second attachment portion can further include an aperture in the laterally-disposed arm to accept a fastener therethrough. The first attachment portion may also include one or more projections configured to engage a complementary projection on the upstanding form. In one form, the first attachment portion is engaged with the upstanding form through a frictional fit between cooperating projections. More particularly, the projections engage one another through a plurality of interlocking prismatic members. Preferably, the angle subtended between the second attachment portion and the projection of the first attachment portion is substantially ninety degrees. Furthermore, the upstanding form includes a pair of substantially planar walls that are disposed substantially parallel to one another, thereby defining a thickness dimension from outer face to opposing outer face. Preferably (although not out of necessity), the thickness dimension is less than that of the smaller dimension of a conventional two-by-four piece of lumber. For example, the thickness dimension is less than about one and one-half inches, and can be narrower, for example less than about one inch, one-half inch, or other desired dimension. The upstanding form may further comprise one or more chamfers, wherein the chamfer may further comprise a knife-edge sealing projection configured for substantially discrete engagement with the panel-forming surface. The chamfers can include a projection similar to that that of the aforementioned first attachment portion such that upon securing the base clip to the upstanding form, the projection from the chamfer engages the first attachment portion, thus further securing the two. In one form, one chamfer is positioned on one side of the upstanding form while another chamfer is positioned on an opposing side of the upstanding form. Like the upstanding portion, the base clip can include one or more chamfers, which may be integrally formed with the base clip. The material making up the bulkhead can be any that facilitate simple, low-cost manufacture that combine desirable structural properties. In one form, the material can be extrudable, and more particularly, a plastic. By way of example, either or both of the upstanding form and base clip can be fabricated from the group consisting of plastic, metal, fibrous composites, or combinations thereof. In an additional option, the bulkhead is an extruded member, and more particularly, an extruded plastic member.
[0006] According to another embodiment of the present invention, a bulkhead is disclosed. The bulkhead includes an upstanding form and a base clip. The upstanding form is substantially similar to that of the previous embodiment, while the base clip includes a first attachment portion configured to engage the upstanding portion and a second attachment portion configured to engage the panel-forming surface. The second attachment portion includes a proximal end and a distal end. The first attachment portion is located at the proximal end of the second attachment portion and extends away from an attachment plane defined by the second attachment portion. The distal end of the second attachment portion is substantially free of structure extending away from the attachment plane. Optionally, the second attachment portion defines a substantially planar profile from the proximal end to the distal end. In addition, the second attachment portion defines a substantially planar base clip anchoring zone between the proximal end and the distal end. The base clip can also be configured such that substantially all structure extending away from the attachment plane is defined by the first attachment portion. More particularly, it can be configured such that substantially all of the first attachment portion extends from the proximal end of the second attachment portion.
[0007] According to another embodiment of the present invention, a bulkhead with an upstanding form and a base clip is disclosed. The upstanding portion is similar to that of the previous embodiments. The base clip includes an upper anchoring member, a lower anchoring member substantially aligned with the upper anchoring member along a fastening axis such that both the members are configured to accept a fastener therethrough, and a pedestal that couples the upper anchoring member to the lower anchoring member. Unlike the previous embodiments, the base clip is configured such that any fastener attached thereto is disposed not only below the upstanding form, but beneath it as well. In the present context, one item is considered to be “below” another when it occupies a lower vertical position relative to the other without regard to axial alignment along the vertical axis, while the same item would be considered “beneath” the other when it is not only below the other, but also directly underneath it such that they at least partially lie along the same vertical axis.
[0008] Optionally, the upper anchoring member is substantially planar. In one form, the upstanding form defines a monolithic structure, and may further include one or more chamfers disposed substantially adjacent the second end of the upstanding form. The upper anchoring member may further define an aperture therein for receiving the fastener. The pedestal can be configured to engage at least one complementary surface on the upstanding form. For example, the complementary surfaces engage one another through a plurality of interlocking prismatic members. In one form, the pedestal can include a pair of laterally-spaced projections that together are configured to form a friction fit with the upstanding form. More particularly, a plurality of interlocking prismatic members can be used to promote the friction fit. Preferably, the base clip is free of projections above the upper anchoring member. In another option, the lower anchoring member defines a flange, which may additionally extend laterally beyond the upstanding form, thus allowing the flange and the pedestal to form a detent receiving chamber between them. In still another option, one end of the upstanding form terminates in at least one projecting detent such that the detent can fit within the detent receiving chamber upon connection of the upstanding form to the base clip. A fastener can further be included to extend from the upper anchoring member through the lower anchoring member.
[0009] According to another embodiment of the present invention, a panel forming system is disclosed. The system includes a plurality of bulkheads, each similar to that of one or more of the previous embodiments, and a plurality of connectors. The plurality of connectors may include at least one of a corner connector, in-line joint connector and a T-joint connector, each of which can be disposed between adjacent end portions of respective bulkheads to provide connectivity between them. The connectors and the bulkheads can be arranged to produce a panel of desired shape and dimension, including a substantially rectangular panel form. Through the use of multiple bulkheads and connectors, multiple-cavity panels can be formed. In the case of substantially rectangular panels, the forms include at least four bulkheads and at least four corner connectors. The pair of substantially rectangular panel forms can further include a plurality of in-line joint connectors to make extended-size panels.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
[0011] FIG. 1A is a sectional view of one bulkhead of the panel-forming system of the present invention, showing it being secured to a panel-forming surface;
[0012] FIG. 1B shows the bulkhead of FIG. 1A with the components thereof in their separated state;
[0013] FIG. 2 is a schematic illustration of a panel forming system according to the present invention;
[0014] FIG. 3 is an alternate configuration of the bulkhead of FIG. 1 ;
[0015] FIG. 4A is an alternate configuration of the bulkhead of FIG. 1 ;
[0016] FIG. 4B is an alternate configuration of the lower projecting edge of the chamfer of FIG. 4A ;
[0017] FIG. 5 is a perspective view of a corner connector according to the present invention;
[0018] FIG. 6 is a perspective view of a T-joint connector according to the present invention; and
[0019] FIG. 7 is a perspective view of an in-line connector according to the present invention.
DETAILED DESCRIPTION
[0020] Referring first to FIGS. 1A, 1B and 2 , a single bulkhead 10 and a panel-forming system 60 made from a plurality of bulkheads 10 , both according to the present invention, are shown. By contrast to traditional wooden forms, which may be dimensioned as two-by-four, two-by-six or two-by-twelve (or similar related size, depending on the application) pieces of lumber that are placed edgewise into channels of a separate base, the thickness dimension T of the present bulkhead 10 may be significantly smaller. This reduced dimension, while still possessive of the necessary strength and rigidity, leads to considerably lighter components that are both more portable and storable than that of the prior art. Each bulkhead 10 may comprise a monolithic upstanding form 15 and base clip 20 that together define the bulkhead 10 . For the purposes of defining and describing the present invention, it is noted that a monolithic structure is one of unitary construction, such that it constitutes a single unit devoid of any disconnecting joints or seams. Such structures can be produced through a variety of known fabrication techniques, such as casting, molding or extrusion, the last of which is frequently used where the finished product has a constant cross-section along its longitudinal dimension. In operation, the upstanding form 15 is placed edgewise into base clip 20 , the latter being secured to a panel-forming surface 5 . When the desired panel shape is created (typically with one or more of the bulkheads 10 ) the material that will make up the panel is introduced, in uncured form, into one or more panel cavities 62 , 64 (shown with particularity in FIG. 2 ), flowing until it encounters bulkhead 10 , which then substantially constrains the further flow of the material to that along the longitudinal dimension of the bulkhead 10 until the shape defined by the cavities 62 , 64 is filled, after which the material is allowed to harden.
[0021] The upstanding form 15 is defined by a first end 12 and a second end 13 . The upstanding form 15 comprises a pair of walls 16 defining a height dimension H and are spaced from each other to define a thickness dimension T. Each of the upstanding walls 16 comprises an exterior face 17 and an interior face 18 , the latter between which one or more cross-sectional support members 19 may extend. At least one of the cross-sectional support members 19 may be located at a point along the height dimension of the upstanding form 15 so as to provide substantial resistance to reduction of the width dimension under pressure applied to one of the exterior faces 17 . In this manner, the integrity of the panel shape defined by each panel cavity 62 , 64 of the panel forming system 60 may be maintained under the significant pressure created by uncured panel-forming material present therein. The cross sectional support members 19 may simply comprise a single linear extension that is substantially perpendicular to the pair of upstanding walls 16 , or as more complex structures arranged in perpendicular or non-perpendicular configurations. For example, as shown in the figure, the bulkhead 10 can employ a plurality of these types of cross sectional support members 19 spaced along the height dimension H of walls 16 , including at or near one or both of the opposing ends. The first end 12 may comprise an end cap 12 A or a locking channel (not shown) to permit repeatable engagement and disengagement between adjacent upstanding forms 15 , or between the upstanding form 15 and connectors or braces (to be discussed later). Details of such features can be found in co-pending application Ser. No. 10/290,118, entitled PANEL FORMING SYSTEM AND COMPONENTS, filed Nov. 7, 2002, assigned to the present assignee and incorporated herein by reference.
[0022] The base clip 20 is used to secure the upstanding form 15 to the panel-forming surface 5 . To effect this, the base clip 20 can accommodate any number of suitable securing means, including adhesives, adhesive tapes, and mechanical fasteners, such as nails or screws. As shown with particularity in FIG. 1B , the base clip 20 , being removable from bulkhead 10 , is not part of the aforementioned monolithic structure defined by the upstanding form 15 , although it is not outside the scope of the present invention for the base clip 20 to be integrated into the monolithic structure. The base clip 20 includes a first attachment portion (made up of projections 20 A and 20 B) and a second attachment portion 20 C that extends laterally such that an upper surface of the second attachment portion 20 C can be accessed from above without either of projections 20 A and 20 B or any other projection (not shown) on base clip 20 getting in the installer's way. Since the space between projections 20 A and 20 B defines a relatively deep, narrow channel 20 E that is generally not conducive for attaching a conventional fastener 9 , the second attachment portion 20 C (in the form of an arm-like extension), with its extended and substantially planar lower surface, allows easy access for an installer to secure the base clip 20 to the panel-forming surface 5 . This is advantageous in that it allows an installer to align and secure the base clip 20 to the panel-forming surface 5 (such as through fastener 9 , both of which are shown in FIG. 1A ) prior to the attachment of the second end 13 of upstanding form 15 to the base clip 20 without interference from projections that would otherwise hamper the ability to place and subsequently secure the fastener 9 . The inclusion of the laterally-disposed second attachment portion 20 C also increases the footprint of base clip 20 , making it more stable prior to being secured to the panel-forming surface 5 , thereby allowing the installer additional flexibility and “fine-tuning” in arranging various bulkheads 10 . This extra footprint is especially helpful for thin bulkheads that would otherwise be more susceptible to tipping prior to being secured to the panel-forming surface 5 . Second attachment portion 20 C of base clip 20 can also have an aperture 20 D placed through its generally planar surface to facilitate the placement and subsequent anchoring of fastener 9 . The first attachment portion engages complementary projections 15 A, 15 B and 15 C that extend downwardly from the second end 13 of upstanding form 15 . Although not shown, it will be appreciated by those skilled in the art that base clip 20 may alternatively be attached to the panel-forming surface 5 with an adhesive instead of a fastener 9 .
[0023] Various configurations for the cooperative engagement between the upstanding form 15 and the base clip 20 are possible. Referring with particularity to FIGS. 3 and 4 A, an alternative configuration for the connection between the bulkhead 10 and the panel-forming surface 5 is shown. Unlike the previous configuration, where the portion of the base clip 20 that receives the fastener 9 is laterally offset relative to the connection between the upstanding form 15 and the base clip 20 (as shown in FIGS. 1A and 1B ), the components of the present base clips 120 , 220 are in substantial alignment with one another along a fastening axis F. Thus, in the orientation shown, an upper anchoring member 120 A, 220 A represents the vertically uppermost portion of the base clip 120 , 220 , and forms a generally planar surface through which a fastener 9 can be placed. A lower anchoring member 120 B, 220 B is configured to rest upon panel-forming surface 5 , and is substantially aligned with upper anchoring member 120 A, 220 A along fastening axis F such that fastener 9 can engage with surfaces of both members to secure the base clip 120 , 220 to panel-forming surface 5 . A pedestal 120 C, 220 C connects the upper anchoring members 120 A, 220 A to lower anchoring members 120 B, 220 B, and also defines a projection that can be used to engage complementary surfaces on upstanding form 15 . The projection formed by pedestal 120 C, 220 C preferably achieves engagement with upstanding form 15 through a frictional fit. Particular forms of frictional fit are emphasized in the two figures. FIG. 3 represents one form, where numerous interlocking prismatic retention members 120 D interact with complementary surfaces on the downward-projecting lower surfaces of upstanding form 15 . The prismatic retention members 120 D could be triangular, saw-tooth or trapezoidal in shape, for example. In one embodiment, the relationship between the prismatic retention members 120 D and the surface of the second end 13 of upstanding form 15 is such that a permanent lock can be formed, while in another, the relationship can be readily engaged and disengaged. In the present context, a locking arrangement is considered “permanent” where the connection between two members is such that they cannot be separated without severely curtailing or disabling their subsequent connective properties. FIG. 4A includes a detent receiving chamber 220 D formed by T-shaped pedestal 220 C that can grab and hold a pair of detents 15 D extending from the second end 13 of the upstanding form 15 . As with the prismatic retention members 120 D of FIG. 3 , the engagement between the detent receiving chamber 220 D and detents 15 DA of FIG. 4A can be configured to be permanent or repeatably engageable. By virtue of having there be no projections extending upward from the base clip 120 , 220 of the embodiments of FIGS. 3 and 4 A above the upper anchoring member 120 A, 220 A, the attachment of the base clip 120 , 220 to a panel-forming surface 5 is made easier, as an installer can grasp and place fastener on the upper anchoring surface 120 A, 220 A, even in situations where the lateral thickness dimension T of the upstanding form 15 is relatively narrow compared to a conventional two-by-four or related form.
[0024] Referring again to FIG. 2 , a plurality of bulkheads 10 are joined by connectors 30 , 40 , 50 to form a panel-forming system 60 . Typically, the panel-forming system 60 is placed on a substantially smooth, planar surface, such as panel-forming surface 5 . A panel-forming material may be poured or otherwise introduced into respective cavities 62 , 64 of the panel forming system 60 and subsequently cured to form monolithic panels (not shown). The cured panels may be removed from the cavities 62 , 64 and used in a variety of applications including, but not limited to, tilt-up and other pre-cast construction applications. A rustication 120 may be utilized to create a particular profile or pattern in the surface of the panel. The panel forming system 60 and its various components may be formed from any of variety of suitable materials including, but not limited to, plastics, metals, resins, fibrous composites, and combinations thereof. These materials may be partially or fully synthetic, and in one form, can be an extrudable material such as an extrudable plastic. Indeed, certain embodiments of the present invention relate directly to the bulkhead as an extruded member. As will be appreciated by those familiar with the art of extrusion, an extruded member defines a substantially uniform extruded cross section that extends along substantially the entire length of the member. Insignificant variations in the uniformity of the cross section due to fabrication process errors or post fabrication process steps are contemplated. For example, holes may be drilled in an extruded member in specific locations after the member is extruded. Similarly, cuts or cutouts may be formed in the extruded member after it is extruded.
[0025] Referring again to FIGS. 1A, 1B , 3 and 4 A, the bulkhead 10 may further include chamfers 22 A, 22 B to form beveled surfaces on the edges of the panels. The chamfers may be formed integral with the upstanding form 15 , the base clip 20 , or both. For example, as shown with clarity in FIG. 1B , the upstanding form 15 can include an integrally formed chamfer 22 A extending from one of the walls 16 at or near second end 13 , while the base clip 20 include an integrally formed chamfer 22 B extending from one of the projections 20 B of the first attachment portion. It will be appreciated by those skilled in the art that the configuration depicted in the figure is notional, and that it is within the scope of the present invention to have the chamfers mounted in other ways, such as having both chamfers 22 A, 22 B formed with the upstanding form 15 , an example of which is depicted in FIGS. 3 and 4 A. Moreover, the surface of the chamfer that engages the panel-forming surface. 5 need not be planar; referring with particularity to FIG. 4B , an alternate configuration of the end of chamfer 22 A that engages the panel-forming surface 5 is shown. In this configuration, rather than forming a substantially planar lower surface, the chamfer 22 A forms a more discrete, knife-edge contact at end 25 . This shape, disclosed in co-pending application Ser. No. 09/918,965, entitled TILT-UP CONSTRUCTION CHAMFERS, filed Jul. 31, 2001, assigned to the present assignee and incorporated herein by reference, helps to form a seal between the chamfer 22 A and the panel-forming surface 5 , thereby reducing or eliminating the leakage of uncured panel material into the space between the bulkhead and the surface 5 . Although the knife-edge seal 25 is notionally shown on chamfer 22 A, it will be appreciated that such an edge is equally applicable to any of the other chamfers shown or described herein.
[0026] Referring now to FIGS. 5 through 7 , the bulkhead connectors 30 , 40 , 50 are shown. Each connector 30 , 40 , 50 comprises a base portion 32 , 42 , 52 and an upstanding portion 34 , 44 , 54 . As with the bulkhead 10 (shown previously), the connectors 30 , 40 , 50 can be defined by a monolithic structure. The upstanding portions 34 , 44 , 54 comprise at least one pair of walls 36 , 46 , 56 . Each connector defines at least one bulkhead receiving area 38 , 48 , 58 bounded in part by the pair of walls 36 , 46 , 56 and the base portion 32 , 42 , 52 . Each of the bulkhead receiving areas 38 , 48 , 58 defines dimensions sufficient to accommodate an end portion of bulkhead 10 securely therein. The extent to which the connectors 30 , 40 , 50 are secured to the bulkheads 10 is preferably sufficient to serve as a barrier to the flow of uncured panel-forming material between the connectors 30 , 40 , 50 and the bulkhead 10 . The connectors 30 , 40 , 50 are characterized by a rigidity sufficient to resist significant deformation and breakage under cross-longitudinal panel forming pressure exerted upon a bulkhead under the load of poured panel-forming material. In a manner analogous to the upstanding form 15 of FIG. 1A , the connectors 30 , 40 , 50 may further comprise at least one cross-sectional support member 39 , 49 , 59 extending between walls 36 , 46 , 56 , while the base portion 32 , 42 , 52 may comprise chamfers 22 . The connectors 30 , 40 , 50 may further comprise connector caps 35 , 45 , 55 sized and configured to complement the size and configuration of the upstanding portions 34 , 44 , 54 of the connectors 30 , 40 , 50 . The connector caps 35 , 45 , 55 may be configured to form a sealed interface with the upstanding portions 34 , 44 , 54 and may comprise locking projections 33 , 43 , 53 configured to engage an end portion of a bulkhead secured within the bulkhead receiving areas 38 , 48 , 58 . It will be appreciated that the connector configuration shown is exemplary only, as other connectors of suitable design could also be used.
[0027] Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention. | A pre-cast panel forming system. The system includes one or more bulkheads to constrain the flow of uncured panel-forming material. The bulkhead is made up of an upstanding form and a base clip to secure the upstanding form to a panel-forming surface. The base clip is configured to promote ease of attachment to the panel-forming surface, even though the thickness dimension of the upstanding form is reduced relative to conventional forms. In accordance with 37 CFR 1.72(b), the purpose of this abstract is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract will not be used for interpreting the scope of the claims. |
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FIELD OF THE INVENTION
This patent application is a continuation-in-part of application Ser. No. 585,824, filed Mar. 2, 1984, now abandoned.
This invention relates generally to prestressed structures, and more particularly to prestressed composite structures and methods for making prestressed composite structures.
BACKGROUND OF THE INVENTION
The present invention relates generally to composite structures, those comprising two or more dissimilar materials, and such structures are well-known and in widespread use. One common type of composite structure is a ferroconcrete girder made from one or more steel beams with a concrete overlayment. The steel portion of the composite structure is situated toward the bottom of the structure whereas the concrete lies atop the steel. This arrangement takes advantage of the structural properties of the steel and concrete and makes for a cost-effective structure which has an adequate factor of safety.
Further with regard to ferroconcrete composite structures, the steel portion of the structure is commonly in the form of an "I" beam and the concrete is cast upon the I-beam with the two materials forming a homogeneous or integral unit once the concrete has cured. The steel forms a "tensile layer" whereas the concrete forms a "compressive layer." That is, it is desirable to fabricate the ferroconcrete structure such that most of the concrete lies above the neutral plane of the structure so that the concrete is substantially under compression due to the dead and live loads on the composite structure. On the other hand, the steel is located primarily below the neutral plane so that the steel can absorb the tensile stresses which are incurred by the composite structure when the structure is subjected to the dead and live loads. As well known to those skilled in the art, the I-beam of a ferroconcrete composite structure is not typically subjected solely to tensile stresses, but the phrase "tensile layer" will be used to refer to the I-beam or like elements in other composite structures for the sake of brevity.
The foregoing is quite well known to those skilled in the art, and the particular arrangement of steel and concrete in a ferroconcrete composite structure is chosen primarily due to the weakness of concrete in tension and due to the fact that concrete makes a superior overlayment and is sufficiently strong in compression.
A composite structure of the type discussed above should be distinguished from reinforced concrete and the like. Reinforced concrete is comprised primarily of concrete but includes one or more slender members typically made of steel which are held in tension by the concrete. That is, the concrete is compressed by the steel cable or rods whereas the rods are held in tension by the concrete, and this compression of the concrete tends to overcome any deliterious effects caused by placing the concrete in tension.
In contrast to reinforced concrete, the present invention relates to a true composite structure such as a ferroconcrete girder. In a composite structure of the type contemplated by the present invention, the steel reinforcing layer is capable of withstanding bending stresses and does not primarily function to place a portion of the concrete in compression as was the case in reinforced concrete structures.
As well known to those skilled in the art, composite structures are not limited to ferroconcrete girders. Ferroconcrete composite structures can be used for other structural members and the present invention is not limited to a ferroconcrete girder, i.e. a horizontal main structural member that supports vertical loads.
Furthermore, other materials can be used for fabricating composite structures and are contemplated by the present invention. Wood and laminated wood can be used for a tensile layer, for example, and, in fact, wood can also be used for the compressive layer. The present invention is not limited to any particular material or combination of materials as is clear to those skilled in the art of the fabrication of structural members. However, for the sake of brevity, and only as an example, the present description of the prior art and the detailed description of the invention will be limited to ferroconcrete structues.
As noted above, the present invention is related to composite structures, but more particularly it is related to "prestressed" composite structures. It is well known in the art to "prestress" a composite structure to take better advantage of the properties of the materials. For example, it is well known to prestress a steel beam to produce a convex surface and a concave surface in the beam and then cast the concrete layer on the convex surface of the beam. Once the concrete has cured, the bending moment is removed and the concrete layer is subjected to compression while the uppermost layer or flange of the steel beam is subjected to tension and the lower flange of the beam is held in compression. The concrete layer, or "compressive" layer, in effect "locks in" the stresses in the steel beam formerly induced by the bending moment. With the upper portion of the steel beam in tension and the lower portion in compression the beam is prestressed and is better able to accommodate dead and live loads. That is, the concrete which forms the compressive layer absorbs a portion of the dead and live loads as it compresses, but the concrete also serves to maintain the prestress in the steel beam so that it can better absorb the tensile stresses at the bottom flange induced by the dead and live loads. The end result is that the cross-section of the steel beam can be reduced while at the same time the applicable factor of safety is met. Clearly, this reduction in the cross-section of the steel beam results in a considerable cost savings. Alternatively, the cross-section of the steel beam can be maintained and the prestressed composite structure can withstand larger loads than a visually similar structure which has not been prestressed.
As well known in the art of ferroconcrete fabrication, the compressive and tensile layers, the concrete slab and steel beam, must be bound together so as to act as a single integral structural unit. This can be accomplished either by securely bonding the concrete to the steel beam or by using a shear connector of some type. Shear connectors are also well known in the art, one type being a stud which projects from the upper flange of the steel beam and around which the concrete is cast. Shear stresses are transmitted through the studs from one layer of the composite structure to the other. Other types of shear connectors are contemplated by the present invention, such as a spiral device which is welded to the top flange of the beam.
Various methods for making prestressed composite structures have been proposed. One method for making composite structures is represented by the method shown in U.S. Pat. No. 4,006,523, issued to Mauquoy. In this method, transmission elements are securely attached to the bottom flange of the steel beam at opposite ends of the beam. High strength wires or cables pull the transmission elements toward one amother to bend the beam and encasing concrete is cast around the beam, transmission elements and cable.
Several shortcomings are perceived with this method for prestressing a composite structure. First, the transmission elements must be securely attached to the bottom portion of the beam using, for example, a welding process. This step is time consuming and expensive. Secondly, the cables and transmission elements must produce very large forces in order to sufficiently bend the beam prior to pouring the encasing concrete. This is due to the limited moment arm that the transmission elements provide. The very large forces induced in the cable and transmission elements poses a safety problem.
The method as shown in U.S. Pat. No. 4,006,523 also requires that there be sufficient clearance below the beam for the welding and encasing processes. In some cases, this clearance is not available such as in bridge construction where overhead clearance is critical.
Additionally, this method of prestressing a composite structure would be difficult if not impossible to implement with preexisting structures. For example, on occasion it is desirable to increase the load-carrying capability of a girder which have been in operation for some time. It would be desirable to prestress the girder by removing and recasting the concrete without having to remove the girder from the bridge. The method represented by the method shown in U.S. Pat. No. 4,006,523 clearly suffers from shortcomings when preexisting structures are involved: the clearance problem discussed above might preclude the use of this method altogether, and it might be very difficult in some cases to adequately access the bottom flange of the beam to weld the transmission elements in place.
Still another prestressing method that has been suggested includes simply supporting the steel beam at its ends, and allowing the center portion of the beam to sag between the support points. Forms are attached to the beam and concrete is cast such that it is in contact with the bottom flange of the beam. The weight of the form and the concrete causes the beam to sag even further. The bending moment created by the weight of the beam, form and concrete induces a prestress in the beam and the composite structure.
When the concrete has sufficiently cured, the composite structure is flipped or rotated so that the concrete is on the top side of the composite structure, the concrete forming an overlayment for the structure. The concrete locks the prestress into the structure and the dead and live loads applied to the structure are more easily handled. That is, the dead and live loads cause the concrete to compress and the steel beam to bend in a direction opposite to the sag or bend which was initially preset into the composite structure. The prestresses which were induced and locked into the steel beam are opposite to the stresses induced in the beam due to the dead and live loads and therefore the prestresses act to counter the stresses due to the loads on the composite structure and particularly on the steel beam.
This method for making a prestressed composite structure also possesses several shortcomings. As noted above, once the concrete has cured, the composite structure must be rotated prior to use. Even if such composite structures are fabricated in a manufacturing plant, this flipping procedure is difficult and expensive since the composite structure is typically quite massive and unwieldy.
Furthermore, this method of casting the concrete on the underside of the inverted beam cannot easily be used with pre-existing structures. For example, if this method were attempted to be used to increase the load carrying capability of a bridge girder, the bridge girder would have to be removed from the bridge and reworked or prestressed. The concrete casting process clearly would not be accomplished while the beam is in place in the bridge structure since the resulting composite structure could not be flipped without removing it from the bridge.
The present invention is directed to the shortcomings noted above with respect to the prior art methods. The present invention is a method for prestressing a composite structure which does not require the attachment of transmission elements or the like to the tensile layer, the steel beam in a ferroconcrete composite structure. Furthermore, the present invention does not require that the resulting composite structure be flipped following the engagement of the compressive layer with the tensile layer. On the contrary, the present method is quite simple to use and, in fact, can be utilized to rehabilitate preexisting structures without requiring the removal of the structures or structural components from the main body of the structure. In other words, the method can be used in situ.
SUMMARY OF THE INVENTION
In its broadest form, the present invention is primarily directed to a method for making a prestressed composite structure, wherein the structure includes a tensile layer and a compressive layer. The method includes the steps of applying a center force to the tensile layer near the center of the tensile layer with a force applying apparatus in operative contact with the tensile layer. A first end force is applied to the tensile layer near a first end region of the tensile layer, wherein the first end force is in a direction opposite to the center force on the tensile layer. A second end force is applied to a second end region of the tensile layer and in the same direction as the first end force. The forces, the center force and the first and second end forces, combine to form a bending moment which elastically deforms the tensile layer, creating a tensile layer convex surface and a tensile layer concave surface opposite the convex surface.
A compressive layer is operatively engaged with the convex surface of the tensile layer, and the bending moment is removed. The composite structure, made up of the tensile layer and compressive layer, is thereby prestressed with the compressive layer locking in the stresses induced by the bending moment.
A preferred method also includes applying the end forces by supporting the center region of the tensile layer by a center force applying apparatus and allowing the weight of the first end of the tensile layer and the weight of the second end of the tensile layer to contribute to the bending moment.
A preferred method also includes utilizing first and second end forces applying apparatus to exert end forces on the tensile layer to bow the tensile layer.
Still another preferred method includes positioning a dummy layer proximate to the tensile layer and interconnecting the ends of the tensile layer and the dummy layer. In one preferred method, a center force applying apparatus also acts on the dummy beam and the center region of the tensile layer to bow the center region upward while the ends of the tensile layer are restrained by the dummy layer.
Another preferred method includes engaging the compressive layer by casting a layer of concrete in operative contact with the convex surface of the bowed tensile layer, allowing the layer of concrete to cure to a degree sufficient to substantially withstand the compressive stress which is created in the compressive layer following the removal of the bending moment.
Preferably, the tensile layer includes a steel beam. Similarly, preferably the dummy layer includes a steel beam. I-beams or built-up beams are, of course, useful for these purposes.
The present invention also includes a prestressed composite structure made according to the methods discussed above.
Still another method according to the invention is for rehabilitating bridge girders. One preferred rehabilitating method involves using a crane to bend a girder to crack its concrete layer and induce a prestress. Other preferred methods involve use of a dummy beam to bend the girder.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a tensile member for use in the present invention including a steel I-beam.
FIG. 2 is a side elevational view of the tensile member of FIG. 1 and a dummy beam spaced therefrom with force exerting apparatus between the beams.
FIG. 3 is a side elevational view of the force applying apparatus in use causing the tensile member to elastically bend.
FIG. 4 is a side elevational view of the bowed tensile member of FIG. 3 including a layer of concrete on its convex surface.
FIG. 5 shows a side elevational view of the completed prestressed composite structure following the removal of the bending moment.
FIG. 6 shows an end elevational view of the prestressed composite structure of FIG. 5.
FIGS. 7a-7d show side elevational views of an existing bridge girder being rehabilitated, wherein a dummy beam is positioned below the girder.
FIGS. 8a-8d show side elevational views of an existing girder being rehabilitated, wherein a dummy beam is positioned above the girder.
DETAILED DESCRIPTION OF THE INVENTION
As noted above, the present invention is primarily directed to a method for making a prestressed composite structure. The following description focuses on the fabrication of a ferroconcrete girder which includes a steel I-beam and a concrete slab. As noted above, the invention is not limited to these particular materials as is clear to those skilled in the art. Furthermore, the invention is not limited to the fabrication of a prestressed composite structure utilizing the precise technique discussed below, the technique presented below being merely a preferred embodiment of the invention.
The first step of the preferred method is the choice of an appropriate "tensile member" for the prestressed composite structure. As noted above, it is recognized that the tensile member is subjected to compressive stresses during the prestressing and use: the label "tensile member" or the like is utilized for the sake or brevity. In the drawing, wherein like reference numerals represent like parts throughout the several views, FIG. 1 shows such a tensile member or layer 10 which includes an I-beam 12 having a plurality of shear connectors 14 attached to an upper flange 16 of the I-beam 12. As well known to those skilled in the art, beam 12 can be any material which can withstand the prestress and the stresses induced by the live and dead loads. For example, the beam 12 could be a built-up beam or could be made of wood.
As noted above, the shear connectors 14 function to transmit shear stress from the structural beam 12 to the compressive layer which is operatively engaged to the top flange 16 of the beam 12. The shear connectors 14 are preferably non-threaded studs having heads which are welded to the top flange 16 of the beam 12 and extend substantially perpendicular thereto, as shown in FIG. 6. The shear connectors 14 are preferably spaced according to the shear force distribution in the structure as well known to those skilled in the art. Furthermore, the shear connectors 14 can be of any type, including threaded studs or threaded studs having heads.
A bottom flange 18 of the structural I-beam 12 forms a pair of holes 20 at a first end 21 of the tensile member 10 and likewise forms a pair of holes 22 at a second end 23 of the tensile member 10. The holes 20 and 22 are preferably symmetrically disposed on opposite sides of a web 24 which interconnects the top flange 16 and the bottom flange 18.
The first step of the preferred method is, in a sense, the selection of an appropriate tensile member.
FIG. 2 illustrates the next step of a preferred method of the present invention. A dummy beam 26, preferably an I-beam having similar physical characteristics to the structural beam 12, is disposed so that it is substantially parallel to the structural beam 12 and displaced from the structural beam 12 by a predetermined distance. A screw jack 28 is placed into contact with the bottom flange 18 of the structural beam 12 and a top flange 30 of the dummy beam 26. Preferably, the screw jack 28 is substantially centered between the first end 21 and the second end 23 of the tensile member 10 for reasons discussed below.
FIG. 2 also illustrates the preferred technique of interconnecting the first end 21 of the tensile member 10 to the dummy beam using a pair of first rods 32. The first rods 32 are preferably threaded and are operatively engaged by first nuts 34. The first rods 32 are symmetrically disposed about the web 24 of the structural beam 12, and likewise are symmetrically disposed about a web 36 of the dummy beam 26.
Similarly, second rods 38 engage the second end holes 22 of the bottom flange 18 of the structural beam 12 and are connected to the top flange 30 of the dummy beam 26 in like fashion. Second nuts 40 engage the second rods 38 and the second rods 38 are symmetrical with respect to the webs 24 and 36.
It will be understood by those skilled in the art that the screw jack 28 could be replaced by any similarly functioning device, for example a hydraulic jack or the like. Furthermore, the rods 32 and 38 could be replaced by other means for interconnecting the flanges 18 and 30.
FIG. 3 illustrates the next step of a preferred method, the use of the jack 28 and the rods 32 and 38 to bend the tensile member 10. Preferably, the screw jack 28 is expanded so as to increase the distance between the center region of the bottom flange 18 and the top flange 30 of the dummy beam 36. Also, preferably, the nuts 34 and 40 are rotated with respect to rods 32 and 38, respectively, so as to draw the first and second ends 21 and 23, respectively, of the structural beam 12 toward the dummy beam 36. The end result is to bow or bend the structural beam 12 so as to create a concave surface on the jack side of the bottom flange 18 of the beam 12 and a convex surface on the shear connector side of the top flange 16 of the beam 12. Clearly, as also well known to those skilled in the art, the top flange 16 is thus placed substantially in tension whereas the bottom flange 18 is subjected to a compressive stress.
As is quite clear to those skilled in the art, it is not necessary that the screw jack 28 be expanded while the rods 32 and 38 are utilized to draw the ends of the structural beam 12 downward. Alternatively, the ends could be simply held in position by the rods 32 and 38 while the center region of the beam 12 is pushed upwards. Similarly, the screw jack 28 could simply be used to hold the center region at a fixed distance from the dummy beam 26 while the ends 21 and 23 are drawn downward. The net effect in each of these cases is to generate a bending moment on the beam 12, the beam 12 being elastically deformed to create a convex surface 42 and a concave surface 44 on the structural beam 12.
Although the use of the dummy beam 26 is preferred, it is not necessary that a dummy beam be utilized. That is, the screw jack 28 and the rods 32 and 38 could be directly put into contact with any relatively unyielding structure or surface. It is only necessary that the anchoring structure or surface be strong enough to withstand the large compressive stresses generated by the screw jack 28 and the large tensile stresses generated by the rods 32 and 38 when these components are employed to bend the structural beam 12.
The amount of bend or bow in the beam 12 depends on the amount of prestress which is desired. Those skilled in the art recognize that the more that the beam 12 is bent, the more the upper flange 16 is put into tension and the more that the lower flange 18 is put into compression. The properties of the concrete slab (discussed below) and the shear connectors 14 must be taken into consideration since these elements of the composite structure serve to lock in or hold the prestress on the beam 12. A very large prestress in the beam 12 necessitates very strong shear connectors 14 and a compressive layer (discussed below) that can withstand very large compressive stress. On the other hand, as clear to those skilled in the art, shear connectors may be unnecessry if the bond between the tensile layer and the compressive layer is quite strong.
It should also be noted that the screw jack 28 could be replaced by an apparatus which pulls on the center region of the beam 12 from above the top flange 16. For example, a crane (not shown) could be used to pull on the center region of the beam as the ends of the beam are restrained. Similarly, the end forces which pull on the first and second ends 21 and 23 of the tensile member 10 could be exerted by the use of apparatus which push downward on the upper flange 16 of the beam 12. For example, large weights could be placed in the ends 21 and 23 to bow the beam 12 as it is centrally supported by the screw jack 28. Alternatively, the weight of the beam itself, coupled with the weight of the compressive layer, is sufficient to adequately prestress the beam 12 in some cases.
FIG. 4 shows a side elevational view of the prestressed tensile member 10 illustrating the next step of the preferred method of the present invention. Concrete is poured into a form (not shown) which is operatively engaged to the top flange 16 of the beam 12 and upon curing a concrete layer 46 is formed. The concrete layer 46 adhesively engages the top flange 16 and envelopes the shear connectors 14 so that shear stresses are transmitted between the concrete layer 46, the compressive layer, and the structural beam 12, the tensile layer of the composite structure. As noted above, the concrete layer 46 "locks" the prestress into the beam 12 once the dummy beam 26, jack 28 ad rods 32 and 38 are removed, thereby removing the applied bending moment from the composite structure.
Clearly, the concrete layer 46 can be "Portland" cement concrete or any other material that can be formed and cured with comparable compressive strength, e.g., polymer concrete, latex-modified concrete, or epoxy-modified concrete. Also, as noted above, those skilled in the art will appreciate that the compressive layer need not be comprised of concrete at all and can in fact be any material which can withstand the compressive stresses generated by the tensile layer.
FIG. 5 shows a completed prestressed composite structure 48 following the removal of the bending moment induced by the dummy beam 26, the screw jack 28 and the rods 32 and 38 and attendant parts. The prestressed composite structure 48 includes a compressive layer 46, a concrete layer in the preferred method, and a tensile layer or member 10 comprised primarily of the steel beam 12 in the peferred embodiment.
FIG. 6 shows an end elevational view of the prestressed ferroconcrete structure 48 showing the preferred placement of the shear connectors 14, symmetrical with respect to the top flange 16 of the beam 12. It should be noted that the prestressed structure 48 includes a single I-beam but that the method of the present invention is not so limited. In fact, the prestressed composite structure could have two or more tensile members in a given structure fabricated according to the present invention.
It should also be noted that the concrete layer 46 is typically allowed to cure until its ultimate compressive strength has reached a safe stress prior to removing the bending moment by removing the temporary supports. Those skilled in the art will recognize that the properties of the material which comprises the compressive layer establish the "safe stress" in a particular embodiment. Those skilled in the art will also recognize that in many applications the shear connectors 14 will protrude through the concrete layer 46. The present invention is clearly not limited to the specific embodiment shown in the drawing.
It should further be noted that the present method is applicable to preexisting structures. For example, a bridge girder can be rehabilitated by pulling upward on the center region of the girder through the use of a crane with the ends of the girder bolted down on the foundation or other attachment point, thus causing the concrete to crack typically in several places. The concrete can then be entirely removed, shear connectors attached if necessary, and a new slab cast, or the cracks can be filled with a high-strength concrete such as polymer concrete to complete the compressive overlayment layer. Once the compressive layer has sufficiently cured, the upward force generated by the crane can be removed and the prestressed composite structure can thereafter carry greater loads than the former girder which was not prestressed.
A preferred rehabilitation method is illustrated in FIGS. 7 and 8. Referring in particular to FIG. 7, an existing composite (e.g., ferroconcrete) girder 60 spans between stationary attachment points 62a and 62b (e.g., other girders or ground areas). The ends 64a and 64b of girder 60 are securely bolted or otherwise connected to the stationary areas 62. Girder 60 also has a middle region 66, and includes a tensile layer or I-beam 68 and a compressive layer or concrete layer 70.
Positioned beneath girder 60 is a dummy beam 72 having ends 74a and 74b and a middle region 76. End 74a of dummy beam 76 is tied to end 64a of beam 68 preferably through the use of a threaded rod 78a. End 74b of beam 72 is likewise connected to end 64b of beam 68 preferably through the use of a threaded rod 78b. Finally, a jack 80 separates the middle regions 76 and 66 of the beams 72 and 60, respectively.
As shown in FIG. 7B, the jack 80 is extended to force the beam's middle regions 66 and 76 apart, thus bending girder 60 such that concrete layer 70 is subjected to a tensile stress sufficient to cause it to crack. Rods 78 hold the beams' ends 74 and 64 together.
Referring to FIG. 7C, the concrete layer 70 can then be removed and replaced, or the cracks in the concrete can be filled with a high strength concrete. In either case, shear connectors can be added if necessary. The new or reinforced concrete layer is assigned reference number 82 in FIGS. 7 and 8.
Additional support plates 84, illustrated in FIGS. 7C and 7D, can be bolted or bonded to the concave side of beam 68 to assist the concrete layer in maintaining the beam's prestress. The plates 84 can be high strength steel or graphite-reinforced epoxy, for example.
Once the new concrete layer 82 cures sufficiently, whether it be an entirely new layer or a combination of old concrete and high strength crack filler, the girder 60 is fully rehabilitated (prestressed) and the dummy beam 72 and its attendant parts can be removed.
FIG. 8 illustrates another preferred rehabilitation process according to the invention. The illustrated method is substantially identical to the method shown in FIG. 7 except for the fact that the dummy beam 72 is located atop girder 60 in FIG. 8. The middle regions 76 and 66 of the beams 72 and 68, respectively, are tied together by threaded rod 78; and ends 64 and 74 are forced apart by jacks 80. In view of the similarities between the processes, the reference numerals of FIG. 7 are utilized in FIG. 8. The method illustrated in FIG. 8 is particularly useful when it is desirable to avoid reducing the clearance below the girder 60 during the rehabilitating process.
It should particularly be noted that any combination of lifting, pulling, or pushing devices could be used to bend the girder 60 during the rehabilitating process. For example, sand boxes or various types of hydraulic devices could be employed.
Other modifications of the invention will be apparent to those skilled in the art in light of the foregoing description. This description is intended to provide specific examples of individual methods and embodiments which clearly disclose the present invention. Accordingly, the invention is not limited to these methods and embodiments or to the use of elements having specific configurations and shapes as presented herein. All alternative modifications and variations of the present invention which follow in the spirit and broad scope of the appended claims are included. | A prestressed composite structure (48) and method for making same. The ferroconcrete prestressed structure (48) includes a tensile member (10) which includes a steel I-beam (12) which has on its upper flange (16) a plurality of shear connectors (14). The beam (12) is bent or bowed by pushing on the center region of the beam (12) with a screw jack (28) or the like while forces are applied to the first and second ends (21) and (23), respectively, of the beam (12). The end forces can simply be due to the weight of the beam (12) or can be supplemented, in one embodiment, through the use of threaded rods (32) and (38) which interconnect the beam (12) and a dummy beam (26). The bowed beam (12) has a convex surface (42) on which a compressive layer (46) is attached. Preferably, a concrete layer (46) is utilized with the concrete bonding to an upper flange (16) of the beam (12) and the concrete layer (46) encasing or enveloping the shear connectors (14) to make the composite unit (48) act as a single structural device. Once the concrete layer (46) has sufficiently cured, the bending moment created by the screw jack (28) and rods (32) and (38) is removed and the resulting composite structure (48) is prestressed and is therefore better able to withstand dead and live loading. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of my co-pending application Ser. No. 12/150,826 filed on Apr. 30, 2008, entitled “Underwater Trenching Device” the full disclosures of which are incorporated by reference herein and priority of which is hereby claimed.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an underwater trenching system, and more particularly, to a trench making equipment that enlarges an underwater trench for burying a pipeline.
[0003] Many oil and gas production sites require installation of miles of pipelines for delivery of the produced material to a refinery or other destination. Often times, the pipelines are laid underwater, especially in shallow coastal waters. The pipes are usually buried at the bottom of a waterway, such as a river, marsh, or sea. In some locations, the pipes are simply laid along the bottom of a waterway and left exposed, to be buried by the action of the currents. In other uses, a trenching tool, such as a water jet, a cutter head, or a scoop, or clam shell digger digs a trench around the pipe, which then settles into the trench.
[0004] The bottom sediment eventually settles around the pipe although a large portion of it is carried to other areas of the waterway. The time when the sediment remain in suspension varies although it is known to have a potential for creating serious environmental damage to plants, animals, marine life, and the water. Over time, the sediment has a tendency to shift the pipeline, which causes it to rise from the bottom or from the trench. Current governmental regulations prohibit disturbing the waterway bottom for the second time, such that digging out the original trench for adjusting position of the pipeline is not a viable option. As a consequence, the only viable alternative is to excavate the side of the trench near the bottom and cause the pipeline to drop into the new indentation in the soil.
[0005] In short, all currently known equipment and methods for underwater trenching create large clouds of silt and debris that remain in suspension for a long time and seriously disrupt the ecology of the waterway. Reforming the trench by additional excavation of the bottom is not allowed.
[0006] There exists therefore a need for an underwater trenching system that avoids bottom trenching, while achieving the goal of lowering the pipeline into a trench without excavating the bottom of the trench.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to provide an underwater trenching system that is capable of evacuating sediment from a side of the trench without substantially disturbing the soil.
[0008] It is another object of the invention to provide an underwater trenching system that allows the pipe to settle back into the trench.
[0009] It is a further object of the present invention to reduce the time and cost of trenching by omitting the necessity to employ underwater divers.
[0010] These and other objects of the invention are achieved through a provision of an underwater trenching apparatus for repairing a trench formed in a bed of a waterway, within which a pipeline is located. The trenching apparatus comprises an elongated boom assembly having a proximate end configured for hingedly securing to a side of a floating vessel, such as a barge. A trenching unit is secured to a distal end of the boom assembly and moves between an above-water position and an underwater position with the help of a lifting means positioned on the deck of the barge, such for instance a lifting crane, a cable of which is detachably secured to the boom assembly.
[0011] The trenching unit comprises a pair of spaced-apart opposing sparge assemblies that deliver water and air under pressure to the trench where the pipeline is located. The water and air disturb the underwater formation and move the disturbed sediment or loose formation away from the pipeline in the trench. An elongated conduit admits the sediment through a bottom inlet opening and discharges the sediment through an upper outlet opening. An airlift unit mounted inside the tubular member is connected to an above-water air supply. The airlift unit creates turbulence inside the tubular member, causing sucking of the sediment into the tubular member and lifting the sediment and water toward the discharge opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Reference will now be made to the drawings, wherein like parts are designated by like numerals, and wherein
[0013] FIG. 1 is a schematic view illustrating the underwater trenching apparatus of the instant invention in operation.
[0014] FIG. 2 illustrates the underwater trenching apparatus of the instant invention in transit or storage position.
[0015] FIG. 3 is a detail view showing the trenching unit connected to a single manifold.
[0016] FIG. 4 is a detail view showing the trenching unit with its pair of sparge assemblies.
[0017] FIG. 5 is detail, partially cut-away view showing one of the sparge assemblies and the airlift insert.
[0018] FIG. 6 is a detail view showing the airlift assembly mounted in the inlet portion of the tubular conduit.
[0019] FIG. 7 is detail view of the bottom of the sparge assembly illustrating the direction of intake flow entering the inlet portion of the tubular conduit.
[0020] FIG. 8 is a detail view of the nozzle of the sparge conduit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Turning now to the drawings in more detail, the system of the present invention is designated by numeral 10 . The system 10 comprises an elongated boom assembly 12 , a proximate end 14 of which is secured to a barge 16 or other suitable vessel. Conventional trenching equipment is usually centered on the barge. The system 10 , in contrast, is positioned on a side of the barge, with the boom assembly 12 secured to the starboard 20 of the barge 16 . Of course, the boom assembly 12 may be also secured to the port of the barge hull, depending on the location of the pipeline in the waterway. In FIG. 1 , the trenching system 10 is mounted on the barge 16 that moves in the direction of arrow 17 .
[0022] The proximate end 14 boom assembly 12 is hinged to a hinge plate 18 , which can be formed from a length of an I-beam, attached to the starboard 20 . The hinge plate 18 extends substantially horizontally, transversely to the starboard 20 and suspends the boom assembly 12 off the side of the barge 16 . The boom assembly 12 can move up and down in relation to the hinge plate 18 . A support bracket 22 supports the hinge plate 18 from below and absorbs some of the vertical and horizontal forces applied to the hinge plate 18 when the boom assembly 12 moves between a transport position shown in FIG. 2 to an operating position shown in FIG. 1 . A second reinforcing bracket 24 may be secured to the hinge plate 18 to further reinforce the position of the hinge plate 18 on the side of the barge 16 .
[0023] A distal end 26 of the boom assembly 12 is selectively secured to a lifting means 30 , which can be a deck crane, positioned on the deck 32 of the barge 16 . A lifting cable 34 detachably secures the boom assembly 12 to the lifting crane 30 to raise and lower the boom assembly 12 . The distal end 26 of the boom assembly 12 carries a trenching unit 40 that is lowered below the waterline 42 to reach the mud line 46 .
[0024] The boom assembly 12 comprises a pair of elongated beams 48 , 50 which are spaced from each other and are retained in a substantially parallel relationship by a plurality of transverse braces 54 and diagonal braces 56 . A mesh walkway 60 is secured between the beams 48 , 50 , allowing operators to access the trenching unit 40 and to measure the depth, at which the pipeline 62 extends below the mud line 46 . The depth measuring can be conducted using conventional devices that are well known in the industry and are not part of the instant invention.
[0025] Mounted on the deck 32 of the barge 16 is water and air supply units that deliver water under pressure and pressurized air to the trenching unit 40 . As can be seen in FIG. 3 , an air compressor 64 is positioned on the deck 32 and is connected to the trenching unit 40 by air supply conduits 68 , 69 . Water to the trenching unit 40 is supplied by a pair of jet pumps 70 , 72 that deliver water to the trenching unit 40 via water conduits 74 , 76 , respectively. The jet pumps 70 , 72 can produce 300 p.s.i. of pressure to the trenching unit 40 . The jet pumps are self-contained with fuel tanks, powered generator and an air compressor.
[0026] The trenching unit 40 comprises a pair of sparge units 80 , 82 that are connected to a single manifold 84 that supplies water under pressure through manifold connectors 86 , 88 , 90 , and 92 . Only two manifold connectors are active at a particular time during operation of the trenching unit 40 . Depending on the diameter of the pipeline 46 and the width of the desired trench, the trenching unit can be connected, through the manifold connectors to either two adjacent manifold connectors or to a pair of further spaced-apart manifold connectors. In the example illustrated in FIG. 3 , manifold connector 88 and 92 are used to supplying the pressurized water to the sparge units 80 , 82 .
[0027] The sparge units 80 and 82 are mirror images of each other. Each of the sparge units comprises a tubular conduit 94 that has a first inlet portion 96 , 98 , respectively, and a second discharge portion 102 , 104 , respectively. The discharge portions 102 , 104 are oriented at an angle to longitudinal axes of the first inlet portions 96 , 98 . The outlet openings of the second discharge portions 102 , 104 are oriented in opposite directions so that effluent is discharged away from the pipeline 46 .
[0028] The air supply conduit 68 is secured to the side of the first inlet portion 98 for delivering pressurized air to the interior of the first inlet portion 96 . Mounted inside the first inlet portion is an airlift insert 106 that has exterior dimensions slightly smaller than the interior of the first inlet portion conduit 98 . The insert 106 is secured inside the conduit defined by the first inlet portion and has a flared inlet opening 108 .
[0029] A plurality of openings 110 is formed in the walls of the insert 106 allowing air delivered through the air conduit 68 to enter the interior of the insert 106 and create turbulence inside the insert 106 . The turbulent flow carries the sediment, as will be explained in more detail hereinafter, toward the second discharge portion 102 and ultimately—to the discharge opening 112 of the second discharge portion 102 . As shown in FIG. 5 , the air supply conduit 68 is connected to the interior of the first inlet portion 98 at a level where the openings 110 in the insert 106 are located.
[0030] The openings 110 are preferably formed at an angle to the longitudinal axis of the insert 106 , as shown in FIG. 5 . The inclined openings 110 , which can be inclined at about 45 degrees in relation to the longitudinal axis, force the air upward into the first inlet portion 98 and create a turbulent flow therein. The flared bottom of the insert 106 and a reduced size of the remainder of the insert body 106 also facilitate the creation of a sucking force by creating a venturi effect and drop in pressure as the flow moves through the tubular portions 96 , 102 ( 98 , 104 ).
[0031] Each sparge unit 80 , 82 is provided with a sparge conduit 120 , 122 , respectively. The sparge conduits 120 , 122 are connected to the manifold 84 through manifold connector flanges 124 , 126 . Each sparge conduit 120 , 122 is provided with a plurality of discharge nozzles 128 , 130 that jet pressurized water/air mixture into the waterway bed 140 in the area adjacent the pipeline 46 . The nozzles 128 , 130 are detachably mounted in the corresponding openings formed in the wall of the sparge conduits 120 , 122 .
[0032] Each nozzle has exterior threads 131 that allow the nozzle to be threaded into the opening in the wall of the sparge conduit. An inlet opening 132 of the nozzle 128 (or 130 ) has a generally conical configuration, as can be seen in more detail in FIG. 8 . An outlet opening 134 has a diameter smaller than the diameter of the inlet opening 132 , such that the velocity of the fluid exiting the nozzle 128 ( 130 ) is increased causing a jetting effect. The water and air exiting the outlet opening 134 blast away sediment from the bottom of the waterway enlarging the trench 142 surrounding the pipeline 46 .
[0033] The disturbed sediment is sucked into the bottom opening 146 of the first inlet portion 98 and moves through the insert 106 under the force of the flow created by the incoming air flow. Some of the water moving through the sparge conduit 120 is diverted to the first inlet portion 98 below the airlift insert 106 by a pair of water hoses, or pipes 148 , 150 to facilitate movement of the sediment through the trenching unit 40 . The sediment can be discharged to the waterway bed 140 above the mud line 46 or, if the trench is shallow—even to the banks of the waterway.
[0034] To ensure alignment of the trenching unit 40 with the pipeline 46 , the trenching unit 40 is provided with a guiding means, which comprises a plurality of rotating guiding rollers. A transverse roller 152 is secured between the sparge conduits 120 , 122 at a position downstream from the inlets openings of the sparge conduits 12 , 122 . In the embodiment shown in FIG. 4 , the transverse roller 152 is positioned at an approximate level above an anticipated depth of the pipeline 46 .
[0035] A pair of vertical guiding rollers 154 , 156 is positioned in a general vertical alignment with the first inlet portion 96 , and a similar pair of vertical guiding rollers 158 , 160 is positioned in a general vertical alignment with the first inlet portion 98 . The rollers 154 , 156 , 158 , and 160 prevent the trenching unit 40 from significantly deviating from the dimensions created by the sides of the trench, where the pipeline 46 is located. The distance between the rollers 154 , 156 and 158 , 160 is selected to conserve energy and enlarge the trench 142 only as necessary for the pipeline 46 .
[0036] The barge 16 can be propelled by a tug boat 170 shown in phantom line in FIG. 1 , or by other suitable means that allow the trenching unit 40 to move along the pipeline and enlarge or form a trench. If desired, the roller guides 154 , 156 , 158 and 160 can be distanced to straddle the pipe 46 and keep the trenching unit 40 aligned with the pipeline 46 . The rollers are also important in protecting the conduits from contact with rocky trench walls.
[0037] If desired the nozzles 128 , 130 can be strategically spaced along the length of the inlet portions such that the majority of the nozzles are located closer to the bottom of the trench, while fewer nozzles are located in an area that would be approximately above the pipeline 46 . The depth of the pipeline 46 embedment can be measured prior to lowering the trenching unit 40 into water.
[0038] The barge 16 is propelled along the waterway at a desired speed, allowing the sparge units 80 , 82 to disturb underwater sediment and for the airlift force to lift the disturbed sediment away from the trench. The actual speed of travel depends on the condition of the waterway bed. Naturally, slower speed will be necessary where there exists clay bottom than where the bed is sandy. It is envisioned that a land vehicle may be employed for transporting the trenching apparatus of the present invention. Depending on several factors, such as the width of the waterway, the location of the pipeline and the depth, at which the pipeline is buried the land vehicle with the boom assembly mounted thereon may be employed.
[0039] Many changes and modifications can be made in the design of the present invention without departing from the spirit thereof. I therefore pray that my rights to the present invention be limited only by the scope of the appended claims. | An underwater trenching system is mountable on a side of a barge to be propelled by the barge along a waterway, the bed of which contains a trench with a laid pipeline. To remove the excess sediment from the trench the trenching unit delivers pressurized water and air to the trench. A sparge assembly with jet nozzles directs jets of water, breaking up the formation that has built up around the pipeline. The airlift assembly creates a turbulent flow to lift the disturbed sediment and remove it from the created trench. |
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BACKGROUND OF THE INVENTION
1. Field of Invention
[0001] The present disclosure relates to a system for navigating past obstacles in a wellbore. More specifically, the present disclosure relates to selectively reorienting a shaped guide member to negotiate past irregular sections in a wellbore.
2. Description of Prior Art
[0002] Downhole operations in hydrocarbon producing wellbore often involve deploying a tool or a string in the wellbore to a designated depth. Advances in hydrocarbon exploration and production have led to wells with more deviations, thereby introducing curves and bends in the wellbores that introduce obstacles to navigating tools or strings through the wellbore. Further, wellbore systems have been developed that include lateral wellbores that branch from a primary wellbore. Negotiating a tool or string across the angle between a primary wellbore and a lateral wellbore introduces additional difficulties. Further, a tool or string sometimes becomes lodged against washouts or other discontinuities in the wellbore wall when being lowered in an uncased wellbore.
SUMMARY OF THE INVENTION
[0003] Disclosed herein is an example of a downhole system for use in a wellbore and which includes a downhole tool having an axis, and that is deployed on wireline and a guide assembly. Here the guide as is made up of a connector coupled to the downhole tool, a sleeve with an end coupled to the connector and another end distal from the connector so that a portion of the circumference of the another end lies in a plane substantially perpendicular with the axis, and another portion that lies in a plane that is oblique with the axis, a pedestal having an outer periphery, and a ledge on the outer periphery that faces the sleeve, and that is profiled generally complementarily with the another end of the sleeve, so that when the ledge is axially urged against me another end t the sleeve, the pedestal rotates relative to the sleeve, a tip member having a curved surface and that is coupled to the pedestal. The downhole system can also a spring in the sleeve that is coupled to the sleeve and to the pedestal, and becomes rotationally tensioned with relative rotation of the sleeve and pedestal. In one example the tip member is an elongated member, and having a curved surface along an elongate lateral side. Optionally, the tip member can have a substantially planar surface along an elongate lateral side that is angularly spaced away from the curved surface. In an embodiment, the planar surface projects along a path that is oblique with the axis. The portions each optionally extend about 180 degrees around a circumference of the end of the sleeve. A standoff can be included on the sleeve.
[0004] Another example of a downhole system for use in a wellbore is described herein and which includes downhole tool that is selectively disposed in the wellbore, a wireline connected to an end of the downhole tool, and a guide assembly connected to an end of the downhole tool opposite the wireline, and that includes a downwardly projecting tip member and a means for orienting the tip member in a designated orientation for navigating past obstacles in the wellbore. The means for orienting the tip member can include a sleeve having an end that terminates at varying axial positions along a circumference of the sleeve, and a pedestal having a ledge on an outer periphery of the pedestal, where the ledge faces the sleeve and is profiled complementarily with the end of the sleeve, so that the pedestal rotates with respect to the sleeve when the ledge is put into abutting contact with the end of the sleeve. In an embodiment, the sleeve is coupled to the downhole tool, and the pedestal is coupled to the tip member, so that relative rotation of the pedestal and sleeve rotates the tip member with respect to the downhole tool. The tip member can be an elongate member having a curved elongate surface, and a planar elongate surface on a side opposite the curved elongate surface, and wherein the planar elongate surface is oblique to an axis of the guide system.
[0005] Also described herein is an example of a method of wellbore operations and which includes deploying a downhole string in a wellbore and on a wireline, where the downhole string includes a downhole tool equipped with a guide assembly having an obliquely angled tip member, lading the tip member on an obstacle in the wellbore, lifting the downhole string from the obstacle, reorienting the tip member along a path directed away from the obstacle, and lowering the downhole string so that the tip member slides past the obstacle. The obstacle can be a discontinuity along a sidewall of the wellbore, such as a washout, a ledge, a curved portion of the wellbore, or an entrance to a lateral wellbore. The method can include repeating the steps of lifting the downhole string and reorienting the tip member. In an alternative, the tip member is reoriented at an angle of around 120 degrees. The method can also include sensing when the tip member lands on the obstacle in the wellbore and lifting the downhole string from the obstacle in response to the step of sensing. An optional step of sensing can include receiving a signal with a controller on surface from as proximity sensor disposed in the guide assembly.
BRIEF DESCRIPTION OF DRAWINGS
[0006] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0007] FIG. 1 is a side sectional view of a tool string landing on an obstruction in a wellbore, where an example of a guide system is mounted to the tool string.
[0008] FIG. 2 is as side sectional view of the tool string of FIG. 1 being raised upward from the obstruction, and where the guide system is reorienting a tip member.
[0009] FIG. 3 is a side sectional view of the tool string of FIG. 2 being lowered in the wellbore for navigating past the obstacle.
[0010] FIGS. 4A and 4B are side perspective views of examples of the guide system of FIG. 1 .
[0011] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0012] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term “about” includes +/−5% of the cited magnitude. In an embodiment, usage of the term “substantially” includes +/−5% of the cited magnitude.
[0013] It is to be further understood that the scope. of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
[0014] Shown in side sectional view in FIG. 1 is an example of a downhole system 10 being lowered within a wellbore 12 , wherein well bore 12 is formed through a formation 14 . As shown, the downhole system 10 is approaching a deviated section 16 of wellbore 12 while being lowered on wireline 18 . The downhole system 10 includes a downhole tool 20 , which can be for example a perforating gun, an imaging or logging tool, or other tubular being set downhole. A guide system 22 is shown mounted to a lower end of downhole tool 20 opposite its connection to wireline 18 . The guide system 22 includes art orientation assembly 24 with a tip member 26 that depends downward from orientation assembly 24 and is a generally elongate member. One elongate side of tip member 26 is shown having a curved surface 28 , wherein an opposite side of tip member 26 has a generally planar surface 29 . Further illustrated in FIG. 1 is a surface truck 30 shown mounted on surface 32 . Wireline 18 connects to a reel (not shown) within surface truck 30 and spools over sheaves and into a wellhead assembly 34 , shown mounted over an opening of wellbore 12 . Further shown in FIG. 1 is a controller 36 , shown in dashed outline within surface truck 30 , can be used for sending and receiving data and control signals to and from downhole system 10 .
[0015] Tip member 26 of FIG. 1 is shown having landed against an obstacle 38 on the sidewall of wellbore 12 . In the example, the obstacle 38 is the angled sidewall of the wellbore 12 in the deviated section 16 . Other examples of obstacles include washouts, ledges, and entrances into lateral wellbores from a primary wellbore. Referring now to FIG. 2 , one example of navigating past the obstacle 38 is demonstrated by lifting the downhole system 10 upwards within wellbore 12 and from obstacle 38 . As will be described in more detail below, the guide system 22 automatically reorients tip member 26 as shown so that the curved surface 28 is now facing the direction of obstacle in wellbore 12 . Shown in FIG. 3 is a subsequent step of an example of navigating past the obstacle 38 where the downhole system 10 is lowered on wireline so that tip member 26 is proximate obstacle 38 . As shown, the strategic positioning of tip member 26 orients the curved surface 28 so it faces obstacle 38 , which enables the downhole system 10 to slide past obstacle 38 and make its way deeper into wellbore 12 and past the deviated section 16 .
[0016] In side perspective views in FIGS. 4A and 4B are example embodiments of the guide system 22 . A connector 40 is shown on one end of guide system 22 which is a generally annular member with an open end revealing a hollow portion, inside of hollow portion is an inner surface. Threads 42 are depicted formed within the inner surface of connector 40 and for connecting to the downhole tool 20 ( FIG. 1 ). An end of connector 40 opposite its open end connects to an annular sleeve 44 , shown having an axial bore 45 extending therethrough. Sleeve 44 has an end 46 distal from its connection to connector 40 , and wherein end 46 has a beveled profile such that the end 46 terminates at different axial locations with respect to a circumference of sleeve 44 . More specifically, a portion 48 of the circumference of end 46 lies in a plane that is substantially perpendicular with an axis A of guide assembly 22 . Another portion 50 of the circumference of end 46 projects along a varying axial location and thus lies in a plane that is substantially oblique with axis A y . The portions 48 , 50 define a Shane that is sometimes referred to “mule shoe”. Also included with guide assembly 22 is a standoff 52 , which is made up of a collar 54 that is shown circumscribing a portion of sleeve 44 . Ridges 56 are mounted on collar 54 at angular locations around collar 54 , and are elongate members that project along the axial length of collar 54 .
[0017] A generally cylindrical pedestal 58 is shown disposed adjacent end 46 of sleeve 44 . The diameter of pedestal 58 transitions radially outward proximate to sleeve 44 , and which defines a ledge 62 that faces sleeve 44 . Similar to the end 46 , ledge 62 has a portion 64 that extends along a part of the circumference of ledge 62 , and which is lies in a plane generally perpendicular with axis A y . Another portion 66 of ledge 62 extends along another part of the circumference of lodge 62 , and which is complementarily formed to portion 50 . Thus portion 66 extends along a plane that is generally oblique with axis A y . Examples exist wherein each of the portions 48 , 50 , 64 , 66 extend about 180 degrees around the respective circumferences of the end 46 and the ledge 62 . Optionally, multiple portions 48 , 50 , 64 , 66 can be formed on the end 46 and ledge 62 , wherein the angular lengths of each of the portions 48 , 50 , 64 , 66 is less than 180 degrees. Optionally, embodiments having multiple portions 48 , 50 , 64 , 66 can give the end 46 and ledge generally castellated appearance. When assembled, the smaller diameter section of pedestal 58 between ledge 62 and sleeve 44 inserts into bore 45 of sleeve 44 . As shown in FIG. 4A , a bore 68 is formed within pedestal 58 and sized to receive a post 70 mounted on an end of tip member 26 . As depicted in FIGS. 4A and 4B , an axis A TM of tip member 26 is generally oblique with axis A y .
[0018] In one example of operation of the guide system 22 , applying a force F against end of tip member 26 as shown in FIG. 4A , urges pedestal 58 against sleeve 44 so that ledge 62 is in close contact with end 46 of sleeve. 44 . An example of force F can occur when tip member 26 lands on obstacle 38 ( FIG. 1 ). As the ledge 62 is profiled complementary to end 46 , the pedestal 58 will rotate with respect to sleeve 44 until the portions 48 , 64 are aligned, and portions 50 , 66 are aligned. A spring 72 which is coupled to both the pedestal 58 and sleeve 44 is torqued into compression and stores energy while the sleeve 44 and pedestal 58 are abutted against one another. When the force F is removed, such as the step illustrated in FIG. 2 so that the tip member 26 is freely suspended and not landed n a solid surface, the compressed torsion in spring 72 is released and causes rotation of pedestal 58 and tip member 26 relative to sleeve 44 and downhole tool 20 ( FIG. 1 ). As such, the curved surface 28 can be strategically reoriented so that when the downhole system 10 of FIG. 1 is relowered, the curved surface 28 (and thus smoother surface) of the tip member 26 can engage obstacle 38 with less resistance than when in other orientations, so that the downhole system 10 can be urged further within wellbore 12 . Moreover, orientating tip member 26 so that its axis A TM is oblique to the axis A y provides an increased offset angle with respect to obstacle 38 thereby enhancing the ability of the guide system 22 to direct the downhole system 10 past the obstacle 38 .
[0019] Referring back to FIG. 1 , a proximity sensor 74 is shown within guide system 22 and which ran sense when the pedestal 58 and sleeve 44 are in close contact, thereby indicating the tip member 26 has landed on an obstacle 38 or other solid mass that blocks passage of downhole system 10 . Sensor 74 can he in contact with controller 36 via wireline, so that operations personnel on surface 32 can detect when the downhole system 10 lands on an obstacle 38 . Upon detection of landing, operations personnel can commence the actions of lifting the downhole system 10 and then relowering as illustrated in FIGS. 2 and 3 , Other ways of sensing may be included, such as monitoring tension in the wireline 18 .
[0020] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A downhole system is deployed on wireline and includes a tool and a guide system on it a lower end of the tool for navigating past obstacles within a wellbore. A selectively rotatable tip member projects downward from the guide system. A side of the tip member is curved, so when the tool encounters cm obstacle downhole, the tip member rotates so the curved side faces the obstacle and the downhole system can be urged past the obstacle. The guide system includes a sleeve and pedestal that abut one another on opposing ends that are complementarily profiled. When the sleeve and pedestal axially contact one another, the profiled ends produce relative rotation of the sleeve and pedestal. The pedestal is coupled with the tip member and the sleeve is coupled to the tool, so that the relative rotation of the sleeve and pedestal causes the tip member to rotate relative to the tool. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a septic system for handling household waste water. More particularly, the present invention relates to a septic system that can expand the amount of filtering material around or adjacent to a conventional new or existing septic gallery to expand a septic gallery capacity.
[0003] 2. Description of the Related Art
[0004] Septic systems are well known in the art. One such septic system is disclosed in U.S. Pat. No. 4,759,661 to Nichols, et al. (hereinafter “Nichols”). Nichols discloses a leaching system conduit made from a thermoplastic member having lateral sidewalls with a number of apertures. The thermoplastic member is an arch shaped member in cross section and has the apertures for the passage of liquid therethrough. The lateral sidewalls also have a number of corrugations formed in a rectangular shaped manner.
[0005] Such septic systems are deficient in their operation. First of all, zoning ordinances for certain sized homes require larger septic systems. Such larger septic systems may not fit on the desired building lot. A large number of bedrooms in a new home construction require according to some zoning laws that a certain sized septic system be used or that the certain sized septic system have a predetermined volume. This can be problematic under certain circumstances because the desired septic system may not fit in a certain lot and the new home owner may be limited to only a second sized septic system that is less than desired. With this smaller septic system, the new home builder thus must reduced the size of the new home. Secondly, in other circumstances homeowners may wish to expand the capacity of the septic system in a retrofit manner from a first size to another second size to accommodate a larger home.
[0006] However, a known problem in the art is that the under this arrangement, the second sized larger septic system like Nichols' leaching system will require the homeowner to excavate the leaching system and remove the leaching system. Thereafter, the homeowner will have to remove additional soil and dirt and then insert a new second sized larger septic system. Thereafter, the homeowner may have to perform additional work to the home to accommodate the home with this replacement and further obtain all of the requisite permits and variances to the zoning laws.
[0007] Accordingly, there is a need for a septic system that increases an amount of filtering medium so smaller septic systems may be used with larger homes thus maintaining an amount of effluent entering the septic system. There is also a need for a septic system that does not require replacement of the entire septic system for an upgrade. There is also a need for a septic system that has a more productive filtering. There is a further need for a septic system that has an attachment that can expand a complementary filtering area of the septic system.
[0008] There is also a need for such a system that eliminates one or more of the aforementioned drawbacks and deficiencies of the prior art.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a septic system for a residential home or commercial building.
[0010] It is another object of the present invention to provide a septic system that can be connected in a modular fashion to an existing septic system.
[0011] It is yet another object of the present invention to provide a septic system that increases a surface area on a lateral side of an existing septic system.
[0012] It is still another object of the present invention to provide a device that adds capacity to an existing septic system.
[0013] It is still yet another object of the present invention to provide a septic system that has a large capacity in a smaller footprint or space underneath ground.
[0014] It is a further object of the present invention to provide a septic system that has a baffling arrangement on a lateral side for an improved interface with ground.
[0015] It is a further object of the present invention to provide a septic system that has a triangular baffling arrangement on a lateral side of an existing system for an improved interface with sand.
[0016] These and other objects and advantages of the present invention are achieved by a septic system of the present invention. The system has a modular appendage for a septic gallery and the appendage has a first modular section for connection to a lateral side of the gallery with the first modular section having a apertures thereon. The first modular section has a first area, and the lateral side of the septic gallery has a second area, with the first area greater than the second area of the gallery.
DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 illustrates a prior art septic gallery;
[0018] FIGS. 2 a and 2 b illustrate a top plan view of the appendages of the present invention connected to a septic gallery;
[0019] FIG. 3 illustrates a front view of the appendage for the septic gallery;
[0020] FIG. 4 illustrates a cross-sectional view of the septic gallery taken along line 3 - 3 of the gallery of FIG. 1 ;
[0021] FIG. 5 illustrates a top plan view of two appendages of the present invention connected to each other without a septic gallery; and
[0022] FIG. 6 illustrates a front view of the appendages of FIG. 5 of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring to FIG. 1 , there is shown a septic gallery 5 as is known in the art. The septic gallery 5 is preferably a container that is placed in a leaching field, such as ground or sand, and is utilized for drainage of effluent. Effluent is a term commonly used for waste materials such as liquid and solid industrial refuse or liquid and solid residential sewage that flows out of a source and is discharged into the environment. The effluent is carried from a source such as a bathroom to the septic tank, then to the leaching field for dispersion, diffusion, or percolation, into surrounding soil.
[0024] Known pipes carry the effluent discharge and release the material into a chamber, or vault such as the septic gallery 5 . The gallery 5 as is known will have a number of perforation or holes leading from the septic gallery 5 . The gallery 5 is usually buried in a trench to facilitate dispersion of the effluent into the soil. All of the solid effluent stays in the septic tank, and only the liquid and liquid effluent diffuses into the sand.
[0025] In some systems, the gallery 5 is defined by a large diameter perforated conduit. In other systems, the gallery 5 is perforated to provide direct dispersion into the sand. The effluent is then dispersed into the soil either through the soil serving as the floor of the gallery 5 or, when effluent accumulates in the gallery, through passages in side walls thereof.
[0026] One known problem in the art is that the interface between the gallery 5 and the ground only allows for a finite flow or dispersion rate of liquid waste from the gallery to the soil or sand on the other side. The inventor of the present invention has recognized this known problem and has solved the problem with the present invention that has a number of unexpected benefits that increase a capacity for liquid waste of the gallery 5 , and allows an increased amount of liquid and liquid waste to diffuse into the ground.
[0027] A prior art septic gallery 5 is commonly concrete or formed of plastic resin material and corrugated for strength. This septic gallery 5 is formed in sections that are mated to vary the effective length of the leach field. Sometimes multiple septic galleries 5 are connected to one another to increase the length and capacity of the leaching field, for example a home.
[0028] Referring now to FIG. 2 a , there is shown the septic gallery 10 of the present invention buried beneath the ground. The septic gallery 10 is preferably connected to an effluent source, and has a first conduit 12 or pipe that is connected to a septic tank or pump chamber. In one embodiment, the septic gallery 10 has a four foot width although galleries can be provided in a variety of standard and/or conventional sizes to accommodate homes and or properties of differing sizes. The septic gallery 10 preferably has a first conduit 12 on a first side 14 of the gallery, and a second conduit 16 on a second side 18 of the gallery. The effluent is in a liquid form and preferably enters the gallery 10 from the first conduit 12 and the second conduit 16 to fill the gallery over time to capacity. Capacity is the number of gallons of effluent and depends on the size of the residence or waste source above ground. After a period of time, prior art galleries becomes full with liquid effluent, and must be replaced.
[0029] What is desirable is a device that may increase a capacity of the septic gallery while liquid effluent is not be stored therein. Instead, the liquid effluent is diffused to the surrounding environment to percolate through ground for filtering thereof. Most preferably, the present invention achieves this need in an unexpected manner.
[0030] The gallery 10 has a first appendage 20 on the first lateral side 14 of the gallery 10 . Preferably, the first appendage 20 contacts the ground or sand in the ground contacting side, and also communicates with the first conduit 12 on the first side 14 of the gallery opposite the ground contacting side. The surrounding earth or sand presses appendage 20 to gallery 10 . Alternatively, the appendage 20 and the gallery 10 may be formed as one integrated structure or as separate discrete pieces. The first appendage 20 , in one embodiment, may be permanently connected to the septic gallery 10 by a connector. Alternatively, the first appendage 20 may be a modular member that is removably connected to the septic gallery 10 , for easier replacement thereof.
[0031] Preferably, the first appendage 20 has a number of shaped members to permit enhanced diffusion of the effluent into the ground. The first appendage 20 has any acceptable shape to permit diffusion into the ground from the gallery 10 in a rapid manner. Preferably, the first appendage 20 has a number of three-sided or triangular shaped members generally represented by reference numeral 22 with each having an apex 24 and a base portion 26 . Alternatively, the three-sided members could have a rounded tip instead of an apex. The triangular shaped members 22 collectively preferably form a baffle. Each member 22 is preferably a triangular member having two equal sides to form a substantially isosceles triangle. However, each member 22 can be a substantially equilateral triangle in which each angle includes approximately 60 degrees. Still further, each member 22 may be any three side polygonal member. Each member 22 is made from a material capable of withstanding the environment of the septic tank and gallery, such as, for example, a plastic resin material that would include resilient thermoplastic, polycarbonate, polyvinyl chloride (PVC), achrilonitride-butadiene-styrene (ABS), polyurethane, or acrylic resin.
[0032] In one non-limiting embodiment, the base portion 26 has a width of about one foot. A diffusion space 28 is formed between a first triangular member 30 and a second triangular 32 member of the baffle 22 . The diffusion space 28 is also triangular shaped and is preferably allowed to fill in with an acceptable ground contacting material such as sand, gravel, or any combination thereof, for diffusion. Likewise, a second diffusion space 28 is formed between the second triangular member 32 and a third triangular member 34 . This structure continues along the length of the septic gallery 10 .
[0033] Referring to FIG. 3 , there is shown a frontal view of the baffle with the diffusion spaces 28 . The baffle 22 has a number of apertures 36 thereon. The liquid effluent preferably traverses through the apertures 36 and then diffuses into the soil, sand, gravel, or ground. The baffle 22 preferably increases a surface area of the lateral side of the first appendage 20 of the septic gallery 10 to allow an increased amount of liquid effluent to escape from the first appendage, and traverse through the apertures and for diffusion to the sand, or ground.
[0034] Referring to FIG. 4 , there is shown a cross sectional view of the first appendage 20 along line 4 - 4 of FIG. 2 a . The base portion 26 of each triangular member of the baffle 22 has the apertures 36 in a configuration.
[0035] Preferably, the septic gallery 10 also has a second appendage 38 located on a second side 16 of the septic gallery 10 as shown in FIG. 1 . Additionally, the first and the second appendages 20 , 38 may form modular members to retrofit to an existing septic gallery 10 to increase a capacity thereof. Appendages 20 and 38 can be fabricated to accommodate existing and new galleries. Spaces between first and second appendages 20 and 38 , respectively, can be filled with mason sand or any such material that can accept the fluid. Referring to FIG. 2 b . gallery 10 could also have an additional third appendage 39 affixed to an end thereof to provide diffusion capability on three sides.
[0036] Referring to FIGS. 5 and 6 , a second embodiment of an appendage system 40 of the present invention, is shown. System 40 has two appendages 42 and 44 that are abutting each other. Each appendage 42 and 44 can have any number of triangular elements 46 to form a baffle 48 . Each baffle 48 has numerous apertures 54 to allow for passage of effluent into leaching field. Triangular elements 46 can have rounded tips 50 to further increase the surface area of diffusion of liquid into the soil 52 in the leaching field. Baffle 48 preferably increases a surface area of the lateral side of the first appendage 42 and 44 to allow an increased amount of liquid effluent to escape from the appendages and channel 56 , and traverse through the apertures and for diffusion to the sand, or ground.
[0037] It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the scope of the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances. | A modular appendage for a septic gallery has a first modular section for connection to a lateral side of the gallery with the first modular section having a number of apertures thereon. The first modular section has a first area. The lateral side of the septic gallery has a second area. The first area is greater than the second area for increased drainage and thus adds capacity to the gallery. |
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The invention relates to an inductive safety sensor for monitoring doors and gates and, more particularly, of elevators and/or lifts.
[0002] Two-channel inductive safety sensors are used for monitoring electrically and mechanically actuated revolving doors, sliding doors, rolling gates, flaps and hatches. Safety sensors ensure a secure monitoring of the open and closed position of doors and gates. Whereas commercially available inductive proximity switches can be actuated by means of virtually all metallic objects, the invention starts with the idea of further developing the proximity switch such that it emits a signal only by means of an especially constructed actuating element. It is an object of the invention to provide such an inductive proximity switch which has a constructively simple design.
[0003] The invention achieves this task by a safety sensor for monitoring the condition of doors and gates, particularly of elevators, that has a sensor device, which emits a signal only when sensing a target made of a defined material and switches from a first constant current to another constant current.
[0004] In contrast to the single-channel mechanical safety switches of the prior art, the safety sensors according to the invention, in particular, have the following advantages:
[0005] The sensor and the target operate in a contactless manner.
[0006] No mechanical wear occurs as a result of friction or burn-up at the contacts.
[0007] The sensor and the target can have a two-channel construction.
[0008] The sensor and the target can be mutually adapted. As a result of suitable measures, it can be ensured that a manipulation by foreign targets (non-ferrite) is excluded. A manipulation by magnets, jumpers and similar materials is, therefore, not possible. An internal signal evaluation takes place by way of interference-immune phase demodulation.
[0009] Protection Type IP67 can be implemented.
[0010] Several switch points can be securely monitored.
[0011] Changes of the distance between the sensor and the target by material fatigue are detected and are reported by the safety bus system to, for example, a control unit (preventive maintenance).
[0012] As a result of the linkage to a safety bus system, such as the applicant's (CAN OPEN SAFETY), the output signals are monitored in a redundant manner. The signal transmission to the bus node takes place by interference-immune current loops.
[0013] The fastening of the safety sensor can take place in a simple manner by thread bolts or internal threads.
[0014] According to a variant, a balancing of the operating data of the sensor (switching interval) can be implemented by an advantageously uncomplicated construction of the sensor coil.
[0015] According to an embodiment, the sensor reacts only to ferrite, for example, and, in the event of a detection, switches from one constant current to another constant current. This permits line monitoring because operating currents other than the defined currents indicate a cable interference.
[0016] For safety-related reasons, the sensor has a redundant construction; that is, each sensor housing contains two sensor systems which are mutually, completely separated, with the exception of the positive supply voltage. The two systems are identical, with the exception of the excitation frequency, which must differ slightly in order to prevent a mutual influencing. In the further course, only one system which therefore be discussed.
[0017] Other aspects of the present invention will become apparent from the following detailed description of the invention, when considered in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a block diagram of an inductive sensor according to the invention.
[0019] [0019]FIG. 2 is a schematic diagram of an oscillator for an inductive sensor according to the invention.
[0020] [0020]FIGS. 3 a and 3 b are diagrams which reflect the behavior of the impedance when various targets are used in the resonant proximity.
[0021] [0021]FIGS. 4 a and 4 b are diagrams which reflect the behavior of the phase angle when various targets are used in the resonant proximity.
[0022] [0022]FIG. 5 is an exploded view of a coil for the sensor according to the invention.
[0023] [0023]FIG. 6 is a schematic diagram of a zero crossing detector for a sensor according to the invention.
[0024] [0024]FIG. 7 a is a schematic diagram of a phase comparator for a sensor according to the invention.
[0025] [0025]FIG. 7 b is a truth table for a phase comparator.
[0026] [0026]FIG. 7 c is a graph of various phase diagrams.
[0027] [0027]FIG. 8 is a schematic diagram of a threshold value switch for a sensor according to the invention.
[0028] [0028]FIG. 9 is a schematic diagram of a voltage regulator for a sensor according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] First, a block diagram of the sensor S with the target T according to FIG. 1 will be described. A sensor S is arranged, for example, in a part of a door (not shown here), and the target—if it is to be monitored whether the door is open or closed—is arranged in a second part of the door which is movable relative to the first part. The construction of this sensor S is as follows.
[0030] An oscillator 1 generates a crystal-precise rectangular oscillation which is supplied to two additional modules. By way of a resistor R 5 , the signal drives an oscillating circuit 2 consisting of capacitor C 1 and indicator L 1 , which reacts to field changes by external objects. The signal from the oscillator 1 is also supplied to a phase comparator 3 which compares the phase of this signal with the phase of the oscillating circuit 2 .
[0031] Since the phase comparator 3 processes only digital signals, the sinusoidal oscillation of the LC circuit 2 is first fed to a zero crossing detector (comparator) 4 , which converts the sinusoidal oscillation into a square wave signal. The phase comparator 3 is designed such that it reacts only to negative phase angles. On the output of the phase comparator 3 , a PWM signal is generated whose pulse to separation ratio is a measurement of the change of the LC circuit.
[0032] The PWM signal is transformed by an integrator 5 into a direct voltage following the pulse/separation ratio and is fed to a threshold switch 6 . The threshold switch 6 is dimensioned such that only the change of the oscillating circuit which is caused by a special material (ferrite, for example) at a precisely defined interval from the sensor results in a switching of this switch. As a result of this operation, another current is added to the operating current by a connected resistor. Because the entire circuit is maintained at a constant voltage by a controller 7 , the voltage change before the threshold value switch 6 has therefore become a current change by a voltage to current transformation.
[0033] Additional figures illustrate, among others, additional details of the above-explained components of the sensor according to the invention. The individual circuit components will be explained in detail with reference to the additional figures.
[0034] [0034]FIG. 2 shows the detailed construction of the oscillator 1 . A precision oscillator 1 includes the following components: inverters IC 3 and IC 4 , frequency divider IC 5 , crystal X 1 , capacitors C 10 and C 11 and resistor R 6 . The combination with the frequency divider IC 5 is based on cost because, as a result, very inexpensive quartzes in the megahertz range can be used. Also, it offers a maximum of flexibility with respect to the frequency selection. A last reason is the absolute symmetry (pulse to separation ratio=1) of the square wave signal. Because the inputs of the frequency divider IC 5 , for example, an HC4040, are edge-triggered, the signal of gate or inverter IC 4 is buffered by the gate or inverter IC 3 .
[0035] According to FIG. 1, the rectangular oscillation is supplied by the resistor R 5 to the oscillation circuit 2 with the capacitors C 1 and the coil L 1 . The size of the resistor R 5 is in the order of the active resistance of the LC circuit at resonance.
[0036] The rough position of the excitation frequency depends on the size of the ferrite coil or the quality maximum (parameter of the ferrite coil independently of the resonance of the LC circuit) of this coil in order to achieve maximal sensitivity.
[0037] The position of the excitation frequency with respect to the resonance frequency decisively determines the behavior of the sensor with respect to the different materials (targets). In principle, several different detection behaviors can be achieved. In order to differentiate ferrite from other materials according to the demands, an excitation frequency must be selected at which, for all proximity distances, phase angles occur for just this material which are achieved in no other damping situation. The precise position of this point can be determined in that, above the frequency, impedances |Z| and phase angles Phi are measured in the case of different damping materials (ferrite, iron, nonferrous heavy metals) at different distances (0<s<sn).
[0038] [0038]FIGS. 3 a and 3 b show graphs for undamped or no target, ferrite, steel and aluminum, within the resonance of the coil, at various frequencies for the impedance in resonance and the phase angle in resonance. The impedance is maximum at a zero phase angle for no target, ferrite or steel. The maximum for aluminum at zero phase angle is at a substantially lower frequency off the chart of FIGS. 3 a and 3 b.
[0039] [0039]FIGS. 3 a and 3 b show the materials at a distance SN, and FIGS. 4 a and 4 b show the impedance and phase angle over the same frequency range at a distance of zero. The distance for 3 a is 6 millimeters. In FIG. 4 a, the undamped impedance or no target is not shown since it is off the chart and is the same as in FIG. 3 a. With respect to the ferrite, it is barely visible, but it has a constant 90 degree phase angle.
[0040] The adjoining phase comparator 3 is designed such that it can react only to negative phase angles which are caused by materials of a high magnetic permeability. The resonance frequency of the LC circuit 2 is usefully designed such that the excitation frequency is situated on the trailing edge of the resonance curve. Here, the sensor exhibits its highest sensitivity. Because of the very narrow bandwidth of the LC circuit, these two frequency values differ only by several Hertz. Consequently, the oscillating circuit 2 has to be balanced because the precise position of the resonance cannot be achieved with the usual component tolerances.
[0041] Furthermore, this results in the demand to balance the LC circuit 2 as such. This led to the construction of coils which can be balanced according to FIG. 5.
[0042] Deviating from the conventional coils for proximity switches, in this construction, the wound body 100 was designed to be slightly flatter, and the coils can be adjusted in its position by an adjusting mechanism. Only one of a pair of coils is shown in FIG. 5. The wound bodies 100 are inserted into a housing 102 . They have terminal pins 103 , and their height can be adjusted by the spring 104 and the screw 105 . The pot core 101 , the printed circuit board 106 as well as the wound body 100 are fixed at the housing by a fixing pin 107 .
[0043] As a result, inductivity changes of 10% can be achieved which are sufficient for balancing the tolerances to be expected in the winding and in the core material. The balancing will then take place as follows: The sensor is damped by a desired target at the nominal switching interval. The winding body 100 position is adjusted by screw 105 until the output signal changes (switches). After the adjusting, the complete sensor is sealed by epoxy resin in order to ensure a durable stability and resistance with respect to environmental influences.
[0044] According to the definition, the sensor should react only to a certain counterpart or target. The target is naturally accommodated in a separate housing and electronically consists only of two pot cores of the same construction, as those used in the sensor. Under defined installation conditions, the pot core halves are situated opposite one another in pairs. The line-of-force path of the LC circuit is now drastically reduced, which results in an increase of inductivity and therefore in a lowering of the resonance frequency.
[0045] In the following, the zero crossing detector (comparator) 4 will be described by means of FIG. 6. The base of the LC circuit from C 1 and L 1 is on half the operating voltage. This point is also situated on the non-inverting input of the comparator 4 (IC 6 ). This voltage is generated by the resistors R 1 , R 8 connected in series between ground and Vcc.
[0046] With respect to the phase comparator 3 , it should be noted that normally EXCLUSIVE-OR gates are used for the phase detection. The basic circuit application also uses this possibility which in this application would, however, be difficult, because it cannot differentiate between phase angles with respect to the sign.
[0047] If, instead of the EXCLUSIVE-OR gate, a D Flip-Flop in a suitable arrangement is used, as shown in FIG. 7 a, it is possible to completely extract the reaction to the undesired positive phase angles. Under the condition that the clock inputs and data inputs of the delay element are constantly on a high potential, the truth table can be shown in a simplified manner as follows:
Set Reset Q L L H L H H H L L H H No Change
[0048] The pulse diagrams (FIG. 7 c ) will now illustrate that only negative phase angles cause a change of the pulse separation ratio. For negative phase angles of ferrite, the pulse width is greater than that of the set signal, or, for metal, the pulse width of the output Q is the same as that of the set signal from the oscillator 1 . If the reset signal from the oscillator 1 has a 1:1 ratio of pulse to separation from the desired target, the pulse to separation ratio of the sensor is greater than the pulse to separation ratio of the oscillator 1 , as shown in the top FIG. 7 c. For metal, the pulse to separation ratio of the oscillator 1 is equal to that of the pulse to separation ratio of the sensor.
[0049] The PWM signal from phase comparator 3 is integrated by resistor R 2 and capacitor C 4 of integrator 5 . A time constant of approximately 1 ms is far above the period of the oscillator, but is still fast enough in order to achieve the required switching frequency. A direct voltage, which can vary between 2.5 V (corresponds to 0°) and 5 V (corresponds to −90°), is outputted which is proportional to the phase angle.
[0050] The following is achieved by the threshold value switch 6 of FIG. 8. By means of the two comparators IC 1 A and IC 1 B of the IC 1 , in addition to the operating current, is almost constant, two more currents are produced and added to the operating current. One current is produced when the nominal or designed target switching interval is reached. A second current is produced when a slightly lower diagnostic switching interval (yellow or warning state) is reached. This second switching interval can be used for detecting a mechanical wear of the system. The threshold of the nominal switching interval results directly from the phase position or the frequency spacing which is necessary for detecting the target or ferrite. It is defined by resistors R 7 and R 9 /R 10 for each comparator. Switching hystereses are generated by resistors R 4 or R 12 , respectively. The outputs appear across resistors R 3 and R 11 .
[0051] The voltage controller or regulator V_REG of FIG. 9 provides a constant operating voltage of the entire sensor circuit. The entire sensor circuit operates completely with relative levels and would therefore be able to operate within wide ranges without such a precise voltage control. However, with the constant voltage, constant currents are generated which are independent of the input voltage. Thus, by means of this circuit arrangement, a controllable current source is implemented.
[0052] Landing Entrance Door and Cage Door Monitoring
[0053] The safety door switches are installed, for example, on an elevator landing entrance door and an elevator cage door for monitoring the locking and the closed position.
[0054] In the normal operation, it should not be possible to open a landing entrance door when the elevator cage is not situated behind this door or is situated within the unlocking zone. The safety door switches are used, for example, in the case of power-operated landing entrance doors driven jointly with the elevator cage door.
[0055] The mounting of the safety door switch on the landing entrance door takes place according to EN81 7.7.3.1. In the case of this application, the mechanical locking element is monitored by the safety door switch. The effective locking of the closed landing entrance door must precede the movement of the elevator cage. The elevator cage should not start before the locking device has engaged at least 7 mm. The safety door switch and target S-T monitors the position of the locking device in a two-channel manner. The required redundancy is ensured by the sensor node. The sensor node reports the position of the locking device to the bus master.
[0056] Closed Position
[0057] The safety door switches are used for monitoring the closed position according to EN 81 7.7.4.1, 7.7.6.2 and 8.9.2.
[0058] According to EN 81, the gap between the door blades or leaves should not be larger than 10 mm. If the distance between the door blades is larger than 10 mm, the elevator system should be brought into a secure condition. Should the gap, for example, be larger than 7 mm, this condition is detected by the safety door switch and by way of the safety bus additional information is supplied for adjusting the door.
[0059] By linking the elevator cage signals and the landing entrance door signals, it can, for example, be detected that, when the landing entrance door is opened (by an emergency unlocking), the elevator cage door or the elevator cage is not behind the landing entrance door. As a result of this analysis, the elevator system is brought into a secure condition.
[0060] When a mechanic opens the landing entrance door at the lowest stop in order to carry out maintenance work in the elevator shaft pit, he should actuate the emergency brake switch for safety purposes. Should the landing entrance door close before the emergency brake switch was actuated, the elevator system can start when an external call is present.
[0061] By analyzing the landing entrance door signals and the cage door signals, it is detected that a manipulation is present (landing entrance door was open; cage door closed). When this combination is present, a starting of the elevator system is prevented by the analysis of the signals in the control.
[0062] As a result of this combination, it is also ensured that a surfing on the cage roof as a result of the manipulation of the door switches is not possible.
[0063] In the case of mechanical door switches, such a logical linking of signals is not possible.
[0064] Although the present invention has been described and illustrated in detail, it is to be clearly understood that this is done by way of illustration and example only and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims. | Inductive safety sensor for monitoring the condition of doors and gates, particularly of elevators, having a sensor device for sensing a target which is designed such that it emits a signal only when sensing a target made of a defined material and switches from a first constant current to another constant current when the target is sensed. |
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BACKGROUND OF THE INVENTION
It has long been a problem to prevent ice and snow from collecting in roof spouting or gutter and clogging the spouting or gutter and the drains under thawing and freezing conditions and various efforts have been made to alleviate the problem.
It has been proposed, for example, to provide eaves trough covers as described in Goetz U.S. Pat. No. 2,672,832, which require supporting spikes to be driven into the building wall below the eaves to carry tubular members, to which discs are soldered for mounting the eaves trough covers. Consequently, the supporting assembly cannot readily be removed in the spring.
A shield partially covering the spouting has also been proposed as in Cassen U.S. Pat. No. 836,012. In this case, however, the installation is permanent, requiring braces nailed to the shingles and to the wall and riveted to the shield. An effort to overcome the disadvantages of a permanent installation which would prevent the eaves trough from functioning normally is represented by a proposal to provide a hinged or pivoted tin cover as described in Schaffert U.S. Pat. No. 274,393 of 1883. In this case, however, it is impracticable to uncover the trough except when opened for cleaning. Thus the problem has existed nearly a century.
Roof gutter screens for keeping out leaves and such debris have also been proposed as in Couture U.S. Pat. No. 2,805,632 and Steel U.S. Pat. No. 2,734,467. The former involves the use of riveted clips joining the screen to the gutter and rather complicated clamping means, not readily disassembled.
SUMMARY OF THE INVENTION
In carrying out the invention in a preferred form thereof, snow and ice are prevented from collecting in roof spouting or gutter and clogging the outlets, as well as building up excessive weight, which may result in collapse or sagging of the roof gutter. This is accomplished by provision of improved protector strips arranged in alignment and provided with improved means for mounting and securing the protector strips in position covering the roof gutter and closing it from accumulation of ice and snow.
In a preferred embodiment of the invention, the protector strips are comprised of plastic sheeting for lightness and an opaque or dark plastic is used to absorb the sun's rays to absorb heat. Resultant, slight warming of snow as it falls promotes melting and tends to eliminate ice and snow. Roof gutter or spouting, as usually made, includes a lip which is utilized for engagement of fastening means fitting thereunder and secured to the protector strip to act as securing clamps. The plastic protector strips are mounted to conform to the roof edge with the upper edge of the protector strip fitting under the lowermost row of shingles.
DRAWINGS
A better understanding of the invention will be obtained from the following description considered in conjunction with the drawings in which:
FIG. 1 is fragmentary schematic elevation of a shingle-roofed building showing in cross-section the lower portion of a sloping roof, the adjacent roof spouting or eavestrough, a protector mounted in place and securing means therefor.
FIG. 2 is fragmentary side view of overlapping end-portions of adjacent aligned lengths of protector strip showing the manner of overlay.
FIG. 3 is a plan view of one of the protector strips showing the spacing of securing posts.
FIG. 4 is a plan view of a fastener strip for securing the protector strip.
FIG. 5 is a plan view of a modified protector strip having rainwater deflecting means for use above doorways.
FIG. 6 is a fragmentary plan view of the overlapping ends of protector strips mounted in place at the corner of a hip roof.
Like reference characters are utilized throughout the drawings to designate like parts.
DETAILED DESCRIPTION
In the embodiment of the invention illustrated in FIGS. 1 to 4 of the drawings, a protector strip 11, preferably composed of plastic sheeting, fiberglass or the like, is mounted in position to cover the entire open top of spouting or a roof gutter 12, which is secured to the wall 14 of a building 15. The protector strip 11 is secured to extend from under the lowermost row of shingles 19 and the building 15 to beyond the outside edge of the gutter 12 to form a snow shield. The lower edge 16 of the protector strip 11 may, if desired, be provided with reinforcement 17, but successful results have been obtained without such reinforcement.
In mounting the protector strip 11, its upper edge 18 is inserted under the lowermost row 19 in the shingles of the roof 13. It will be understood that in the usual roof construction only the upper ends of shingles are nailed down, for example, at the point 21.
The invention is not limited to the use of strips 11 of specified dimensions. However, for convenience in connection with spouting or roof gutter of conventional size, strips 11 may be used which are eight inches wide and four feet long and 1/16" to 1/8" thick. The last strip in an aligned row may be sawed off to reach the edge of the roof. Preferably, successive strips 11 in a row are overlaid to eliminate any opening between successive strips and prevent entry of snow into the spouting or roof gutter 12. As shown in FIG. 2 the overlay is accomplished by forming the strips 11 with offset end portions 22 to lap the adjacent and portion 23 of the next strip 11.
Conventional spouting or roof gutter 12 as ordinarily supplied, is formed with a lip 24. This is utilized for securing the strips 11 and preventing them from sliding or from being lifted in the wind. Fastener strips 25 which may also be composed of plastic are provided, which fit at one end 26 under the lip 24 and bear at the other end 27 against the lower surface of the protector strip 11.
Each fastener strip 25 has non-rotatably secured thereto, a threaded post 28 adapted to receive a mating element such as a wing nut 29. Preferably the strip 25 and post 28 are formed integrally, composed of plastic. A series of holes 31 are punched in the protector strips 11 to receive the posts 28 of the fastener strips 25. Moreover, especially when the protector strips are made of opaque or black or dark plastic, the posts 28 are formed with screwdriver slots 32 in the upper ends thereof, which are aligned with the length of the fastener strip. In this manner, a screwdriver may be employed to turn the fastener strip to the proper position transverse to the spouting lip 24.
In addition, the direction of the slot 32 may be observed to provide an indication to the installer when the fastener strip 25 is in the proper angular position notwithstanding the fact that the fastener 25 may not be visible under an opaque protector strip 11.
The protector strips 11 may readily be installed before the advent of snow and freezing weather. The fastener strips 25 are first assembled with the protector strips 11 by passing the posts 28 through the holes 31 and loosely applying the wing nuts 29. Starting at one end of the roof a protector strip 11 is placed in position over the spouting or gutter 12 with the upper edge 18 under the lower row of shingles 19. Before securing the strip 11, the fastener 25 is turned, if necessary, to clear the lip 24, then turned to a position transverse to the lip 24 by means of a screwdriver acting in the slot 32. Thereupon the wing nut 29 may be tightened to draw up the fastener strip 25.
The next strip 11 is positioned in a similar manner with the offset end 22 overlapping the flat end 23 of the previous protector strip already in place. If necessary, a remaining fraction of the last protector strip positioned at one side of the roof is sawed off to fit the roof. If a hip roof is involved having a corner 33 as illustrated in FIG. 6, a protector strip 34 is merely positioned in the manner previously described, transverse to an end strip 35 and with an offset end 36 overlaying the end of the strip 35.
If it is desired to prevent rainwater and melting snow from dripping down over a doorway or entrance stoop, this is accomplished by the positioning on the eaves over the doorway of a special protector strip such as illustrated in FIG. 5. In this case the strip 11 has deflector strips 37 and 38 formed on the strip 11 or secured thereto transverse to the plane of the strip 11. The deflectors 37 and 38 meet at an obtuse angle, as shown, and slope downwardly.
While the invention has been described as embodiment in concrete form and as operating in a specific manner in accordance with the provisions of the patent statutes, it should be understood that the invention is not limited thereto since various modifications thereof will occur to those skilled in the art without departing from the spirit of the invention. | A protector for roof spouting or eavestroughs is formed from lengths of dark, sun-heat-absorbing plastic, secured with one edge under the lowermost shingles of a roof and the other edge overhanging the lip of the spouting and secured thereto by fastener strips fitting under the spouting lip. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the U.S. National Phase of PCT/EP2010/055796 filed Apr. 29, 2010, which claims priority of European Patent Application 09163988.0 filed Jun. 29, 2009.
FIELD OF THE INVENTION
The present invention relates to a building assembly with a corner profile.
BACKGROUND OF THE INVENTION
In WO 00/26483 a method and a profile for connecting building blocks is described resulting in a wall in a building system. According to this method, two construction blocks are joined along an edge face of each block abutting each other by a profile having a web and two flanges on each side with a perpendicularly extending flap at the distal ends of these two flanges. These flaps are inserted into a groove in the construction blocks whereby the blocks are held together.
This method is advantageous since prefabricated construction blocks may be provided off site and transported to the building site together with other materials and may be assembled on the building site. However, if the rectangular frame is subjected to a twisting force, the gripping flanges may slide out of the slits in the insulation making the entire building system unstable.
In WO 2004/076764 a joining device for joining building boards is described wherein a sandwich-construction is provided by covering panels and an insulation layer enclosed thereby. According to the device a wood material body, bonded to at least one of the covering panels, can be inserted between the building boards. Further, the disclosed joining device may be used in connecting two building boards in a right angle using U-shaped bars, having a base element and two legs abutting the covering panels of the building boards.
This method is advantageous since connecting two building boards in a right angle using U-shaped bars may form a construction wherein weight is supported by both the U-shaped bars and the covering panels. However, in some situations it is not desirable to have weight supported by both the U-shaped bars and the covering panels and in addition, the joining device disclosed in WO 2004/076764 is not well protected against thermal and acoustic bridging.
SUMMARY OF THE INVENTION
By the present invention it is realised that a building structure may be provided utilising this connecting method, disclosed in WO 00/26483, for both internal as well as external building structures. Further, it is realised that corners of said building structure may be provided utilising U-shaped bars as disclosed in WO 2004/076764.
Accordingly, in one aspect of the invention, there is provided a building assembly for an insulation building system, such as a wall, roof, ceiling or floor structure, said building assembly having an internal side and an external side and said building assembly comprising first and second joining profiles provided with first and second joining profile contact sides, a corner profile provided with at least first and second corner body portions, said corner body portions comprising associated first and second corner profile contact sides, first insulation panels orientated in a first plane between the first joining profile and the corner profile, and second insulation panels orientated in a second plane between the second joining profile and the corner profile, said second plane being different from said first plane, wherein, respectively, the first and second joining profile contact sides and the associated first and second corner profile contact sides are adapted for receiving opposite contact sides of the first and second insulation panels, said opposite contact sides being provided with a shape matching the contact side surfaces, such that the first and second insulation panels are retained between the corner profile and the first and second joining profile, respectively, and wherein said matching shape comprises at least one corner profile contact side comprising a flange portion adapted for engagement with an associated groove portion provided by the insulation panel.
The corner profile may be used in corners formed by two walls meeting or where two or more walls intersect, such as two walls intersecting or meeting in a 3-way junction, such as a T intersection.
In a preferred embodiment, the building assembly comprises at least one frame profile, such as two frame profiles arranged opposite each other peripherally on the building structure, such as a top and a bottom profile; a plurality of joining profiles between said oppositely arranged frame profiles, said joining profiles having a first and second side surfaces which are abutted by the first and second contact sides, respectively, of adjacent insulating panels on each side of said joining profiles, and wherein the opposite profile contact sides of the insulation panels are provided with a shape matching the first and second profile side surfaces, respectively, such that the insulation panels are retained between two profiles.
The building assembly may be used in a self-supporting system for an internal or external wall, floor, ceiling or roof in a building structure. In a vertically arranged building structure according to the invention, it is found that by providing preformed insulation panels between the corner and joining profiles, the corner and joining profiles are prevented from buckling due to the compression load, since the insulation panels are not only retained at the first set of opposite sides abutting the adjacent corner and joining profiles but are also retained by the frame profiles at the other peripheral sides. By an assembly according to the invention, the form stability in the insulation panel, such as but not limited to mineral fibrous insulation material, is utilised to prevent displacement in the building structure.
By an assembly according to the invention, it is realized that a fast installation time on the building site may be achieved. Moreover, it is a cost-effective and simple solution with a high degree of flexibility, as the system according to the invention may be used for different building applications.
In a preferred embodiment, the corner profile is at least partly covered on the external side by at least one covering insulation portion. Hereby, thermal bridging and acoustic bridging will be reduced significantly. Moreover the covering insulation portion may protect the corner profile in case of fires or the like.
In one embodiment, the covering insulation portion comprises a flex zone, by which tight junctions, such as tight junctions between a covering insulation portion and an insulation panel, are achieved next to the corner profiles.
A flex zone/flexible zone is a portion of an insulation panel or a covering insulation portion made less rigid during the manufacture, e.g. by pressing rollers into the zone and moving them along the edge. This has the advantage that this zone is compressible and may be compressed in order to provide a tight junctions, such as junctions between insulation portions, or in order to fit between the rafters and beams of a building structure. Further, the need for different formats of panels is reduced by using a flexible zone comprising a flexible section along one side of the insulation panel or the covering insulation portion.
A flex zone may be provided by softening the respective side by compressing or stretching the edge portion during manufacture and thereby reducing the fibre bonding in the flexible section. Hereby, the fibre bondings are partly broken making the fibrous insulation element flexible without reducing the density and without significantly influencing the thermal insulation properties.
In another embodiment, the first and/or the second insulation panel may be integrally provided with at least one covering insulation portion. This is advantageous, because the number of insulation slabs is thereby reduced and as a result thermal bridging and acoustic bridging may be further reduced.
In one embodiment, the first and second corner profile contact sides comprise flange portions extending from an exterior side of a hollow body portion, and the hollow body portion may have a rectangular, triangular, polygonal or round cross sections. The hollow body portion may comprise insulation material, whereby the building assembly is further isolated.
In another embodiment, the first corner body portion is adapted for engagement with the second corner body portion, whereby an angle is formed between the first and second corner body portion. The angle formed is preferably equal to the angle of the corner of the corresponding building structure. In a related embodiment, the first corner body portion is adapted for pivotal engagement with the second corner body portion. This is an advantage since the configuration of the corner profile may thereby easily be adapted for corners having different angles. Further, in another related embodiment, the first corner body portion is hinged with the second corner body portion.
The insulation panels are preferably made of a mineral fibre wool material with a density between 30-150 kg/m 3 , preferably 50-125 kg/m 3 , more preferably 60-100 kg/m 3 . Mineral fibre wool panels, such as stone wool fibre panels, are advantageous since a non-combustible building system is thereby provided. However, it is realised that other materials could be used, such as polystyrene foam, polyisocyanurate resin, wood-fibre insulation or the like.
By the present invention, it is found that the insulation panels may have a total thickness ranging from 75 mm to 500 mm. Hereby also modern insulation requirements for domestic housings can be met by a building system according to the invention. In one embodiment, each insulation panel consists of one insulation slab. However, the invention may in one embodiment be used with an arrangement of double or multiple layers of insulation slabs, e.g. each insulation panel may comprise two or more insulation slabs provided in a stacked and/or layered configuration, whereby the total thickness of the insulation panel becomes roughly the sum of the thicknesses of the provided insulation slabs, which is suitable in particular for large thicknesses of insulation. Further, for large thicknesses of insulation, the corner and joining profile may comprise fixing means, like claws or clamps, that may be bent out from the body portion of the profiles to secure the different insulation layers.
Preferably, the side surfaces of the corner profiles and the corresponding contact surfaces on the insulation panels are shaped such that an insulation panel retaining is provided. In particular, the corner profiles are advantageously provided with retention profile members at both the first and second side of the partitioning assembly and preferably at least one of retention profile members of the corner profiles are adapted for subsequent mounting. In a particular embodiment, the corner profile comprises corner body portions which are generally I- or H-shaped. I- and H-shaped profiles are similar when rotated, although in practice there is distinguished between both due to the proportions of the flanges in relation to the body. By such suitable shape of the profile, the insulation panels are accommodated in the profile frame structure and prevented from being displaced, e.g. by a twist in the frame structure. By the invention it is realised that other suitable shapes may be used, such as C-shaped, U-shaped or Z-shaped profiles or combinations thereof. Moreover, it is also realised that profile assemblies may be provided e.g. for increased structural strength. Examples of such profile assemblies are shown in the FIGS. 13-19 .
The first and/or second joining profile contact sides and/or the first and/or second corner profile contact sides may comprise a portion bent in one piece or otherwise formed from sheet metal. For instance, at least one corner profile may comprise corner profile contact sides comprising flange portions, which are preferably made of sheet metal, such as galvanised steel, preferably with a thickness of 0.5-4 mm. The flange portions may be provided with a thickness which is at least 50% greater than the thickness of an associated body portion provided between them. Further, the first and/or second corner profile contact sides may extend from an exterior side of a hollow body portion. In addition, the flange portions may be formed by a double-layered sheet portion with a single-layered body portion therebetween. In one embodiment, at least one corner profile contact side extends substantially perpendicular from an exterior side of the corner body portion. Further, the flange portions may be bent or otherwise formed from sheet metal. In a preferred embodiment, the thickness of the sheet metal is approx. 0.75 mm. More preferably the sheet metal may have a thickness of 0.5-4 mm and yet more preferably 0.7-1.5 mm, in particular 0.6 mm, 0.8 mm, 1 mm or 1.2 mm.
The body portion of the corner profile may have additional holes, such as apertures, openings or slits. These may prove advantageous in reducing the thermal conductivity of the corner profiles.
According to an embodiment of the invention, the corner profiles are made of wood. Hereby, the thermal conductivity is reduced due to the low thermal conductivity of the material. In another embodiment, the corner profiles are made of reinforced plastic or steel.
Preferably, a first cover structure is provided on the first side of the assembly, and a second cover structure on said second side thereof.
In an embodiment, the second cover structure may be a climate shield cover, such as an insulated outer wall system. Hereby, a low energy solution having high thermal insulation properties is provided when using the system according to the invention for an external building structure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further explained in the following under reference to the accompanying drawings in which:
FIG. 1 is a schematic horizontal cross section view of a corner profile according to the invention and a covering insulation portion;
FIG. 2 is a schematic horizontal cross section view of a corner profile according to one embodiment.
FIG. 3 is a schematic horizontal cross section view of a building assembly with a corner profile;
FIG. 4 is a cross sectional view of a building assembly showing a first embodiment of a corner profile;
FIG. 5 is a cross sectional view of a building assembly showing a second embodiment of a corner profile;
FIG. 6 is a cross sectional view of a building assembly showing a third embodiment of a corner profile;
FIG. 7 is a cross sectional view of a building assembly showing a fourth embodiment of a corner profile;
FIG. 8 is a cross sectional view of a building assembly showing a fifth embodiment of a corner profile;
FIG. 9 is a cross sectional view of a building assembly showing a sixth embodiment of a corner profile;
FIG. 10 is a cross sectional view of a building assembly showing a seventh embodiment of a corner profile;
FIG. 11 is a cross sectional view of a building assembly showing an eighth embodiment of a corner profile;
FIG. 12 is a schematic horizontal cross section view of a building assembly showing a corner profile and two joining profiles with insulation panels between;
FIG. 13 is a schematic cross-section view of another embodiment of a corner profile according to the invention;
FIG. 14 is a cross-section view of a building assembly with a corner profile of FIG. 13 ;
FIG. 15 is a cross-section of a further embodiment of a building assembly according to the invention;
FIG. 16 is a cross-section of an embodiment of an external corner in a building assembly of the invention;
FIG. 17 is a cross-section of an embodiment of an inner corner in a building assembly of the invention;
FIG. 18 is a cross-section of an embodiment of a window or similar frame termination of a wall according to a building assembly of the invention; and
FIG. 19 is a cross-section of an embodiment of both an external corner and an inner corner in a building assembly of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-3 , there is shown embodiments of a corner profile 2 with a hollow rectangular body portion 3 having four corner profile contact sides comprising flange portions 4 extending perpendicular from the body portion 3 and matching associated groove portions provided by corresponding insulation panels 1 . Two or more of the flange portions 4 may be bent in one piece or otherwise formed from sheet metal and connected to the hollow body portion 3 by a suitable attachment, such as weldings, gluing or the like, cf. FIG. 2 . With reference to FIG. 3 , a corner profile 2 is shown with a covering insulation portion 5 , for reducing thermal and acoustic bridging, and building elements 6 which may be connected to the corner profile 2 . The building elements 6 may support a stiffening external cladding or bracing 7 . The insulation panels 1 may have a high wool density, preferably in the range of 60-100 kg/m 3 , and may support the corner profile 2 , by strong lateral forces, such that the corner profile 2 is less susceptible to bending.
With reference to FIGS. 4 , 5 , 6 , and 7 , building assemblies having corner profiles with corner profile contact sides comprising flange portions 4 and hollow body portions 3 , having rectangular or triangular shapes, are shown in four embodiments.
With reference to FIGS. 8 , 9 , 10 , and 11 , building assemblies having corner profiles comprising C- or U-profiles and I- or H-profiles are shown in four embodiments. With reference to FIG. 8 , the corner profile is formed by first and second corner body portions 8 , 9 connected in a right angle. The first corner body portion 8 comprises two associated first corner profile contact sides comprising flange portions 4 , such that the first corner body portion 8 has a C-shape. The second corner body portion 9 comprises four associated second corner profile contact sides comprising flange portions 4 , such that the second corner body portion 9 has an I-shape.
With reference to FIG. 9 , the corner profile is formed by first and second corner body portions 8 , 9 each comprising two associated corner profile contact sides comprising flange portions 4 , such that each of the two corner body portions has a C-shape. Alternatively, the corner profile may be formed as one corner body portion comprising four associated corner profile contact sides comprising flange portions 4 , such that the corner body portion has an I-shape.
With reference to FIGS. 10 and 11 , corner profiles are formed by first and second corner body portions 8 , 9 each comprising two associated corner profile contact sides comprising flange portions 4 , such that each of the two corner body portions has a C-shape. In an alternative embodiment, the corner body portions may have a U-shape. The corner body portion 8 is connected to the corner body portion 9 , such that an angle is formed between them. The connection may be formed by hinging, whereby a corner profile may easily be adapted for different corner angles.
With reference to FIG. 12 , there is shown another embodiment of a building assembly having two joining profiles 10 , a corner profile 2 with a hollow body portion 3 , and insulation panels 1 between the joining profiles 10 and the corner profile 2 . The insulation panels 1 may support the corner profile 2 and the joining profiles 10 , by strong lateral forces, such that the corner profile 2 and the joining profiles 10 are less susceptible to bending.
FIGS. 13 to 19 show various other embodiments of corner or termination profiles according to the invention. In FIG. 13 there is schematically shown an example of a corner profile 2 which is made up by two times six U- and/or C-shaped profiles making up a hollow profile section 3 on each corner side by two oppositely arranged U and/or C profiles with flanges 4 facing each other and each with a third U or C profile in a back to back arrangement with one of these profiles and comprising distal flange portions 4 penetrating into the insulation panels. FIG. 14 illustrates an example of an external corner building assembly with this corner profile assembly shown in FIG. 13 . If required, the two hollow profile sections 3 may be fixedly connected or hinged at their common point of contact as to form the corner profile 2 .
In FIG. 15 an example of an inner corner is shown, where the corner profile assembly is also made up by a number of U shaped profiles but in a different configuration than in FIG. 14 so that it is ensured that the profiles are arranged on the inside of the wall section in the building assembly, hereby preventing thermal bridging.
In FIG. 16 is shown a cross-section of an embodiment of an external corner in a building assembly of the invention similar to the corner assembly shown in FIG. 14 but with an extra insulation panel layer on the inside. As can easily be seen from this drawing the hollow profile section 3 may as an alternative also be build from one single rectangular profile instead of two oppositely arranged U or C profiles.
Similarly, in FIG. 17 there is shown a cross-section of an inner corner in a building assembly of the invention similar to the corner shown in FIG. 15 but with an additional internal layer of insulation thereon.
In FIG. 18 there is shown a cross-section of an embodiment where the wall section is provided with a building opening such as a window, door or similar frame termination 20 , since it is realised by the invention that the corner profile can also be used as a termination profile in the area of building openings providing suitable possibilities for the fixation of e.g. window and/or door frames 20 .
In FIG. 19 variants of the corner profile assembly of U- and/or C-shaped profiles are shown. Accordingly, both an external corner and an inner corner in a building assembly of the invention are shown where the corner is different than 90 degrees.
As illustrated in the FIGS. 13-19 it is found advantageous to provide the corner profile as a profile assembly made up by a plurality of U- and/or C-shaped profile sections which are sub-assembled to suit the actual corner in the building design. Said plurality of profile sections may be fixedly attached to each other by e.g. screws, rivets, welding, gluing or other suitable means or methods. An advantage by these embodiments is that due to structural considerations, the corner profiles can be modified to increase their strength.
The building assembly according to the invention may be used as a part of a insulating building system in a building structure where top and bottom frame profiles are joined by a plurality of joining profiles wherein insulation panels are retained between frame profiles, joining profiles and/or corner profiles and wherein corner and joining profiles have flange portions adapted for matching insulation panels with corresponding profile contact sides. When mounted, the insulation panels support the joining and corner profile by strong lateral forces, such that the corner profile and joining profile are less susceptible to bending.
Above, some embodiments currently considered advantageous are described. However, by the invention it is realised that other advantageous embodiments may be provided without departing from the scope of the invention as set forth in the accompanying claims. For instance, any of the structures shown in the embodiments above may be used with different orientations, vertically, horizontally or inclined, and may also be used for either internal or external partitioning building structures in a building. | The present invention concerns a building assembly comprising joining profiles provided with profile contact sides, a corner profile provided with corner profile contact sides, and insulation panels orientated in two planes wherein the joining profile contact sides and the corner profile contact sides are adapted for receiving opposite contact sides of the insulation panels, such that the insulation panels are retained between the corner profile and the joining profiles. |
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BACKGROUND
[0001] In downhole industries such as hydrocarbon recovery, and Carbon Dioxide sequestration, for example, formation treatments such as “fracing” and “acidizing” are well-known parts of downhole processes designed to increase permeability in or stimulate a formation. In general, a fracing process includes the employment of hyperbaric pressures applied from a surface location and directed through ports in a tubing string. The increased pressure while it does indeed result in formation fracture does not necessarily fracture the formation in optimum or even very controlled locations. Acidizing is similarly less than optimumly targeted. Since fractures and acidizing points can dramatically improve the efficiency of a downhole completion, the art will well receive alternate formation treatment systems and methods.
SUMMARY
[0002] A formation treatment system includes an annulus spanning member having one or more openings therein; a tubular having one or more ports therein in fluid communication with the one or more openings; and a sleeve capable of isolating or communicating the one or more ports with an ID of the tubular.
[0003] A method for effecting precision formation treatment including setting an annulus spanning member in a formation to bring one or more openings in the annulus spanning member proximate a formation wall; revealing one or more ports in a tubular member; communicating a tubular ID to the one or more openings in the annulus spanning member; applying fluid through the tubular ID; and directing the fluid to the formation through the one or more openings.
[0004] A method for effecting precision formation treatment including deploying a plug member to a formation treatment system includes an annulus spanning member having one or more openings therein; a tubular having one or more ports therein in fluid communication with the one or more openings; and a sleeve capable of isolating or communicating the one or more ports with an ID of the tubular; setting the annulus spanning member in a formation to bring one or more openings in the annulus spanning member proximate a formation wall by pressurizing a chamber defined by the annulus spanning member and the tubular; revealing one or more ports in the tubular member by moving the sleeve pursuant to pressure upon the plug on a seat in the sleeve; communicating a tubular ID to the one or more openings in the annulus spanning member; applying a fluid through the tubular ID; and directing the fluid to the formation through the one or more openings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Referring now to the drawings wherein like elements are numbered alike in the several Figures:
[0006] FIG. 1 is a cross sectional view of a first embodiment of a formation treatment system as disclosed herein in a run in position;
[0007] FIG. 2 is the formation treatment system of FIG. 1 in a formation treatment position;
[0008] FIG. 3 is another embodiment of a formation treatment system in a run in position;
[0009] FIG. 4 is the formation treatment system of FIG. 3 in a setting position;
[0010] FIG. 5 is the formation treatment system of FIG. 3 in a formation treatment position;
[0011] FIG. 6 is an enlarged schematic view of a portion of a annulus spanning member with a nozzle opening.
DETAILED DESCRIPTION
[0012] Referring to FIGS. 1 and 2 , a first embodiment of a formation treatment system 10 as disclosed herein is illustrated. The system 10 includes an annulus spanning member 12 (in a run-in or resting position) that may be a deformable element and may in some embodiments also act as a seal. The member 12 includes one or more openings 14 through which at least pressure is transmittable at selected times. It may however be desirable to plug the one or more holes at one or more times during the life cycle of the system. More information will be provided on this point later in this disclosure. In one embodiment the member 12 will include pips 16 that extend radially outwardly of a body 18 of the member 12 regardless of the position of the member 12 . Member 12 is positioned radially outwardly of a tubular 20 that includes one or more ports 22 . Further is a sleeve 24 acting as a valve in combination with the tubular 20 . The sleeve includes one or more passageways 26 extending radially therethrough. The sleeve 24 is translationally supported within the tubular 20 such that the one or more passageways 26 are alignable and misalignable with the one or more ports 22 .
[0013] In use, a first action is to cause the annulus spanning member 12 to span an annulus 28 between the system 10 and a formation 30 in which the system 10 is disposed. This can be done in a number of ways, some of which result in a compressive load being placed axially of the member 12 , resulting in its deformation radially outwardly as shown in FIG. 2 . Also notable in FIG. 2 is that the embodiment illustrated includes pips 16 and those pips 16 are embedded in the formation. This serves to segregate an annular space 32 in fluid connection with the one or more openings 14 , the one or more ports 22 and the one or more passageways 26 to provide a fluid conduit from the formation 30 to an inside dimension (“ID”) of the system 10 . The pips, then, assist in directing fluid pressure to the target area. The segregation of the area is also useful for purposes such as matrix acidizing since due to the confined nature of application, less acid would be needed to effect the desired result of formation stimulation, for example.
[0014] Those of skill in the art will recognize the system will be a part of a string 34 and the “ID” will be fluidically accessible to surface for pressurization. As illustrated in FIG. 2 , the sleeve 24 has already been shifted to align the passageways 26 with the ports 22 and the openings 14 . It is to be assumed that somewhere downhole of the system 10 the ID is plugged so that applied pressure from uphole of the system 10 finds an exit from the string only at or at least primarily at the openings 14 . Because of this condition, applied pressure or acid is directed to a very small portion of the formation and fracture initiation is very likely to occur there and acid treatment will certainly be applied directly there. Accordingly, through use of the system and method hereof, great precision in fracture initiation or acidizing is effected.
[0015] In another embodiment, referring to FIGS. 3-5 , a system 110 is illustrated that is similar to that of FIGS. 1 and 2 but is configured for use in situations where one or more fractures are planned or areas for acid treatment along a borehole are planned. More specifically, the system 110 employs a ball or other droppable or pumpable plug member 140 can be used to plug a particular system 110 to treat a certain target spot and then another plug 140 can be used for a next target spot and so on for as many systems 110 as are employed in a particular borehole.
[0016] The system 110 includes a member 112 similar to the member 12 of FIGS. 1 and 2 but that is actuated differently. The member 112 is configured to create a chamber 142 with tubing 120 upon which the member 112 may slide. The member 112 and tubing 120 are sealed to one another by o-rings 144 or equivalent. An actuation port 146 is located through the tubing 120 to allow pressure to be increased in the chamber 142 for actuation of the member 112 .
[0017] The system 110 further includes in one embodiment a one way movement configuration 148 , which in one embodiment may be a body lock ring or other ratcheting type configuration. The configuration 148 functions between the member 112 and tubing 120 to allow for the member 112 to move downhole relative to the tubing 120 (as illustrated but it is to be understood that this could be configured oppositely). The purpose and function of the configuration 148 is to accept movement imposed by the chamber 142 and then deny movement of the member 112 to a relaxed position after the force imposed by the chamber 148 is withdrawn.
[0018] System 110 further includes one or more openings 114 and one or more ports 122 . The ports 122 and openings 114 are initially fluidly isolated from the ID of the system 110 by a sleeve 150 . In one embodiment, the sleeve 150 includes an optional plug seat 152 receptive of a plug 140 as illustrated. The sleeve includes seals 154 that straddle the ports 122 during a nonoperational position of the system 110 . Finally the system 110 includes a release mechanism 156 which in some embodiments may be a shear arrangement such as one or more shear screws.
[0019] It is to be appreciated that the one or more openings 14 and 114 in annulus spanning members 12 and 112 can form a jet of fluid therethrough simply because the openings are relatively small in dimension. An even more effective jet can be formed if individual openings are configured through the thickness of the material of the annulus spanning member in a conical manner. The openings so configured would then act to some degree as nozzles. An enlarged schematic view of such is included as FIG. 6 . Such a jet of fluid will aid in the initiation of a fracture by disrupting a surface of the formation through fluid erosion.
[0020] During use of the system 110 , the system is run to a target location in a borehole and then a plug 140 is dropped or pumped to the location of the system 110 . Upon seating in the seat 152 , the plug 140 prevents fluid in the ID of the string from flowing past the seat 152 . Referring to FIGS. 3 and 4 , fluid pressure accordingly builds on an uphole side of the plug 140 (could be reversed for downhole if desired but must be upstream of the fluid flow). Increasing pressure acts upon chamber 142 to increase a dimension thereof that is longitudinal of the system 110 . Increasing this dimension of the chamber 142 causes the member 112 to buckle radially outwardly toward and ultimately, in some embodiments, into contact with the formation 30 . Referring to FIG. 5 , once a threshold pressure is reached at which it is expected the member 112 will be fully deployed, the release member 156 releases and the sleeve 150 moves downhole (downstream) thereby opening the one or more ports 122 to allow the application of pressure to reach the openings 114 and the formation 30 . Note that a shoulder 160 is provided to stop movement of the sleeve 150 after the one or more ports 122 are revealed. At this point the pressure can be increased to fracing pressure and the fracture will tend to initiate between pips 116 as in the embodiment of FIGS. 1 and 2 (or as noted above, acid can be applied to the formation between the pips. The system 110 can work with other systems 110 further upstream since after the treatment occurs as stated, flow is restored sufficiently to land another plug 140 at a more uphole sleeve 150 and the process as described again is repeated.
[0021] While one or more embodiments have been shown and described, 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 illustrations and not limitation. | A formation treatment system includes an annulus spanning member having one or more openings therein. A tubular having one or more ports therein in fluid communication with the one or more openings. A sleeve capable of isolating or communicating the one or more ports with an ID of the tubular. A method for effecting precision formation treatment is included. |
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation application of my prior copending application Ser. No. 683,650, filed May 6, 1976, now abandoned.
BACKGROUND OF THE INVENTION
In drilling wells, the passage of the drill string through highly porous gas formations causes considerable difficulty since the liquid, such as mud, in the well which can prevent a blowout can rapidly flow into the formation and the gas from the formation enters the well bore with limited prospects of immediately controlling the gas and continuing drilling into a lower oil formation.
SUMMARY
The present invention provides an improved method of any apparatus for drilling a well to minimize the danger of a gas blowout and allow control of the gas whenever a porous formation having gas is encountered by the drill string.
The method includes the steps of supporting a liner on the drill string during drilling which has external seals for sealing against the casting in the well bore. Further steps include supporting the liner, retrieving the drill string, running a cementing string, cementing the annulus around the liner and retrieving the cementing string.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the improved method and apparatus of the present invention are hereinafter set forth with reference to the drawings wherein:
FIG. 1 (including FIGS. 1A, 1B, 1C, 1D and 1E) is a sectional view of the improved well tool of the present invention being used in drilling a well bore with a liner supported on the string.
FIG. 2 (including FIGS. 2A, 2B, 2C and 2D) is a similar view illustrating the liner supported in the well bore with the drill string removed.
FIG. 3 (including FIGS. 3A, 3B, 3C and 3D) is another similar view illustrating the cementing of the liner.
FIG. 4 (including FIGS. 4A, 4B, 4C and 4D) is a partial sectional view of the drilling apparatus of the drill string.
FIG. 5 is a sectional view taken along line 5--5 in FIG. 4A to illustrate the driving connection between the telescoping components of the drilling apparatus.
FIG. 6 is another sectional view of the underreamer taken along line 6--6 in FIG. 4D.
FIG. 7 is still another sectional view of the underreamer reamer taken along line 7--7 in FIG. 4D.
In those drawings having multiple portions, the A portion of the drawing illustrates the upper section of the tool and subsequent portions of the drawing illustrate the progressively lower sections of the well tool.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The improved well tool of the present invention is shown in FIG. 1 in a well bore 10 lined with the casing 12 and drilling downwardly to extend the depth of the well bore 10 below the lower end of casing 12. The drilling apparatus on the lower end of the well tool, as shown in FIG. 1E, includes the drill bit 14, the first underreamer 16, the second underreamer 18 and the third underreamer 20. All of said underreamers are expansible so that they progressively expand the well bore diameter to its desired maximum diameter. The details of the underreamers are shown in FIG. 4 and are hereinafter described in relation thereto. Suitable means, such as mud motor 21, is provided to rotate the drilling apparatus.
Drill collars 22 are connected above the third underreamer 20. The stabilizer 24 is connected to the drill collars 22. The drill string 26 is connected above the drill collars 22 and the stabilizer 24 and extends to the drilling rig (not shown). The liner 28 is supported from the drill string 26 as best shown in FIG. 1A. The section 30 of the drill string 26 has an exterior surface 32 which tapers downward and outward to coact with the threaded collet 34 to support the liner 28 from the drill string 26 during the running of the apparatus into the well bore and during drilling. The seal 33 is positioned within the groove 35 in the exterior cylindrical portion of section 30 to provide a seal as hereinafter explained.
Release of the support between the drill string 26 and the liner may be accomplished by right-hand rotation of the drill string 26 which causes the threads on collet 34 to be unthreaded from the mating threads on the interior of liner 28. The connection between the drill string 26 and the liner 28 is made up by lowering the drill string through the liner 28. When the collet 34 engages the threads on the liner 28, the shoulder 36 on drill string 26 engages the upper end of collet 34 and forces collet 34 into mating engagement with the liner threads. With the liner 28 supported on the drill string 26, their running and the subsequent drilling may proceed. The use of the releasable connection allows the drill string, drill collars, mud motor, drill bit and underreamers to be pulled with the liner 28 remaining within the well bore 10 to replace the cutters. Thereafter, the drill string 26 and drilling apparatus may be run through the liner 28 and the collet 34 is forced into secured position so that the liner 28 may again be supported from the drill string 26 after it is released from its support in the well bore.
Since a prime function of the liner 28 is to assist in the controlling of a potential gas blowout, the upper exterior of the liner 28 includes the upward facing sealing cups 38 and the downward facing sealing cups 40. To support the sealing cups 38 and 40, the liner 28 includes the inner tubular member 42 which is threadedly connected to the upper liner mandrel 44 and is secured at its lower end to the liner collar 46 by the shear pin 48. The seal 33 engages the polished bore 45 of upper liner mandrel 44 to provide a seal there between. The downward facing shoulder 50 on the interior of collar 46 is in engagement with the enlargement 52 on the lower end of tubular member 42. The liner section 54 conects to the collar 46 and provides the upward facing shoulder 56 which limits the relative movement between the member 42 and the collar 46 when pin 48 is sheared as hereinafter explained. The sealing cups 38 and 40 each have a support ring 58 and spacer tubes 60 spacing them along the sealing support tube 62. The lower end of support tube 62 is secured to collar 46 and the upper end includes the flange 64 which retains the upper end of the upper spacer tube 60. The spring 66 surrounds tubular member 42 and engages between shoulder 68 on mandrel 44 and the upper surface of flange 64 to maintain the sealing cup assembly 70 in its position with the sealing cups 38 and 40 in sealing engagement with the interior of casing 12. The centralizer 72 is provided with the sealing cup assembly 70 to hold it in a central position within the casing 12 to assure proper sealing of the sealing cups 38 and 40.
As mentioned above, it is desired that the liner 28 be capable of supporting itself within the casing 12 so it includes the hanger assembly 74. Such hanger assembly 74 includes the body 76 having upper gripping elements 78 and lower gripping elements 80 supported on the body 76 and extending upward and downward therefrom, respectively. The drag springs 82 are supported on the body 76 and are adapted to engage the interior of the casing 12 so that when desired the liner 28 may move axially through the body 76.
The releasable connection between the body 76 and liner 28 is provided by the pin 84 secured in the liner 28 and extending into engagement in the H-shaped slot 86 in the body 76. This type of connecting means is commonly referred to as a pin and J-slot connection. As can be seen in FIG. 1C, one leg 88 of the slot is shorter than the other leg 90 and they have the central opening 91 connecting between the two legs 88 and 90. With the pin 84 in the short leg 88, the body 76 moves with liner 28. The limited length of leg 88 is not sufficient to allow either the upper expander cone 92 or the lower expander cone 94 to move under their respective gripping elements 78 and 80. When it is desired to set the hanger assembly 74, the liner 28 is moved axially one direction to assure the pin 84 is in one end of the short leg 88. Thereafter, the liner 28 is moved axially the distance of one half the length of leg 88 and then rotated to the left to position the pin 84 in the leg 90. Thereafter, the liner 28 is lowered to move the upper cone expander 92 under the upper gripping elements 78 to wedge them into gripping engagement with the interior of casing 12. In this position, the hanger assembly 74 supports the liner 28 within the casing 12 and the drill string 26 may be removed as shown in FIG. 2.
The lower expander cone 94 is provided to assure that a pressure kick which might remove the upper expander cone 92 from under the upper gripping elements 78 would move the lower expander cone 94 under the lower gripping elements 80 to hold the liner 28 in the casing 12 against the pressure which develops in the annulus between the liner 28 and the casing 12.
In operation, drilling and enlargement of the well bore 10 proceeds with the drill string 26 having the drill bit 14 and the three-stage underreamers thereon and the liner 28 supported thereon. This is shown in FIG. 1. When drilling has proceeded to the point where liner 28 is to be cemented, the liner is rotated to the left after centering pin 84 in the leg 88 of slot 86. This moves the pin 84 into the leg 90 to allow the drill string 26 and liner 28 to be lowered, moving expander cone 92 under the gripping elements 78 to set the hanger assembly 74. With the hanger assembly 74 set, rotation of drill string 26 to the right results in unthreading the collet 34 from the threads on the interior of mandrel 44. Thereafter, the drill string 26 is retrieved through the liner 28 which remains in the well bore 10 supported by the hanger assembly 74, This is shown in FIG. 2.
Cementing of the liner 28 in position within the casing 12 is begun by running the cementing string 96. The cementing string 96 includes the sleeve 98 having upper and lower external seals 100 and 102, and the mandrel 104. When run into liner 28, the seal 100 seals against the interior of the mandrel 44 immediately below the threads into which collet 34 engages and the seal 102 seals against the interior of tubular member 42 in the area of the enlargement 52. Between seals 100 and 102, there is provided an annular space 106 which is in communication with check valve 108 at its upper end and with port 110 at its lower end. When shear pin 48 is sheared as hereinafter explained, the relative movement of support tube 42 with respect to collar 46 brings port 110 through tube 42 into registry with port 112 through collar 46. With this communication open during cementing, the cement flowing upward in the annulus around the liner 28 passes inward through ports 110 and 112 upthrough annular space 106 and out through check valve 108 to bypass the sealing cup assembly 70. Check valve 108 is designed to permit flow from the annular space 106 to the annulus surrounding the liner 28 while preventing flow in the opposite direction.
The actuation of the liner 28 for cementing is accomplished by the engagement of ring 116 against the inner shoulder 116 on mandrel 44. When the cementing string 96 exerts a weight on mandrel 44, the pin 48 shears and the mandrel 44 and the tubular member 42 move downward until the lower end of member 42 engages on the shoulder 56 on the interior of liner section 54. Liner section 54 is held against axial movement by the hanger assembly 74. When member 42 bottoms on shoulder 56, the ports 110 and 112 are in registry and the flow of cement is commenced. Cement flows downwardly through cementing string 96, the interior of liner 28 filling the well bore below liner 28. The cement then flows upwardly through the annulus surrounding liner 28, then through ports 110 and 112, the annular space 106 and out check valve 108. In cementing, the plug 120 is pumped down following the cement and seats in the lower end of the liner 28.
The bypass flow of cement around the sealing cup assembly 70 assures that the liner is not lifted sufficiently to unset the hanger assembly 74.
The drilling apparatus including the drill bit 14 and the three-stage underreamers 16, 18, and 20 are disclosed in greater detail in FIGS. 4, 5, 6 and 7. In FIGS. 4A and 4B, the upper end of the drilling apparatus is shown including the connection to the mud motor 21 and the telescoping joint 122. The joint 122 includes the sub 124, the outer tubular member 126, the inner mandrel 128 and the sleeve 130. The sleeve 130 is slidable axially relative to and in the space between tubular member 126 and mandrel 128. As shown in FIG. 5, the sleeve 130 is provided with splines 132 which engage within the grooves 134 in outer tubular member 126. Each of the splines 132 is protected by the wear inserts 136 positioned on both sides of the splines 132, as shown.
The body 138 of the underreamers is connected to the lower end of sleeve 130 and inner mandrel 128 extends downwardly through the interior of body 138. Each of the underreamers 16, 18 and 20 have substantially the same structure except that they extend outward to varying diameters so that the well bore is progressively enlarged by the underreamers.
Each of the underreamers, as best seen from FIG. 4D, includes an arm 140 which is pivotally mounted to the body 138 by the pin 142 and includes a roller cutter 144 mounted on the outer end of the arm 140. The inner surface of arm 140 has a cam surface 146 which coacts with block 148 attached in the offset portion 150 of the inner mandrel 128. The screw 152 secures the block 148 in position. The lower end of the offset portion 150 includes the port 154 through which drilling fluid is directed into the space around body 138 to assist in the removal of the formation material removed by the underreamer. If desired, the port 154 includes a hardened insert to minimize wear of the drilling fluid passing therethrough.
The lower end of inner mandrel 128 extends downward through seal 156 which is mounted in body 138 and seals between the exterior of mandrel 128 and the interior of body 138.
The drilling apparatus is lowered through the casing 12 with the liner 28 suspended from the drill string 26. The drilling apparatus with the underreamers retracted easily passes through the liner 28. In running, the underreamers 16, 18 and 20 are withdrawn within the body recesses. When in drilling position, the liner 28 terminates above the upper underreamer 20. When the drill bit 14 sets on the bottom of the well bore 10, the weight of the string above the drilling assembly causes the inner mandrel 128 to move downward with respect to sleeve 130. This movement forces the blocks 148 downward against the cam surfaces 146 wedging the lower ends of the arms 140 outward to move the cutter 144 to its underreaming position. Circulation of drilling fluid through the motor 21 rotates the drilling apparatus to drill additional well bore. | The method and apparatus for drilling a well bore and setting a liner therein in which the drill string with a bit and underreamers thereon also includes a liner supported thereon which has a gripping assembly with two sets of gripping elements and a pair of external tapers on the liner each of which coacts with one of the sets of gripping elements, one of which wedges one set of gripping elements into set position responsive to the liner weight and the other of which is spaced from said one a sufficient distance that said one is removed from wedging engagement when said other wedges the other set of gripping elements into set position responsive to upward forces on said liner, and a normally closed bypass around the sealing means on the liner which may be opened responsive to manipulation of the liner to allow cementing of the liner in position within the well bore and the steps of lowering the liner on the drill string as the well bore is being formed, setting the liner, gripping assembly and sealing means, opening the bypass around the liner sealing means and cementing the lever in the well bore. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an expandable sand screen. More particularly the present invention relates to an expandable sand screen that permits fracturing of a hydrocarbon bearing formation after the well screen is expanded in a wellbore.
2. Description of Related Art
Hydrocarbon wells are typically formed with a central wellbore that is supported by steel casing. The casing lines the borehole in the earth and the annular area created between the casing and the borehole is filled with cement to further support and form the wellbore.
While some wells are produced by simply perforating the casing of the central wellbore and collecting the hydrocarbons, wells routinely include portions of wellbore that are left open or unlined with casing. Because they are left open, hydrocarbons in an adjacent formation migrate into these wellbores where they are affected along a perforated tubular or sand screen having apertures in its wall and some kind of filtering material to prevent sand and other particles from entering. The sand screen is attached to production tubing at an upper end and the hydrocarbons travel to the surface of the well via the tubing. In this specification “open” and “horizontal” wellbore refers to an unlined bore hole or wellbore.
Because open wellbores have no support provided along their walls, and because the formations accessed by these wellbores have a tendency to produce sand and particulate matter in quantities that hamper production along a sand screen, open wellbores are often treated by fracturing and packing. Fracturing a wellbore or formation means subjecting the walls of the wellbore and the formation to high pressure solids and/or fluids that are intended to penetrate the formation and stimulate its production by increasing and enlarging the fluid paths towards the wellbore. Packing a wellbore refers to a slurry of sand that is injected into an annular area between the sand screen and the walls of the wellbore to support the wellbore and provide additional filtering to the hydrocarbons. Fracturing and packing can be performed simultaneously. A cross-over tool is typically utilized to direct the fracturing/packing material towards the annulus of the open wellbore while returning fluid is circulated up the interior of the screen and returns to the surface of the well in an annular area of the central wellbore.
There are problems associated with the packing of an open wellbore. One such problem relates to sand bridges or obstructions which form in the annulus between the sand screen and the wall of the wellbore. These sand bridges can form anywhere along the wellbore and they prevent the flow of injected material as it travels along the annulus. The result is an incomplete fracturing/packing job that leaves some portion of the sand screen exposed to particulate matter and in some cases, high velocity particles that can damage the screen.
Today there exists a sand screen that can be expanded in the wellbore. This expandable sand screen “ESS” consists of a perforated base pipe, woven filtering material and a protective, perforated outer shroud. Both the base pipe and the outer shroud are expandable and the woven filter is typically arranged over the base pipe in sheets that partially cover one another and slide across one another as the ESS is expanded. The foregoing arrangement of expandable sand screen is known in the art and is described in U.S. Pat. No. 5,901,789 which is incorporated by reference herein in its entirety. Expandable sand screen is expanded by a cone-shaped object urged along its inner bore or by an expander tool having radially outward extending rollers that are fluid powered from a tubular string. Using expander means like these, the ESS is subjected to outwardly radial forces that urge the walls of the ESS past their elastic limit, thereby increasing the inner and outer diameter of the ESS.
The biggest advantage to the use of expandable sand screen in an open wellbore like the one described herein is that once expanded, the annular area between the screen and the wellbore is mostly eliminated and with it the need for a gravel pack. Typically, the ESS is expanded to a point where its outer wall places a stress on the wall of the wellbore, thereby providing support to the walls of the wellbore to prevent dislocation of particles.
While the ESS removes the need for packing the wellbore with sand, it does not eliminate the need to fracture the formation in order to improve production. Fracturing prior to expanding the screen in the wellbore is not realistic because the particulate matter, like the sand used in the fracturing will remain in the annulus and hamper uniform expansion of the screen. Fracturing after expansion of the expandable sand screen is not possible because, as explained herein, the annular path for the fracturing material has been eliminated.
There is a need therefore for an expandable sand screen for use in a wellbore to be fractured. There is a further need for an expandable sand screen that can be expanded prior to the fracturing of the wellbore surrounding the screen. There is yet a further need for an expandable sand screen that forms a path or conduit for the flow of fracturing material along its outer surface after it has been expanded.
SUMMARY OF THE INVENTION
The present invention provides apparatus and methods for expanding an expandable sand screen in an open wellbore and then fracturing the wellbore. In one aspect of the invention, an expandable sand screen includes a perforated inner pipe and outer shroud. The outer shroud includes a plurality of longitudinal channels that retain their general shape after the expandable sand screen is expanded. In the expanded state, the channels provide a fluid conduit along an area between the screen and the wall of the wellbore. In a subsequent fracturing operation, a slurry travels along the conduits permitting communication of the slurry with hydrocarbon bearing formations to effectively fracture the formation. In another aspect, a method of fracturing includes expanding an expandable well screen in a wellbore whereby the expanded screen provides longitudinal channels in communication with the hydrocarbon bearing formation. Thereafter, fracturing slurry is injected and travels along the channels, thereby exposing the slurry to the formation. In yet another aspect of the invention, joints of the ESS are assembled together into sections and the channels on the outer surface of each joint are aligned to ensure that the longitudinal channels are aligned throughout the ESS section.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a section view showing an open, horizontal wellbore with an expandable sand screen disposed therein.
FIG. 2 is an exploded view of an expander tool.
FIG. 3 is a section view of the expandable sand screen in an unexpanded state.
FIG. 4 is a section view of the wellbore with the screen partially expanded.
FIG. 5 is a section view of the expandable sand screen in an expanded state.
FIG. 6 is a section view of the wellbore being treated with material injected from the surface of the well through a cross-over tool.
FIG. 7 is a section view of the wellbore tied back to the surface of the wall with a production tubing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a section view of a wellbore 200 with an expandable sand screen 210 according to the present invention disposed therein. The wellbore includes a central wellbore which is lined with casing 215 . The annular area between the casing and the earth is filled with cement 220 as is typical in well completion. Extending from the central wellbore is an open, horizontal wellbore 225 . A formation 226 is shown adjacent the wellbore 225 . Disposed in the open wellbore is an expandable sand screen (ESS) 210 . As illustrated in FIG. 1, the ESS 210 is run into the wellbore on a tubular run-in string 230 . Disposed at the end of the run-in string is an expander tool 100 . In the embodiment shown, the expander tool 100 is initially fixed to the expandable sand screen 210 with a temporary connection 235 like a shearable connection or some other temporary mechanical means. Typically, the ESS 210 is located at the lower end of a liner 218 which is run into the well and hung from the lower portion of the casing 215 by some conventional slip means. Below the liner top, the outer diameter of the liner 218 is reduced to a diameter essentially equal to the diameter of the ESS.
FIG. 2 is an exploded view of an exemplary expansion tool 100 . The expansion tool 100 has a body 102 which is hollow and generally tubular with connectors 104 and 106 for connection to other components (not shown) of a downhole assembly. The connectors 104 and 106 are of a reduced diameter compared to the outside diameter of the longitudinally central body part of the tool 100 . The central body part has three recesses 114 to hold a respective roller 116 . Each of the recesses 114 has parallel sides and extends radially from a radially perforated tubular core (not shown) of the tool 100 . Each of the mutually identical rollers 116 is somewhat cylindrical and barreled. Each of the rollers 116 is mounted by means of an axle 118 at each end of the respective roller and the axles are mounted in slidable pistons 120 . The rollers are arranged for rotation about a respective rotational axis which is parallel to the longitudinal axis of the tool 100 and radially offset therefrom at 120-degree mutual circumferential separations around the central body. The axles 118 are formed as integral end members of the rollers and the pistons 120 are radially slidable, one piston 120 being slidably sealed within each radially extended recess 114 . The inner end of each piston 120 is exposed to the pressure of fluid within the hollow core of the tool 100 by way of the radial perforations in the tubular core. In this manner, pressurized fluid provided from the surface of the well, via a tubular, can actuate the pistons 120 and cause them to extend outward whereby the rollers contact the inner wall of a tubular to be expanded.
FIG. 3 is a section view of the expandable sand screen 210 of the present invention in a wellbore 200 prior to expansion. The ESS includes a base pipe 240 having perforation 242 formed therein, woven filter material 245 and an outer shroud 250 having perforations 255 formed therein and also having outwardly formed longitudinal channels 260 formed thereupon. The channels 260 are formed by bending the surface of the outer shroud 250 between perforations 255 to create two sides 265 , 270 and a bottom portion 275 . In the preferred embodiment illustrated in FIG. 3, the bottom portion of each channel is welded or otherwise attached to the base pipe in at least one location 280 . The woven filter material 245 is held between the bottom 275 of the channel 260 and the base pipe 240 . The outer shroud 250 may be formed by any well-known metal working means including pressing and bending. A longitudinal seam (not shown) is formed by the cylindrical shroud after it is wrapped around the base pipe and filter material and its free ends are connected.
FIG. 4 is a section view illustrating the wellbore 200 and the ESS 210 partially expanded therein. As shown in the figure, the expansion tool 100 has been activated with its rollers 116 contacting the inner wall of base pipe 240 and applying an outward radial force thereto. Typically, the temporary connection 235 between the expander tool 100 and the ESS 210 is disengaged as the expander tool is actuated and thereafter, the expander tool moves independently of the expandable sand screen 210 . By using the run-in string 230 to move the expander tool axially and rotationally within the ESS, the ESS 210 can be circumferentially expanded into or nearly into contact with the wellbore therearound.
FIG. 5 is a section view illustrating the expandable sand screen 210 of the present invention after it has been expanded in a wellbore 200 . Radial force applied to the inner wall of the base pipe 240 has forced the pipe past its elastic limits and also expanded the diameter of the base pipe perforations 242 . Also expanded is the shroud 250 with its formed channels 260 . As shown in the figure, the shroud is expanded to a point wherein the upper edges of the sides 265 , 270 of the channel 260 are either in contact or almost in contact with the wellbore 200 . The decision relating to contact between the expanded sand screen in a wellbore depends upon the needs of the user. Contact between the screen 210 and the wellbore 200 can place a slight stress on the wellbore and reduce the risk of particulate matter entering the wellbore. On the other hand, leaving a slight space between the edges of the channel and the wellbore leaves a greater fluid path for fracturing material to reach areas of the wellbore between the channels.
FIG. 6 is a section view of the wellbore 200 illustrating an apparatus used to fracture the well after the ESS 210 has been expanded. As illustrated, a string of tubulars 300 is inserted into the top of the liner. An assembly at the lower end of the string of tubulars is typical of one used in fracturing operations and includes a cross-over tool 310 made up of an exit port 315 (not shown) permitting fluids to exit the tubular and a first and second packer 320 , 325 disposed on either side of the exiting port to isolate the port from the annular area between the liner and the run-in string. A sliding sleeve (not shown) on the liner permits fluid communication between the interior of the string 300 and the exterior of the liner. As illustrated by arrows 330 , a slurry of fracturing and/or packing material is injected from the surface of the well down the tubular string 300 . At some predetermined location below the top of the liner 218 , the cross-over tool 310 permits the material to flow to an annular area outside of the liner and the expanded sand screen. In this manner, the material flows to the outer surface of the expanded sand screen and longitudinally flows along the channels 260 formed on the exterior of the ESS 210 . The particulate material is left within the annular area and within fractures extending outwardly from the wellbore and fluid (illustrated by arrows 335 ) is returned to the surface of the well in the interior of the string and subsequently, via the annular area between the string 300 and the casing 215 of the central wellbore. In use, a slurry of sand and gel or other fracturing material at an elevated pressure is carried into the central wellbore 200 in a tubular. Using a cross-over tool or other apparatus, the slurry is directed from the tubular to the outer surface of the expanded sand screen where it travels from a heel 226 of the wellbore 225 towards the toe 227 thereof. In this manner, the walls of the wellbore 225 and the formation 226 therearound are exposed to the high pressure slurry via the channels 260 formed on the outer surface of the shroud 250 . Return fluid is carried back towards the surface of the well in the interior of the base pipe 240 .
One method of utilizing the expandable sand screen of the invention is as follows: A section of expandable sand screen 210 is formed at the surface of a well to an appropriate length by threading joints of screen together. The channels 260 formed in the shroud 250 of each subsequent joint are aligned as the joints are assembled together. The unexpanded section of ESS is then run into the wellbore 200 on a tubular string having an expander tool 100 disposed at the end thereof. The expander tool, or alternatively the run-in string adjacent the tool, is temporarily connected to the expandable sand screen 210 with a temporary connection 235 . As the ESS 210 reaches its desired location in the wellbore 200 , the expander tool 100 is actuated and the ESS is expanded in at least two points about is circumference. In this manner, the ESS is anchored in the wellbore. By providing a pulling, pushing or rotational movement to the string and expander tool, the temporary connection 235 between the tool 100 and the sand screen 210 is disengaged an d the activated expander tool can move independently of the screen 210 .
By moving the actuated tool 100 within the sand screen, both rotationally and axially, the screen is expanded to take on an appearance illustrated in FIGS. 5 and 7. With the screen 210 in its expanded position within the wellbore 200 , the expansion tool 100 and run-in string are removed and a tubular having a cross-over tool at the end thereof is run into the wellbore. The cross-over tool permits fluid communication between the tubular and the channels 260 on the outer surface of the expanded screen 210 . As pressurized slurry travels down the tubular, it is directed by the cross-over tool to the longitudinal channels and is placed in communication with the wellbore.
FIG. 7 is a section view of a central 200 and a lateral 225 wellbore after the ESS 210 has been expanded into position and the well is producing hydrocarbons. A string of tubulars 400 like a string of production tubing has been inserted into the upper portion of the liner 218 and sealed therein with a packer 410 . This sealing and arrangement between the liner and the production tubing ties the liner back to the surface of the well. Hydrocarbons illustrated as arrows 415 migrate into the expanded sand screen 210 where they are collected in the interior of the screen and the liner. The hydrocarbons then move directly towards the surface of the well in the conduit provided by production tubing string 400 .
While the liner 218 and ESS 210 are shown run into the wellbore on a run in string of tubulars, it will be understood that the apparatus of the invention can be transported into the wellbore using any number of means including coiled tubing. For example, using coiled tubing and a mud motor disposed thereupon, the apparatus can be utilized with rotation provided by the mud motor. A fluid powered tractor can be used to provide axial movement of the apparatus into the lateral wellbore 225 . These variations are within the scope of the invention.
As the foregoing demonstrates, the present invention provides an apparatus and methods to utilize expandable sand screen in an open wellbore in a way that minimizes the need to fill an annular area around the screen with gravel. Additionally, the invention provides for an effective fracturing of an open wellbore without the risk of sand bridges being formed between the screen and the walls of the wellbore.
The apparatus described herein is a sand screen intended to filter hydrocarbons. However, the structure described relating to the grooves could be utilized with any expandable wellbore component leaving a fluid path along the outer surface thereof after expansion. Other uses include water wells and injection wells.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | The present invention provides apparatus and methods for expanding an expandable sand screen in the wellbore and then fracturing the wellbore. In one aspect of the invention, an expandable sand screen includes a perforated inner pipe and outer shroud. The outer shroud includes a plurality of longitudinal channels that retain their general shape after the expandable sand screen is expanded. In the expanded state, the channels provide a fluid conduit along an area between the screen and the wall of the wellbore. In a subsequent fracturing operation, slurry travels along the conduits permitting communication of the fracturing slurry with hydrocarbon bearing formations. |
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TECHNICAL FIELD
[0001] The technical field which deals with the present invention is about prefabricated buildings, specifically the ones referred to modular type constructions.
STATE OF THE ART
[0002] The following techniques described in this document differ from the conventional prefabricated construction techniques, where the conventional prefabricated constructions do not manufacture walls, instead, they are manufactured (in situ) from (prefabricated) simple panels, which require first completing the exterior structure, then the power current installation and the placement of doors and windows, resulting into additional operations and costs, considering that these constructions also are subject to individual client's designs, translating into individual initiation and operation costs, while this alternative system, is based on predetermined modular house, which represents the core invention, since these models are created on the basis of three (3) related inventions, which results in simplifying dozens of processes or maybe more, of a typical construction. In the manufacture of these three (3) interrelated basic inventions with which, the predetermined models hereunder presented, were finally developed. These three (3) basic inventions possess unique claim characteristics, which achieve an unequaled simplicity in the construction of prefabricated houses, result in savings in operation costs resulting in a very low cost and price. This document describes a “UNIT OF INVENTION”.
“UNIT OF INVENTION” DESCRIPTION
[0003] The following invention consists in the integral manufacture of various predetermined house models in bases of WALLS, CONNECTORS and ROOF COMPONENTS completely equal one to the other, in order to optimize the process.
[0004] This means, that with three (3) types of sub-products, we can build a house. This does not imply that in some punctual cases, some unnecessary details may be omitted, which simplify even more the manufacturing process of these three (3) basic elements; inventions in their own right.
[0005] This system achieves two important things: First the setup of a very simple factory, since only three (3) elements need to be manufactured, making the initial capital investment much smaller than what it would normally be, and second optimizing a house construction process and cost operation into a house manufacturing process and cost operation. (very important), meaning that with this integral system, the construction processes are replaced with manufacturing processes, optimizing in this way the production capacity, as well as optimizing the production system, and optimizing the products due to the possibility of specialization in the production process. It's worth mentioning that if on one side we have the benefits of serial production just described, on the other we are limited to our plans and to the predetermined requirements of our system of production and manufacture. We want to emphasize that this system finally results in making houses, but for this end, we need to do three (3) semi-products with specific details which are explained hereunder, which are universal and unique in a construction, and each one does not function without the other components, reason why it is called an integral system. It is very important to highlight in our application that our system is a group of inventions related to each other, denominated “UNIT OF INVENTION”.
[0006] *Adding another virtue to the invention, we are achieving a new standard of quality of life for the low income families thanks to the reduction in operating costs achieved with the Units of Invention.
[0007] The three System Elements are three related inventions which are components that make up a principal invention, which are the models shown hereunder.
a) The Universal Wall:
[0009] The walls have the distinction to possess all exterior and interior finishing detail, as well as door, window, drain and water circuits, outlet and inlet switches. These walls contain a unique power current circuit in the interior which allows a coincidence with the other walls, as well as when referred to the plumbing circuit.
[0010] This wall is a standard piece, which is made so that this same unit can be used for the assembly of various models of modular homes, that is universal standard walls, which can be connected wall with wall, through a universal connector, and always after connecting, it permits the correct functioning of the services (electrical and plumbing) once the installation of the houses is complete. With respect to this last point, this standard universal prefabricated wall contains in a fixed and predetermined position, spaces, openings, electrical and plumbing circuit, as well as switches, sockets, amongst other electrical devices, as well as predetermined positions for doors and windows.
[0011] The wall may function with various construction materials, such as the concrete, wood, melamine, plastic, metal amongst others. The universal walls rest in channels placed in the floor which seal and waterproof all of the house perimeter and interior areas, so that once connected these walls form the desired modules according to the predetermined model plans.
[0012] All universal walls have in common that the exhibit a 2.40 m high, 3 meters high and 10 cm thickness; and all exhibit the same power, water and drain circuit, ready to be used, or simply circumvent it if not required. The simplification of the dimension and circuits positions is a factor for the lowering the manufacturing operations, for being only one the wall to manufacture and in this way optimize the production speed to the maximum, since it is a universal wall which will be manufactured in series.
b) Universal Wall Connector:
[0014] It is constituted by a square tube where each one of the sides have two guides which serve to fasten the “C” channel which finally will hold the wall, and a cover which covers the unused sides. In the top inner part of the connector, are the power current connector “female-ended” which split on all sides and will plug in with the wall connectors “male-ended”.
[0015] In the inferior part of the Universal Connector, is a free pass which gives play to the flexible tubes (not rigid) that come out of the wall, for the water connection which is always straight in our designs.
[0016] The inner part of the Universal Connector is filled with thermal acoustic material, to insulate the cold/water pass and sound through them.
[0017] Finally the cover guides for the sides in disuse, which also function as decorative pieces.
[0018] This Universal Connector was created to standardized spaces composed by the Universal Walls by a facilitating their homogeneous placement, and the pass of power, water and other services through them.
[0019] In the sides of the Universal Walls are the Universal Connectors, which, as their name indicates serve to connect one Universal Wall with another, at the same time serve to connect the circuits (cables and ducts), in such a way that, when the placement is finished, all circuits of water and drain and light and power switch will be ready to use.
[0020] Within our Universal Connector, we have an electric power pass, permitting the necessary current flow to each wall at the moment of installation.
[0021] We also have, covers for the sides of the Universal Connector that are not in use, or which are not necessary for the moment until the next house remodeling.
[0022] Once connected the light and water and their respective plugs and jacks, we use bolts to bolt in the “C” channel of the Universal Connector with the Universal Wall, in order to secure it in this way.
c) Universal Roof Piece
[0024] The roof is a piece with strategic electric current connection points, which coincide symmetrically one with the other with the wall outlet point, which is special for its position and coincidence in all our house models constructed with this system, and which are numbered and shown in our claims and figures. This roof piece, once installed, will have the lights placed and correctly functioning in all of the house, by being in coordination with the spatial distribution of the light switches in all of the Universal Walls, resulting in the correct “off and on” switching of roof lights.
[0025] These roof pieces are fastened one to the other with metal plates which serve as leveling pins, to obtain an even and leveled roof , a flat ceiling is seen from the inside of the house, and the view from the outside shows a gable roof, or flat roof without changing the system, it being an obvious detail. In the graphics we appreciate a roof piece where in each extreme, it has a square shape, one smaller than the other, which permits mounting these two extremes, while joining roof blocks from right to left, instead than from bottom end to upper end, in order to achieve a waterproof effect between blocks or roof pieces. Our roof piece is also symmetrical and universal, as the Universal Wall.
[0026] This Universal Roof pieces has a hollow interior where the light system of cold light has already been installed, chosen not only for energy savings but also because it offers higher security than conventional systems of light. Each Universal Roof piece has a current inlet and an outlet always in the same site, it has Universal Roof piece to Universal Roof piece auto connectors, as well as Universal Roof piece to Universal Wall direct connections, plugable to one another, always in the same site and position, making thus our roof pieces a Universal Roof pieces, characteristic which is crucial in our system, due to its simplicity and operation savings.
BRIEF FIGURE DESCRIPTION
[0027] We want to make clear that in order to capture explanatory figures in this document, circumscribe the system hereto described, to the materials exposed in certain figures. In this system or unit of invention, no matter what materials are used, what matters is the correct functioning of the system.
[0028] FIG. 1 : This figures shows the basic wall, without details, of 2.40 mts high and 3.00 mts wide and 10 cm thick.
[0029] FIG. 2 : This figures shows the position of the door, window, power switch, power outlet in each wall, the door and window can be bypassed in case of not being needed, creating savings in specific cases.
[0030] FIG. 3 : Power current position links are shown in green ( 3 . 1 ) and water and sewer connection link in blue ( 3 . 2 ).
[0031] FIG. 4 : Another view of the power current and water and sewer links ( 3 . 1 , 3 . 2 ).
[0032] FIG. 5 : Lateral view of the wall with water and current links.
[0033] FIG. 6 : View in perspective of wall/roof power current links ( 6 . 1 ) and electrical outlet and switch ( 2 . 2 ).
[0034] FIG. 7 : Possible internal structure of universal wall, not necessarily the only one.
[0035] FIG. 8 : Shows wall fastening channels.
[0036] FIG. 9 : A possible inner structural distribution of the universal wall, frontal view.
[0037] FIG. 10 : Electrical distribution of the universal wall.
[0038] FIG. 11 : Wall with water outlets and plumbing network links.
[0039] FIG. 12 : View in perspective of wall connector with interconnecting channels.
[0040] FIG. 13 : 3-D view of the “C” channel showing “T” rails, which fit the square tube guides (connector), shown hereunder.
[0041] FIG. 14 : Plant view with the rails placed and in placement as well.
[0042] FIG. 15 : Perspective view of the decorative cover of the connector.
[0043] FIG. 16 : Explains the positions of the placement of channels, which can be of 2 to 4 used sides.
[0044] FIG. 17 : Sample of a current network distribution for it to be universal.
[0045] FIG. 18 : Plant view of a sample of electric distribution.
[0046] FIG. 19 : Sample of connections of wall and floor.
[0047] FIG. 20 : Sample of roof piece and its structural parts, such as special top structures for right to left coupling, flat support, and a top linking structure.
[0048] FIG. 21 : Sample of electrical current inlet position in the roof piece , unique light position in all pieces and current network.
[0049] FIG. 22 : Another lateral view of the roof piece.
[0050] FIG. 23 : Depicts special form of coverage, where the left side wraps around the rights side, in such a way as to prevent water leaking; view of three separate roof pieces, ready for right to left coupling.
[0051] FIG. 24 : Top Plant view of the distribution of all the pieces that make up the roof and the fit of the wall and roof connectors.
DETAILED DESCRIPTION OF THE INVENTION
[0052] An integral system of assembly and fabrication of architectural modular houses, which simplifies all building construction processes to three basic elements, meaning simplifying the construction of building to a process of building installation, with intelligent and interchangeable walls, which include a) wall with a network for an electrical circuit, plumbing circuit; b) wall to wall connectors which give symmetry and homogeneity to the distributions, a requisite which became indispensable in order to achieve the universality and homogeneity of the basic elements; c) universal roof which make the installation simple and quick.
a) The Universal Wall
[0053] The walls have the distinction to possess all exterior and interior finishing detail, as well as door, window, drain and water circuits, outlet and inlet switches. These walls contain a unique power current circuit in the interior which allows an coincidence with the other walls, as well as when referred to the plumbing circuit.
[0054] This wall is a standard piece, which is made so that this same unit can be used for the assembly of various models of modular homes, that is universal standard walls, which can be connected wall with wall, through a universal connector, and always after connecting, it permits the correct functioning of the services (electrical and plumbing) once the installation of the houses is complete. With respect to this last point, this standard universal prefabricated wall contains in a fixed and predetermined position, spaces, openings, electrical and plumbing circuit, as well as switches, sockets, amongst other electrical devices, as well as predetermined positions for doors and windows.
[0055] The wall may function with various construction materials, such as the concrete, wood, melamine, plastic, metal amongst others. The universal walls rest in channels placed in the floor which seal and waterproof all of the house perimeter and interior areas, so that once connected these walls form the desired modules according to the predetermined model plans.
[0056] All universal walls have in common that the exhibit a 2.40 m high, 3 meters high and 10 cm thickness; and all exhibit the same power, water and drain circuit, ready to be used, or simply circumvent it if not required. The simplification of the dimension and circuits positions is a factor for the lowering the manufacturing operations, for being only one the wall to manufacture and in this way optimize the production speed to the maximum, since it is a universal wall which will be manufactured in series.
b) The Universal Connector
[0057] Conformed by a universal connector ( 12 ) which is a structural quadrilateral tube, characterized because in the interior it contains a network of electrical wiring in the top part, and a free bass for plumbing piping in the inferior part, where the connection points in the wall ( 1 ) and of coupling and fastening structure of the “C” channel, which holds the wall ( 1 ).
[0058] Additionally, the connector ( 12 ) may rest on channels which are found in the perimeter of the house and interiors for a better alignment, disposition and built of living spaces.
[0059] The connector's empty spaces ( 13 ) may be filled with thermo-acoustic material, to minimize sound and temperature fluctuations.
[0060] The “C” channel ( 13 ), is characterized because it supports a wall ( 1 ) and facilitates its connection with the connector ( 12 ), that is with another wall ( 1 ), it has 2 spaces, where the space is found in the top part and permits the pass of the electrical wiring, and the bottom spacing permits the pass of the plumbing circuit; it is characterized as well because it has the channels which are coupled to the guides.
[0061] The top cover ( 15 ) has an exterior and interior part, where the exterior part is flat and the interior part has channels which couple to the guides.
c) The Roof Piece
[0062] The roof ( 20 ) is composed, by pieces which are characterized because they have a universal interior structure which contains the electrical wiring network, and has a linear form, also the top plate of the roof piece has a water fall aligned to the house roof, the structure, is covered by the top and bottom part respectively, for a better finishing and to cover more effectively the structure. The structure of the bottom plate has two holes for the placing of lightning fixtures, while the structure of the top plate does not have holes. Each piece also possesses a top structure in its superior part, which serves as a hook to other roof pieces ( 20 ), like mouth-and-tongue, and is characterized because its possesses a similar dimension to the plate underneath, with an transversal area which includes a central trough and elevated unequal quadrangular borders, one lesser than the other, which serves for the hitching of one top structure from another roof piece ( 20 ).
Prototype
[0063] In order to realize the actual invention, a prototype was constructed that served to define the function details which brought conclusions which led to this invention unit. | This system has achieved in making unique pieces in order to generalize the construction of buildings by simplifying the construction process to the manufacture of three (3) products, to achieve our modular house models.
This simplification in the manufacture process results in the simplification of the infrastructure of the installed plant capacity. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This application relates generally to window components, and more particularly to a draft guard window balancer system.
[0003] 2. Description of Related Art
[0004] Fenestration products, such as windows and doors, clearly benefit from weather barriers such as weatherstripping as well as sound and tight fitting interrelational parts and components. Such weather barriers serve not only to prevent drafts, but also deter moisture entry as well as insect, dust and pollen infiltration. Over the years, energy efficiency standards as well as an overall awareness of the environmental benefits of energy efficient fenestration products have furthered the demand for proper and improved weather barriers, seals, and fittings. Many improved weatherstripping products now exist to perimeter seal windows and doors. While perimeter weatherstrips are necessary and highly beneficial, there are small openings in windows and doors that, without proper seals, can leak air, water, dust, pollen or even insects into the interior airspace of a building. Often these small openings are due to an interoperable mechanical arrangement that may be difficult to seal off without impacting the mechanical functionality between attendant components. One example of such a situation is that of the ever popular double hung window. A double hung window commonly has two sashes that travel vertically in a tracked frame. A spring assembly is often utilized to facilitate ease of vertical travel of each sash. Oftentimes, a pivot bar inserts into a balancer shoe which connects to a spring assembly to allow a sash to tilt out for cleaning. The use of a tracked frame and a traveling sash setup, while practical, creates a break in the weather barrier of the window that allows air, dust, pollen, moisture, or even insects, to travel up the track and into the building. In a strong wind, the track may even create a chimney effect where cold outside air is forced up the track and into the building through the meeting rail and sill areas. Since the sashes and related components move in the track, it has been difficult to properly weather seal this area of a double hung window. It is therefore an object of the present invention to provide a draft guard that seals the track of a double hung window from environmental factors. It is another object of the present invention to provide a draft guard that travels with a moveable window sash in a double hung window. It is another object of the present invention to provide a draft guard that works in conjunction with a pivoting sash arrangement for a double hung window. It is yet another object of the present invention to provide a draft guard that does not interfere with normal usage movement of a sash in a double hung window. It is a further object of the present invention to provide a window balancer with a draft guard. It is yet another object of the present invention to provide a method of manufacturing a double hung window.
[0005] These and other objects of the present invention will be further brought to light upon reading this specification and claims and viewing the attached drawings.
BRIEF SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, there is provided a draft guard for a window balancer comprising a vertical component having a first edge, a second edge, a third edge and a fourth edge; a horizontal component having a first edge, a second edge, a third edge and a fourth edge; the second edge of the horizontal component being joined to the second edge of the vertical component at a generally right angle; the horizontal component further having a first cut and a second cut in proximity to and generally parallel to the second edge; and the vertical component having a pivot bar hole.
[0007] The foregoing paragraph has been provided by way of introduction, and is not intended to limit the scope of the invention as described by this specification, claims, and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention will be described by reference to the following drawings, in which like numerals refer to like elements, and in which:
[0009] FIG. 1 is a plan view of a double hung window with cut line A-A;
[0010] FIG. 2 is a cutaway view of the double hung window taken along cut line A-A of FIG. 1 ;
[0011] FIG. 3 is a front plan view of a balancer showing the draft guard in use;
[0012] FIG. 4 is a perspective view of a balancer showing the draft guard in use;
[0013] FIG. 5 is a right side view of a balancer showing the draft guard in use;
[0014] FIG. 6 is a rear plan view of a balancer showing the draft guard in use;
[0015] FIG. 7 is a top plan view of a balancer showing the draft guard in use;
[0016] FIG. 8 is a bottom plan view of a balancer showing the draft guard in use;
[0017] FIG. 9 is a top plan view of the draft guard;
[0018] FIG. 10 is a left side view of the draft guard;
[0019] FIG. 11 is a front plan view of the draft guard;
[0020] FIG. 12 is a right side view of the draft guard;
[0021] FIG. 13 is a bottom plan view of the draft guard;
[0022] FIG. 14 is a perspective view of the draft guard;
[0023] FIG. 15 is a rear plan view of the draft guard;
[0024] FIG. 16 is a flattened plan view of the draft guard;
[0025] FIG. 17 is a plan view of the sash side of the balancer shoe;
[0026] FIG. 18 is a bottom plan view of the sash side of the balancer shoe;
[0027] FIG. 19 is a left side view of the sash side of the balancer shoe; and
[0028] FIG. 20 is a right side view of the sash side of the balancer shoe;
[0029] The present invention will be described in connection with several preferred embodiments; however, it will be understood that there is no intent to limit the invention to the embodiments described. On the contrary, the intent is to cover all alternatives. modifications, and equivalents as may be included within the spirit and scope of the invention as defined by this specification, claims, and the attached drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Balances or balancers, as used herein, describe the mechanical component or components that contain a spring or balance assembly that connects a window sash to a master frame to allow for ease of operation. While such balances or balancers are commonly used with double hung windows, other window arrangements may benefit from such hardware such as, for example, sliding windows. Windows may be wood, vinyl, aluminum. fiberglass, or the like. A window balancer configuration allows a window sash to be tilted in to a plane outside its normal operating plane to allow for cleaning.
[0031] The present invention solves the problem of a draft or chimney effect originating from the hollow chamber tracks in a window frame and the space between a sash and master frame, by adding a draft guard component to a balance or balancer. The draft guard mechanically attaches to a constant force balancer and the balancer pivot bar at the balancer shoe of a block and tackle balancer or a spiral balancer. The present invention includes not only the draft guard, but a balance or balancer having a draft guard, along with a method of manufacturing fenestration products that have a draft guard. In addition, the present invention includes modifications, variations, additions, improvements and enhancements to the present invention that will be known or contemplated after reading this specification and the accompanying drawings.
[0032] For a better understanding of the present invention and the various embodiments described and envisioned herein, a double hung window is depicted in FIGS. 1 and 2 . While arguably the most common application of the present invention, applicability is not limited to double hung windows, but the present invention may find suitable and useful applications in other fenestration products as well.
[0033] FIG. 1 is a plan view of a double hung window 100 with cut line A-A. Two window sashes can be seen contained by a tracked frame. The tracks are contained in the frame and make contact with the two vertical edges of each window sash. It is within these tracks that a balancer, spring and draft guard are contained. This arrangement can be better seen in FIG. 2 , which is a cutaway view 200 of the double hung window taken along cut line A-A of FIG. 1 . The window extrusion chamber hollows can be clearly seen in this cutaway view. A first sash 209 and a second sash 211 can be seen in FIG. 2 . In addition, four draft guards can be seen, two per sash. A first draft guard 201 and a second draft guard 203 can be seen at either end of the first sash 209 . In a similar arrangement, a third draft guard 205 and a fourth draft guard 207 can also be seen at either end of the second sash 211 . The draft guards visible in FIG. 2 are attached to the bottom of a balancer arrangement that is also in use, but cannot be clearly seen in FIG. 2 . The balancer arrangement provides mechanical connectivity between the moveable sash and the fixed master frame, with a spring or balance assembly there between for ease of operation. The details of such an arrangement will be further described by way of the remaining figures.
[0034] FIGS. 3-8 depict a balancer system showing the draft guard in use. FIG. 3 is a front plan view of a balancer and pivot bar 300 showing the draft guard in use. The upper structure in FIG. 3 is the frame side of the balancer 301 and the lower structure in FIG. 3 is the sash side of the balancer 303 . The pivot bar 307 inserts into the shoe of the sash side of the balancer 303 . The frame side of the balancer 301 and the sash side of the balancer 303 may be made from a plastic such as polypropylene, nylon or the like, or from a metal such as aluminum. Preferentially, a material with a low coefficient of friction should be used to provide smooth operation. Various plastics fall into this category. The frame side of the balancer 301 and the sash side of the balancer 303 may be injection molded, or machined, for example. Between the frame side of the balancer 301 and the sash side of the balancer 303 is a spring 305 . The spring 305 may be a constant force spring made from, for example, flat stock and wound steel or stainless steel. The spring may also be a spiral spring or a block and tackle spring assembly, and may contain a separate balancer shoe not directly attached to a spring housing. Further depicted in FIG. 2 is a pivot bar 307 . The pivot bar 307 can be better seen in FIG. 4 . The pivot bar 307 is typically made from a metal such as steel, and may be coated, painted or galvanized for rust prevention. The pivot bar 307 is cast, machined or stamped and retains the bottom edge of a window sash connecting directly to a balancer shoe. The figures depict a three hole arrangement for placing screws through the pivot bar 307 . Other configurations, such as two holes, one hole, four holes, and the like, and other fasteners may, in some embodiments of the present invention, be used. The pivot bar 307 may, in some embodiments of the present invention, pivot to allow the attached window sash to tilt for cleaning. In some embodiments, the pivot bar engages with a balancer shoe cam that in turn pushes a tab outward to create friction against the track that the balancer shoe rides in, thus allowing the window sash to be tilted for cleaning while maintaining a fixed position in the track. Connected to the balancer and pivot bar is a draft guard 900 . FIGS. 9-16 will depict the draft guard removed from the balancer and pivot bar. The draft guard 900 is attached to the pivot bar and attaches to the balancer with an adhesive, a barbed fastener, a rivet, a snap, a mechanical connecting guide, a hook and loop fastener, or the like. Mechanical coupling of the draft guard 900 is to the sash side of the balancer. The placement of the draft guard 900 , in use, prevents air, water, dirt, pollen, or insect infiltration up the track and into the building. In addition, the draft guard 900 prevents dirt and debris from entering the track and creating unnecessary friction. In use, the draft guard 900 is bent along and makes contact with surfaces of the window assembly to provide enhanced and improved sealing. A full complement of views of the balancer 300 and draft guard 900 is conveyed by way of FIGS. 4-8 . FIG. 4 is a perspective view of a balancer and pivot bar 300 showing the draft guard 900 in use. FIG. 5 is a right side view of a balancer 300 showing the draft guard 900 in use. FIG. 6 is a rear plan view of a balancer 300 showing the draft guard 900 in use. FIG. 7 is a top plan view of a balancer 300 showing the draft guard 900 in use. FIG. 8 is a bottom plan view of a balancer 300 showing the draft guard 900 in use and also showing the pivot bar in place.
[0035] FIGS. 9-16 depict the draft guard 900 removed from the balancer. The draft guard 900 is made from a weatherstopping material such as, for example, ethylene propylene diene monomer (EPDM) rubber, and extruded, die cut, or the like. Other materials that may be used to make the draft guard 900 are thermoplastic elastomers (TPE) that may be extruded, injection molded, die cut, or the like. Another material that may be used to make the draft guard 900 is thermoplastic polyolefin (TPO) and may be processed by injection molding, extruded, thermoformed, die cut, or the like. Other examples of materials that may be used to make the draft guard 900 include polystyrene, foam rubber, silicone, closed cell foam, felt, and the like. Materials used to make the draft guard 900 may also, in some embodiments of the present invention, be treated with an antimicrobial chemical to reduce mold, mildew and degradation related to other organism. An example of such treatment is disclosed in U.S. Pat. No. 5,681,637 to Kessler and Abramson and entitled Microorganism Resistant Pile Weatherstripping, the entire disclosure of which is incorporated herein by reference. FIG. 9 is a top plan view of the draft guard 900 . The draft guard 900 comprises a vertical component and a horizontal component. The vertical component 901 has a generally rectangular shape and has a first edge, a second edge, a third edge and a fourth edge. The vertical component 901 can be more clearly seen in FIG. 14 . The vertical component 901 has a pivot bar hole 1101 that can be seen in FIG. 14 to accommodate the pivot bar which in turn attaches to the balancer shoe area of a balancer. (not shown in FIG. 9 , see FIG. 4 ). The vertical component 901 is joined to horizontal component 903 at a generally right angle. The horizontal component 903 has a generally rectangular shape and has a first edge, a second edge, a third edge and a fourth edge. The horizontal component 903 further has a first cut 905 and a second cut 907 in proximity to and generally parallel to the second edge. Various embodiments of the draft guard of the present invention may have varying cuts, thicknesses, shapes, and materials that are based, for example, on specifications of the window. In some embodiments the vertical component 901 and the horizontal component 903 are made from a single material and may be formed as one part. Processes to allow the horizontal component 903 and the vertical component 901 to be formed as one part include, but are not limited, to, injection molding, extruding, and the like. FIG. 10 is a left side view of the draft guard 900 . FIG. 11 is a front plan view of the draft guard 900 . The pivot bar hole 1101 can be clearly seen. The pivot bar hole 1101 accommodates the pivot bar of the balancer shoe (not shown in FIG. 11 , see FIG. 4 ). In some embodiments, the pivot bar hole 1101 may be round, oval, square, rectangular, octagonal, or of another geometry that allows a pivot bar to pass freely. FIG. 12 is a right side view of the draft guard 900 . FIG. 13 is a bottom plan view of the draft guard 900 . In some embodiments of the present invention, the first and third edges of the horizontal component are beveled. As well, the first and third edges of the vertical component may also be beveled. The bevel may be a 45 degree bevel, or may be of some other angle, or may be a roundover with any radius useful in reducing the sharp angle of the edge and thus provide ease of operation and reduced friction in use. FIG. 14 is a perspective view of the draft guard 900 that clearly shows the orientation of the vertical and horizontal components and the attributes associated with each. FIG. 15 is a rear plan view of the draft guard 900 . FIG. 16 is a flattened plan view of the draft guard that clearly shows both the horizontal and the vertical component. A dotted line indicates the fold line of the draft guard. In some embodiments of the present invention, the 1 ( )draft guard may be flat as shown in FIG. 16 prior to assembly and attachment to a pivot bar and balancer. In other embodiments of the present invention, the balancer may be molded or otherwise fabricated with a generally right angle already intrinsic in the draft guard, as shown, for example, in FIG. 14 .
[0036] Lastly, FIGS. 17-20 depict a constant force balancer with an exemplary mechanical coupling arrangement for coupling the draft guard (not shown in FIGS. 17-20 , see previous figures) to the sash side of the balancer. The example in FIGS. 17-20 is not to be considered limiting. Adhesives, rivets, snaps, mechanical connecting guides, hook and loop fasteners, and other devices and techniques may be used alone or in combination to attach the draft guard to the balancer. FIG. 17 is a plan view of the sash side of the constant force balancer 300 showing an example of the use of a first fastener 1701 and a second fastener 1703 to retain the draft guard to the balancer. The first fastener 1701 and the second fastener 1703 are barbs that may be molded into the sash side of the balancer 303 or may be metal barbs that are inserted into the sash side of the balancer 303 as a secondary operation. These barbs are also shown in FIG. 18 as a bottom plan view of the sash side of the balancer. FIG. 19 is a left side view of the sash side of the balancer and FIG. 20 is a right side view of the sash side of the balancer. Each of FIGS. 17-20 depicts an example of a mechanical coupling fastening technique. Other techniques may be used alone or in combination. The draft guard will, however, be fastened securely to the sash side of the balancer and pivot bar.
[0037] The draft guard is used in a fenestration product such as a double hung window. It may be incorporated into the fenestration product during manufacture and assembly, or may, in some embodiments of the present invention, be added to an existing fenestration product either by fastening the draft guard to an existing balancer or balancer shoe, or replacing the balancer with a new balancer or new balancer shoe having a draft guard. To manufacture a double hung window using the present invention, a sash side of the balancer and pivot bar having a draft guard is attached to a first sash, a frame side of a balancer is attached to a double hung window frame, the first sash is installed in the double hung window frame, and a spring is connected between the sash side of the balancer having a draft guard and the frame side of the balancer. Modifications and variations to this manufacturing process may also be contemplated after reading this specification and viewing the attached drawings.
[0038] It is, therefore, apparent that there has been provided, in accordance with the various objects of the present invention, a draft guard for a balancer. While the various objects of this invention have been described in conjunction with preferred 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 present invention as defined by this specification, claims and the attached drawings. | A draft guard balancer is provided that attaches to, or is otherwise mechanically coupled to, or an integral part of, an existing balance shoe or balancer for a fenestration product such as a double hung window. The draft guard balancer creates a weatherstop along the track of the fenestration product that resists air, water, dirt, dust, pollen, and insects from entering the track and then the building. The draft guard balancer may be used with a balancer having a variety of springs, spring assemblies, balancer shoes and pivot bar arrangements. The draft guard balancer creates a seal that also prevents the increased friction that results from dirt and debris entering the track, thus making for a more energy efficient, easier to operate fenestration product. The draft guard balancer is equally applicable to both top and bottom sashes of a double hung window as well as other fenestration products. |
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RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 61/298,859 filed Jan. 27, 2010, entitled Weight Plate, the contents of which are incorporated in their entirety herein.
FIELD OF THE INVENTION
The present invention relates to portable shelters and advertising displays and, more particularly, to devises and methods for securing such structures.
BACKGROUND OF THE INVENTION
The evolution of light-weight, easily erected, and economical portable shelters, advertising stands and similar structures has led to the increasing commercial and private use of these structures. However, due to the light-weight construction of such structures, the structures must often be anchored or stabilized so as to prevent movement of the structure caused by physical contact in highly congested areas such as convention centers or by environmental elements such as wind.
Various methods and portable devices have thus far been used to stabilize these structures. For example, systems employing guy-lines have been used in which one end of the guy-line is attached to a shelter awning or a leg of the structure and the other end of the guy-line is anchored to the ground or floor. While these guy-line systems may serve to improve stability, they have the disadvantage of effectively increasing the foot-print of the structure due to the guy-lines extending outward away from the perimeter of the structure. Guy-lines also create a hazard for people walking in the area of the shelter.
Other methods and devices for stabilizing the shelters are directed towards adding weight to the legs of the shelter or to the bases of the legs of the shelter. One approach has been to place an object such as a relatively thick piece of metal over the base and around a portion of the leg of the structure. Such weights have the disadvantage of being relatively high-profile, effectively decreasing the available space around the leg of the structures, and being awkward or inconvenient to transport due to their relatively heavy compact form. Another approach has been to employ relatively large, usually plastic containers or vessels that, again, rest on top of the base and around the leg of the shelter. Such plastic containers are intended to be deployed about the leg of the structure and then filled with a substance that can later be removed from the container, such as sand or water. An obvious disadvantage of these systems is that the user must not only transport the plastic containers but must also transport or otherwise locate, and then later dispose of, the sand or water used to fill the container. Like the weight systems described above, these systems also effectively decrease the available space around the legs of the structures.
The fact that the known solutions for stabilizing portable structures effectively decrease the usable area around the legs of the structure is not trivial. For example, creating unusable areas around the leg of a portable shelter used at a trade convention or other venue in which displays and structures must abut one another not only decreases the usable space under the structure but may also prevents structures from being erected immediately next to one another.
What is needed in the art is a low-profile, easily transportable device and method for stabilizing the legs of portable shelters, advertizing stands, and similar structures.
OBJECTS AND SUMMARY OF THE INVENTION
The present invention provides a weight plate having a mass sufficient to stabilize the leg of a portable shelter or advertizing stand and a profile that is sufficiently low so as avoid occupy space within or outside of the structure. The weight plate of the present invention employs a low-profile, planar plate having an aperture formed therethrough. The aperture is configured so as to allow the base of the leg of a structure to pass through. The plate is subsequently transposed so as to lock the base of the leg underneath the plate while the leg of the shelter passes through the plate and an opposite side of the plate extends away form the leg.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects, features and advantages of which embodiments of the invention are capable of will be apparent and elucidated from the following description of embodiments of the present invention, reference being made to the accompanying drawings, in which
FIG. 1 is a plan view of a weight plate according to certain embodiments of the present invention.
FIG. 2 is a perspective view of a weight plate in operation according to certain embodiments of the present invention.
FIG. 3 is a perspective view of a weight plate in operation according to certain embodiments of the present invention.
FIG. 4 is a perspective view of a weight plate in operation according to certain embodiments of the present invention.
FIG. 5 is a perspective view of a weight plate in operation according to certain embodiments of the present invention.
DESCRIPTION OF EMBODIMENTS
Specific embodiments of the invention will now be described with reference to the accompanying drawings. 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. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
As shown in FIGS. 1 and 2 , according to one embodiment of the present invention, a weight plate 5 comprises a plate 10 formed in an elongated shape such as a rectangle. For example, a length of the plate 10 is approximately 355.6 mm and a width of the plate 10 is approximately 127 mm and a thickness of the plate 10 is approximately 2.2 mm to 2.5 mm. The plate 10 has a plate-like form that is approximately planar. The plate is formed of a material such as a metal, alloy, polymer, or a combination thereof. For example, the plate 10 may be formed of an alloy and coated with a different material so as to provide a texture or a protective and/or non-corrosive coating.
A first or primary aperture 20 is formed through the plate 10 . The aperture 20 has an irregular shape comprising a proximal portion 22 connected to a distal portion 24 through a central portion 26 . The proximal portion is positioned at or near a mid-point of the plate 10 and has a triangular shape. For example, the proximal portion 22 may be a right triangle having catheti of approximately 82 mm in length. As shown in FIG. 2 , the proximal portion 22 of aperture 20 is sized so as to receive or pass a base 32 of a leg 34 of a portable shelter (not shown in its entirety) therethrough. For example, the base 32 of the leg 34 of the portable shelter may have a triangular form that is similar to the triangular shape of the proximal portion 22 but smaller than the triangular proximal portion 22 of the aperture 20 . It will be under stood that alternative shapes of the proximal portion 22 of the aperture 20 are contemplated so as to correspond with the assorted shapes of the bases 32 of the legs 34 of portable shelters.
The distal portion 24 is positioned or offset towards one side of the plate 10 and has an approximately rectangular shape. The central portion 26 also forms a rectangular shape and connects one side of the proximal portion 22 to one side of the distal portion 24 of the aperture 20 . The central portion 26 and the distal portion 24 of the aperture 20 are sized so as to be slightly larger than the leg 34 of the portable shelter and smaller than the base 32 of the leg 34 of the portable shelter. Stated alternatively, the central portion 26 and the distal portion 24 of the aperture 20 are sized such that the leg 34 of the shelter may move freely therethrough but that the base 32 of the leg 34 of the shelter may not pass or move therethrough. For example, the central portion 26 of the aperture 20 may have a width of 33 mm. The central portion 26 of the aperture 20 connects to the distal portion 24 so as to form a shape similar to that of an L, thereby providing a notch into which the leg 34 of the shelter can be positioned and secured so as to discourage movement of the leg 34 back towards the proximal portion 22 .
As shown in FIGS. 1-5 , the plate 10 may employ one or more secondary apertures 40 in addition to the primary aperture 20 . The secondary aperture 40 may be formed in varying sizes and shapes. For example, the plate 10 may employ secondary apertures 40 at each of the four corners of the plate 10 that are smaller than the secondary apertures 40 employed else where within the plate 10 . As shown in FIG. 5 , the secondary apertures 40 may serve to receive or otherwise facilitate engagement with stakes so as to further stabilize the plate 10 and the leg 34 of the shelter. For example, a stake can be passed through the secondary aperture 40 such that a head portion of the stake engages the plate 10 and a shaft portion of the stake engages the ground. The secondary apertures 40 may also serve to reduce the weight of the plate 10 and/or provide a handle so as to facilitate transportation of the weight plate 5 .
With reference to FIG. 2 , in use, a portable shelter or similar structure is first erected. Once erected, the base 32 of one of the legs 34 of the portable shelter is passed through the proximal portion 22 of the aperture 20 . The plate 10 is then maneuvered such that the leg 34 of the shelter passes through the central portion 26 and into the distal portion 24 of the aperture 20 . In this manner the base or foot 32 of the leg 34 of the portable shelter is confined beneath the plate 10 and the leg 34 of the shelter passes through the distal portion 24 of the aperture 20 . Since the distal portion 24 of the aperture 20 is positioned so as to be offset to one side of the plate 10 , the remaining portion or opposite side of the plate 10 is cantilevered away from the leg of the shelter.
As shown in FIGS. 3 and 4 , the above-described configuration of the present invention also facilitates further stabilization of the plate 10 and the leg 34 of the shelter by providing a planar surface extending away from the leg 34 upon which objects such as water jugs and coolers can be place to add additional weight and stability to the system.
The low-profile, planar form of the weight plate 5 provides the additional benefit of being efficiently stacked so as to facilitate transporting and displaying the weight plate for consumer sales.
Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof. | A weight plate for securing portable structures employing a low-profile, planar plate having an aperture formed therethrough. The aperture is configured so as to allow the base of the leg of a structure to pass through. The plate is subsequently transposed so as to lock the base of the leg underneath the plate while the leg of the shelter passes through the plate and an opposite side of the plate extends away form the leg. |
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This application is a continuation of U.S. Patent Application Ser. No. 886,105, filed Mar. 13, 1978, now abandoned, which is a continuation-in-part of U.S. Patent Application Ser. No. 756,129, filed Jan. 3, 1977, now U.S. Pat. No. 4,078,613, which is a continuation of U.S. Patent Application Ser. No. 602,680, filed Aug. 7, 1975, now abandoned, which is a continuation-in-part of U.S. Patent Application Ser. No. 534,778, filed Dec. 20, 1974, now U.S. Pat. No. 3,982,591.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a multistage gas generator for use in a borehole for recovering hydrocarbons or other materials from the subsurface formations.
It is a further object of the present invention to provide a multistage gas generator wherein each stage is selectively controllable to increase or decrease the BTU output or to vary other characteristics of the output. By the use of a plurality of stages, each selectively controllable, the system can be controlled digitally by a computer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the gas generator located in a borehole for use for recovering hydrocarbons from the subsurface formations.
FIGS. 2A and 2B illustrate the gas generator in cross-section. The top portion of FIG. 2B is a continuation of the bottom portion of FIG. 2A.
FIG. 3 illustrates all of the stages of one embodiment of the gas generator.
FIG. 4 is a view of FIG. 2A taken along the lines 4--4 thereof.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is illustrated a cased injection borehole 31 which penetrates a subsurface oil bearing formation 33. Supported in the borehole is a gas generator 39 for producing hot gases to thermally or permanently reduce the viscosity of the oil to be recovered by the most economical process available. In the recovery process, the oil in the formation 33 is driven to other spaced boreholes (not shown) which penetrate formation 33, for recovery purposes, in a manner well known to those skilled in the art.
Referring also to FIGS. 2-4, the gas generator 39 comprises a cylindrical shell 41 defining a main chamber 43 and having a top wall 45 and a lower outlet 49 which may be restricted and formed by cylindrical structure 51 as shown in FIG. 2B. Attached to the top wall 45 is support structure 53 defining an open space 55. Attached to the support structure 53 is a main support conduit 57 which extends to the surface and supports the gas generator in the borehole. Conduit 57 is supported at the surface by structure not shown. A packer 59 for engaging the walls of the borehole is supported around cylindrical structure 51.
Attached to the top wall 45 is a pilot stage 61 which comprises a pilot chamber 63 formed by cylindrical wall structure 65. A restricted outlet 67 extends through wall 45 from the pilot chamber 63 to the main chamber 43. Located along the length of the shell 41 between the pilot stage 61 and the lower restricted outlet 49 are a plurality of intermediate stages 71-80. Stages 74-80 are not shown in FIG. 2A but are illustrated in FIG. 3. Stages 74-80 are the same as stages 72 and 73. Located between stage 80 and the restricted outlet 49 is a final stage 81.
Extending from the surface to the pilot stage 61 are a hydrogen supply conduit 91 and an oxygen supply conduit 93. Coupled to conduits 91 and 93, near the gas generator are remotely controllable valves 95 and 97. At the surface, hydrogen supply conduit 91 is coupled to a source of hydrogen 99 and oxygen supply conduit 93 is coupled to a source of oxygen 101. A flow meter 103 and flow regulator 105 are coupled to the hydrogen supply conduit 91 and a flow meter 107 and flow regulator 109 are coupled to the oxygen supply conduit 93. Also coupled to the hydrogen supply conduit 91 by way of a conduit 111 is a source 113 of hypergolic fuel such as triethyl borane. A three way valve 115 controls the flow of either hydrogen or the hypergolic fuel through conduit 91 downhole to the gas generator.
At the surface, the main support conduit 57 is coupled to the hydrogen source 99 by way of a conduit 117 whereby hydrogen is supplied downhole through conduit 57. A flow meter 119 and a flow regulator 121 are coupled to conduit 117.
In the gas generator, the first intermediate stage 71 includes an oxygen nozzle 71B and a water nozzle 71C for injecting oxygen and water into the main chamber 43. Each of the other intermediate stages 72-80 includes a hydrogen nozzle, an oxygen nozzle and a water nozzle for injecting hydrogen, oxygen, and water into the main chamber 43. The hydrogen, oxygen and water nozzles of stage 72 are identified at 72A, 72B, and 72C, respectively. The hydrogen, oxygen and water nozzles of stage 73 are identified at 73A, 73B, and 73C, respectively. The final stage 81 has only water nozzles for injecting water into the lower end of the main chamber. These water nozzles total 10 in number and are identified at 81C.
Downhole, a water conduit 131 is coupled to the water nozzle 71C of stage 71 and has its end 131A open to the water 132 in the borehole for supplying borehole water to the nozzle 71C. A remotely controllable valve 133 is coupled to conduit 131 for allowing or terminating the flow of borehole water to the nozzle 71C.
A conduit 135 extends from the oxygen source 101 at the surface downhole to oxygen nozzle 71B of stage 71 for supplying oxygen to this nozzle. At the surface, a flow meter 137 and a flow regulator 139 are coupled to conduit 135. In the borehole near the gas generator, a remotely controllable valve 141 is coupled to conduit 135 for allowing or terminating the flow of oxygen to nozzle 71B.
Downhole, a conduit 151 extends from the main support conduit 57 to the hydrogen nozzle 72A of stage 72 to supply hydrogen to this nozzle. In the borehole near the gas generator, a remotely controllable valve 153 is coupled to conduit 151 for allowing or terminating the flow of hydrogen to nozzle 72A.
A conduit 155 extends from the oxygen source 101 at the surface downhole to oxygen nozzle 72B of stage 72 for supplying oxygen to this nozzle. At the surface a flow meter 157 and a flow regulator 159 are coupled to conduit 155. In the borehole near the gas generator, a remotely controllable valve 161 is coupled to conduit 155 for allowing or terminating the flow of oxygen to nozzle 72B.
Water 132 from the borehole is supplied to the nozzle 72C of stage 72 by way of a conduit 163 which is coupled to the nozzle and has its end 163A open to the water in the borehole. A remotely controllable valve 169 is coupled to conduit 163 for allowing or terminating the flow of water to nozzle 72C.
Each of the other stages 73-80 has hardware similar to that of stage 72 for supplying hydrogen, oxygen, and water to its hydrogen, oxygen and water nozzles. In this respect, each of the other stages 73-80 has a conduit similar to conduit 151 coupled from main support conduit 57 to its hydrogen nozzle with a remotely controllable valve similar to valve 153 coupled to this conduit. Each of the other stages 73-80 has a conduit similar to conduit 155 extending from the oxygen source 101 downhole to its oxygen nozzle with a flow meter and flow regulator similar to flow meter 157 and flow regulator 159 located at the surface and a remotely controllable valve similar to valve 161 located downhole near the gas generator. In addition, each of the other stages 73-80 has a conduit similar to conduit 163 coupled to its water nozzle with a remotely controllable valve similar to valve 169 coupled to the conduit.
The final stage 81 has 10 conduits 171 coupled to its 10 water nozzles respectively for supplying water from the borehole to the water nozzles. Each conduit 171 has a remotely controllable valve 173 coupled thereto (only 5 are shown) for allowing or terminating the flow of water to its water nozzle.
Each of the downhole remotely controllable valves 95, 97, 133, 141, 153, 161, 169, 173, and those not shown but employed for stages 73-80 are separately controllable from the surface by an uphole digital computer illustrated at 181. Valve 95 will be described as typical. It comprises a ball valve operable by pneumatic or hydraulic pressure from the surface. It has two conduits 183 and 185 extending to the surface to a source 187 of pneumatic or hydraulic fluid and which is controlled by a control system 189 for opening or closing the valve. Control system 189 in turn is controlled by computer 181 through a control line 191. Each of the other downhole remotely controllable valves is a ball valve having conduits similar to conduits 183 and 185 extending to the surface to a pneumatic or hydraulic supply and control system similar to 187 and 189, each of which is separately controllable by the computer 181 for selectively opening or closing each of these valves.
Each of the uphole flow regulators of the oxygen conduits of stages 61, and 71-80 is separately controllable by the computer to selectively control the amount of oxygen flowing to the stages 61 and 71-80. For example, the computer 181 senses the flow through oxygen conduits 93, 155 and 135 by way of lines 201, 203 and 205 coupled to flow meters 107, 157 and 137 and operates flow regulators 109, 159 and 139 by way of lines 207, 209 and 211 to selectively control the amount of oxygen flowing to stages 61, 72, and 71 depending upon the desired results. It is to be understood that the computer will be coupled to the flow meters and flow regulators of the oxygen conduits of stages 73-80 to selectively control the amount of oxygen flowing to these stages.
The amount of hydrogen flowing through conduits 57 and 91 also is selectively controlled by the computer. In this respect, the computer senses the flow through lines 91 and 57, 117 by way of lines 215 and 217 coupled to flow meters 103 and 119 and operates flow regulators 105 and 121 by way of lines 219 and 221 to selectively control the amount of hydrogen flowing to stage 61 and through conduits 117, 57 to stages 72-80.
The computer 181 also controls the three way valve 115 by way of line 223.
Although not shown, each of the uphole controls 189 for its respective downhole valve will have a manual control to selectively control the downhole valves manually in case of computer breakdown. In addition, each of the uphole flow regulators will have a manual control to selectively control manually the amount of hydrogen and oxygen flowing downhole to the different stages in case of computer breakdown.
After the gas generator and equipment has been inserted into the borehole to the desired depth and the borehole has been filled with water to the desired level, the system is ready for operation. Start up operation is as follows assuming that all 10 stages 71-80 are desired to be operated. Initially, all of the downhole valves will be closed. Valve 115 also will be closed to block the flow of fluid downhole through conduit 91. All of the uphole flow regulators will be actuated and set to the desired value to allow hydrogen and oxygen to flow downhole through the various conduits to the closed downhole valves. As mentioned above, valve 115 at this time will block the flow of fluid downhole through conduit 91. Valve 115 will be actuated to allow a slug of the hypergolic or start-up fuel to flow downhole through conduit 91 to closed valve 95. Next valve 115 will be actuated to allow hydrogen to flow downhole through conduit 91 behind the slug of hypergolic fuel in conduit 91. Valves 95 and 97 then will be opened to allow the slug of hypergolic fuel and oxygen to flow into the pilot chamber 63 where the hypergolic fuel will spontaneously ignite when it contacts the oxygen. The hydrogen which follows the hypergolic slug in conduit 91 then will be ignited and burned in the pilot chamber 63. Combustion will be supported by the oxygen flowing through conduit 93 into chamber 63. Reference is made to U.S. Pat. No. 4,053,015 for a more detailed description of this type of ignition process. The resulting hot gases flow through restricted outlet 67 into the main chamber 43. Preferably, the combustible mixture in pilot stage 61 is hydrogen rich to maintain the temperature below 2,000° F.
Next valves 141 and 133 will be opened allowing oxygen and water to be injected into the main chamber 43 through nozzles 71B and 71C. Valve 141 will be opened first followed by the opening of valve 133. The oxygen allows the excess hydrogen flowing through restricted outlet 67 to be burned and the water maintains the temperature in the zone of stage 71 between 1,600° F. to 2,000° F. At this time, one of the water valves 173 will be opened to inject borehole water into the lower end of the chamber 43 to further cool the exhaust gases.
Valves 161, 153 and 169 of stage 72 next will be opened to inject oxygen, hydrogen, and water into the main chamber through nozzles 72B, 72A and 72C. The sequence of opening will be valve 161 first, valve 153 next and valve 169 last. The combustible mixture of hydrogen and oxygen from nozzles 72A and 72B is ignited by the hot gases resulting from the burning of hydrogen and oxygen from stage 71. The water from nozzle 72C cools the generator and maintains the temperature in the zone of stage 72 between 1,600° F. and 2,000° F. At this time another water valve 173 will be opened. The hydrogen, oxygen and water valves of each of stages 73-80 will be sequentially opened whereby the hydrogen and oxygen from each of these stages will be ignited by the hot gases from the preceeding stage. The temperature in the zones of each of these stages will be maintained between 1,600°-2,000° F. by the water injected from the stages. As each stage is turned on, one of the water valves 173 will be opened to further cool the exhaust gases and to maintain the exhaust temperature at about 600° F. The exhaust gases and steam flow through the restricted outlet 49 into the borehole and through casing perforations 271 into the formations. The uphole computer 181 will sense the hydrogen and oxygen pressure by way of the uphole flow meters and control the downhole hydrogen and oxygen flow by way of the uphole flow regulators in accordance with desired values.
Shut down is carried out by sequentially closing the downhole valves hydrogen and oxygen valves of stages 61 and 71-80 in a reverse manner. The water valves will be turned off as a final step.
If less than the maximum obtainable BTU output is desired, a selected number of the intermediate stages 72-80 will be shut off preferably starting with the lowest stage 80. The remaining intermediate stages including stage 71 and pilot stage 61 then will be operated to obtain the desired BTU output. If it is desired to obtain a hydrogen rich output for insitu hydrogenation, a selected number of downhole oxygen valves of the intermediate stages 72-80 will be closed preferably starting with the downhole oxygen valve of the lowest operating stage. The hydrogen valves of all of the operating stages will be open. Similarly, if it is desired to obtain an oxygen rich output, a selected number of downhole hydrogen valves of the intermediate stages 72-80 will be closed preferably starting with the downhole hydrogen valve of the lowest operating stage. The oxygen valves of all of the operating stages will be open. Thus, all of the system operating modes (steam, excess oxygen, excess hydrogen) may be computer controlled by above ground ingredient flow measurements, thus eliminating the necessity of downhole pressure temperature instrumentation.
In one embodiment, the gas generator 39 including shell 41, top 45, output structure 51 and pilot stage 61 and other equipment may be constructed of 310 stainless steel. The main support conduit 57 may have an inside diameter of 27/8 inches with the oxygen conduits and hydrogen conduit 91 having an inside diameter of 1/2 of an inch. Suitable filters will be employed for the downhole water conduits. The hydrogen and oxygen conduits 91 and 93 supply hydrogen and oxygen from the surface at twice the pressure for the other stages. The above sizes were based on the ten stage design operating at 20 to 60 million BTU per hour at a depth of 3,000 feet. For a total output of 20 million BTU per hour, the system may be designed and operated in the following manner. 32.78 pounds per hour of hydrogen and 38.48 pounds per hour of oxygen are fed to pilot stage 61. Its temperature is maintained at about 2000° F. 221.72 pounds per hour of oxygen and 814.2 pounds per hour of water are fed to stage 71. The combined output of stages 61 and 71 is 2 million BTU per hour at 1,600° F. 32.78 pounds per hour of hydrogen, 260.2 pounds per hour of oxygen and 814.2 pounds per hour of water are fed to stage 72. Its output is 2 million BTU per hour at 1,600° F. Each of stages 73-80 are operated in the same manner as stage 72. 571.51 pounds per hour of water are fed to each of nozzles 81C of stage 81 to lower the exhaust temperature to 600° F. For this data, the combined output of the 10 stages is steam at 16,787 pounds per hour with a total BTU output of 20 million per hour.
The ten stages 71-80 shown in FIGS. 2A, 2B and 4 were chosen for ease of computer programming and system design calculations. It is to be understood that the gas generator may have a different number of intermediate stages.
For a 10 stage system, the system would operate in the 100 percent steaming mode from 20 to 60 million BTU per hour. For any given total flow, the system is capable of a 10 to 1 flow change without changing supply pressure by shutting off stages. If the system is operating at 20 million BTU per hour flow then the flow range would be 2 to 20 million BTU per hour in increments of 2 million BTU per hour. If the total flow is 60 million BTU per hour the flow change possible per stage would be 6 million BTU per hour or the system would have a 3 to 1 flow change by changing supply pressure. The system would offer the maximum flow with minimum pressure drop therefore increasing the efficiency over fixed orifice systems by reducing the energy required to pressurize the hydrogen and oxygen. The system is ideal for computer control since it will be digital in nature rather than analogue, which would be the case if the system flow was controlled by pressure and fixed orifices. The system is easy to shift from pure steam to excess hydrogen or oxygen since all that would be required is the shutting off of the required number of valves in the selected stages. The hazards associated with high-flow start-up has been eliminated by the pilot generator that would operate at 2,000° F. using only hydrogen and oxygen. As indicated above, ignition is achieved by placing a charge of triethyl borane in the hydrogen line to pilot generator and allowing it to flow to the bottom shut off valve. The generator then is ignited by the hypergolic reaction of triethyl borane with oxygen. The other stages are introduced into the main generator in a manner programmed to achieve stable combustion and flow without hot spots and chamber burn thru. One of the major advantages of the ten stage system is the large increase in reliability due to the natural redundency created by the stages being in parallel.
Although hydrogen and oxygen were described as being used as the fuel and fluid oxidizer for the system, it is to be understood that other fuels and oxidizers may also be used. In addition, hypergolic fuels other than triethyl borane may be used to achieve ignitions. Other types of hypergolic fuels are disclosed in U.S. Pat. No. 4,053,015. The packer 59 may be a commercially available packer. One suitable commercial packer is known as the EMJAY Packer. It is mechanically actuated by rotating the gas generator by way of the main support conduit 57 which is fixedly attached to the gas generator and extends to the surface. | A multistage gas generator for use in a borehole for recovering hydrocarbons from the subsurface formations. The gas generator has an upper end and a lower restricted outlet. A pilot stage is located at the upper end and a plurality of spaced apart intermediate stages are located between the pilot stage and the lower restricted outlet. Hydrogen and oxygen are fed to the pilot stage for ignition. Oxygen is fed to a first intermediate stage and hydrogen and oxygen are fed to each of the other intermediate stages for injection into the gas generator. Excess hydrogen from the pilot stage is burned in the zone of the first intermediate stage and hydrogen and oxygen of each succeeding stage is ignited by the preceeding stage. Water for cooling purposes also is fed to each intermediate stage. Downhole valves selectively controllable from the surface are provided for the pilot stage and each of the intermediate stages. These valves allow the intermediate stages to be selectively operated to increase or decrease the BTU output or to vary other characteristics of the output. |
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of application Ser. No. 60/756,156 filed Jan. 4, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The subject invention relates to system and method for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material.
[0004] 2. Description of the Prior Art
[0005] Drainage systems are important when working with concrete surfaces. Specifically, drainage systems may be used to move a fluid from an expansion joint between two concrete surfaces. As the fluid flows into the expansion joint, changes in temperature cause the fluid to expand and contract, which can crack the concrete surfaces. Therefore, it is necessary to move the fluid away from the concrete surface to reduce the fluid in the expansion joint.
[0006] Various drainage systems are known in the art. One such drainage system is disclosed in U.S. Pat. No. 5,908,266 to Miller (the '266 patent). The '266 patent discloses a drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material. The drainage systems of the prior art include a conduit that has an outer surface that defines an inner chamber. The conduit has a length that extends between distal ends of the conduit and an axis that extends along the length. The drainage systems of the prior art also include a catch disposed on the outer surface of the conduit for directing the fluid from the aperture into the inner chamber.
[0007] Although the drainage systems of the prior art move the fluid away from the hardenable material, there remains an opportunity to improve upon the prior art drainage systems to prevent the conduit from collapsing and to maintain a flow of the fluid from the aperture into the inner chamber.
SUMMARY OF THE INVENTION AND ADVANTAGES
[0008] The invention provides for a drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material. The system includes a conduit having an outer surface defining an inner chamber and a length extending between distal ends with an axis extending along the length. A catch is supported by the outer surface of the conduit for directing the fluid from the aperture into the inner chamber. The catch includes a first tab extending along a portion of the length of the conduit and a second tab extending along a portion of the length of the conduit with the second tab radially spaced from the first tab about the axis for insertion into the hardenable material about opposing sides of the aperture to prevent collapsing of the conduit and to maintain a flow of the fluid from the aperture into the inner chamber.
[0009] The invention further provides for a method of making a drainage system. The system includes a hardenable material for forming a hardened layer, a conduit having an outer surface defining an inner chamber, and a catch having a first tab and a second tab. The method includes the steps of disposing the catch on the outer surface of the conduit, applying the hardenable material over the conduit and the catch, curing the hardenable material to form the hardened layer for embedding the first tab and the second tab within the hardened layer, and cutting the hardened layer to form an aperture. The method further includes the step of cutting the outer surface of the conduit between the first tab and the second tab to form a drainage opening simultaneously with the forming of the aperture and with the drainage opening in fluid communication with the aperture.
[0010] The invention further provides for a catch for a conduit for draining a fluid from a hardenable material. The catch includes a base defining a length with the base being adapted for mounting to the conduit. The catch further includes a first tab extending from the base along the length and defining a first plane. In addition, the catch includes a second tab extending from the base along the length spaced from the first tab and the second tab defining a second plane angled relative to the first plane for inserting the first tab and the second tab into the hardenable material to prevent collapsing of the conduit and to maintain a flow of the fluid into the conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0012] FIG. 1 is a perspective view of a first environment utilizing a drainage system in accordance with the subject invention;
[0013] FIG. 2 is a perspective view of a second environment utilizing the drainage system in accordance with the subject invention;
[0014] FIG. 3 is a perspective view of a conduit and a catch used with the drainage system in accordance with the subject invention;
[0015] FIG. 4 is a cross-sectional view of the conduit and the catch used with the drainage system of FIG. 3 in accordance with the subject invention;
[0016] FIG. 5 is a perspective view of an end cap used with the drainage system in accordance with the subject invention;
[0017] FIG. 6 is a perspective view of the conduit, the catch, an the end cap as shown in FIG. 5 assembled in accordance with the subject invention;
[0018] FIG. 7 is a side view of the drainage system disposed below a hardened layer in accordance with the subject invention;
[0019] FIG. 8 is a perspective view of the drainage system disposed below the hardened layer and having an aperture, a fluid passage, and a drainage opening in accordance with the subject invention;
[0020] FIG. 9 is a side view of one embodiment of the drainage system as shown in FIG. 8 in accordance with the subject invention;
[0021] FIG. 10 is a side view of another embodiment of the drainage system as shown in FIG. 8 in accordance with the subject invention;
[0022] FIG. 11 is a side view of the drainage system disposed below the hardened layer in accordance with the subject invention;
[0023] FIG. 12 is a perspective view of the drainage system having at least one drain hole formed in the hardened layer in accordance with the subject invention;
[0024] FIG. 13 is a perspective view of the drainage system having at least one slot formed in the hardened layer in accordance with the subject invention; and
[0025] FIG. 14 is a perspective view of the drainage system having a combination of the at least one drain hole and the at least one slot formed in the hardened layer in accordance with the subject invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a drainage system 20 is disclosed generally at reference numeral. As shown in FIGS. 1 and 2 , the drainage system 20 is used below a hardenable material 22 , such as a concrete driveway or sidewalk. Referring to FIGS. 3 and 4 , the drainage system 20 includes a conduit 24 having an outer surface 26 defining an inner chamber 28 . A length extends between distal ends of the conduit 24 with an axis A extending along the length. A catch 30 is disposed on the outer surface 26 of the conduit 24 and extends along at least a portion of the length of the conduit 24 . The catch 30 includes a first tab 32 having a first tab length that extends along the catch 30 . In one embodiment, the first tab 32 defines a first plane P 1 that extends through the first tab 32 and through the axis A. The catch 30 also includes a second tab 34 having a second tab length equal to that of the first tab length. Like the first tab 32 , the second tab 34 defines a second plane P 2 that extends through the second tab 34 and through the axis A. It is within the scope of the subject invention that the second plane P 2 extends from the length angled relative to the first plane P 1 , causing the first plane P 1 and the second plane P 2 to intersect, and the axis A may be defined by where the first plane P 1 and the second plane P 2 intersect.
[0027] A base (not shown) may be located on the outer surface conduit 24 , generally opposite the catch 30 . The base may have a shape similar to the catch 30 , and the first and second tabs 32 , 34 , but is not limited so such shape. The base acts to increase the stability of the drainage system 10 .
[0028] In addition, at least one of the first tab 32 and the second tab 34 may extend from the outer surface 26 of the conduit 24 perpendicularly to the outer surface 26 . Alternatively, at least one of the first tab 32 and the second tab 34 may extend from the outer surface 26 of the conduit 24 obliquely. Since it is within the scope of the subject invention that the first plane P 1 and the second plane P 2 not intersect, the axis A is then defined by conduit 24 . In addition, the first tab 32 may extend continuously along the portion of the length of the conduit 24 parallel to the second tab 34 . In yet another alternative, the catch 30 may include a base 36 that is disposed on the outer surface 26 of the conduit 24 that extends along the portion of the length of the conduit 24 to interconnect the first tab 32 and the second tab 34 . The length of the base 36 may be greater than or equal to the first tab length and the second tab length. It should be understood that the first tab 32 and the second tab 34 may have different shapes or be arranged differently with respect to one another. For instance, the first tab 32 and the second tab 34 may be curved.
[0029] Furthermore, the base 36 is shaped or adapted to mount onto the outer surface 26 of the conduit 24 . For example, if the conduit 24 is a pipe having a cylindrical cross-section, the outer surface 26 is rounded, and therefore, the base 36 of the catch 30 has an arcuate cross-section to fit onto the conduit 24 . It should be understood that the conduit 24 may have alternative cross-sections as is known in the art.
[0030] The second tab 34 extends along the portion of the length of the base 36 and is radially spaced from the first tab 32 about the axis at an angle θ relative to the first tab 32 . The angle θ is less than 90 degrees, however, it should be understood that the angle θ may be any angle. Additionally, as shown in FIGS. 5 and 6 , end caps 38 may be disposed on the conduit 24 that are transverse relative to and extend between the first tab 32 and the second tab 34 and parallel to one another. With the end caps 38 , the first tab 32 and the second tab 34 enclose the portion of the length of the conduit 24 .
[0031] The catch 30 , which includes the first tab 32 , the second tab 34 , the end caps 38 , and alternatively, the base 36 , may be disposed on the conduit 24 in various ways. For example, the base 36 may be adhered to the conduit 24 with an adhesive 40 or a fastener. Alternatively, the catch 30 may be integrally formed with the conduit 24 so that the conduit 24 and the catch 30 are formed from a single piece of material. In yet another alternative, the catch 30 may simply rest on the conduit 24 . It should be understood that these and other alternatives for disposing the catch 30 on the conduit 24 are within the scope of the subject invention.
[0032] Referring to FIG. 7 , after the catch 30 has been disposed on the outer surface 26 of the conduit 24 , the conduit 24 and the catch 30 are partially buried in a ground layer 42 . It should be understood that the conduit 24 may be partially placed in the ground layer 42 before disposing the catch 30 on the outer surface 26 of the conduit 24 . Once the catch 30 and the conduit 24 are placed in the ground layer 42 , the hardenable material 22 is applied over the entire catch 30 and over the portion of the length of the conduit 24 such that the first tab 32 and the second tab 34 extend into the hardenable material 22 . The hardenable material 22 may be sloped toward the catch 30 and the conduit 24 . After the hardenable material 22 is applied to the conduit 24 and the catch 30 , the hardenable material 22 is cured to a sufficient hardness. Once cured, a hardened layer 44 is formed and the first tab 32 and second tab 34 are embedded in the hardened layer 44 .
[0033] Next, referring to FIGS. 8-10 , the hardened layer 44 is cut to form an aperture 46 . Simultaneously, the conduit 24 is cut to form a drainage opening 48 . If the catch 30 includes the base 36 as previously described, then the base 36 is simultaneously cut with the conduit 24 and the hardened layer 44 to form a fluid passage 50 . The aperture 46 , the fluid passage 50 , and the drainage opening 48 may be cut to form at least one slot 52 , such as an expansion joint. An expansion joint filler 54 may be placed in the at least one slot 52 as is known in the art. Alternatively, at least one drain hole 56 may be drilled through the hardened layer 44 , the catch 30 , and the conduit 24 to form the aperture 46 , the fluid passage 50 , and the drainage opening 48 , respectively. A drain cap 58 may be placed over the at least one drain hole 56 . Furthermore, as shown in FIG. 7 , the drainage opening 48 in the conduit 24 is defined by the outer surface 26 between the first tab 32 and the second tab 34 of the catch 30 , and the drainage opening 48 is in fluid 60 communication with the aperture 46 . The base 36 of the catch 30 defines the fluid passage 50 , which is in fluid 60 communication with the aperture 46 and the drainage opening 48 .
[0034] Referring specifically to FIG. 9 , the fluid passage 50 and the drainage opening 48 may be cut or drilled to an equal width as the aperture 46 . In an alternative embodiment, as shown in FIG. 10 , the aperture 46 has a first width while the fluid passage 50 and the drainage opening 48 have a second width that is smaller than the first width. It should be understood that the width of the aperture 46 , the fluid passage 50 , and the drainage opening 48 may be a diameter if the aperture 46 , fluid passage 50 , and the drainage opening 48 are circular in shape, such as the at least one drain hole 56 .
[0035] As previously shown in FIG. 4 , cutting the conduit 24 may cause the conduit 24 to collapse and close the drainage opening 48 . However, by inserting the first tab 32 and the second tab 34 into the hardenable material 22 and embedding the first tab 32 and the second tab 34 into the hardened layer 44 , the catch 30 can prevent the conduit 24 from collapsing. Although the hardenable material 22 need not be completely cured before cutting through the hardened layer 44 to form the aperture 46 , when the drainage opening 48 is cut in the conduit 24 , the first tab 32 and the second tab 34 must be embedded in the hardened layer 44 and the hardened layer 44 must be strong enough to hold the drainage opening 48 open. If the hardened layer 44 has not cured enough to hold the drainage opening 48 open, the conduit 24 may collapse and close the drainage opening 48 .
[0036] Referring now to FIG. 11 , the aperture 46 is formed in the hardened layer 44 , the drainage opening 48 is formed in the conduit 24 in fluid 60 communication with the aperture 46 , and the fluid passage 50 is formed in the base 36 of the catch 30 in fluid 60 communication with the aperture 46 and the drainage opening 48 . Now, a fluid 60 can flow from the hardened layer 44 and through the aperture 46 , the fluid passage 50 , and the drainage opening 48 into the inner chamber 28 of the conduit 24 . The first tab 32 and the second tab 34 embedded in the hardened layer 44 hold the drainage opening 48 open and help reduce the fluid 60 from flowing between the hardened layer 44 and the conduit 24 through capillary action. The conduit 24 then carries the fluid 60 away from the hardenable material 22 . It should be understood that the conduit 24 may be any fluid-carrying device known in the art such as, but not limited to, a pipe or tube. In addition, the conduit 24 may be made of any material known in the art capable of carrying the fluid. Such materials include polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), or Acrylonitrile Butadiene Styrene (ABS). It should be understood that conduits 24 made of other materials are within the scope of the subject invention.
[0037] Referring to FIGS. 12-14 , the aperture 46 , the fluid passage 50 , and the drainage opening 48 may be various shapes. In FIG. 12 , the aperture 46 , the fluid passage 50 , and the drainage opening 48 are the at least one drain hole 56 . As shown in FIG. 13 , the aperture 46 , the fluid passage 50 , and the drainage opening 48 are the at least one slot 52 . As shown in FIG. 14 , the aperture 46 , the fluid passage 50 , and the drainage opening 48 are a combination of the at least one drain hole 56 and the at least one slot 52 .
[0038] Obviously, many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described within the scope of the appended claims. | A drainage system for draining a fluid from a hardenable material as the fluid flows through an aperture formed in the hardenable material includes a conduit and a catch. The conduit has an outer surface defining an inner chamber. The catch is supported by the outer surface of the conduit for directing the fluid from the aperture into the inner chamber. The catch includes a first tab and a second tab that extend along a portion of the length of the conduit, and the second tab is spaced from the first tab. Both the first tab and the second tab are inserted into the hardenable material about opposing sides of the aperture to prevent a collapsing of the conduit and to maintain a flow of the fluid from the aperture into the inner chamber. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is believed to be found in the field of static structures or buildings and more particularly in the field of an attachment system for prefabricated building panels.
2. Description of the Prior Art
The art of attaching pre-fabricated panels to the under-structure of a building is known. The known prior art systems employ a ship lap or a tongue and groove type of joint. These presently used joining systems require the sequential placement and fastening of the panels to the buildings under-structure.
These known prior art systems require that all phases of the building process be precisely timed to provide an economical building process. This building process involves the co-ordination of many trades. The use of a ship-lap or tongue and groove joint in the panel requires that each panel be attached to the building in a sequential order.
Not only does installation of the panels present a timing problem but removal of any one panel from a curtain wall most likely will require removal of several panels in addition to the panel to be removed.
It has therefore been determined that there is a need for a panel system which may be attached to the building structure which would allow independent installation or removal of each panel. This system should provide a curtain wall which protects the building under-structure from harmfull weather conditions and provides an envelope for the buildings contents.
SUMMARY OF THE INVENTION
This invention may be summarized, at least in part, with respect to its objects. It is an object of this invention to provide and it does provide a panel system which allows for the installation of substantially all individual panels independently of the next panel.
It is an object of this invention to provide and it does provide a panel mounting system which allows for the removal of substantially any and all panels independently of an adjacent panel.
It is an object of this invention to provide a panel mounting system which allows for the expansion and contraction of individual panels in two directions.
It is an object of this invention to provide and it does provide a panel attaching system which is economical and labor saving.
In addition to the above summary, the following disclosure is detailed to insure adequacy and aid in the understanding of this present invention. This disclosure, however, is not intended to cover each new and inventive concept, no matter how it may later be disguised by variation in form, additions, or by further improvements. For this reason, there has been chosen specific embodiments of an attaching system for pre-fabricated building panels. This system is particularly adapted for use in new and old construction.
These specific embodiments have been chosen for the purpose of illustration and description, as shown in the accompanying drawings wherein
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 represents a partial front elevational view, partly diagrammatic, of a curtain wall employing panels and support system of the present invention.
FIG. 2 represents a side elevational view, in section, of the present invention, this view taken along line 2--2 of FIG. 1.
FIG. 3 represents and alternate embodiment of an intermediate support member of the present invention.
FIG. 4 represents a fragmentary sectional view of a joint between two panels, this view taken along line 4--4 of FIG. 1.
FIG. 5 represents a fragmentary sectional view, in a reduced scale, of the application of the present system to a soffit area.
In the following description and in the claims, various details are identified by specific names for convenience. These names are intended to be generic in their application. The corresponding reference characters refer to like members throughout the several figures of the drawings.
The drawings accompanying, and forming a part of this specification disclose certain details of construction associated with the present invention. These details are only for the purpose of explanation, but structural details may be modified without departure from the principles of the present invention. It is anticipated that this invention may be incorporated into forms other than as shown.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a portion of a curtain wall 20 is shown. This curtain wall 20 includes a plurality of panel members 22. These panel members 22 have been shown as being rectangular and flat for convenience of this description. These panel members 22 may be flat or curved to suit a particular design. The panels 22 may also have shapes other than rectangular to suit a particular design. The panels 22 are preferably positioned with a predetermined space there-between to define a joint 24. The joint 24 may be further defined as being a lower joint 24L, an intermediate joint 24I, an upper joint 24U, and a substantially vertical joint 24V. Each of these joints may be more clearly seen in FIGS. 2 and 4.
Still referring to FIG. 1, the curtain wall 20 is shown having a window or louver panel 26. The support system of the present invention will allow panels such as windows louvers, doors and the like to be mounted by the support system or by their own mounting system. Typical jointing arrangements are shown adjacent the panel 26. It is anticipated that other combinations of joints may be employed for a specific application.
Referring now to FIG. 2, each panel 22 has a predetermined thickness resulting in a exterior surface 30 and an interior surface or plane 32. Engaging means 34 and 36 are provided along the periphery of the panel 22. Preferably these engaging means are located at opposite sides to provide maximum retention of the panels 22. Each of the engaging means 34 and 36 may be an integral part of the panel as shown at 34 or as a separately attached part as shown at 36. Engaging means 34 and 36 may be characterized as outwardly extending flanges of a predetermined length and thickness. These engaging means may be substantially continuous or may be provided at spaced intervals.
Referring still to FIG. 2, the lower joint 24L comprises a first support member 40 which is disposed in a substantially continuous array. This first support member 40 preferably is formed with a substantially L-shaped profile. One leg member 42 of the first support member 40 is securely fastened to the under-structure 44 of the building, by and with a suitable means such as a threaded fastener 46. The other leg 48 of the first support member 40 extends outwardly from the under-structure 44. The first support member 40 has a substantially continuous channel 50 formed on the interior surface of its leg 48. Preferably this channel is formed at or near the interior corner formed by the first leg 42 and the other leg 48. This channel 50 is sized and shaped to receive the engaging mean 34 of the panel 22. It is to be noted that this channel may be located at any convenient point along the leg 48.
Still referring to FIG. 2, an upper joint 24U comprises a second support member 52 being disposed in a substantially continuous array. This second support member 52 is formed with a substantially L-shaped profile also. A first leg 54 is securely fastened to the under-structure 44 of the building by an appropriate means such as fastener 46. This second support member 52 is fastened to the under-structure in a selectively spaced alignment with the first support member 40. This selective spacing allows for the insertion of a panel substantially as shown. The first leg 54 is shown with rib members 56A; 56B; and 56C integrally formed there-on. These ribs 56 act as spacers and are used for installation convenience. It is anticipated that a standard shim may be used as a spacer under the first leg 54.
A second leg 58 of the second support member 52 extends outwardly from the under-structure 44 for a predetermined distance. A leaf spring 60 is securely fastened to the interior surface of the second leg 58 by a suitable means such as a rivet, screw, or the like. The free end of the leaf spring 60 is oriented to face the interior corner 62 of the second support member 52. Preferably a biasing means 64 such a rubber strip or urethane spring is attached to the second support member 52 at the interior corner 62. The space between the free end of the leaf spring 60 and the biasing means 64 is sufficient to allow the second engagement means 36 to be retentively held there-between. This second support member may be used along the coping line of a building by attaching a clip for providing a hidden retainer for the coping shown in dashed outline.
When it may be necessary to install at least one row of panels 22 above a bottom row of panels 22 an intermediate joint 24I is formed. This intermediate joint 24I comprises an intermediate support member 68 which is selectively disposed and positioned intermediate the first support member 40 and the second support member 52. This intermediate support member 68 is also securely attached to the under-structure of the building by means of a suitable means such as fastener 46. The position of the intermediate support is dictated by the size of the panel 22. This intermediate support 68 is formed in a more or less T-shape. The intermediate support 68 is securely attached to the under-structure 44 of the building by a suitable means such as a threaded fastener 46. The intermediate support 68 has its leg member 70 extending outwardly from the under-structure. A leaf spring 60 is selectively mounted to the leg 70 by a suitable means as discussed above. A biasing means 62 is provided at the interior corner 72 to aid in the retention of the panel 22.
An elongated groove 74 is formed in the intermediate support 68. This elongated grove 74 is selectively sized and shaped to receive and retain the engaging means 34 of the panel 22.
It is to be noted that the intermediate support may have profiles other that as shown in FIG. 2. It is quite possible to use a two piece intermediate support which is made from first support 40 and second support 52 or provide an alternate profile as shown in FIG. 3.
USE AND OPERATION
The type and quantity of support members 40; 52, and 68 is dependent on the number of rows of panels 22 to be installed. If the installation is only one panel high, a first support 40 and second support 52 are only required. The intermediate support 68 is used when more than a single row of panels is to be installed. Referring to FIG. 2, it can be seen that a panel can easily be installed in the lower position or the upper position. The installer places the engaging means 34 into either the channel 50 or the groove 74 and pushes the panel 22 into retentive engagement by the spring 60. The biasing means 62 is used to automatically adjust for manufacturing tolerances. After the panel 22 is retained by the leaf spring 60 a second panel 22 may be easily inserted above, below, or on either side of the installed panel. The installer may use a gauging means to provide a desired space to form joint 24V or he may use a substantially continuous T-shaped gasket 80 carried on a support bar 82, as may be seen in FIG. 4. This gasket 82 is carried substantially continuously between its associated support members 40 and 62; 62 and 62; or 62 and 52. After the panel 22 has been correctly positioned the installer would caulk the joints with a suitable sealant.
Removal of a panel is made possible by inserting a bar to deflect the leaf spring 60 from engagement with the engaging means 36; rotating the panel outward; then disengaging the engagement means 34 from the channel 50 of groove 74. If the caulking has been installed around the panel it is necessary to remove the caulking first.
It is anticipated that the present mounting system can successfully be used with various types of panels 22. The panels 22 may be of a substantially uniform cross-section, a laminated insulated panel, a window, a lover, vent. The present system is adaptable to receive and retain any of the various panels which may be part of the overall design of the structure.
Referring to FIG. 5, there is shown an example of the present mounting system being used in connection with a soffit of a building. In this particular arrangement, the engaging means extends from the interior plane 32 of the soffit panel 90. In this particular instance the engaging means 34 is supported by a modified first support 40, It is anticipated that a special soffit support may be formed if the quantity was sufficient to justify the manufacture, The soffit panel 90 also has a engaging means 36 opposite said engaging means 34. This engaging means 36 would be retained by another support member such as the second support 52. It is to be noted that the support members may be modified to fit a particular installation by cutting, notching, or bending. The fascia 92 may be covered with a panel having similar construction as panel 90. It can clearly be seen that the present system is versatile in its use and may be adapted to many conditions which exist at and on a building.
Referring to FIG. 3, an alternate embodiment of an intermediate support is shown. This alternate intermediate support member, generally identified as 168, includes a plurality of rib members 94 extending from its attaching leg 96; and a safety lug 98. The safety lug 98 provides a means for preventing the engaging means 36 of the panel member 22 from moving away from engagement from the leaf spring 60. This safety lug may also be provided on the second support member 52 as well as intermediate support member 68. This safety lug 96 provides a quick indication means to ascertain that the proper spacing has been maintained between support members, by not allowing the engaging means 36 to be engaged by the leaf spring 60.
The support members 40; 52; 68; and 168 are presently anticipated as being manufactured from a metal material, such as an aluminum extrusion, but other suitable materials may be used such as Steel, Reinforced Plastics or the like.
The present system has been shown in the drawings as having the various support members as being fastened to the under-structure in a substantially horizontal alignment. It is anticipated that the present system may be employed by fastening the various support members in positions other than horizontal.
Terms such as "left", "right", "up", "down", "bottom", "top", "front", "back", "in", "out", and the like are applicable to the embodiments shown and described in conjunction with the drawings. These terms are merely for the purpose of description and do not necessarily apply to the position in which the panel mounting system the present invention may be utilized.
While these particular embodiments of an improved panel mounting system have been shown and described, it is to be understood that the invention is not limited thereto and protection is sought to the broadest extent the prior art allows. | A prefabricated building covering system having an arrangement of support members selectively arrayed on a building under-structure, said under-structure adapted for supporting the walls and roof of the building including a plurality of panel members, a first support member, a second support member, and intermediate support members. Said intermediate support members are used as and when needed. Said second support member and intermediate member having a leaf spring mounted there-on for allowing installation or removable of said panels as and when desired without disturbing adjacent panels. |
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PRIORITY CLAIM
This patent application claims priority to U.S. Provisional Patent Application No. 61/366,921, entitled “Flexible Hollow Sleeve Frame Support Structure with Integral Fabric Hub Intersections,” filed Jul. 22, 2010, which is incorporated herein in its entirety.
FIELD OF INVENTION
The present invention generally relates to tent constructions, and more specifically, to an improved tent assembly that can easily be erected by a user, where the improved tent assembly uses a web truss for providing an internal frame structure, where the web truss is a flexible hollow sleeve frame support structure with integral fabric hub intersections.
BACKGROUND OF THE INVENTION
Tents of conventional construction are typically time-consuming to erect. For example, tents with conventional internal frames require substantial effort by more than one person to place all the poles in position and then build a tent body around the pole structures. Some prior art tent assemblies allow for tent bodies to have provisions for pole structures to enable ease of construction. However, even in such tent assemblies, it is difficult to enable the tent body to form a certain structure without provisioning additional poles within the tent assembly. Moreover, given the number of poles that need to be erected to provide frame support on each side of the tent assembly, users have to hassle with dealing with a large number of poles during the assembly of the tent. Also, when erecting prior art tent assemblies, a fly sheet and/or tent body has to be added to the tent assembly to provide adequate structural integrity to the tent assembly. Attaching fly sheets or tent bodies is particularly challenging in high wind conditions. Several other such disadvantages exist in prior art necessitating a need for an improved tent assembly. Overall, the examples herein of some prior or related systems and their associated limitations are intended to be illustrative and not exclusive. Other limitations of existing or prior systems will become apparent to those of skill in the art upon reading the following Detailed Description.
SUMMARY OF THE DESCRIPTION
In at least one embodiment, the techniques described herein relates to a structure and method of assembling and positioning compression members using a singular or plurality of flexible hollow sleeve structures with integral fabric hub intersections that are held in tension in combination with compression members that can be used for a variety of applications. The present invention makes assembling structures significantly easier than known prior art since the intersecting flexible hollow sleeve structures can be made continuous. This allows users to erect the structure without the need for additional help. In addition, the improved tent assembly discussed herein is significantly stronger when deployed with compression members because the hollow sleeve structures, with integral fabric hub intersections, can be tensioned, thus significantly increasing the strength of the overall structure.
In embodiments, a further advantage of the improved tent assembly includes ease of assembly in, for example, high wind conditions. The web truss of the disclosed tent assembly may be set up merely with the tent poles without a need for a flysheet and/or a tent body. The pole sleeves of the web truss may be tensioned merely using provisions of the web truss it self, at which time the tent assembly is at full strength even before the flysheet and/or tent body is added. In embodiments, the tent assembly achieves complete structural integrity when the web truss is fitted with the poles. In prior art, since poles are added to the tent body or flysheet one at a time, high wind conditions often damage (e.g., snap) the poles and damage the tents, especially because complete structural integrity of the tent is not attained until the tent is fully erected with all tent poles in position.
In at least these respects, the improved tent assembly discussed here substantially departs from the conventional concepts and designs of the prior art. Other advantages and features will become apparent from the following description and claims. It should be understood that the description and specific examples are intended for purposes of illustration only and not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF DRAWINGS
These and other objects, features and characteristics of the present invention will become more apparent to those skilled in the art from a study of the following detailed description in conjunction with the appended claims and drawings, all of which form a part of this specification. In the drawings:
FIGS. 1 to 6 illustrate examples of pitching an improved test assembly;
FIG. 7 illustrates one exemplary embodiment where the pole sleeves may be tightened for providing additional tension;
FIG. 8 depicts an embodiment of the improved tent assembly that specifically illustrates an example of a flexible hollow pole sleeve structure with 12 integral fabric hub intersections;
FIG. 9 illustrates one exemplary embodiment of a pole intersection point;
FIG. 10 illustrates an example of how a tent pole is automatically guided in the correct pole sleeve section inside the integral fabric hub intersections because of the curved shape of the integral fabric hub intersections;
FIG. 11 illustrates an embodiment of a fully assembled flexible hollow pole sleeve structure with integral flexible material hub intersections, flysheet and tent poles;
FIG. 12 further depicts an embodiment of a fully assembled flexible hollow pole sleeve structure with integral fabric hub intersections, flysheet, and tent poles with the flysheet door open;
FIG. 13 illustrates the rear of the flysheet on an exemplary embodiment of a tent assembly;
FIG. 14 illustrates a tent body affixed to the flexible hollow pole sleeve structure with clips;
FIG. 15 illustrates a scenario where a plastic clip with a stainless steel gate is used for secure attachment to an o-ring;
FIG. 16 illustrates an embodiment of the tent assembly with a different method of attaching the tent body;
FIG. 17 shows an end view of an exemplary embodiment of a flexible hollow pole sleeve structure with an inner tent body;
FIG. 18 shows the vestibule area inside the flysheet and in front of the tent door;
FIG. 19 illustrates a single wall tent with a waterproof coated fabric in combination with a flexible hollow pole sleeve structure;
FIG. 20 illustrates flexible an exemplary embodiment of a hollow pole sleeve frame structure with integral fabric hub intersections that form of a sphere; and
FIG. 21 illustrates an embodiment of an improved tent assembly where a display banner is attached from the interior of the flexible hollow pole sleeve frame structure.
DETAILED DESCRIPTION OF THE INVENTION
Various examples of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these examples. One skilled in the relevant art will understand, however, that the invention may be practiced without many of these details. Likewise, one skilled in the relevant art will also understand that the invention can include many other obvious features not described in detail herein. Additionally, some well-known structures or functions may not be shown or described in detail below, so as to avoid unnecessarily obscuring the relevant description.
The terminology used below is to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the invention. Indeed, certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.
FIGS. 1 to 6 illustrate examples of pitching an improved test assembly. FIG. 1 depicts an exemplary embodiment of a flexible hollow pole sleeve structure 100 . The overall web of sleeve structures may sometimes be referred to herein as a web truss. Such a web truss provides the basic framework allowing a user to build a tent assembly frame, as will be explained in detail herein.
FIG. 2 illustrates examples of tent poles (or simply, “poles”) 105 used in conjunction with the improved tent assembly. In embodiments, the tent poles 105 are segmented and are held together with special elastic cord such as a shock cord. FIG. 3 illustrates an exemplary procedure for sliding in or directing poles within the web truss. As illustrated in FIG. 3 , a first tent pole 105 is inserted into the opening of one of the flexible hollow pole sleeve structures 100 . It is noted that while some of these exemplary figures show equal length tent poles fully inserted in the flexible hollow pole sleeve structure 100 , it is envisioned that non-equal poles may also be used as required in a particular application.
FIG. 5 illustrates an embodiment of an improved tent assembly where a water resistant or waterproof flysheet 130 is placed over the flexible hollow pole sleeve structure 100 to form a weatherproof enclosure. It is noted that the improved tent assembly can be configured to form a frame with either a flysheet or a tent body (that is internal to the frame formed by the web truss) as will be discussed further below. It is important to note that the frame, enabled by the insertion of the tent poles within the sleeve structures of the web truss, is independent of and does not require either for fly sheet or the tent body for completion of formation of a structurally complete structure for use as a tent. In contrast, all known prior art tent assemblies utilize either a fly sheet or a tent body as an essential component of formation of the eventual frame structure of a tent assembly.
FIG. 6 illustrates an embodiment of the improved tent assembly where a flysheet is partially draped over the flexible hollow pole sleeve structure 100 . A zipper 140 entrance on the flysheet allows for user ingress and egress. FIGS. 1 through 6 discussed an exemplary embodiment of an improved tent assembly where multiple poles were used in conjunction with multiple pole sleeves of a web truss in order to create a frame structure that formed the improved tent assembly. While the exemplary figures illustrate the use of as many as 6-12 web hubs (or fabric hubs) that provide housing for pole intersections, it is understood that a frame may be formed using a web truss that has even a single fabric hub. In such an embodiment, two poles may be used to intersect within the fabric hub and still be able to provide support to form a structurally sound frame. In the disclosed embodiments, as can be evidenced from the supporting figures, the improved tent assembly allows for continuous feeding and insertion of tent poles from just one end or base of the web truss. The tent pole extends all the way out to the other end. Issues are normally encountered when two tent poles need to cross over or intersect each other. In such scenarios, the web hubs of the disclosed improved tent assembly has separate angled housing that, as discussed herein, allows the two intersecting tent poles to slide through without allowing the two to collide with each other. This enables a user to simply feed in the poles from just one end of the web truss, while the pole sleeves and the web hubs cause the tent poles to be slid through in a direction and structure so as to form the entire frame of the improved tent assembly.
FIG. 7 illustrates one exemplary embodiment where the pole sleeves (and hence the corresponding web hubs coupled with the pole sleeves) may be tightened for providing additional tension (and hence additional strength) to the overall frame. In the illustrated embodiment, the web truss includes tent body grommet tab 125 , grommets 120 , webbing 170 loop, perimeter fabric skirt 150 , tension wings 155 , tensioning system 160 for the flexible hollow pole sleeve structure 100 , pole sleeve opening 175 , pole sleeve reinforcements 155 and o-ring 180 . In the disclosed exemplary embodiment, the tensioning system 160 for the flexible hollow pole sleeve structure 100 comprises of a buckle 165 which is attached to or near the pole sleeve opening 175 and a webbing 170 strap that is affixed at one end to the o-ring 180 , with the opposite end of the webbing 170 threaded through the tensioning buckle 165 . In the illustrated embodiment, the tension of the flexible hollow pole sleeve structure 100 can be adjusted by pulling 190 on the webbing 170 strap as shown in FIG. 7 . The amount of tension applied to the flexible hollow pole sleeve structure 100 may be adjusted based on the need for additional strength for extreme environmental conditions such as high wind or heavy snow loads. It is understood that the above description is merely one example of how the tensioning system may be applied to the web truss in order to enable control of tension applied to adjust and control the tension (and corresponding strength) of the frame of the improved tent assembly. For example, the arrangement of the o-ring, the webbing, the tensioning buckle, etc. may be altered with respect to the web truss and the sleeve structures as may be suited for a particular design or an application of the tent assembly. Other arrangements or provisions for providing a tensioning mechanism, as may be understood by people of ordinary skill in the art may also be used to substitute the illustrated tensioning mechanism.
FIG. 8 depicts an embodiment of the improved tent assembly that specifically illustrates an example of a flexible hollow pole sleeve structure 100 with 12 integral fabric hub intersections 195 . The flexible hollow pole sleeve structure 100 has an inner 270 flexible material layer and an outer 275 layer of flexible material. When joined, the inner and outer layers of material form the flexible hollow pole sleeve structure 100 with integral fabric hub intersections 195 . The tent poles are fed into the flexible hollow pole sleeve structure 100 at any pole sleeve opening 175 . The tent poles are located in-between the inner 270 flexible material layer and an outer 275 flexible material layer which form the flexible hollow pole sleeve structure 100 .
FIG. 9 illustrates one exemplary embodiment of a pole intersection point 200 . The integral fabric hubs 195 help guide the tent poles 105 in the correct direction without snagging or hanging up on another tent pole 105 or fabric. FIG. 10 illustrates an example of how a tent pole 105 is automatically guided in the correct pole sleeve section 205 inside the integral fabric hub intersections 195 because of the curved shape 265 of the integral fabric hub intersections 195 . In the illustrated embodiment, the integral fabric hubs 195 can be cut on the straight of grain and eliminates bias stretch which helps increase the strength of the structure by holding the poles 105 more securely in place. FIG. 10 shows the outer 275 and inner 270 integral fabric hub intersections 195 .
FIG. 11 illustrates an embodiment of a fully assembled flexible hollow pole sleeve structure 100 with integral flexible material hub intersections 195 , flysheet 130 and tent poles 105 . In the illustrated embodiment, a perimeter skirt 150 is shown with a modified tension wing 155 . The tension wings 155 have been connected to create a perimeter sidewall 210 . The perimeter sidewall 210 helps keep wind blown snow, spindrift, rain, etc. from entering the tent assembly. FIG. 12 further depicts an embodiment of a fully assembled flexible hollow pole sleeve structure 100 with integral fabric hub intersections 195 , flysheet 130 and tent poles with the flysheet door 215 open.
FIG. 13 illustrates the rear of the flysheet 130 on an exemplary embodiment of a tent assembly. This embodiment further illustrates a perimeter sidewall 210 . FIG. 14 illustrates a tent body 220 affixed to the flexible hollow pole sleeve structure 100 with clips 225 . FIG. 15 illustrates a scenario where a plastic clip 225 with a stainless steel gate 230 is used for secure attachment to an o-ring 180 . In embodiments, this protects the clips 225 from disengaging from the o-rings 180 when encountering, for example, high buffeting winds. In embodiments, the tent body 220 may be affixed to the flexible hollow pole sleeve structure 100 via clips, webbing, grosgrain, o-rings, quick links, carabineers, hooks or other temporary or permanent means as may be understood by a person of ordinary skill in the art.
FIG. 16 illustrates an embodiment of the tent assembly with a different method of attaching the tent body 220 to the o-rings 180 located on the flexible hollow pole sleeve structure 100 . In embodiments, multiple webbing 170 straps are attached to a plurality of o-rings 180 that are attached to the webbing or a flexible material, which are turn is attached the flexible hollow pole sleeve structure 100 . The clip 225 on the tent body 220 may then be attached to a single o-ring 280 on the flexible hollow pole sleeve structure 100 .
FIG. 17 shows an end view of an exemplary embodiment of a flexible hollow pole sleeve structure 100 with an inner tent body 220 . In embodiments, the tent body 220 is shaped in such a manner as to create several vestibule areas 235 when the flysheet is engaged. FIG. 18 shows the vestibule area 235 inside the flysheet 130 and in front of the tent door 240 . FIG. 19 illustrates a single wall tent 285 with a waterproof coated fabric in combination with a flexible hollow pole sleeve structure 100 . This configuration is an example of a preferred structure for mountaineers. FIG. 20 illustrates flexible an exemplary embodiment of a hollow pole sleeve frame structure 100 with integral fabric hub intersections 195 that form of a sphere. In embodiments, the poles are connected at the terminal ends to form a continuous loop inside flexible hollow pole sleeve frame structure 100 to create the sphere structure. Here, in embodiments, the tent poles are inserted or removed via an opening 255 in a pole sleeve segment 250 . The flexible hollow pole sleeve frame structure 100 can be tensioned as per the pole sleeve tensioning system illustrated in FIG. 7 .
FIG. 21 illustrates an embodiment of an improved tent assembly where a display banner 260 is attached from the interior of the flexible hollow pole sleeve frame structure 100 with integral fabric hub intersections 195 . The display material may be held in place by o-rings 180 or webbing 170 loops located on the inner 270 layer of the flexible hollow pole sleeve frame structure 100 .
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 (i.e., to say, in the sense of “including, but not limited to”), as opposed to an exclusive or exhaustive sense. As used herein, the terms “connected,” “coupled,” or any variant thereof means any connection or coupling, either direct or indirect, between two or more elements. Such a coupling or connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above” “below,” and words of similar import, when used in this application, refer to this application as a whole and not to any particular portions of this application. 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.
The above Detailed Description of examples of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific 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. While processes or blocks are presented in a given order in this application, alternative implementations may perform routines having steps performed in a different order, or employ systems having blocks in a different order. Some processes or blocks may be deleted, moved, added, subdivided, combined, and/or modified to provide alternative or sub-combinations. Also, while processes or blocks are at times shown as being performed in series, these processes or blocks may instead be performed or implemented in parallel, or may be performed at different times. Further any specific numbers noted herein are only examples. It is understood that alternative implementations may employ differing values or ranges.
The various illustrations and teachings provided herein can also be applied to systems other than the system described above. The elements and acts of the various examples described above can be combined to provide further implementations of the invention.
Any patents and applications and other references noted above, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions, and concepts included in such references to provide further implementations of the invention.
These and other changes can be made to the invention in light of the above Detailed Description. While the above description describes certain examples of the invention, and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Details of the system may vary considerably in its specific implementation, while still being encompassed by the invention disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific examples disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed examples, but also all equivalent ways of practicing or implementing the invention under the claims. | Disclosed are structures and methods of assembling and positioning an improved tent assembly where members of the assembly use flexible hollow sleeve structures with integral fabric hub intersections that are held in tension in combination with compression members that can be used for a variety of applications. Disclosed techniques make assembling tent assemblies significantly easier than known prior art since the intersecting flexible hollow sleeve structures can be made continuous. In addition, the improved tent assembly is significantly stronger when deployed with compression members because the hollow sleeve structures, with integral fabric hub intersections, can be tensioned, thus significantly increasing the strength of the overall structure. |
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TECHNICAL FIELD
[0001] The present invention relates to an electric actuator for driving a home-automation screen, of any of the following types: roller blind, shade, curtain, gate, projection screen, or garage door. The actuator of the invention is provided with a spring brake. This type of brake is more particularly adapted to tubular motors.
STATE OF THE ART
[0002] Use of a helical-spring brake in actuators for home-automation screens is known, in particular from Patent Document FR B 2 610 668. In that document, a helical spring is mounted in a friction part. At least one turn of the spring is stressed radially by a bore in the friction part. Each end of the spring forms a tab extending radially towards the inside of the spring. Each tab can be moved in order to drive the spring in rotation about its axis. The inlet part, the outlet part, and the spring are arranged specifically to obtain the following dynamic behavior: action from the inlet part situated on one side of the first tab causes the spring to move in rotation in a first direction. This movement releases the outlet part, i.e. it tends to reduce the diameter of the outside envelope of the spring. Thus, the friction between the bore in the friction part and the turns of the spring decreases, thereby reducing the radial stress between the spring and the friction part. Conversely, action from the outlet part on the opposite side of the first tab causes the spring to move in rotation in the second direction, i.e. in the opposite direction. This movement blocks the outlet part, i.e. it tends to increase the diameter of the outside envelope of the spring. The friction between the bore in the friction part and the turns of the spring therefore increases. The same applies for the radial stress between the spring and the friction part. In addition, the inlet part can also act on the second tab of the spring in order to drive the spring in rotation in the second direction, while also releasing the outlet part. Furthermore, the outlet part can also act on the second tab of the spring in order to drive the spring in rotation in the first direction. In which case, the outlet part is blocked, or at least is braked by means of the spring rubbing against the friction part. Therefore, the inlet part moving in rotation makes it possible for the spring and for the outlet part to be moved in rotation, while the outlet part moving in rotation blocks the movement begun by the outlet part.
[0003] The main braking of the outlet part is thus obtained by the spring rubbing against the friction part. A second phenomenon contributes to the braking of the outlet part, namely the outlet part rubbing at its guide means. This rubbing is directly related to the torque applied to the brake. When drive torque is exerted on the inlet part, the inlet part applies a force on the outlet part via a tab of the spring. Since that force is asymmetrical about the axis of the outlet part, it induces a radial force that causes the outlet part to be moved until it bears against its guide means. That contact brakes the outlet part. When torque is exerted on the outlet part, said outlet part applies a force on a tab of the spring that tends to hold the spring stationary in rotation. In reaction to that asymmetrical force, a radial force causes the outlet part to be moved until it bears against its guide means. Thus, in conventional spring brake designs, secondary braking torque exists that is added to the main braking torque of the spring against the friction part. That secondary braking torque is then applied both while the screen is being raised and also while it is being lowered.
[0004] In Patent EP-B-0 976 909, a spring brake comprises an inlet part having two teeth, an outlet part also having two teeth, a spring, and a friction part. The drive torque exerted on the inlet part is transmitted to the outlet part via a tooth bearing against one of the tabs of the spring, which tab bears against a tooth of the outlet part. Since the force exerted on the outlet part is asymmetrical, it results in a radial force being applied to said outlet part and thus in secondary braking torque being applied. When torque is applied to the outlet part, a phenomenon occurs that is similar to the phenomenon that occurs in the brake of FR-B-2 610 668. A tooth of the outlet part bears against a tab of the spring that blocks the spring. In reaction to that asymmetrical force, a radial force causes the outlet part to be moved until it bears against its guide means.
[0005] The way in which conventional spring brake designs as described in the preceding examples operate suffers from drawbacks in certain configurations. When the actuator drives a screen in the lowering direction, i.e. when the load torque exerted by the weight of the screen at the outlet part is in the same direction as drive torque from the actuator that is exerted at the inlet part, it is advantageous for secondary braking torque to be added to the main braking torque because that reduces the response time of the brake, thereby making the installation safer. Unfortunately, the existence of secondary braking torque while the screen is being raised, i.e. when the load torque exerted by the weight of the screen at the outlet part is opposed to drive torque from the actuator that is exerted at the inlet part, is particularly disadvantageous because the brake brakes continuously, thereby requiring the motor to be over-dimensioned. The motor must not only raise the load, i.e. exert torque that is greater than the load torque, but must also compensate for the secondary braking torque, since said secondary braking torque is added to the load torque.
SUMMARY OF THE INVENTION
[0006] The invention proposes an electric actuator provided with a spring brake that improves the operation of the above-described brakes, while also preserving the advantages of those brakes. In order to optimize dimensioning of the motor, the invention aims to eliminate the secondary braking torque while the load is being raised. To this end, the invention provides an electric actuator for driving a home-automation screen mounted to move between an open position and a closed position, said actuator being provided with a spring brake, said brake comprising:
a helical spring, each end of which forms a respective tab extending radially or axially relative to a central axis of the spring; a friction part having a substantially cylindrical friction surface against which at least one turn of the helical spring bears radially; an inlet part driven by an electric motor of the actuator, and suitable for coming into contact with at least one tab of the spring, in such a manner as to drive the spring in rotation about a central axis of the brake, in a direction making it possible to reduce the contact force between the helical spring and the friction surface; and an outlet part connected to the screen and suitable for coming into contact with at least one tab of the spring in such a manner as to drive the spring in rotation about the central axis of the brake, in a direction making it possible to increase the contact force between the helical spring and the friction surface.
[0011] In this actuator, while the screen is being lowered, the inlet part drives the spring in rotation with the contact force being decreased to the extent that the outlet part is released in rotation, without direct contact between the inlet part and the outlet part. According to the invention, the inlet part has at least two contact surfaces suitable for transmitting drive torque for raising the screen, by direct contact, to at least two corresponding contact surfaces of the outlet part.
[0012] The screen generates load torque at the outlet part, which torque makes it possible to generate secondary braking torque. As a result, this actuator is particularly suitable for screens that move vertically and whose weight makes it possible to generate the preceding load torque. This may be for winding an apron around a tube or for swinging a garage door between a horizontal position and a vertical position.
[0013] The inlet part and the outlet part are in direct contact only while the screen is being raised. Thus, during lowering, these two parts are not in direct contact for transmitting the drive torque. During lowering, the inlet part releases the brake by acting only on one of the tabs of the spring. The drive torque is exerted on that tab. No force is transmitted between the inlet part and the outlet part. The outlet part is retained by the other tab of the spring. As a result, it exerts a force, generated by the load torque, on that tab only, so as to drive the spring in rotation about the central axis of the brake, in a direction making it possible to increase the contact force between the helical spring and the friction surface.
[0014] In the present description “direct contact” between two parts means that one part acts on the other either by direct co-operation of complementary surfaces, or by co-operation between complementary surfaces through another part that is rigid disposed between these surfaces, or else by a combination of the preceding types of co-operation. Direct contact can be obtained by one or more contact surfaces disposed on the outlet part, such a contact surface being a surface against which there comes to bear a complementary contact surface of the inlet part or a complementary surface of an intermediate part urged by the inlet part. In order to implement the invention, it is necessary for the torque to be transmitted via at least two contact surfaces of the outlet part.
[0015] The balancing of the drive torque that makes it possible to reduce the secondary braking torque during raising can be achieved astutely by transmitting the drive torque via a plurality of sets of contact surfaces disposed, about the axis of rotation of the spring, in a manner such that the drive torque is transmitted in substantially balanced manner, making the outlet part relatively unstressed radially. These sets of surfaces can be disposed about the axis of the outlet part in a manner such as to reduce or eliminate the induced radial force. For example, the torque can be transmitted via two contact surfaces of the outlet part that are substantially identical and that are diametrically opposite each other about the axis of the outlet part. This solution is simple to implement.
[0016] Advantageously, operation of the brake is identical, regardless of the direction of the drive torque for raising the screen. This characteristic makes it possible to obtain a versatile actuator that can be installed independently of the configuration of the screen. For example, for a tubular actuator that fits into a winding tube, operation of the actuator is identical regardless of whether the screen is wound in one direction or in the opposite direction. This symmetrical operation of the brake makes it possible to rationalize a product range and to facilitate installation of the actuator because there is no need to distinguish whether the motor should be mounted in a particular manner relative to the screen.
[0017] According to other advantageous but non-essential aspects of the invention:
in the absence of drive torque, the outlet part exerts a force on the tab of the spring in such a manner as to drive the spring in rotation about the central axis of the brake, in a direction making it possible to increase the contact force between the spring and the friction surface; at at least one contact surface, the direct contact between the inlet part and the outlet part is achieved by means of a rigid part such as one of the tabs of the spring; the configuration of the contact surfaces makes it possible to balance the transmission of the raising drive torque, in such a manner as to eliminate or significantly reduce the radial component, relative to the axis of rotation of the spring, of the forces transmitted to the outlet part; and the two contact surfaces of the outlet part are diametrically opposite each other about the axis of the outlet part.
[0022] Provision may be made for the outlet part to be suitable for coming into contact with a part having dynamic behavior different from that of the outlet part, in particular a part secured to or integral with the friction part or the inlet part, when a radial force is exerted on the outlet part, said radial force being generated only while the screen is being lowered.
[0023] The outlet part is advantageously suitable for coming to bear against a centering member for centering the outlet part relative to the inlet part under the effect of the radial component of the resultant of the load torque exerted by the screen, while the screen is being lowered.
[0024] Provision may be made for the outlet part to be guided in rotation relative to the inlet part. The inlet part and the outlet part must be centered relative to each other. The inlet part and the outlet part may be centered by a shaft passing through said parts. The shaft is mounted in tight-fitting manner in the inlet part or in the outlet part and is mounted to slide in the other part, i.e. respectively in the outlet part or in the inlet part. This centering is simple to achieve and is compact. The sub-assembly formed by the inlet part and by the outlet part is then advantageously centered relative to the friction part. This centering may be achieved either by the outlet part, or by the inlet part. Preferably, the sub-assembly is centered by the inlet part, because that makes it possible to reduce the vibration of the brake considerably.
DESCRIPTION OF THE DRAWINGS
[0025] The invention can be better understood on reading the following description given merely by way of example and with reference to the accompanying drawings, in which:
[0026] FIG. 1 is a diagrammatic view of the architecture of a tubular actuator of the invention that incorporates a spring brake of the invention;
[0027] FIG. 2 is an exploded perspective view of a spring brake belonging to the actuator of FIG. 1 ;
[0028] FIG. 3 is a diagrammatic cross-section view of operation of the spring brake 2 of FIG. 2 during raising of a load;
[0029] FIG. 4 is a diagrammatic cross-section view of operation of the spring brake 2 during lowering of a load;
[0030] FIG. 5 is a diagrammatic cross-section view of operation of a prior art spring brake during raising of a load;
[0031] FIG. 6 is an exploded perspective view of a second embodiment of a spring brake that can be part of the actuator of FIG. 1 ;
[0032] FIG. 7 is an exploded perspective view from a different angle of certain component elements of the spring brake of FIG. 6 ;
[0033] FIG. 8 is a diagrammatic end view seen looking along arrow F in FIG. 6 , and partially in cross-section, showing operation of the spring brake of FIG. 6 during raising of a load that generates torque in the clockwise direction on the outlet part of the brake;
[0034] FIG. 9 is a diagrammatic end view partially in cross-section analogous to FIG. 8 , showing operation of the spring brake of FIG. 6 during lowering of a load that generates torque in the clockwise direction on the outlet part of the brake;
[0035] FIG. 10 is a diagrammatic end view partially in cross-section analogous to FIG. 8 , showing operation of the spring brake of FIG. 6 during raising of a load that generates torque in the counterclockwise direction on the outlet part of the brake; and
[0036] FIG. 11 is a diagrammatic end view partially in cross-section analogous to FIG. 8 , showing operation of the spring brake of FIG. 6 during lowering of a load that generates torque in the counterclockwise direction on the outlet part of the brake.
DESCRIPTION OF EMBODIMENTS
[0037] FIG. 1 diagrammatically shows a rotary tubular actuator 100 designed to drive in rotation a winding tube 1 on which an apron 2 for closing an opening 0 can be wound to various extents. The tube 1 is driven by the actuator 100 in rotation about an axis of revolution X-X that is disposed horizontally at the top of the opening. For example, the opening O is an opening provided in the walls of a building. The actuator 100 , the tube 1 , and the apron 2 then form a motor-driven roller blind.
[0038] The actuator 100 comprises a stationary cylindrical tube 101 in which a motor-and-gearbox unit 102 is mounted that is made up of an electric motor 103 , a first gearbox stage 104 , a spring brake 105 , a second gearbox stage 106 , and an outlet shaft 107 that projects at one end 101 A of the tube 101 , and that drives a wheel-ring 3 that is constrained to rotate with the tube 1 .
[0039] The winding tube 1 turns about the axis X-X and about the stationary tube 101 by means of two pivot couplings. A bearing-ring 4 mounted on the outside periphery of the tube 101 in the vicinity of its end 101 B opposite from the end 101 A forms the first pivot coupling. The second pivot coupling is installed at the other end of the tube 1 and is not shown.
[0040] The actuator 100 further comprises a fastening part 109 that projects from the end 101 E and that makes it possible to fasten the actuator 100 to a frame 5 . Said fastening part 109 is, in addition, designed to close off the tube 101 and to support a control module 108 for controlling the power supply to the motor 103 . Said control module is powered via a mains power supply cable 6 .
[0041] While the tubular actuator 100 is operating, the motor-and-gearbox unit 102 drives in rotation the shaft 107 which, in turn, drives in rotation the tube 1 via the wheel-ring 3 . For example, when the actuator 100 is installed in a roller blind case, the shaft 103 rotating causes the opening O to be opened and to be closed in alternation. The apron 2 thus moves vertically in the opening O, between an opening high position and a closure low position.
[0042] FIGS. 2 to 4 more particularly show the structure of the spring brake 105 in a first embodiment of the invention. As shown in FIG. 1 , a rotor of the motor 103 drives an epicyclic gear train of the first gearbox stage 104 . The cylinder 110 of the epicyclic train that carries three planet gears also forms an inlet part of the brake 105 . The brake 105 includes a helical spring 130 having its turns centered on an axis X 130 that coincides with the axis X-X when the brake 105 is in place, as shown in FIG. 1 . Said spring is mounted in tight-fitting manner inside a bore 141 in a friction part 140 . In other words, the outside envelope 131 of the spring 130 , which envelope is defined by the outside generator lines of its turns, bears against the radial surface of the bore 141 , thereby tending to secure together the spring 130 and the part 140 by friction.
[0043] Each end of the spring 130 forms a tab 132 a, 132 b extending radially towards the axis X 130 and towards the inside of the spring, from its turns.
[0044] The inlet part 110 is provided with two protuberances or “teeth” 111 a and 111 b that fit into the helical spring 130 . Each protuberance 111 a or 111 b has a face 113 a or 113 b suitable for being in contact respectively with a surface 133 a of a first tab 132 a forming the first end of the spring or with a surface 133 b of the second tab 132 b forming the second end of the spring. The surface 133 a is disposed in a manner such that action on said surface causes the spring to be moved in rotation about the axis X 130 in a direction that is opposite from the direction of rotation of the spring if the action is exerted on the surface 133 b.
[0045] Action by one of the teeth 111 a or 111 b on a surface 133 a or 133 b tends to release the brake, i.e. to move one of the tabs 132 a or 132 b in a manner such that the radial stress between the outside envelope 131 of the helical spring 130 and the friction surface of the bore 141 decreases. This action from one of the teeth 111 a or 111 b tends to contract the spring 130 radially about the axis X-X, so that its outside envelope moves away from the surface of the bore 141 . The part 110 thus makes it possible to act on the spring 130 to reduce the contact force between the spring and the friction surface of the bore 141 . The spring can then turn about the axis X 130 that coincides with the central axis X 105 of the brake 105 , itself coinciding with the axis X-X when the actuator 100 is in the assembled configuration shown in FIG. 1 . A direction or a dimension is said to be “axial” when it extends or is measured parallel to the axis X 105 . A direction is said to be radial when it is perpendicular to and intersects the axis X 105 .
[0046] An outlet part 120 of the brake 105 is situated in register with the inlet part 110 . The outlet part is provided with two lugs 121 a, 121 c also fitting into the helical spring 130 . The lug 121 a is provided with two recesses or setbacks 122 a, 122 b disposed on either side of said lug. Each recess 122 a or 122 b is designed to receive a respective one of the tabs 132 a, 132 b of the spring and is defined partially by a surface 124 a, 124 b suitable for being in contact with a surface 134 a, 134 b of a tab 132 a, 132 b. The surfaces 134 a and 134 b are opposite from respective ones of the surfaces 133 a and 133 b.
[0047] Action on one of the surfaces 134 a, 134 b tends to move the tabs 132 a and 132 b apart, thereby causing the turns of the spring 130 to expand radially relative to the axis X 130 and increasing the contact force between the spring 130 and the friction surface of the bore 141 . This results in actuating the brake, i.e. in blocking or in strongly braking the rotation of the spring 130 relative to the part 140 . Thus, the radial stress between the outside envelope 131 of the helical spring and the friction surface 141 increases, thereby holding the part 120 stationary or braking it strongly about the axes X 105 and X 130 .
[0048] In order to enable the brake to operate, it is necessary to have angular clearance between the teeth 111 a and 111 b of the inlet part 110 and the tabs 132 a and 132 b of the spring. Similarly, angular clearance is also necessary between the lug 121 a and the tabs 132 a and 132 b of the spring. The width of the lug 121 a is designed for this purpose. In addition, the axial length L 111 or L 121 of the portions 111 a, 111 b, and 121 a is slightly greater than the axial length L 130 of the spring.
[0049] The outlet part 120 is also provided with a set of teeth 129 forming the interface with the second gearbox stage 106 .
[0050] The necessary centering of the outlet part 120 relative to the inlet part 110 is achieved by a shaft 118 projecting axially relative to the inlet part, on the same side as the outlet part 120 . Said shaft 118 serves as guide means for guiding the outlet part, by means of a bore 128 provided through the center of said outlet part.
[0051] As appears more particularly from FIGS. 3 to 4 , the load L constituted by the apron 2 can be considered as being secured to the outlet part 120 , via the elements 1 , 3 , 106 , and 107 , as indicated by the vertical dashed line in FIGS. 3 and 4 .
[0052] The weight of the load L exerts torque C L on the outlet part 120 that tends to cause it to turn about the axis X 105 , in the clockwise direction in FIGS. 3 and 4 .
[0053] Reference X 120 designates the central axis of the outlet part 120 , which axis coincides with the axis X 105 when the brake is in the assembled configuration.
[0054] While the load L is being raised, and as shown diagrammatically in FIG. 3 , rotation of the outlet part 120 in the clockwise direction in FIG. 3 , which rotation is normally induced by the torque C L , is blocked by the inlet part 110 . The inlet part 110 is driven in rotation in the counterclockwise direction in FIG. 3 by torque C M generated by the motor and weighted by the efficiency of the first gearbox stage 104 . The two protuberances 111 a and 111 b of the inlet part 110 pivot about the coinciding axes X 105 and X-X until one of the protuberances 111 a or 111 b is in contact with a face 123 a or 123 b of the lug 121 a of the outlet part. Whereupon, the other protuberance 111 b or 111 a also enters into contact with one of the faces 123 c or 123 d of the second lug 121 c of the outlet part. Therefore, the drive torque C M is transmitted to the outlet part via two sets of contact surfaces, formed between the faces 113 a and 113 d and the faces 123 a and 123 d that are diametrically opposite each other about the axis X 105 and about the axis X 120 of the outlet part, thereby causing the radial component of the resultant of the torque C M exerted on the outlet part 120 to be reduced or eliminated. The drive torque C M is of opposite direction to the load torque C L . The faces 123 a and 123 d constitute the contact surfaces of the outlet part 120 .
[0055] The balance of the forces to which the outlet part 120 is subjected is shown in FIG. 3 . The load torque C L is balanced by forces F 1a and F 1b resulting respectively from the surface 113 a of the tooth 111 a and the surface 123 a of the lug 121 a bearing against each other, and from the surface 113 d of the tooth 111 b and the surface 123 d of the lug 121 c bearing against each other. These two forces F 1a and F 1b express in terms of forces the drive torque C M necessary for overcoming the load torque C L . Since the two forces F 1a and F 1b are of substantially the same magnitude and are substantially symmetrical about the central axis X 120 of the outlet part, the radial component of the resultant of the torque C M of the outlet part 120 is negligible, or even zero. It should be noted that the shaft 118 of the inlet part making it possible to center the outlet part is not in contact with the bore 128 of the outlet part in this configuration, due to the fact that the radial component of the above-mentioned resultant is negligible.
[0056] In order to raise the load, the torque C M must be greater than the sum of the load torque C L and of the drag torque of the brake spring due to the residual friction between the outside envelope 131 of the spring and the friction surface of the bore 141 . At start-up, the torque C M to be exerted must be larger because, in order to release the brake 105 , it is necessary to overcome a static friction force. Thus, the protuberance 111 a acts on one of the tabs of the spring, which tab is, in this example, the tab 132 a, received in the recess 122 a, as soon as the lug 121 a is driven in rotation.
[0057] While the load L is being lowered, and as shown diagrammatically in FIG. 4 , the outlet part rotating in the clockwise direction in FIG. 4 is not stopped by the inlet part but by the spring 130 . Thus, the load torque C L presses the lug 121 a against one of the tabs 132 a or 132 b, namely the tab 132 a in this example. The effect of this is to expand the turns of the spring 130 radially and to activate the brake 105 , as explained above. The torque C L exerted by the lug 121 a on the surface 134 a of the tab 132 a is weighted by the efficiency of the second gearbox stage 106 . The tab 132 a is engaged in the recess 122 a. The drive torque C M is in the same direction as the load torque C L .
[0058] The balance of the forces of the outlet part is shown in FIG. 4 . The load torque C L is balanced by two forces F 2a and F 2b . The first force F 2a corresponds to the reaction of the face 134 a of the tab 132 a of the spring 130 against the bearing face 124 a of the recess 122 a. Since said first force F 2a does not make it possible to compensate for the load torque C L fully, the outlet part 120 tends to move perpendicularly to the axis X 105 , relative to the preceding bearing configuration, until the outlet part comes into contact with its guide means formed by the shaft 118 that is secured to or integral with the inlet part 110 . The bore 128 for guiding the outlet part thus comes into contact with the shaft 118 , then generating the second radial force F 2b making it possible to balance the load torque C L . Said second force F 2b generates friction during the downward movement of the load. This friction brakes the load and is added to the braking torque of the spring. It thus contributes to the reactivity of the brake. The response time of the brake is faster than the response time of a brake for which said friction does not exist.
[0059] It should be noted that, for this embodiment, the inlet part 110 is itself centered relative to the friction part 140 by means of a cylindrical web whose envelope surface (not shown) co-operates with the bore 141 in the friction part. Therefore, the preceding force F 2b induces an equivalent force (not shown) between the inlet part 110 and the friction part 140 . Said equivalent force participates in the secondary braking torque and contributes to the reactivity of the brake.
[0060] In order to make it possible to lower the load, it is necessary to release the brake. For this purpose, the drive torque C M drives the protuberances 111 a and 111 b of the inlet part 110 in rotation, the protuberance 111 b being driven by said drive torque until it comes into abutment against the face 133 b of the tab 132 b of the spring 130 . By this action, the spring 130 is relaxed and the outlet part 120 can turn, by means of the load torque C L . The parts 110 and 120 are then not in direct contact.
[0061] If the direction of winding of the load is reversed, operation is identical. Operation of the brake is thus symmetrical, which makes it easier for it to be installed because the performance of the brake is the same, regardless of the raising direction of the actuator, i.e. regardless of the direction of the drive torque C M that serves to raise the screen 2 .
[0062] FIG. 5 shows a conventional prior art spring brake, and more particularly how it behaves during raising. The portions of the brake that are shown in FIG. 5 and that are analogous to the portions of the brake 105 bear like references minus 100 . For that type of brake, the outlet part is not designed to balance the load torque during raising. The outlet part 20 is provided with one lug 21 a only. During raising, operation is similar to operation of the brake 105 in the configuration shown in FIG. 3 . The drive torque C M drives a protuberance 11 a in rotation until said protuberance comes into contact with one face 33 a of a tab 32 a of the spring 30 . The opposite face 34 a of the tab is in abutment against a face 23 a of the lug 21 a of the outlet part 20 by means of the load torque C L .
[0063] Therefore, the drive torque C M is transmitted to the outlet part 20 via the tab 32 a of the spring 30 .
[0064] In the embodiment of the invention that is described above with reference to FIGS. 1 to 4 , the drive torque is transmitted directly to the outlet part 120 by contact between one face 113 a of the inlet part 110 and one face 123 a of the outlet part 120 , the spring tab then being retracted into the recess 122 a provided for this purpose. This makes it possible to achieve better torque transmission and to stress the parts less.
[0065] In the brake shown in FIG. 5 , the load torque CL is not sufficiently taken up by a tab 32 a of the spring to balance said torque, and therefore induces a radial force on the outlet part 20 . That radial force causes the outlet part to move until it is in contact with its guide means that are formed by the bore 41 in the friction part 40 . The outlet part 20 has a cylindrical web whose envelope surface 25 makes it possible to perform the guiding in the bore 41 . Thus, the load torque is balanced firstly by a force F′ 1a corresponding to the lug 21 a bearing against the tab 32 a of the spring 30 and secondly by a force F′ 1b , resulting from the outlet part 20 bearing against the bore 41 in the friction part 40 . Given that, during raising, the outlet part 20 has a relative speed relative to the friction part 40 , said force F′ 1b generates friction during the load-raising movement. In order to lift the load L, the drive torque C M must therefore be greater than the sum of the load torque C L , of said friction, and, on start-up, of the torque necessary to release the brake. Therefore, said friction adversely affects the dimensioning of the motor because said motor must be more powerful in order to compensate for the additional friction resulting from the force F′ 1b .
[0066] For lowering the load, operation is analogous to the operation shown in FIG. 3 for the brake of the invention. Balancing of the forces is, however, more similar to the balancing shown in FIG. 5 . The load is braked by the braking torque of the spring 30 and by the friction with the guide means formed by the bore 41 in the outlet part.
[0067] FIGS. 4 and 5 show two different guide means for guiding the outlet part 20 or 120 . In FIG. 4 , the outlet part 120 is guided relative to the inlet part 110 . The inlet part 110 is also centered relative to the friction part 140 . In FIG. 5 , the outlet part 20 is guided relative to the friction part 40 that is stationary. Tests have shown that the brake 105 behaves better in the FIG. 4 situation. The centering of the outlet part relative to the inlet part makes it possible to reduce the vibration of the brake.
[0068] FIGS. 6 to 11 show a second embodiment of the brake. The operating principle is close to the first embodiment. The references of these parts are analogous to the references of the first embodiment, plus 100 .
[0069] The outlet of the epicyclic gear train of the first gearbox stage 104 drives in rotation a part 210 forming the inlet of the brake 105 . The inlet part 210 is provided with a polygonal shaft 219 designed to receive and to transmit torque coming from the gearbox stage 104 . The brake 105 includes a helical spring 230 whose turns are centered on an axis X 230 that coincides with the axis
[0070] X-X when the brake 105 is in place as shown in FIG. 1 . The axes X 230 and X-X coincide with the central axis X 105 of the brake 105 when an actuator 100 incorporating the brake 105 of this second embodiment is in the assembled configuration.
[0071] The spring 230 is mounted in tight-fitting manner inside a bore 241 in a friction part 240 . In other words, the outside envelope 231 of the spring 230 , which envelope is defined by the outside generator lines of its turns, bears against the radial surface of the bore 241 , thereby tending to secure together the spring 230 and the part 240 by friction.
[0072] Each end of the spring 230 forms a tab 232 a, 232 b extending radially towards the axis X 230 and towards the inside the spring, from its turns.
[0073] The inlet part 210 is provided with a protuberance or “tooth” 211 a that fits into the helical spring 230 , between the tabs 232 a and 232 b. Said tooth 211 a has two faces 213 a, 213 b suitable for being in contact respectively with a surface 233 a of a first tab 232 a forming the first end of the spring and with a surface 233 b of the second tab 232 b forming the second end of the spring. The surface 233 a is disposed in a manner such that action on said surface causes the spring to be moved in rotation about the axis X 230 in a direction that is opposite from the direction of rotation of the spring if the action is exerted on the surface 233 b.
[0074] Action by the tooth 211 a on a surface 233 a or 233 b tends to release the brake, i.e. to drive the tab 232 a or 232 b in rotation about the axes X 230 and X 105 , in a direction such that the radial stress between the outside envelope 231 of the spring 230 and the friction surface of the bore 241 decreases. Action from the tooth 211 a on one of the faces 233 a or 233 b tends to contract the spring 230 radially about the axis X-X, so that its outside envelope moves away from the surface of the bore 241 . The part 210 thus makes it possible to act on the spring 230 to reduce the contact force between the spring and the friction surface of the bore 241 .
[0075] An outlet part 220 of the brake 105 is situated in register with the inlet part 210 . The outlet part is provided with two lugs 221 a, 221 b also fitting into the helical spring 230 . Each lug is provided with a recess or a setback 222 a, 222 b designed to receive a respective one of the tabs 232 a, 232 b of the spring 230 . Each recess 222 a, 222 b is defined partially by a surface 224 a, 224 b suitable for being in contact with a surface 234 a, 234 b of a tab 232 a, 232 b. The surfaces 234 a and 234 b are opposite from respective ones of the surfaces 233 a and 233 b.
[0076] Action on one of the surfaces 234 a, 234 b tends to move the tabs 232 a and 232 b towards each other, thereby causing the turns of the spring 230 to expand radially relative to the axis X 230 and increasing the contact force between the outside envelope 231 of the spring 230 and the friction surface of the bore 241 . This results in actuating the brake, i.e. in blocking or in strongly braking the rotation of the spring 230 relative to the part 240 . Thus, the radial stress between the outside envelope 231 of the helical spring and the friction surface 241 increases.
[0077] In addition, each lug 221 a, 221 b of the outlet part 220 is provided with a projecting portion 226 a, 226 b extending axially towards the inlet part and suitable for being received in respective ones of banana-shaped slots 216 c, 216 d in the inlet part 210 , once the brake 105 is assembled. Said projecting portions 226 a and 226 b are dimensioned and disposed in a manner such that their faces 227 a, 227 b are in contact with respective ones of inside faces 217 c, 217 d defining the corresponding slots 216 c, 216 d when the face 213 b, 213 a of the tooth 211 a of the inlet part 210 is in contact with the face 223 b, 223 a of a lug 221 b, 221 a of the outlet part 220 .
[0078] FIGS. 8 and 10 show the two possible configurations for the brake 105 . The dimensioning of the slots 216 c, 216 d is such that, outside the two preceding configurations, the projecting portions 226 a, 226 b do not come into abutment against any inside surface of the slot.
[0079] In order to enable the brake to operate, it is necessary to have angular clearance between the tooth 211 a of the inlet part 210 and the tabs 232 a and 232 b of the spring. Similarly, angular clearance is also necessary between the lugs 221 a and 221 b and the tabs 232 a and 232 b of the spring. The width of the tooth 211 a is designed for this purpose. In addition, the axial length L 211 or L 221 of the portions 211 a, 221 a, and 221 b is slightly greater than the axial length L 230 of the spring.
[0080] The necessary centering of the outlet part 220 relative to the inlet part 210 is achieved by a shaft 270 . Said shaft is engaged in a centered bore 218 of the inlet part 210 . A portion of the shaft 270 projects from the same side as the outlet part 220 .
[0081] FIGS. 8 to 11 show how the brake 105 operates. FIGS. 8 and 9 correspond to the screen being wound on the shaft 1 in the clockwise direction in said figures. FIG. 8 shows the load being raised, while FIG. 9 shows the load being lowered. FIGS. 10 and 11 correspond to the screen being wound on the shaft 1 in the counterclockwise direction in these figures. FIG. 10 shows the load being raised while FIG. 11 shows it being lowered.
[0082] Firstly, operation of the brake is explained relative to the first screen-winding configuration, i.e. to winding in the clockwise direction in FIGS. 8 and 9 .
[0083] By default, the weight of the load L exerts torque C L on the part 220 that presses one of the lugs 221 a or 221 b, namely the lug 221 b in this example, against one of the tabs 232 a or 232 b, namely the tab 232 b in this example, as shown in FIG. 9 . The effect of this is to expand the turns of the spring 230 radially and to activate the brake 105 , as explained above. The torque C L exerted by the lug 221 b on the surface 234 b of the tab 232 b is weighted by the efficiency of the second gearbox stage 106 . This torque is shown by a vector associated with the lug 221 b. The tab 232 b is then engaged in the recess 224 b.
[0084] While the load L is being raised, and as shown in FIG. 8 , the inlet part 210 is driven in rotation by torque C M generated by the motor and weighted by the efficiency of the first gearbox stage 104 . The protuberance 211 a of the inlet part then turns until it is in contact with the lug 221 b of the outlet part, at the interface between the surfaces 213 b and 223 b. In order to raise the load, the torque C M must then be greater than the sum of the torque C L and of drag torque of the brake spring due to the residual friction between the outside envelope of the spring and the friction surface of the bore 241 . The torque C M is represented by a vector in dashed lines associated with the inlet part.
[0085] At start-up, the torque C M to be exerted must be larger because, in order to release the brake 105 , it is necessary to overcome a static friction force. In order to release the brake 105 , the protuberance 211 a acts on the tab 232 b received in the recess 222 b whenever the lug 221 b is driven in rotation. The drive torque C M is transmitted from the inlet part 210 to the outlet part 220 by double contact. On one side, the face 213 b of the protuberance 211 a bears against the face 223 b of the lug 221 b. And, diametrically opposite, the inside face 217 c of the slot 216 c bears against the face 227 a of the projecting portion 226 a. Thus, the load torque C L is balanced by efforts F 1a and F 1b resulting from the bearing between the portions 211 a and 221 b, on one side, and 216 c and 226 a, on the other side. Since these two forces are of substantially the same magnitude and are substantially symmetrical about the central axis X 105 of the brake 105 and about the axis X 220 of the outlet part, the radial component of the resultant of the torque C M on the outlet part is negligible, or indeed zero. The faces 223 b and 227 a constitute contact surfaces of the outlet part.
[0086] While the load L is being lowered, as shown diagrammatically in FIG. 9 , the outlet part 220 is not stopped by the inlet part 210 but rather it is stopped by the spring 230 . Thus, the load torque C L presses the lug 221 b against one of the tabs 232 a or 232 b, namely the tab 232 b in this example. The effect of this is to cause the turns of the spring 230 to expand radially and to activate the brake 105 , as explained above.
[0087] The torque C L exerted by the lug 221 b on the surface 234 b of the tab 232 b is weighted by the efficiency of the second gearbox stage 106 . The tab 232 b is engaged in the recess 222 b. The drive torque C M is in the same direction as the load torque C L . The balance of the forces is then different from the balance during raising. The load torque C L is balanced by forces F 2a and F 2b . The first force F 2a corresponds to the reaction of the spring that blocks the load at the interface between the face 234 b of the tab 232 b of the spring 230 and the bearing face 224 b of the recess 222 b of the lug 221 b of the outlet part. Since the first force F 2a does not make it possible to compensate for the load torque C L , the outlet part 220 tends to pivot relative to the preceding bearing configuration until the outlet part is in contact with its guide means formed by the shaft 270 that is secured to or integral with the inlet part 210 . The bore 228 for guiding the outlet part 220 relative to the shaft 270 thus comes into contact with the shaft 270 , thereby generating the second force F 2b making it possible to balance the load torque C L . This force is radial relative to the axis X 220 . This force F 2b generates friction while the load L is moving downwards. This friction brakes the load and is added to the braking torque of the spring. It therefore contributes to the reactivity of the brake. Its response time is faster than the response time of a brake for which such friction does not exist.
[0088] It should be noted that, for this embodiment, the inlet part 210 is itself centered relative to the friction part 240 by means of a cylindrical web whose envelope surface (not shown) co-operates with the bore 241 of the friction part. Therefore, the preceding force F 2b then induces an equivalent force (not shown) between the inlet part 210 and the friction part 240 . This equivalent force participates in the secondary braking torque contributing to the reactivity of the brake.
[0089] In order to enable the load to be lowered, it is necessary to release the brake. For this purpose, the drive torque C M drives a protuberance 211 a on the inlet part in rotation until it comes to bear against the face 233 a of the tab 232 a of the spring 230 . By this action, the spring 230 is relaxed and the outlet part 220 can turn, by means of the load torque C L , since the parts 210 and 220 are then not in direct contact.
[0090] Operation of the brake in the second winding configuration is shown in FIGS. 10 and 11 .
[0091] During raising, and as shown in FIG. 10 , the load torque C L is balanced by the forces F 1a and F 1b resulting firstly from the contact between the face 213 a of the tooth 211 a and the face 223 a of the lug 221 a, and secondly from the contact between the inside face 217 d of the slot 216 d, and the face 227 b of the projecting portion 226 b. Since these forces F 1a and F 2a are balanced, the radial component of the resultant of the torque C M on the outlet part 220 is negligible. The motor must thus deliver drive torque that is greater than the load torque C L to which only the drag torque of the brake is added, which drag torque results from the friction between the spring 230 and the friction part 240 . There is little or no secondary braking torque generated by the friction between the outlet part 220 and its guide shaft 270 . The faces 223 a and 227 b constitute the contact surfaces of the outlet part.
[0092] During lowering, the load torque C L is balanced by the forces F 2a and F 2b . The first force F 2a corresponds to the reaction of the spring 230 blocking the load L at the interface between the face 234 a of the tab 232 a of the spring 230 and the bearing face 224 a of the recess 222 a in the lug 221 a. The second force F 2b corresponds to a localized force at the guide shaft 270 of the outlet part 220 , while the parts 210 and 220 are not in direct contact. This friction generates a radial force braking the load. Thus, the brake reacts rapidly because the secondary braking torque no longer becomes negligible.
[0093] The two embodiments describe a brake spring whose ends are folded over towards the inside of the spring. Naturally, said ends can be folded over towards the outside of said spring. Another variant consists in folding over the ends parallel to the central axis of the spring. The tabs then extend axially on either side of the spring, while extending away from the center of the spring.
[0094] In addition, the spring brake does not specifically have to be received between two gearbox stages. It can be disposed at the outlet of the motor or at the outlet of the gearbox. | This electric actuator for driving a home-automation screen is provided with a spring brake ( 105 ) comprising a helical spring ( 130 ), a friction part ( 140 ) having a friction surface ( 141 ) against which the helical spring ( 130 ) bears radially. Said brake further comprises an inlet part ( 110 ) suitable for driving the spring in rotation in a direction reducing the contact force between the spring ( 130 ) and the friction part ( 140 ), and an outlet part ( 120 ) connected to the screen.
While the screen is being lowered, the inlet part ( 110; 210 ) drives the spring ( 130; 230 ) in rotation with the contact force being decreased to the extent that the outlet part ( 120; 220 ) is released in rotation, without direct contact between the inlet part and the outlet part. The inlet part ( 110; 210 ) has at least two contact surfaces ( 113 a, 113 d; 213 b, 217 c ) suitable for transmitting drive torque (C M ) for raising the screen ( 2 ), by direct contact, to at least two corresponding contact surfaces ( 123 a, 123 d; 223 b, 227 a ) of the outlet part ( 120; 220 ). |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to an apparatus for preventing explosive vapors contained in a sewer from being transmitted to the atmosphere surrounding the sewer. More particularly, the present invention relates to apparatuses for insertion into existing sewer inlets commonly covered by gratings or other sewer covers which prevent explosive vapors contained in the sewer from being ignited by sparks or flames in the atmosphere on the outside of the sewer.
2. Description of the Prior Art
Industries which manufacture and process flammable liquids and gases such as hydrocarbons have difficulty in keeping the hydrocarbons and other flammable liquids from finding their way into the sewer system located beneath the manufacturing facility. Flammable liquids and gases which enter such sewer systems can be easily ignited by welding or cutting operations occurring in the vicinity of the inlets to the sewer system.
Such problems are commonly encountered in the petroleum refining industry. In most petroleum refining facilities elaborate systems are used to recover hydrocarbons in the sewer system for processing into useful product.
Hydrocarbons and other flammable liquids and gases are ever present in the sewer systems of petroleium refiners, and precautions must be taken when performing burning and welding in the facility of sewer inlets. Commonly, the sewer inlet is covered with a vinyl coated canvas having a border filled with sand or sawdust to prevent flammable gases in the sewer from being ignited by burning or welding operations in the refinery. The vinyl cover has a reservoir to retain water which adds weight to the interior of the cover to improve the seal over the inlet. The area immediately surrounding a sewer inlet may be gravel or dirt, but in most cases the surrounding area is either asphalt or concrete.
When the area surrounding a sewer cover is asphalt or concrete it is extremely difficult to seal the perimeter of the sewer cover, even using a vinyl coated canvas cover filled with water, sand and/or sawdust. In addition to placing the sewer cover over the inlet or man way and filling it with water, sand must be placed around the outside of the border to aid in sealing the sewer inlet from the surrounding area. Such a seal is necessary to prevent flammable gases from escaping from the sewer inlet and to keep sparks from burning and welding operations from entering the sewer system and igniting flammable gases therein.
Commonly, in a petroleum refinery while burning or welding is in progress, a water spray is directed toward the sparks generated by the burning and welding to cool the metal being welded or cut and to cool any molten pieces of metal falling from the work area. Canvas blankets are sometimes placed around the site of the burning or welding while the burning or welding is in progress, and a water spray is directed to the exterior of the canvas blankets to prevent sparks from entering the sewer and coming into contact with flammable liquids or gases in the sewer.
Such measures provide minimal protection from explosion and/or fires in the sewer systems of petroleium refiners and other chemical processing plants. The perimeter of the sewer cover even when covered with sand may still allow flammable gases and hot sparks to come into contact with each other, even though canvas blankets may be placed around the site of the cutting or welding.
U.S. Pat. No. 4,305,679 discloses a man hole sealing device to prevent water from entering a man hole through the corbel joint between the man hole casing and the cover frame. The cover disclosed completely seals a man hole. Such a device would not be pertinent to the present invention in which water flow into a sewer is permitted rather than completely stopped.
U.S. Pat. No. 4,045,346 discloses a basement sewer trap comprising a coupling sleeve for a sewer pipe having an interior cup or well, the interior of the cup supporting a funnel tube beneath a water strainer. The water flows through the strainer, down through the funnel tube, upward out of the cup portion, and finally down the open end of the coupling sleeve into a sewer pipe.
U.S. Pat. No. 3,621,623 discloses an apparatus for temporarily closing an opening formed at the top of a vertical wall of a catch basin, man hole or the like, the man hole arrangement employing a trough type member 32 having a removable lid 31 as disclosed in FIG. 6. However, the lid completely closes the man hole and does not allow any flow therethrough, whereas in the present invention it is necessary to have fluid flow through the sewer cover.
U.S. Pat. No. 3,516,541 discloses a drain device comprising a prefabricated structure that may be removably mounted in a vertical drain structure which when partially filled with water provides a seal to prevent upward discharge of explosive vapors through the drain structure into the ambient atmosphere. The structure disclosed therein comprises a first cylinder open at the top and bottom contained within a second outer cylinder having a series of holes therein through which water flowing downwardly through the first cylinder and outwardly from the bottom of the first cylinder may exit.
U.S. Pat. No. 129,246 discloses a cover "E" which is placed on the cap ring of the mouth of a water pipe gate and two other covers "GG" which are placed over pyramidal or conical sections to form a dead air space therebetween.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a self sealing sewer cover assembly for preventing flammable gases from being discharged from a sewer and for preventing the ignition of gases in a sewer by flames and sparks in the area adjacent to the sewer inlet. The apparatus of the present invention comprises a cover assembly which may replace or be use in combination with an existing cover or grating on a sewer inlet and may be inserted into the inlet to a sewer. The apparatus of the present invention provides a water barrier between gases contained in the sewer and the ambient air adjacent to the sewer inlet which prevents the flow of gases from the sewer to the ambient air surrounding the sewer inlet.
In one embodiment of the present invention there is provided a self sealing sewer cover assembly for preventing flammable gases from escaping from a sewer including an insert for placement in a sewer inlet, the insert having a top end and bottom end, the insert having exterior vertical walls for parallel alignment with the vertical interior walls of the sewer inlet, the insert having a trough at the bottom end thereof extending completely around the interior of the exterior vertical walls of the insert for containing water, the trough having an inner vertical wall defining an opening through which water overflowing from the trough can flow, the inner vertical wall having a height less than the height of the exterior vertical wall of the insert, and a lid for placing in the trough and over the opening defined by the trough to prevent gases from traveling through the opening when the trough is filled with water while permitting liquids to flow through the trough openings located in the lid.
In the second embodiment of the invention there is provided a self sealing sewer cover assembly for preventing flammable gases from escaping from the sewer, the assembly including a cover having a top side and bottom side adapted to cover the inlet to a sewer, the cover having a plurality of openings therein through which liquids may flow to the sewer, a pipe having a top end and a bottom end connected to the bottom side of the cover, the pipe being located on the bottom of the cover to receive all liquids flowing through the plurality of openings in the cover, and a pan connected to the bottom end of the pipe, the pan having vertical exterior walls extending perpendicularly to the horizontal bottom of the pan, the pan being adapted to hold liquids and large enough to receive the bottom of the pipe therein, the bottom of the pan being located a distance from the bottom end of the pipe sufficient to permit liquids to flow downward through the pipe and to flow upward from the bottom of the pan over the vertical exterior walls of the pan and into the interior of the sewer inlet.
In the third embodiment of the invention there is provided a self sealing sewer cover assembly for preventing flammable gases from escaping from a sewer inlet including a cover having a top side and a bottom side adapted to cover the inlet to a sewer, the cover having openings therein through which liquids may flow, and a plurality of pipes connected to the bottom side of the cover, one of the pipes being connected to each of the plurality of openings in the cover to receive liquids therefrom, the pipe having a gas trap at the bottom thereof for preventing gas from flowing therethrough, the gas trap being an upwardly curved "U" shaped portion on the bottom of the pipe in which water is contained to prevent gas from traveling through said pipe in out of said sewer inlet.
The sewer cover assembly of the present invention keeps the sewer sealed at all times to prevent any flames or sparks outside of the sewer inlet from igniting gases contained in the sewer. The cover assemblies of the invention are low in cost and easily installed in existing sewer inlets.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of first embodiment of the cover assembly of the present invention;
FIG. 2 is a vertical cross-sectional view of the first embodimetn of the self sealing sewer cover assembly of the present invention taken along lines 2--2 of FIG. 1;
FIG. 3 is an elevational view of the lid shown in FIG. 2;
FIG. 4 is a top plan view of the cover assembly of of the present invention incorporating an alternate embodiment of a lid;
FIG. 5 is a vertical cross-sectional view taken along lines 5--5 of FIG. 4;
FIG. 5a is a perspective view of the lid shown in FIG. 5;
FIG. 6 is a top plan view of a second embodiment of the present invention;
FIG. 7 is a vertical cross-sectional view taken along lines 7--7 of FIG. 6;
FIG. 8 is a top plan view of a third embodiment of the present invention; and
FIG. 9 is a vertical cross-sectional view taken along 9--9 of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and in particular to the embodiment shown in FIGS. 1 through 3, a cylindrical sewer inlet is generally indicated by the numeral 10. The sewer inlet has a recessed shoulder 12 at the top end thereof on which the generally cylindrical insert generally indicated by the numeral 14 is received. Insert 14 preferably provided with an annular lip 16 which rests upon shoulder 12.
As can be seen in FIG. 2, the exterior diameter of insert 14 is less than the interior diameter of sewer inlet 10, thereby allowing insert 14 to be placed in the interior of sewer inlet 10. Preferably a sealing material 15 such as glue, cement, or the like is placed around the exterior walls of insert 14 to form a gas seal between the exterior or vertical wall 18 of insert 14 and the interior walls of sewer inlet 10. Lip 16 of insert 14 defines an opening in the top of insert 14 through which liquid and other fluids may pass. Lying on top of lip 16 is removable cover 20 which has a series of channels or openings 22 therein through which liquids may flow downwardly into the interior of insert 14. Cover 20 is a common sewer inlet cover which lies on top of a sewer inlet and is held in place by gravity.
At the bottom end of insert 14 is a trough generally indicated by the numeral 24. Trough 24 is defined by horizontal annular plate 26 connected to vertical walls 18 of insert 14. Connected to annular plate 26 perpendicularly thereto is interior wall 28. Trough 24 thus defines a compartment extending completely around the interior of insert 14 into which the water may be poured and contained. As can be seen in FIG. 2, the height of interior wall 28 is less than the height of exterior wall 18 of insert 14.
In FIG. 3 is shown a lid generally indicated by the numeral 30. Lid 30 has a horizontal top plate 32 which is circular in shape and has handle 34 connected thereto. Extending perpendicularly down from the perimeter of circular top 32 is vertical exterior wall 36 of lid 30. Wall 36 has a series of supports 38 connected at the bottom thereof to support wall 36 at a desired distance above the bottom 26 of trough 24, the bottom edge 40 of lid 30 being beneath the top edge 28a of trough 24.
Although walls 18, 28 and 36 are preferably vertical as shown in FIGS. 1 and 2, they could be constructed at a small angle with the vertical as will be understood by those skilled in the art.
Thus when trough 24 is filled with water traveling downwardly through openings 22 of cover 20, water will rise to the level equal to the top edge 28a of trough 24 and will flow over the edge 28a through the opening defined by interior wall 28 of trough 24 in a direction indicated by the arrows 29 and downwardly to the sewer lines 42 connected to the base of sewer inlet 10.
The supports 38 for holding lid 30 may be of any desired design as long as the bottom edge 40 of the exterior wall of 36 of lid 30 is above bottom plate 26 and beneath the top edge 28a of vertical wall 28 of trough 24. Supports 38 preferably include a horizontal member 38a connected to a vertical member 38b as shown in FIG. 3 which is rigidly connected to wall 36.
If it is desired to clean the sewer inlet 10 or to place equipment downward in sewer inlet 10, cover 20 may be removed, and lid 30 may be removed through the use of handle 34, thereby exposing the opening defined by vertical wall 28.
In FIGS. 4, 5, and 5a are shown a sewer cover assembly similar to the embodiment shown in FIGS. 1 through 3 with the exception that the support means for lid 30 are different and the cover and insert is in the shape of a rectangle rather than a circle.
A sewer inlet having a rectangular cross section is generally indicated by the numeral 10a in FIG. 5. The sewer inlet 10a has a recessed shoulder 12a at the top end thereof on which the generally rectangular insert indicated by the numeral 14a is received. Insert 14a preferably is provided with an annular lip 16a which rests upon shoulder 12a.
As can be seen in FIG. 4 and 5, the length and width of insert 14a is less than the length and width of sewer inlet 10a, thereby allowing insert 14a to be placed in the interior of sewer inlet 10a. Preferably a sealing material 15a such as glue, cement, or the like is placed around the exterior walls of insert 14a to form a gas seal between the exterior of vertical wall 18a of insert 14a and the interior walls of sewer inlet 10a. Lip 16a of insert 14a defines an opening in the top of insert 14a through which liquid and other fluids may pass. Lying on top of lip 16a is removable cover 20a which has a series of channels or openings 22a therein through which liquids may flow downwardly into the interior of insert 14a. Cover 20a is a common sewer inlet cover which lies a top of a sewer inlet and is held in place by gravity.
At the bottom end of insert 14a is a trough generally indicated by the numeral 24a. Trough 24a is defined by horizontal rectangular shaped plate 26a connected to vertical walls 18a of insert 14a. Connected to rectangular plate 26a perpendicularly thereto is interior wall 28b. Trough 24a thus defines a compartment extending completely around the interior of insert 14a into which the water may be poured and contained. As can be seen in FIG. 5, the height of interior wall 28b is less than the height of exterior wall 18a of insert 14a.
A lid generally indicated by the numeral 30a is shown in FIGS. 5 and 5a. Lid 30a has a horizontal top plate 32a which is rectangular in shape and has handle 34a connected thereto. Extending perpendicularly down from the perimeter of rectangular top 32a are vertical exterior walls 36a of lid 30a. Walls 36a have a series of openings 39 therein at the bottom thereof through which water may flow. The top 39a of openings 39 can be seen in FIG. 5 to be beneath the top edge 28c of trough 24a. Although walls 18a, 28b, and 36a are preferably vertical as shown in FIGS. 4, 5 and 5a, they could be constructed at a small angle with the vertical as will be understood by those skilled in the art.
Thus when trough 24a is filled with water traveling downwardly through openings 22a of cover 20a, water will rise to the top edge 28c of trough 24a and will flow over the edge 28c through the opening defined by interior wall 28b of trough 24a in a direction indicated by the arrows 29a and downwardly to the sewer lines 42 connected to the base of sewer inlet 10.
If it is desired to clean the sewer inlet 10a or to place equipment downward in sewer inlet 30a, cover 20a may be removed and lid 30a may be removed through the use of handle 34a, thereby exposing the opening defined by vertical wall 28b.
Referring now to the embodiment shown in FIGS. 6 and 7, a sewer inlet 10c has a lip 12c and and has the same horizontal flow lines 42 as does the sewer inlet shown in FIG. 2. Connected to the bottom side of cover 20c is conduit 50 which, in the embodiment shown in FIG. 7, has the shape of truncated cone. However, conduit 50 could be a standard cylindrical pipe having parallel side walls if desired so long as all the openings 22c in cover 20c are arranged so that water flowing therethrough flows into the interior of conduit 50. Conduit 50 is connected to cover 20c by welding, screwing, or the like.
Conduit 50 has connected at its bottom end 52 a pan 54 having a circular horizontal bottom 56 and vertical side walls 58 extending perpendicularly upward from circular bottom 56. Pan 54 is connected to the exterior of conduit 50 by a plurality of spaced apart braces 60 which may be connected to pan 54 and conduit 50 by welding, screwing, or the like. Braces 60 are spaced apart to permit water to flow therebetween. The top edge 58a of pan 54 is higher than the bottom edge 51 of conduit 50.
Thus, when pan 54 is filled with water, a water trap is formed therein which prevents gas in the interior of sewer inlet 10c from escaping upwardly through conduit 50. However, water coming downward through conduit 50 enters pan 54 and excess water is forced outwardly over the top edge 58a of exterior wall 58 of pan 54 as indicated by the arrows 55. If desired, reinforcing rods 62 may be utilized to connect conduit 50 to cover 20c. Preferably, a gasket or seal 64 of some common type such as rubber, glue, or cement may be placed around the exterior of the upper end of conduit 50 to seal the upper end of conduit 50 to the interior wall of sewer inlet 10 to prevent any gas from escaping upwardly around the outside of conduit 50 to the atmosphere adjacent to cover 20c.
Referring now to the embodiment shown in FIGS. 8 and 9, sewer inlet 10d has horizontal flow line 42 connected thereto and annular shoulder 12d at the upward end thereof as previously described in the other embodiments. A cover 70 has a series of channels 72 therein which are aligned with pipes 74. Pipes 74 have the general shape of a "J" and have a "U" shaped bottom portion 76 which, when filled with water, forms a gas trap which prevents gases from flowing upwardly from the interior of sewer inlet 10d to the atmosphere adjacent to sewer cover 70. If desired, reinforcement members 78 can be added. Preferably, a gasket or seal 64a of some common type such as rubber glue, or cement may be placed around the exterior of the upper end of conduit 50 to seal the upper end of conduit 50 to the interior wall of sewer inlet 10d to prevent any gas from escaping upwardly around the outside of conduit 50 to the atmosphere adjacent to cover 20c.
Thus, any water flowing onto cover 70 will flow downward through channels 72 and into the "U"-shaped portion 76 of pipe 74. After water has filled the "U"-shaped portion 76 of pipe 74, no gas can escape through pipe 74 since the open end 80 of "U"-shaped pipe 74 will be covered with water through which gas can not flow. However, water can flow out of the open end 80 of pipes 74.
Although the preferred embodiments of the present invention have been disclosed and described in detail above, it should be understood that the invention is in no sense limited thereby, and its scope is to be determined by that of the following claims. | A self sealing sewer cover assembly for preventing flammable gases from being discharged from a sewer and for preventing the ignition of gases in a sewer by flames and sparks in the area adjacent to the sewer inlet. The apparatus of the present invention comprises a cover assembly which may replace or be used in combination with an existing cover or grating on a sewer inlet and may be inserted into the inlet to a sewer. The apparatus of the present invention provides a water barrier between gases contained in the sewer and the ambient air adjacent to the sewer inlet which prevents the flow of gases from the sewer to the ambient air surrounding the sewer inlet. |
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FIELD OF THE INVENTION
[0001] The present invention relates to methods and devices for in situ perforation of landfill gas wells.
BACKGROUND OF THE INVENTION
[0002] The decomposition of waste in a landfill produces methane and other gaseous emissions. Landfill gas recovery wells are used to remove the gases from landfills. Removal of methane and other gases is both an environmental and a safety measure for preventing an accumulation of flammable gases. The gas wells typically consist of pipes made from PVC, high-density polyethylene (HDPE) and similar materials. The gas well's pipes are slotted or perforated to allow for recovery of the gases. However, over time the slots and perforations become clogged as a result of the formation of precipitates and biological films in the well. Consequently, the amount of gas recovered or produced from a well may decrease over time.
[0003] Another problem with the gas well piping is that it is often installed as the landfill lifts are created. Consequently, the top section of the pipe is not perforated because it must be extended over time as additional lifts are added to the landfill.
[0004] The current solution to these problems is to install a new gas well next to the existing, obsolete well. However, this is time consuming and expensive. Thus, a simple and inexpensive solution that allows retrofitting of an existing well to maintain the amount of gas produced over time is needed.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention relates to perforating devices useful for perforating an in situ landfill gas well to increase gas recovery. The perforating device consists of at least one perforator with at least one cutting edge. The perforating device also has a cable for lowering and raising the perforating device in the gas well. The perforating device further features cutting edges in the form of a drilling system and/or rotator to allow perforation of the gas well. Finally, the diameter of the perforating device is less than the inner diameter of the gas well.
[0006] The present invention also relates to methods for in-situ perforation of a landfill gas well to increase gas recovery. A perforating device is lowered into the gas well to a predetermined depth from the landfill surface until the perforating device is adjacent to a portion of the gas well to be perforated. Next, the perforating device is activated at the predetermined depth to perforate a portion of the gas well. After perforating the gas well at one or more predetermined depths, the perforating device is removed from the gas well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an illustration of an embodiment of perforating devices of this invention; and
[0008] FIG. 2 is a cross-sectional representation of the embodiment illustrated in FIG. 1 ; and
[0009] FIG. 3 is an alternative embodiment which illustrates the gas monitoring aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The invention provides a perforating device and method for perforating a landfill gas well in situ.
[0011] FIGS. 1 and 2 illustrate an embodiment of a perforating device 10 used to perforate a landfill gas well 12 in situ. Typically, gas well 12 is constructed of PVC, high-density polyethylene (HDPE) or other similar materials. Gas well 12 typically has an inner wall 28 and an outer wall 38 . Gas well 12 has an effective inner diameter 32 ranging from about six to about twelve inches. Typically, effective inner diameter 32 is about eight inches. Perforating device 10 consists of at least one perforator 14 that has at least one cutting edge 16 . Perforator 14 is made from a material that is able to perforate landfill gas wells, such as steel, and typically weighs one to three pounds or more. Perforating device 10 has a diameter 18 that is less than effective inner diameter 32 of gas well 12 . For instance, diameter 18 of perforating device 10 is four inches, compared to an effective inner diameter 32 of eight inches. Preferably, diameter 18 of perforating device 10 ranges from four to six inches. Perforating device 10 also includes a cable 20 , which may be used to lower and raise perforating device 10 into and out of gas well 12 . Cable 20 has a first end 44 and a second end 42 . Cable 20 is attached at the first end 44 to a top surface 22 of perforator 14 by a connector. The second end 42 is kept at a landfill surface 30 . Cable 20 , in addition, may have a measuring mechanism for determining the distance from landfill surface 30 to perforating device 10 in gas well 12 . For example, the cable may be a hydraulic hose or a stainless steel cable that is graduated to measure length. However, a graduated stainless steel cable is preferable. Perforating device 10 may also include a power source, such as a hydraulically or pneumatically powered motor. Additionally, perforating device 10 has a rotator 24 . Rotator 24 may be any device capable of driving a cutting edge, but will typically consist of a gear and rotating shaft. Rotator 24 activates perforator 14 thus allowing cutting edges 16 to perforate a portion 26 of gas well 12 .
[0012] In another embodiment of the invention, perforating device 10 is a drilling system. The drilling system is hydraulically or pneumatically powered, and made from hardened steel or carbide. Preferably, the drilling system is hydraulic because a hydraulic drilling system can reduce the risks associated with the explosive nature of landfill gas. Furthermore, the drilling system may have adjustable settings. For example, the perforating device 10 may be configured to have four or six perforating drills, with each having a cutting edge 16 to perforate holes into the gas well's circumference. Adjustable settings allow a user of perforating device 10 to select a desired number of perforations to be perforated or drilled in gas well 12 . The adjustable setting is chosen before perforating device 10 is lowered into gas well 12 . The size of the drill bit used to perforate the well may be adjusted to adjust the size of the perforation in the gas well. Typically, a perforation will be approximately one half inch. However, the perforation size may vary in order to keep the perforation size smaller than the gas well's granular backfill material, thus preventing the backfill material from seeping through.
[0013] Another aspect of perforating device 10 is that it may be stabilizable. For example, perforating device 10 may have one or more retractable arms that extend outward to inner wall 28 of gas well 12 . This enhances the stability of perforating device 10 while it perforates gas well 12 by maintaining the position of perforating device 10 in gas well 12 . Moreover, stabilizing the perforating device 10 provides for easier removal of perforating device 10 from gas well 12 .
[0014] The present invention also provides a method of in-situ perforation of a landfill gas well. The method begins by lowering the perforating device 10 into gas well 12 . Gas well 12 generally should have a straight vertical orientation. However, often gas well 12 will not be vertical due to landfill forces that cause some misalignment. This misalignment typically results from extending gas wells to accommodate additional landfill lifts. This invention addresses this problem providing perforating device 10 with a short body, and a smaller diameter than the inner diameter 32 of the gas well. As a result, it is possible to lower the perforating device 10 to gas well depths beyond the misaligned areas. Perforating device 10 is lowered into gas well 12 to a predetermined depth 34 from landfill surface 30 . At predetermined depth 34 , perforating device 10 is adjacent to portion 26 of gas well 12 . Perforating device lowering is done either manually or automatically. Manual lowering is accomplished by manually lowering perforating device 10 into gas well 12 with cable 20 . Automatic lowering may be done with a power source, hydraulic or pneumatic, which may be used to power the lowering of perforating device 10 into gas well 12 .
[0015] Once perforating device 10 is located at a predetermined depth 34 from landfill surface 30 , perforating device 10 is activated. Perforating device 10 perforates portion 26 at predetermined depth 34 , which is adjacent to perforating device 10 . Perforation is accomplished by drilling or cutting system. Perforating device 10 may rotate vertically within gas well 12 , thus perforating gas well 12 in an up and down manner.
[0016] The step of positioning perforating device 10 at predetermined depth 34 from landfill surface 30 and then perforating gas well 12 may be done once or it may be repeated a plurality of times at various predetermined depths from landfill surface 30 . Perforations will be made each time the perforating device 10 is activated at the predetermined depth 34 . Typically, the perforations are done in six-inch increments throughout the gas well 12 . The ability to recover landfill gas is improved by maximizing the number of perforations in the gas well 12 . Perforating the gas well too close to the landfill surface 30 can contribute to air infiltration. Thus, perforations should be made approximately twenty feet from the landfill surface 30 . The steps of the present invention will be repeated until all desired portions of gas well 12 are perforated. After the gas well 12 is sufficiently perforated the perforating device is pulled from the gas well 12 , and back to the landfill surface 30 . The step of pulling perforating device 10 out of gas well 12 may be accomplished manually or automatically. In another embodiment, perforating device 10 is attached to a winch that powers pulling perforating device 10 out of gas well 12 and back to landfill surface 30 .
[0017] FIG. 3 illustrates another embodiment of the method of this invention that includes a step for maintaining the amount of methane gas in gas well 12 outside methane gas's explosivity range. Methane gas has an explosivity range of 5 to 15% by volume. This is a necessary safety precaution, which ensures the methane gas located in gas well 12 does not ignite to cause an explosion during the perforation steps. If while monitoring the amount of methane gas in the gas well it is found to be within methane gas's explosivity range, no perforating of the gas well should be done. For example, to get outside the explosivity range may involve introducing a sufficient amount of inert gas into gas well 12 . For instance, introducing nitrogen into gas well 12 . Monitoring the amount of methane gas inside gas well 12 may be accomplished in several ways. For example, it can be accomplished by monitoring the percent of methane gas in gas well 12 with a gas sensing device 36 that is connected to a sample tube 40 . Gas well sensing device 36 will be placed at landfill surface 30 . Sample tube 40 extends from landfill surface 30 down into gas well 12 , where sample tube 40 is mounted next to perforating device 10 . Attaching sample tube 40 to the cable 20 allows for easier monitoring of gas in the vicinity of the predetermined depth 34 in the gas well 12 . Thus, allowing monitoring of methane gas in the vicinity of predetermined depth 34 . Alternatively, gas sensing device 36 may be attached to perforating device 10 . Gas well sensing device 36 may be a gas well sensor for monitoring methane gas concentration that is known by those of ordinary skill in the art. One common gas well sensor is the GEM™500, which is manufactured by CES-Landtec. The GEM™500 is used to analyze gas content and determine flow from LFG collection wellheads.
[0018] Another embodiment of the method of this invention involves applying steps of the invention's method to a gas well that as become filled with water at the predetermined depth. In other words, the gas well contains water prior to lowering the perforating device into the gas well. The water in the gas well can prevent the extraction of gases from the gas well. The invention's method of perforating the gas well with a perforating device may be accomplished in a water filled portion of gas well 12 to create slots or perforations, for draining the water from the gas well. As a result, it becomes possible to recover gas from previously water filled gas wells.
[0019] The invention is now described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains, to make the same. It is to be understood that the foregoing describes preferred embodiments of the present invention and that modifications may be made therein without departing from the spirit or scope of the invention as set forth in the claims. | The present invention relates to a method and apparatus for perforating a landfill gas well in situ. The invention allows for improved recovery of gas from a gas well without the danger of explosion. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
Homeowners and building owners periodically desire to remodel existing structures by removing the existing windows and replacing them with new windows. In recent years, such remodeling has been particularly desirable in warmer climates of the United States, such as in the South and Southwest, where older buildings generally were constructed with relatively inexpensive aluminum-framed, single pane sliding windows. When energy costs were relatively low, the significant heat loss, which takes place through such windows, was not particularly costly. In recent years, however, energy costs have risen dramatically, and the energy loss through such aluminum-framed, single pane windows, particularly in the hot summer months, results in significantly increased utility bills. In addition, when such windows become old, the tracks sometimes become bent, and the operating mechanisms wear out, necessitating at least repair, if not full replacement of the windows.
Typically, the replacement of windows in a home or other building requires the removal of the existing window, and the frame in which it is mounted. Since window frames, in new construction, are "built into" the window opening, the removal of an existing window frame results in damage to at least one or the other of the interior and exterior finished surfaces surrounding the frame. This requires additional labor to refinish the interior and the exterior of the building around the window opening. The additional repair steps to do this significantly increase the cost of replacing windows, whenever the existing window frames are removed for replacement This is a significant disadvantage to replacing the windows, and frequently deters the homeowner or building owner from effecting such a replacement.
Patents have been granted for casing covers or cladding to refinish the exteriors of existing window frames. These are not directed to replacement windows; but simply are decorative protective covers to provide weather protection and appearance alterations of the window casings or window frames to which they are applied. Three such patents, disclosing window treatments of this type, are the patents to Chalmers No. 4,193,238; Minter No. 4,341,048; and Nassau No. 4,590,723. All of these patents provide Minter are directed to exterior casing coverings, and Nassau is directed to interior casing coverings.
The patent to Tinti No. 4,601,144 is directed to a design of interior wood trim for placement around the edge of a window frame to insulate the seam or gap between the rough opening and the window frame, to prevent the passage of air through this gap. The trim has a channel on its reverse side. The channel is filled with a compressible foam which presses against the adjacent structural members, and bridges the gap or seam between them to provide the desired insulating function.
It is desirable to provide a replacement window construction which can be used to economically and efficiently replace the windows in an existing building without damage to the interior or exterior finish of the building.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved replacement window construction.
It is another object of this invention to provide an improved method for replacing windows in an existing building.
It is an additional object of this invention to provide an improved replacement window structure and method for replacing existing windows in a building without removing the existing window frame.
It is a further object of this invention to provide an improved window structure in which a new window frame in the form of cap extrusions is placed over the existing window frame for subsequent installation of the new window.
In accordance with a preferred embodiment of the invention, a replacement window frame assembly for use in remodeling buildings, in which the windows have been removed from existing window frames, is made of bottom, top, and first and second side jamb cap members, which extend over the existing window frame, and which have a front lip extending over the outside of the window frame. Each of the cap members has a rear edge which abuts the interior sill, top, and side walls on the structure surrounding the window frame. Once the cap members are attached in place over the existing window frame, a new window is installed in the new frame made of the cap members covering the old frame. Alternatively, for fixed frame or art glass applications, the glass may be directly glazed into the new frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a component of a preferred embodiment of the invention;
FIG. 2 is a cross section of the embodiment shown in FIG. 1;
FIG. 3 shows the manner of installation of the embodiment of FIG. 1 in the practice of a preferred embodiment of the method of this invention;
FIGS. 4A through 4G illustrate sequential steps in the practice of the method of the invention; and
FIG. 5 illustrates structural details of the portion 5 circled in FIG. 4G.
DETAILED DESCRIPTION
Reference now should be made to the drawings, in which the same reference numbers are used throughout the different figures to designate the same or similar components.
FIG. 1 shows a perspective view of an elongated aluminum extrusion 10 which is constructed in accordance with a preferred embodiment of the invention. The extrusion 10 includes a flat upper surface 11, with a downwardly extending front lip 12 on one edge, and a downwardly extending rear surface or edge 13 attached to the other edge of the surface 11. Parallel with the surface 13 is an upwardly extending flange 14 having an inwardly turned edge 16 on it, as seen most clearly in FIGS. 1 and 2.
As shown most clearly in FIG. 2, the front lip 12 has elongated score lines, or lines of weakening 24, extending throughout its length, parallel to the surface 11. Similarly, parallel lines of weakening 23 are provided at the same spaced distances apart as the lines 24, along the rear lip or edge 13. As also most clearly shown in FIGS. 1 and 2, the lowermost edge of the rear lip 13 has an inwardly turned leg 18 on it, and above each of the score lines 23, similar inwardly turned legs 19, 20, and 21 are provided. Each of these legs also have scored lines of weakening extending throughout their length parallel to the plane of the surfaces 13 and 14. This again is shown most clearly in FIGS. 1 and 2.
The extrusion shown in FIGS. 1 and 2 may be made of anodized aluminum, other suitable materials, or aluminum with an enameled or painted finish, as desired. Color and surface texture are selected to be complimentary to the installation with which the extrusions are to be used.
As shown in FIG. 3, the extrusion of FIGS. 1 and 2 is made to fit over an existing aluminum or metal window frame 30, for sliding windows, and having a pair of window channels 31 and 32 in it. Typically, such a frame 30 includes inner and outer guide walls or flanges 33 and 34, respectively, which extend upwardly from the building opening 35 in which the frame 30 is installed. In addition, the window sill 36 of the building interior usually is fastened to the bottom of the opening 35 and abuts the flange 33, as illustrated in FIG. 3. Similar side walls 38 and a top interior finish, typically made of drywall or other material, abut against the inner facing surface of the flange 33 in the manner of the sill 36 in the completed installation of a window opening including the metal frame 30.
As illustrated in FIG. 3, once the old window sash and/or glass and center supports carried by the window frame 30 are removed, the extrusion of FIGS. 1 and 2 may be placed as a cap over the existing window frame 30 without removing the window frame 30 from the structure to which it was attached in the initial construction of the building. The score lines or weakening lines 23 and 24 are provided to accommodate different vertical heights of the flanges 33 and 34; so that the surface 11 is parallel to the plane of the opening in which the cap of FIGS. 1 and 2 is placed. As shown in FIG. 3, the bottom two sections of the rear lip 13, including the legs 18 and 19, have been broken away from the cap installed in FIG. 3; so that the inwardly turned leg 20 rests on the window sill 36. The lower surface of the flat portion 11 rests on the upper edges of the flanges 33 and 34. Similarly, the lip 12 on the outside of the building has been broken off at the second notch shown in FIG. 2, to extend over the existing frame 30 to the line of contact between the frame 30 and the outer surface 39 of the building wall. This is readily apparent from an examination or comparison of FIGS. 2 and 3.
Reference now should be made to FIGS. 4A through 4G, which illustrate the method of installing the replacement window frame made from the extrusion shown in FIGS. 1 and 2. FIG. 4A shows an existing standard aluminum window frame 30, with a sliding window 40, and a fixed window 42 mounted in the channels 31 and 32, respectively (see FIG. 3), and separated by a central support or divider member 43. As shown in FIG. 4B, the windows 40, 42, and the center divider 43 are removed in any conventional manner. It is well known that these window elements readily can be removed for repair and replacement purposes with a minimum of effort. The existing metal window frame 30 is left in place in the window opening, as indicated in FIG. 4B.
As shown in FIG. 4C, five cap members, including a bottom 50, first and second sides 51 and 52, and first and second top cap members 53 and 54, are cut from lengths of extrusions of the type shown in FIG. 1. The cap members 50, 51, and 52 are mitered at 45° on both ends. The lengths of these cap members are selected to fit the interior lengths or widths established by the upper edges of the flanges 33 and 34 of the existing metal frame 30 in the location where the new replacement window is to be installed. The top cap members 53 and 54 each comprise a length which is one-half the total length of the bottom member 50. These members are mitered at 45° on opposite ends, as illustrated in FIG. 4C, and are cut to abut one another at a 90° joint in the center.
FIG. 4D then shows the first step in the installation of the cap 50 to form the new window frame over the existing metal frame 30 The cap 50 is simply put in place from the exterior or interior of the building over the existing frame, in the manner shown in FIG. 3. The side caps 51 and 52 then are put in place, as shown in FIG. 4E, again, from the exterior of the building. Where the mitered edges of the caps 51 and 52 engage the cap 50, they serve to secure the cap 50 in place without any additional fastener members. It is noted, from FIG. 3, that the inwardly turned legs or flanges 20 and 21 (or 18, or 19) serve to engage the surface of the flange 33 to prevent the cap members 50 to 54 from being pulled outwardly from the window opening, once they are in place.
FIGS. 4F and 4G illustrate the final assembly steps in the installation of the replacement window frame cap assembly. The first one of the top members (shown as 53 in FIG. 4F) is placed in abutting relationship with the side cap member 51. This member 53 is installed by means of a suitable fastener, such as a screw 56, extended through the existing window frame into the underlying supporting structure 39, as illustrated most clearly in FIG. 5. Once the member 53 has been secured in place, the corresponding or matching member 54 is put in place and secured by means of a screw 57, again, as shown most clearly in FIG. 5. The two screws or fasteners 56 and 57, which are placed through the caps 53 and 54 comprising the top of the replacement window frame assembly, securely hold the entire assembly in place over the existing frame. The assembly cannot be removed by pushing it inwardly, because the lips 12 extend over the outside of the existing window frame. Similarly, the inwardly turned flanges or legs 18, 19, 20, or 21 engage the edge of the inner flange 33 to prevent the replacement window frame assembly from being pushed out of the pre-existing opening.
It is readily apparent from an examination of FIGS. 4A through 4G that installation of the extrusions forming the replacement window frame, do not interfere with or damage in any way, the exterior or interior structure of the building in which the replacement frame is placed.
The upwardly extending flange 14 with the inwardly turned upper edge 16 serves as an abutment for the insertion of a replacement window assembly into the new frame, which is shown in FIG. 4G. A suitable caulking compound or other sealant may be placed in the channel formed by the edge 16, and the inside edge of the surface 11; so that when the new replacement window is pressed into place in the opening, it abuts this surface on the top, bottom, and both sides of the replacement frame. The new window installation then may be secured by any suitable means to the cap members 50, 51, 52, 53, and 54, to complete the installation.
It should be noted that the entire installation of the cap members forming the replacement frame, as well as installation of the replacement window, is effected from the exterior of the building. This is an important feature for the effective remodeling which is brought about by means of the apparatus and method which is described above. No "mess" of any sort is made through the installation of replacement windows in accordance with the embodiment of the invention which has been described above, and which is shown in the drawings. Typically, the new windows, which are installed in the window frame illustrated in FIG. 4G, comprise double paned insulating windows, which significantly reduce heat loss compared with the single pane windows typically replaced. Of course, replacement of inefficient single pane windows is not the only reason for using the replacement windows and method described above, since in at least some instances replacement may be effected simply for a different decorative look.
The cap extrusion replacement window frame and method of installation described above, eliminate many costs otherwise associated with replacement of existing windows. There is no need to cut the interior drywall, which may have wallpaper, tile wood, wiring for the alarm system, mini blinds, and other window treatments already installed on it. Consequently, no patchwork inside the house is necessary.
When the exterior of a house or building is stucco or wood siding, or brick veneer, removal of a window frame usually requires the sawing of the window through the nailing fin. This means dealing with dust, debris, and construction cleanup. Since such sawing is not necessary with the invention described above, the expensive remodeling/construction time normally required is eliminated. In addition, the dust, debris and other construction cleanup are eliminated.
In buildings made of exterior stucco, the stucco is damaged on the returns in order to saw out an existing window frame. Patching and color matching after the removal and re-installation of a new window is a significant part of the installation of such a new window in stucco buildings. Since color matching cannot effectively be accomplished on wet stucco, it generally requires multiple trips to the job site to obtain the proper color match. Since the stucco of an existing building does not need to be broken or damaged in any way, through the use of the above described invention, considerable savings in the replacement of windows in stucco structures is effected through the use of the above described replacement window frame and method of installation. The foregoing description of the preferred apparatus and preferred method of installation should be considered as illustrative only, and not as limiting. For example, while aluminum extrusions appear to be the most efficient structure to use for the cap members, other techniques for forming the cap members, and other materials also may be employed. Various changes and modifications will occur to those skilled in the art, without departing from the true scope of the invention as defined in the appended claims. | A replacement window frame assembly includes bottom, sectioned-top, and first and second side cap members for placement over an existing window frame in a building from which the windows and intermediate support members have been removed. The cap members are made from a uniform aluminum extrusion which has a front lip to extend over the outside of the existing frame, and a lower depending lip, designed to rest on the window sill, or abut against the side and top of the frame opening in which the original frame is placed. The cap members are placed over the existing window frame to form a flat mounting surface for the installation of a replacement window. The entire replacement may be effected from the outside of the building, and is accomplished without destroying or damaging any of the interior or exterior finishes of the building. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 10/367,154, filed Feb. 14, 2003, which is a divisional of U.S. patent application Ser. No. 09/550,508, filed Apr. 17, 2000, now U.S. Pat. No. 6,547,002, which issued Apr. 15, 2003, both of which are herein incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to removable subassemblies in sealing equipment. Specifically, the invention relates to removable subassemblies in oil field rotary drilling head assemblies.
[0004] 2. Description of the Related Art
[0005] Drilling an oil field well for hydrocarbons requires significant expenditures of manpower and equipment. Thus, constant advances are being sought to reduce any downtime of equipment and expedite any repairs that become necessary. Rotating equipment is particularly prone to maintenance as the drilling environment produces abrasive cuttings detrimental to the longevity of rotating seals, bearings, and packing glands.
[0006] FIG. 1 shows an exemplary drilling rig 10 . The drilling rig 10 is placed over an area to be drilled and a drilling bit (not shown) is attached to sections of drill pipe 12 . Typically, a rotary turntable 14 rotates a drive member 16 , referred to as a kelly, which in turn is attached to the drill pipe 12 and rotates the drill pipe to drill the well. In some arrangements, a kelly is not used and the drill string is rotated by a drive unit (not shown) attached to the drill pipe itself. Typically, a mixture of drilling fluids, referred to as mud, is injected into the well to lubricate the drill bit (not shown) and to wash the drill shavings and particles from the drill bit and then return up through an annulus surrounding the drill pipe 12 and out the well through an outflow line 22 to a mud pit 24 . New sections of drill pipe 12 are added to the drill pipe in the well using a crane 26 and a block and tackle 28 to collectively form a drill string 30 as the well is drilled deeper to the desired underground strata 32 . A power unit 34 powers a control unit 36 and associated motors, pumps, and other equipment (not shown) mounted on a drilling platform 38 .
[0007] In many instances, the strata 32 produce gas or fluid pressure which needs control throughout the drilling process to avoid creating a hazard to the drilling crew and equipment. To seal the mouth of the well, one or more blow out preventers (BOP) are mounted to the well and can form a blow out preventer stack 40 . An annular BOP 42 is used to selectively seal the lower portions of the well from a tubular body 44 which allows the discharge of mud through the outflow line 22 . A rotary drilling head 46 is mounted above the tubular body 44 and is also referred to as a rotary blow out preventer. An internal portion of the rotary drilling head 46 is designed to seal around a rotating drill pipe 30 and rotate with the drill pipe by use of a internal sealing element, referred to as a packer (not shown), and rotating bearings (also not shown) as the drill pipe is axially and slidably forced through the drilling head 46 . However, the packer wears and occasionally needs replacement. Typically, the drill string or a portion thereof is pulled from the well and a crew goes below the drilling platform 38 and manually disassembles the rotary drilling head 46 . Typically, a crane 26 is used to lift the rotary drilling head 46 which can weigh thousands of pounds. Because of the size of the drilling head 46 , portions of the drilling platform 38 and equipment are disassembled to allow access to the drilling head and to remove the drilling head from the BOP stack 40 . The drilling head 46 is replaced or reworked and crew goes below the drilling platform to reassemble the drilling head to the BOP stack 40 and operation is resumed. The process is time consuming and can be dangerous.
[0008] Prior efforts have sought to reduce the complexity of the drilling head replacement. For example, FIG. 2 is a schematic cross sectional view of a rotary blow out preventer, similar to the embodiments shown in U.S. Pat. No. 5,848,643, which is incorporated herein by reference. A rotating spindle assembly 48 is disposed within a non-rotating spindle assembly 50 , which in turn, is disposed within a body 52 and held in position by lugs 54 . To remove the entire non-rotating and rotating spindle assembly from the body 52 , lugs 54 are rotated in horizontal grooves 56 and then lifted upwardly through vertical slots 58 in a “twist and lift” motion. However, the assembly can weigh about 1,500 to about 2,000 pounds and still requires use of extra lifting equipment such as the crane 26 . In addition, disassembly of the drilling platform 38 is necessary to provide access and requires manual efforts by the drilling crew.
[0009] Similarly, U.S. Pat. No. 3,934,887, incorporated herein by reference, discloses a BOP body having an assembly of a lower stationary housing 22 and an upper stationary housing 24 . The upper stationary housing 24 houses a stationary tapered bowl 60 , a rotating bowl 62 disposed inwardly of the tapered bowl, and bearings 66 , 68 disposed between the stationary bowl and rotating bowl. A stripper 40 is connected to the rotating bowl 62 . A clamp 28 retains the assembly of the stationary tapered bowl 60 , the rotating bowl 62 , the bearings 66 , 68 , and associated equipment to the upper stationary housing 24 . By unclamping the clamp 28 , the entire assembly may be removed from the BOP body. However, the removable assembly is of such size and weight with the result that crews are needed below the drilling platform and lifting equipment is necessary to lift the assembly from the BOP body.
[0010] FIG. 3 is a schematic cross sectional view of another rotary BOP 60 , similar to the embodiments disclosed in U.S. Pat. No. 4,825,938, incorporated herein by reference. To avoid removing the entire rotary BOP, the reference discloses a pneumatically actuated series of “dogs” 64 which engage a groove 66 on a retainer collar 68 , referred to in that disclosure as “massive”. By actuating pneumatic cylinders 70 to rotate the dogs 64 away from the groove 66 , the “massive” retainer collar 68 , the stinger 72 , stinger flange 74 , a stripper rubber 76 , and associated bearing surfaces 78 , 80 and 82 can be removed and access gained to the inner structures to repair or replace the stripper rubber 76 . This device is similar to the preceding references in that both rotating and non-rotating portions are removed, which add weight and size to the assembly that is removed.
[0011] Another challenge to the rotary drilling head maintenance is bearing life. In a rotary BOP, bearings are used to reduce the friction between the fixed portions of the drilling head and the rotating drill string with rotating portions of the drilling head. As shown in FIG. 2 , the typical assembly includes a lower bearing 84 and an upper bearing 86 axially disposed between a rotating portion 48 and a non-rotating portion 50 of the rotary BOP 50 . The bearings are tightened in position, referred to as pre-loading the bearing, by typically turning a threaded bearing retainer 88 until the bearings are pre-loaded to a desired level. As the bearings wear or otherwise change, the loading changes. The BOP must be disassembled, the bearing readjusted, and the BOP reassembled. Otherwise, the bearings can fail prematurely, causing downtime for the drilling operations. Typically, the bearing retainer is directly inaccessible after assembly into the drilling head and the drilling head must be at least partially disassembled for readjustment.
[0012] There remains a need for an apparatus and method for decreasing the downtime in drilling an oil well by decreasing the time required for removal and replacement/repair of the packer and decreasing the time required to adjust the bearing loading.
SUMMARY OF THE INVENTION
[0013] The present invention generally provides an apparatus and method for sealing about a member inserted through a rotatable sealing element disposed in a drilling head. The rotatable sealing element is removable separately from non-rotating and/or other rotating portions. More specifically, the invention allows a rotatable packer in a drilling head to be removable separately from non-rotating and/or other rotating portions of the drilling head. The invention also provides a fluid actuated system to maintain a pre-load system on the bearing.
[0014] In one aspect, the invention provides a non-rotating portion, a first rotating portion and a second rotating portion, at least one rotating portion being rotatably engaged with the non-rotating portion, and a selectively disengageable retainer disposed adjacent at least one of the rotating portions and adapted to disengage at least one of the rotating portions from the non-rotating portion. In another aspect, the invention provides a non-rotating portion, a rotating portion disposed in proximity to the non-rotating portion, at least one bearing disposed between the non-rotating portion and the rotating portion and having at least one moveable bearing race adjacent a remaining portion of the bearing, and an actuator disposed adjacent the bearing race and adapted to adjust a position of the moveable bearing race relative to the remaining portion of the bearing. In another aspect, the invention provides a method of retaining a packer in a drilling head, comprising disposing a packer in a rotating portion of the drilling head, radially moving a retainer toward the packer, the retainer being at least partially disposed in the rotating portion, and radially engaging the packer with the retainer while maintaining a portion of the retainer in the rotating portion. In another aspect, the invention provides a non-rotating portion, a packer disposed within the non-rotating portion, a retainer ring radially disposed about the packer, and an annular piston radially disposed about the packer and aligned with the retainer ring. In another aspect, the invention provides a method of releasing a packer from a drilling head, comprising disengaging a retainer from a packer and removing a packer from the drilling head while retaining rotating portions of the drilling head with the drilling head. In another aspect, the invention provides a method of adjusting bearing pressure in a drilling head, comprising rotating a rotating portion relative to a non-rotating portion using at least one bearing disposed therebetween, pressurizing a fluid port in said non-rotating portion fluidicly connected to a bearing piston with a fluid, and actuating the bearing piston toward a moveable bearing race adjacent a remaining portion of the bearing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
[0016] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0017] FIG. 1 is a schematic side view of a typical drilling rig.
[0018] FIG. 2 is a schematic cross sectional view of a prior art blow out preventer.
[0019] FIG. 3 is a schematic cross sectional view of another prior art blow out preventer.
[0020] FIG. 4 is a schematic partial view of a drilling rig using the present invention.
[0021] FIG. 5 is a schematic cross sectional view of one embodiment of a rotary drilling head, shown in split FIGS. 5A and 5B .
[0022] FIG. 6 is a schematic top view of the embodiment of FIG. 5 .
[0023] FIG. 7 is a schematic side view of a drive bushing.
[0024] FIG. 8 is a schematic cross sectional view of another embodiment of the invention, shown in split FIGS. 8A and 8B .
[0025] FIG. 9 is a cross sectional schematic view of another embodiment of the drilling head.
[0026] FIG. 10 is a cross sectional schematic view of another embodiment of the drilling head.
[0027] FIG. 11 is a partial cross sectional schematic of a subsea wellbore with a drilling platform disposed thereover.
[0028] FIG. 12 is a cross sectional schematic view of another embodiment of the drilling head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The present invention generally provides a removal system for a packer in a rotary drilling head and an adjustable loading system for bearing loads in the rotary drilling head. Preferably, the removal of the packer and adjustment of the bearing load can be done remotely through a hydraulic, pneumatic and/or electrical system external to the packer or bearing such as through a system mounted on the drilling head or a system distant from the drilling head itself.
[0030] FIG. 4 is a schematic partial view of a drilling rig 100 using the present invention. A stack 102 of flanged connections is located above the well 104 and connects one or more blow out preventers. An annular BOP 106 is disposed above the well in fluidic communication with the well drilling and production fluids. In the case of excess pressure in the well, the BOP will close the well and annular spaces 108 surrounding the drill string 110 in the well. Under normal conditions, the mud used to lubricate equipment in the well and flush drill shavings from a drill bit (not shown) is pumped through the outflow line 112 to mud pits (not shown). A rotary drilling head 114 , also referred to as a rotary BOP, is mounted above the outflow line 112 and assists in sealing the drill string 110 as the drill string slides axially through the internal rotary drilling head surfaces, i.e., axially with respect to the longitudinal axis of the drill string. A kelly 116 is attached to the drill string 110 and is inserted into the rotary drilling head 114 . The kelly 116 is typically hexagonal or square to transmit torque to rotatable portions of the drilling head 114 so that the rotatable portions rotate in conjunction with rotation of the drill string 110 and the kelly 116 . A power unit 118 is mounted in proximity to the stack 102 and provides power to operate the rotary drilling head 114 and associated system equipment on the rig 10 through hydraulic, pneumatic, and/or electrical circuitry. The power unit 118 can be mounted on a skid 120 for portability. The power unit 118 typically houses pumps, valving, motors, and reservoirs for the system within an enclosure 122 . In the embodiment shown, the system is simplified in that two pressure lines 124 travel to the rotary drilling head 112 and two pressure lines 126 travel to a control unit 128 mounted on the drilling platform 130 . The control unit 128 houses valving, meters, gauges, and other equipment and is designed to control the pressure and flow from the power unit 118 . While a hydraulic system is preferred, it is to be understood other systems such as pneumatic systems using gases, electrical systems and combinations thereof can also be used.
[0031] FIG. 5 shows a schematic cross sectional view of one embodiment of the drilling head 114 . The right side of the figure shows the drilling head 114 in an unengaged state without a drill string 110 disposed therethrough and the left side shows the drilling head 114 engaged with a drill string 110 axially disposed therethrough. The main components of the drilling head 114 generally include an annular lower housing 132 , an annular bearing housing 134 , an annular upper housing 136 , an annular packer 138 , an annular drive bushing 140 , a releasing element, such as a retainer ring 182 , and an actuator for the releasing element, such as a main piston 188 , and a lower body 142 .
[0032] The lower housing 132 of the drilling head 114 is attached to an annular lower body 142 which can be attached to the stack 102 , referred to in FIG. 4 , through a flange 150 or other connection. Preferably, pins 144 are radially oriented about the circumference of the lower body 142 and engage recesses 146 on the lower housing 132 . The recesses 146 preferably are conically tapered to receive and engage a taper 145 on the pins 144 . The recesses 146 provide alignment between the lower housing 132 and the lower body 142 . The pins 144 can also engage a radial groove extending around the lower housing, instead of individual recesses. The lower body 142 can also include the main overflow line 148 .
[0033] The bearing housing 134 is attached to the lower housing 132 and engages an upper bearing 152 and a lower bearing 154 . A cap 156 is attached to the upper surfaces of the bearing housing and seals the upper bearing 152 from dust and other contaminants. The cap 156 preferably has a plurality of lifting eyes 158 . An inner housing 160 is disposed radially inward from the upper and lower bearings 152 , 154 and engages the upper and lower bearings. The upper housing 136 is attached to the upper portion of the inner housing 160 and supports the packer 138 disposed inwardly of the upper housing 136 .
[0034] The packer 138 includes a mandrel 206 a , which is an annular elongated metallic body, and an element 206 b coupled to the mandrel, known as a “stripper rubber”. The element 206 b can be non-pressure assisted, as shown in FIG. 5 , or pressure assisted, as shown in FIG. 8 . The tubing string is inserted through the packer 138 and into the wellbore. The packer 138 is disposed inwardly from the upper housing 136 on an upper end of the packer and inwardly from the inner housing 160 on a lower end of the packer. The packer 138 is fixed in relative rotational alignment to the upper housing 136 and inner housing 160 by lugs 139 integral to or otherwise connected to the packer 138 that are disposed in axial slots 137 in the upper housing 136 . The element 206 b is made of elastomeric material such as rubber and is attached to the mandrel 206 a , such as by molding, and forms a sealing surface for the drill string 110 as the drill string axially slides through the rotary drilling head 114 . In an unengaged state, the element 206 b preferably is molded to be biased toward the centerline of the packer 138 . The element 206 b can deflect as the drill string 110 and shoulders 208 at joints on the drill string 110 pass therethrough. The drive bushing 140 is disposed radially inward from the packer 138 and engages tabs 162 on the packer 138 with slots 163 . A drive bushing 140 is not used in some instances when the drill string 110 is rotated without a kelly 116 . In such instances, the packer 138 preferably has sufficient frictional contact with the drill string 110 to rotate with the drill string without using the drive bushing 140 .
[0035] The upper bearing 152 comprises an inner race 172 , an outer race 174 , and a series of rollers 176 annularly disposed inside the bearing housing 134 and outside the inner housing 160 . The outer race 174 engages the bearing housing 134 and the inner race 172 engages the inner housing 160 . The upper bearing 152 is pre-loaded by a bearing actuator, such as an annular bearing piston 178 , disposed in an annular cavity 180 in the bearing housing 134 axially adjacent the outer race 174 of the upper bearing 152 . The bearing piston 178 engages the outer race 174 with pressure exerted from a hydraulic or pneumatic fluid applied to the bearing cavity 180 below the bearing piston 178 to move the outer race toward the rollers 176 and pre-load the upper bearing 152 and lower bearing 154 . The pre-loading force can be monitored and maintained or selectively changed remotely without removing the bearings and associated housings by maintaining or adjusting the fluid pressure exerted on the bearing piston 178 . Alternatively, a bias member (not shown) such as a spring can be used separately or in combination with the fluid pressure to pre-load the bearing. Such movements of the bearing race is deemed “remote” herein, in that the bearing race is moved by an additional member.
[0036] The lower bearing 154 likewise comprises an inner race 164 , an outer race 166 , and a series of rollers 168 annularly disposed inside the lower housing 132 . The outer race 166 engages a bottom portion of the bearing housing 134 and the inner race 164 engages an outside portion of the inner housing 160 . A lower bearing retainer 170 is threadably attached to the inner housing 160 . When the bearing piston 178 moves upwardly and engages the outer race 174 of the upper bearing 152 , the resulting force on the outer race 174 is transmitted through the upper bearing 152 to the inner housing 160 and tends to move the inner housing 160 upwardly. The inner race 164 on the lower bearing 154 moves upwardly with the inner housing 160 and exerts force on the rollers 168 of the lower bearing 154 to pre-load the lower bearing.
[0037] The combination of the lower and upper bearings allows axial and radial loads to be supported in the drilling head 114 as the drill string 110 is inserted therethrough and rotates the packer 138 , the inner housing 160 , the inner races 164 , 172 and the rollers 168 , 176 . The outer races 166 , 174 , bearing housing 134 , and lower housing 132 typically do not rotate. Lubricating fluid, such as hydraulic fluid, preferably is pumped through each bearing 152 , 154 to lubricate and wash contaminants from the bearings.
[0038] An annular retainer ring 182 is disposed in an annular ring cavity 184 formed between an upper portion of the inner housing 160 and a lower portion of the upper housing 136 . The retainer ring 182 is radially aligned with an annular groove 186 on the outside of the packer 138 and inward of the retainer ring 182 . Preferably, the retainer ring is “C-shaped” and can be compressed to a smaller diameter for engagement with the groove 186 . Preferably, in a radially uncompressed state, the retainer ring 182 does not engage the groove 186 and the packer can be removed. An annular main piston 188 is disposed in a lower cavity 190 in the inner housing 160 and protrudes into the ring cavity 184 . The main piston 188 is axially aligned in an offset manner from the retainer ring 182 by an amount sufficient to engage a tapered surface 192 on the outside periphery of the retainer ring 182 with a corresponding tapered surface 194 on the inside periphery of the main piston 188 . The main piston is connected to various fluid passageways for actuation. The retainer ring 182 has a cross section sufficient to engage the groove 186 and still protrude into the ring cavity 184 so as to limit the axial travel of the packer 138 by abutting the lower end of the upper housing 136 and the upper end of the main piston 188 . A bias member (not shown) can be disposed axially adjacent the end of the main piston 188 that is distant from the retainer ring 182 to provide an axial force to the main piston and pre-load the piston against the retainer ring. The bias member can be, for example, a spring, pressurized diaphragm or tubular member, or other biasing elements. An upper cavity 191 is disposed between the main piston 188 and the upper housing 136 and is separate from the ring cavity 184 . An indicator pin 202 is disposed in the upper housing 136 . On the lower end of the indicator pin 202 , the pin engages the upper end of the main piston 188 . The upper end of the indicator pin 202 is disposed outside the upper housing 136 , when the main piston 188 is disposed upwardly in the ring cavity 184 .
[0039] An assortment of seals are used between the various elements described herein, such as wiper seals and O-rings, known to those with ordinary skill in the art. For instance, each piston preferably has an inner and outer seal to allow fluid pressure to build up and force the piston in the direction of the force. Likewise, where fluid passes between the various housings such as the pistons, seals can be used to seal the joints and retain the fluid from leaking.
[0040] FIG. 6 is a schematic top view of the drilling head shown in FIG. 5 . The bearing housing 134 is circumferentially bolted to the lower housing (not shown) and the cap 156 is circumferentially bolted to the bearing housing 134 . The upper housing 136 is disposed radially inward of the cap 156 and is circumferentially bolted to the inner housing (not shown). The upper housing 136 includes two slots 137 in which lugs 139 on the packer 138 are inserted to maintain the relative rotational position of the packer 138 with the upper housing 136 and inner housing 160 . The drive bushing 140 is disposed radially inward of the packer 138 , is supported axially by the packer, and is radially fixed in position relative to the packer 138 by the slots 163 on the drive bushing when engaged with the tabs 162 on the packer 138 .
[0041] FIG. 7 is a schematic side view of the drive bushing 140 . The drive bushing 140 is designed to mate in two or more symmetrical portions 250 , 252 . Each symmetrical portion includes a tab 254 and a slot 256 on opposing sides formed between two or more flanges 258 , 260 , and bolt holes 262 through which bolts 264 are inserted through adjacent symmetrical portions, including the tabs and slots, to retain the symmetrical portions together. The bolts holes 262 are disposed axially, so that if the bolts 264 should be loosened in operation, the bolts would remain in place and the symmetrical portions 250 , 252 be retained together in contrast to a typical radial alignment for the bolts in which loose bolts could be thrown away from an assembled bushing by centrifugal force. The drive bushing 140 has an annular tapered surface 266 to mate with a corresponding tapered surface in the packer 138 , referenced in FIG. 6 , and assist in securing the drive bushing axially in the packer.
[0042] In operation, referencing FIGS. 4-7 , a crane 26 lifts the rotary drilling head 114 onto the stack 102 and the lower body 142 is attached to the stack with bolts in the flange 150 . One or more pins 144 in the lower body 142 engage the recesses 146 to secure both the axial and rotational positions of remaining portions of the drilling head 114 , i.e., those portions of the drilling head detachable from the lower body. Alternatively, the lower body 142 can be attached separately to the stack 102 and the remaining portions of the drilling head 114 attached to the lower body 142 with pins 144 . Fluid, such as hydraulic fluid(s) or pneumatic gas(es), is pumped into the drilling head 114 by the power unit 118 and controlled by the control unit 128 . To engage the retainer ring 182 with the groove 186 , the fluid is pumped into the lower cavity 190 and axially displaces the main piston 188 into engagement with the retainer ring 182 to force the ring radially inward. The engaged position of the retainer ring 182 with the groove 186 is shown on the left side of FIG. 5 . The force exerted between the tapers 192 , 194 compresses the retainer ring 182 radially inward to engage the groove 186 . The indicator pin 202 is pushed outward from the upper housing 136 by the travel of the main piston 188 to indicate the groove 186 is engaged. An assembly (not shown) can be bolted to the upper housing 136 to manually force the indicator pin 202 back into the upper housing 136 , thereby forcing the main piston 188 away from the retainer ring 182 to manually release the packer 138 if desired. Thus, the packer 138 , as a first rotating portion, is releasably retained in the drilling head 114 by the retainer ring 182 . Additionally, the fluid pressure can be maintained on the piston 188 even while the inner housing 160 and upper housing 136 rotate within the bearing housing 134 by the several seals, such as wiper seals and O-rings, located between non-rotating portions and other rotating portions of the drilling head, such as between the bearing housing 134 and the upper housing 136 or the inner housing 160 .
[0043] A drill string 110 , drilling bit (not shown), and a kelly 116 are assembled and inserted through the drive bushing 140 and the packer 138 . The element 206 b deflects radially outward as the drill string 110 is axially forced through the packer 138 and effects a seal about the periphery of the drill string. The kelly 116 is rotated which rotates the drill string, the drilling bit, and rotating components of the drilling head 114 for drilling a well.
[0044] When the packer 138 and particularly the element 206 b is to be replaced, the retainer ring 182 expands radially outward to disengage the packer 138 from the drilling head 114 . Fluid is forced into the upper cavity 191 and axially forces the main piston 188 away from the retainer ring 182 , whereupon the retainer ring decompresses radially outward and disengages the groove 186 , thereby releasing the packer from the non-rotating portions and other rotating portions. A pipe joint on the drill string 110 is separated and the upper portion of the drill string is removed from the drilling head 114 . Because of the relatively light weight of the packer 138 compared to the assembly of rotating components and especially compared to the entire drilling head 114 , neither the crane 26 nor special equipment may be needed to connect to the packer 138 and pull it from the drilling head 114 . The crane 26 may simply lift the drill string 110 and the element 206 b can rest on the pipe shoulder 208 and pull the packer 138 with the drill string 110 . The bearings 152 , 154 , upper housing 136 , inner housing 160 , cap 156 , bearing housing 134 , and lower housing 132 , all can remain attached to the lower body 142 .
[0045] The packer 138 may be reinserted into the drilling head 114 in the opposite manner. The packer 138 is placed on the drilling head 114 and rotated until the lugs 139 on the packer 138 are aligned with the slots 137 in the upper housing 136 and the packer then slides axially into position. The drive bushing 140 , if not already installed, is placed over the packer 138 , the slots 163 are aligned with the tabs 162 on the packer 138 , and the drive bushing is slid into position. The fluid pressure in the upper cavity 191 can be released and the fluid pressure in the lower cavity 190 forces the main piston 188 into engagement with the retainer ring 182 . The retainer ring 182 compresses radially inward and engages the groove 186 . The packer is thus secured and operations can be resumed.
[0046] FIG. 8 is a schematic cross sectional view of another embodiment of the drilling head. The embodiment shows two primary changes where one is to the packer 210 and the other to the manner in which the remaining portions of the drilling head 114 are retained to the lower body 142 . Any of the changes could be used with other embodiments and is not limited to the embodiment shown. In this embodiment, the other portions of the drilling head 114 remain substantially unchanged. The packer 210 includes a mandrel 212 a and a pressure assisted element 212 b is disposed radially inward from the mandrel and is axially bound by the mandrel on either end of the pressure assisted element. The pressure assisted element 212 b is shown in an unengaged mode on the right side of the centerline in FIG. 8 and in an engaged mode with a drill string 110 on the left side of FIG. 8 . A port(s) 214 is disposed through the sidewall of the packer 210 radially outward from the pressure assisted element 212 b and is connected to fluid passageway(s) 213 leading to the power unit 118 and control unit 128 , referenced in FIG. 4 . A drill string 110 having a shoulder 208 at each typical pipe joint is axially disposed through the drilling head 114 on the left side of the centerline. A cavity 216 in the engaged position shown on the left side of FIG. 8 is formed when fluid pressure forces the pressure assisted element 212 b toward the drill string 110 . The pressure assisted element assists in conforming the packer to variations in size and/or shape of different portions of the drill string, such as shoulder 208 , as the drill string is inserted through the drilling head.
[0047] An annular lower housing 218 is attached to an annular piston housing 220 disposed below the lower housing. An annular lower main piston 222 is disposed radially inward of the piston housing 220 and is housed in a lower ring cavity 224 formed between the lower end of the lower housing 218 , the inner periphery of the piston housing 220 , and a shoulder 226 of the piston housing 220 . A lower retainer ring 228 is disposed in the lower ring cavity 224 similar to the retainer ring 182 . The lower main piston 222 is axially aligned with the lower retainer ring 228 in an offset manner and engages the lower retainer ring 228 between tapered surfaces 230 , 232 . A lower groove 234 is formed on the outside circumference of the lower body 142 and is radially aligned with the lower retainer ring 228 . A wear ring 236 is disposed axially adjacent and below the lower retainer ring 228 . An upper cavity 238 is formed between the lower main piston 222 and a lower end of the lower housing 218 . A lower cavity 240 is formed between the lower main piston 222 and the piston housing 220 . A lower indicator pin 242 , similar to the indicator pin 202 , referenced in FIG. 5 , is axially disposed in the piston housing 220 and aligned with the lower main piston 222 .
[0048] In operation, the remaining portions of the drilling head 114 can be inserted over the lower body 142 . Fluid is forced into the upper cavity 238 and applies pressure to the lower main piston 222 . The lower main piston slides axially and engages the lower retainer ring 228 between the tapered surfaces 230 , 232 , thereby radially compressing the lower retainer ring 228 into the groove 234 . The remaining portions of the drilling head 114 are thus secured to the lower body 142 . The lower main piston 222 forces the lower indicator pin 242 axially outward from the piston housing 220 , indicating an engaged mode. If the remaining portions of the drilling head 114 should need removal from the lower body 142 , fluid is forced into the lower cavity 240 , thereby axially displacing the lower main piston 222 away from the lower retainer ring 228 . The lower retainer ring 228 radially decompresses, disengages from the groove 234 on the lower body 142 and releases the remaining portions of the drilling head 114 for removal.
[0049] Furthermore, in operation, a drill string is inserted through the drilling head 114 and axially slides by the packer 210 . Fluid is transported through the port(s) 214 and expands the cavity 216 which in turn forces the pressure assisted element 212 b to radially compress against the drill string 110 . The amount of radial compression on the drill string can be controlled such as by regulating the pressure in the cavity 216 .
[0050] FIG. 9 is a cross sectional schematic view of another embodiment of the drilling head 114 . A lower body 280 generally houses the various rotating and non-rotating elements described in reference to the embodiment shown in FIG. 5 . The lower body 280 includes an attachment member, such as a flange 282 , which defines connecting holes 286 for bolts or other fasteners to pass therethrough into a mating flange (not shown) such as a flange disposed at the top of a well head casing. The lower body 280 also includes an attachment member, such as a flange 284 , which defines connecting holes 288 for bolts or other fasteners to pass therethrough for connecting the lower body 280 to a mating flange 294 on an upper body 292 . The upper body 292 is mounted to the lower body 280 in a sealing relationship with the flanges 284 , 294 and covers the various rotating and non-rotating members housed by the lower body 280 . The upper body also includes an upper flange 296 which defines holes 300 for bolts or other fasteners to pass therethrough into a mating flange (not shown), such as a flange disposed at the bottom of a casing extending downward from a drilling platform. The flange 284 of the lower body defines a lower body seal groove 290 and the flange 294 of the upper body defines an upper body seal groove 302 . The seal grooves 290 , 302 are sized and spaced in a cooperative relationship so that a seal 303 can be disposed therebetween to effect a seal between the flanges. Generally, the upper body and the lower body form an enclosure in connection with adjoining structure for protecting the bearings and packer of the drilling head from a radially external medium such as corrosive fluids, dirt, and other contaminates.
[0051] In general, various rotating and non-rotating members of the drilling head are disposed in a cavity 293 formed by the upper body 292 and lower body 280 . For example, the bearing housing 134 is mounted to the lower housing 280 by a fastening member 307 , such as one or more bolts, snap rings or other known fastening members, disposed within the cavity 293 . The fastening member 307 can also be an arrangement similar to the retainer ring 182 and main piston 188 , shown in FIGS. 5 and 8 , that could engage the bearing housing 134 to the lower body 280 or the upper body 292 . The piston could be remotely actuated so that the bearing housing could be selectively fastened or released. A remote release or fastening could be particularly useful in remote locations such as in subsea applications. A packer 304 , similar to the packer 138 , is disposed within the drilling head 114 inward of an annular upper housing 136 . The packer 304 may extend upward to the elevation of the annular upper housing 136 . The packer 304 includes a mandrel 306 and an element 308 , similar to the mandrel 206 a and element 206 b , respectively, shown in FIG. 5 . The packer 304 is at least partially disposed in a cavity formed between the upper body 292 and the lower body 280 .
[0052] FIG. 10 is a cross sectional schematic view of another embodiment of the drilling head 114 , having members similar to those described in the embodiment shown in FIG. 8 . The lower body 280 includes a flange 282 which defines connecting holes 286 for bolts or other fasteners to pass therethrough into a mating flange (not shown) on an adjacent structure. The lower body 280 also includes a flange 284 which defines connecting holes 288 for bolts or other fasteners to pass therethrough for connecting the lower body 280 to a mating flange 294 on an upper body 292 . The upper body 292 is mounted to the lower body 280 in a sealing relationship with the flanges 284 , 294 and covers the various rotating and non-rotating members housed by the lower body 280 . The upper body also includes an upper flange 296 which defines holes 300 for bolts or other fasteners to pass therethrough into a mating flange (not shown) on an adjacent structure. The flange 284 of the lower body defines a lower body seal groove 290 and the flange 294 of the upper body defines an upper body seal groove 302 . The seal grooves 290 , 302 are sized and spaced in a cooperative relationship so that a seal 303 can be disposed therebetween to effect a seal between the flanges.
[0053] A packer 310 is disposed annularly within the annular upper housing 136 . The packer 310 includes a mandrel 312 and a pressure assisted element 314 that is disposed radially inward from the mandrel. The pressure assisted element 314 is axially bound by the mandrel on either end of the element. The pressure assisted element 314 is shown in an engaged mode with a drill string 110 that is axially disposed through the drilling head 114 . A port(s) 214 is disposed through the sidewall of the packer 310 radially outward from the pressure assisted element 314 and is fluidicly connected to a fluid pressure source. A cavity 216 is formed when fluid pressure forces the pressure assisted element 314 toward the drill string 110 . The pressure assisted element 314 assists in conforming the packer 310 to variations in size and/or shape of different portions of the drill string 110 as the drill string is inserted through the drilling head. The pressure assisted element 314 seals against the drill string 110 and allows differences in pressure between a first zone 316 and a second zone 318 for independent control of the pressures in the zones as described below.
[0054] FIG. 11 is a partial cross sectional schematic of a subsea wellbore 330 with a drilling platform 324 disposed thereover. The flanged embodiments shown in FIGS. 9 and 10 can be used in such an application. A casing 326 is suspended from the drilling platform 324 and extends a distance from the drilling platform to near the sea floor 328 . A drill string 110 is disposed within the casing so that an annular space 344 is formed therebetween. A flange 340 is connected to the lower end of the casing. A flanged drilling head 114 is sealingly connected to the flange 340 with a flange 296 disposed on the top surfaces of the drilling head. Similarly, a flange 286 disposed on the bottom surfaces of the drilling head 114 is sealingly connected with a flange 342 disposed on top of the wellbore 330 .
[0055] As the casing increases in depth, the weight of the water increases the pressure on the external surface of the casing. A sufficiently high pressure can distort or collapse the casing. A counteracting pressure within the annular space 344 in the casing can offset the effects of the external water pressure and minimize pressure differences. For example, the pressure differences can be minimized by flowing a fluid of similar density as sea water into the annular space to lessen the pressure gradient between the internal and external surfaces of the casing.
[0056] However, pressures necessary to drill into a subsea formation in the wellbore 330 may necessitate different pressures than those pressures required to offset the water pressure on the casing 326 . A drilling head 114 , such as the embodiment shown in FIG. 10 , can be mounted between the casing and the wellbore. The pressure assisted packer 310 engages the drill string 110 and creates a first zone 316 above the packer 310 and a second zone 318 below the packer. A first set of pressures can be controlled in the first zone 316 to offset the pressures from the water as the casing increases in depth. A second set of pressures can be controlled in the second zone 318 to enable effective drilling into the various formations and production zones.
[0057] FIG. 12 is a cross sectional schematic view of another embodiment of the drilling head 114 , having members similar to those described in the embodiment shown in FIGS. 9 and 10 . An upper body 350 is coupled to a lower body 280 with flanges 284 , 294 or other coupling members. Alternatively, the upper body 350 and the lower body 280 can be made as a unit with or without the flanges. A bearing housing 362 , similar to bearing housing 134 shown in FIGS. 9 and 10 , is removably coupled to the upper body 350 and/or the lower body 280 . An upper housing 136 is disposed radially inward of the bearing housing 362 . A packer 310 is disposed radially inward of the upper housing 136 . A throat 352 of the upper body 350 is sized to allow the bearing housing 362 and related members to be disconnected from the upper or lower body and be retrieved therethrough.
[0058] One system for coupling the bearing housing 362 is similar to the system of a fastening member such as a retainer ring 186 and a piston 188 , shown in FIGS. 5 and 8 - 10 . As an example, the upper body 350 can include an annular piston cavity 354 in which a piston 356 is disposed and sealably engaged with a wall of the piston cavity. A first port 366 can be used to flow fluid, such as hydraulic fluid or pneumatic gases, to and from a first portion 354 a of the piston cavity to actuate the piston 356 . Another port 368 can be fluidicly coupled to a second portion 354 b of the piston cavity that is formed on an opposite portion of the piston 356 from the first portion 354 a of the piston cavity. Lines or hoses, such as line 369 coupled to port 368 , can deliver fluid to one or both of the ports. Line 369 can be disposed external to the upper body 350 and can be used to remotely actuate the piston. A retainer ring 358 is disposed adjacent an end of the piston 356 and in one embodiment is biased radially outward from the bearing housing 362 . The retainer ring 358 retains the bearing housing as one example of an assembly to the one or more of the surrounding bodies. Other assemblies, whether including one member or a plurality of members, can be retained by the retainer ring 358 . Mating surfaces between the retainer ring 358 and the piston 356 are preferably tapered to allow the piston to force the ring radially inward as the piston moves downward. A corresponding groove 360 formed in the bearing housing 362 is adapted to receive the retainer ring 358 when the retainer ring is biased inward toward the bearing housing. At least one seal 364 can be disposed between the bearing housing 362 and an adjacent surface of the upper body 350 to seal drilling fluids from portions of the piston cavity 354 .
[0059] The embodiment shown in FIG. 12 could also include other packers and related members, such as shown in FIG. 9 . Further, other members of the drilling head 114 could be coupled to the upper or lower bodies in lieu of or in addition to the bearing housing 362 .
[0060] In operation, fluid can flow through the port 366 into the first portion 354 a of the piston cavity 354 to force the piston 356 toward the retainer ring 358 . For example, fluid disposed in the throat 352 can flow through the port 366 into the piston cavity 354 to bias the piston 356 downward during operation. The piston 356 contacts the retainer ring 358 and forces the retainer ring radially inward toward the groove 360 on the bearing housing 362 . The retainer ring 358 engages the groove 360 and retains the bearing housing and related components to the upper body 350 . To release the bearing housing 362 from the upper body 350 , the piston 356 retracts from engagement with the retainer ring 358 . For example, fluid flown through line 369 , through port 368 and into the second portion 354 b of the piston cavity 354 can force the piston 356 upward and override the fluid pressure acting on the top of the piston through port 366 . The retainer ring 358 expands radially outward and away from the bearing housing 362 . A drill string 110 or other member disposed downhole can be used to lift the bearing housing 362 from the upper body to the surface of the well or drilling platform (not shown).
[0061] Variations in the orientation of the packer, bearings, retainer ring, rotating spindle assembly, and other system components are possible. For example, the retainer ring can be biased radially inward or outward. The pistons can be annular or a series of cylindrical pistons disposed about the drilling head. Various portions of the drilling head can be coupled to the upper and/or lower bodies besides the particular members described herein. Other variations are possible and contemplated by the present invention. Further, while the embodiments have discussed drilling heads, the invention can be used to advantage on other tools. Additionally, all movements and positions, such as “above”, “top”, “below”, “bottom”, “side”, “lower” and “upper” described herein are relative to positions of objects such as the packer, bearings, and retainer ring. Further, terms, such as “coupling”, “engaging”, “surrounding” and variations thereof, are intended to encompass direct and indirect “coupling”, “engaging” and “surrounding” and so forth. For example, a retainer ring can be coupled directly to the packer or can be coupled to the packer indirectly through an intermediate member and fall within the scope of the disclosure. Accordingly, it is contemplated by the present invention to orient any or all of the components to achieve the desired movement of components in the drilling head assembly.
[0062] While the foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | The present invention generally provides a reduced downtime maintenance apparatus and method for replacing and/or repairing a subassembly in sealing equipment for oil field use. The invention allows the removal of rotating portions of a rotary drilling head without having to remove non-rotating portions. The reduction in weight and size allows a more efficient repair and/or replacement of a principal wear component such as a packer. Specifically, the packer in a rotary drilling head can be removed independent of bearings and other portions of the rotary drilling head. Furthermore, because of the relatively small size and light weight, the packer can be removed typically without having to use a crane to lift a rotary BOP and without disassembling portions of the drilling platform. In some embodiments, the packer can be removed with the drill pipe without additional equipment. Furthermore, the packer can be removed remotely without necessitating manual disengagement typically needed below the platform. The invention also provides a fluid actuated system to maintain a pre-load system on the bearing. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a polymeric centralizer for centering pipe strings in well bores or within in other pipe strings which can be easily fitted onto a production string or casing during down hole insertion.
More particularly, the present invention relates to a polymeric centralizer for centralizing pipe strings in well bores and within in other pipe strings including a plurality of blades or fins extending substantially longitudinally along an outer surface of the centralizer, a slit through a blade opposite a groove for opening the centralizer so it can be fitted onto a production string or casing, a fastener means for securing or tightening the centralizer to the string or casing and cutaways for allowing wirelines or cables to pass between the centralizer and the production string to protect the cable, where the centralizer is wear and abrasion resistant, safe for use in hazardous environments and does not contribute to metal contamination of the well.
2. Description of the Related Art
In the completion of oil and gas wells it is standard practice to set or cement at least one string of casing within the well bore. Casing strings are cemented in the well bore to prevent fluids from migrating from the production zone through the annulus between the casing string and the well bore to the surface or other zones where for example fresh water may be contaminated. In addition, there are regulations which require that some zones be cemented off.
In cementing a casing string, a cement slurry is pumped down the interior of the casing string, out the lower end, into the annulus between the string and the well bore. However, to effect an efficient cementing job, the complete annulus needs to be cemented without pockets in the cement and without areas in which the string is contacting the wall of the well bore. To facilitate obtaining an effective cementing job the casing is commonly centered in the well bore with centralizers which are disposed about the casing string. In addition, the centralizers aide in running the pipe into the hole without hanging up.
Centralizers may also be used on casing or pipe strings, such as tubing, which are hung within another string of casing or pipe. These inner strings may be cemented within the outer pipe string or they may not be.
Centralizers for casing, tubing or pipe commonly are constructed of a low carbon steel having a tubular body or sleeve adapted to fit around a pipe joint. These prior art centralizers usually include outwardly bowed springs having opposing ends connected to opposite ends of the sleeve. Although the resiliency of the bow strings enables them to move through tight spots in the well bore, they may not support the weight of the casing string, especially in a highly deviated well bore.
In another type prior art centralizer, the bow strings are replaced by solid strips of metal which are tapered at each end to provide outer spaced bearing surfaces for engaging the well bore or the outer casing. Although less prone to collapse than bow springs under the weight of the casing string, these metal strips are often not strong enough to prevent bending upon contacting an obstruction or turn in the well bore. As a result, the centralizer and the casing may become wedged in the well, and, in any case become unsuitable for providing a suitable cementing job.
Another type of prior art centralizer is a non-metallic sleeve centralizer disclosed in U.S. Pat. No.; 5,908,072.
These prior art metal centralizers have further drawbacks, especially, when run and set within another string of pipe. One of the drawbacks of metal centralizer is contact with the outer pipe when the string vibrates. Metal to metal contact may cause a spark, which can be very hazardous in the hydrocarbon filled well. Also, metal centralizers can create a corrosion problem with the casing strings which it contacts through electrolysis. Metal centralizers also are susceptible to damage when running acid and circulating the acid back out of the hole. Additionally, there is a concern with scrapping the inner diameter of stainless steel tubing when running stainless/duplex stainless steel tubing having metal centralizers. The non-metallic sleeve centralizers overcome some of these disadvantages, but sleeve type centralizer are difficult to attach to pre-connected strings.
It would be a benefit, therefore, to have a polymeric centralizer adapted to fit about a string of pipe for centering the pipe in a well bore or within an outer string of pipe such as a production riser which can be easily attached to the string prior to or after make-up. It would be further benefit to have a polymer centralizer that can be used with downhole operations that require control cabling or umbilicals or wirelines where the cabling can be inserted through slots or cutaways in the centralizer.
SUMMARY OF THE INVENTION
The present invention provides a polymeric centralizer for centering a production string or casing within a well bore or within another string of casing or a riser including a plurality of fins or blades extending substantially longitudinally along an outer surface of the centralizer, a slit through a blade opposite a groove which cooperate to allow the centralizer to open so it can be fitted onto a production string or casing, a fastener means for securing the centralizer to the string or casing and cutaways for receiving and protecting wires, cables, umbilicals or other continuous cabling leading from the surface, where the centralizer has structural strength capable of withstanding the forces exerted by a string of pipe contacting a well bore or an outer string of pipe, is non-sparking when contacting metal pipe strings, does not promote electrolysis when in contact with a pipe string and provides cathodic protection between strings of pipe, is resistant to acid, is inexpensive to manufacture and is lightweight and has the tensile and compressive strength required to withstand the forces encountered in centralizing casing as opposed to the forces encountered by sucker rod guides and tube spacers. These centralizers are ideally suited for use with titanium risers attached to floating vessels where the centralizers centers and protects the inner surface of the riser from being damaged during the insertion of production strings.
The present invention also provides a drill or casing string and a plurality of centralizer fitted thereto for centering casing within a well bore or within another string of casing, where the centralizer includes a plurality of fins or blades extending longitudinally along an outer surface of the centralizer, a slit through a blade opposite a groove for opening the centralizer so it can be fitted onto a production string or casing, a fastener means for securing the centralizer to the string or casing and cutaways for allowing wirelines, electrical cables or other continuous cabling leading from the surface to a given distance below the surface.
The present invention provides a method for protecting a production string including the step of attaching to the string at regular or irregular intervals a plurality of centralizers of the present invention.
The present invention also provides a method for protecting a production string or casing including the steps of lowering a production string or casing into a well bore and attaching a polymeric centralizer of the present invention to the string or casing at intervals separated by a distance sufficient to prevent the production string or casing from contacting the well bore or inner pipe to reduce wear and tear and damage to the string or casing.
The present invention further provides a method for fitting a centralizer to a production string or casing including the step of opening the centralizer at a slit through a blade opposite a groove, forcing the opened centralizer over the production string or casing and tightening a fastener to draw the slit tight together and secure the centralizer to the string or casing.
Preferably, the blades have a bearing surface for bearing against a well bore or an outer casing in which the string or casing carrying the centralizer is disposed. The blades extend outwardly from the centralizer to space the carrying string from the well bore or outer casing string.
It is also preferred that the blades have opposing ends tapered outwardly toward one another. However, it is not necessary that the blade ends be tapered. It may also be desired to have the blades sweep at an angle as they extend longitudinally down the sleeve.
The polymeric centralizer may be positioned on the pipe and allowed to float between the collars at adjacent casing joint connections. The centralizer may be connected to the casing joint by an adhesive. The centralizer may be connected to the casing joint by set screw which are adjustably disposed through the centralizer so as to engage the casing joint. The centralizer may be connected to joint and cable protectors such as coupling protectors made by Cannon Services, Inc. of Missouri City, Tex. and described U.S. Pat. No. 4,615,543, incorporated herein by reference. The centralizer may be fixedly connected to the casing joint via stop collars or rings connected to the casing string adjacent opposing ends of the centralizer. The stop rings may be of any type well known in the art such as the Frank's SB stop ring.
Additionally, the stop rings may be constructed of the same or similar polymeric as the centralizers of this invention. Preferably, a stop collar formed of the same or substantially same polymeric material as the centralizer would include an outer ring, an inner ring positioned between the outer ring and the casing joint to be engaged and having an inner face for gripping the casing joint, and an activating mechanism for securing the inner ring to the outer ring and facilitate engagement with the casing joint.
DESCRIPTION OF THE DRAWINGS
The invention can be better understood with reference to the following detailed description together with the appended illustrative drawings in which like elements are numbered the same:
FIG. 1 is a top view of one embodiment of a polymeric centralizer of this invention;
FIG. 2 is a first side view of the centralizer of FIG. 1 showing the groove;
FIG. 3 is a second side view of the centralizer of FIG. 1 showing the fastener;
FIG. 4 shows the centralizer of FIG. 1 in its opened state for fitting over a pipe;
FIG. 5 is a top view of another embodiment of a polymeric centralizer of this invention;
FIG. 6 is a top view of another embodiment of a polymeric centralizer of this invention;
FIG. 7 is a top view of another embodiment of a polymeric centralizer of this invention;
FIG. 8 is a front view of the centralizer of FIG. 1 secured to a pipe; and
FIG. 9 is a perspective view of two centralizer of FIG. 1 secured to a section of a string including a joint and a joint protector showing cabling extending along the string.
DETAILED DESCRIPTION OF THE INVENTION
The inventors have found that a polymeric centralizer can be constructed for use on production string or casing where the centralizer includes a slit through a blade opposite a groove or thin portion of the centralizer for opening the centralizer and fitting the centralizer over the string or casing with cutaways to protect surface cabling extending along a length of the string. Such a centralizer is ideally suited for use downhole operations such as drilling, completion, testing or the like.
The present invention broadly relates to a centralizer including a plurality of longitudinally extending blades or fins, a slit through a blade opposite groove for opening the centralizer so it can be fitted onto a production string or casing string or production riser and a fastener for bringing the slit together and tightening the centralizer onto the string or casing. Preferably, the centralizer also includes an inner cutaway or plurality of cutaways to accommodate cabling or wires extending from the surface down the length of the string.
The present invention also broadly relates to a method for protecting and centering a production string in a well bore or outer casing or production riser including attaching a plurality of centralizers of the present invention at intervals along the string to keep the string centered in the well bore or outer casing or riser and protected from contacting the well bore or outer casing or riser.
The present invention also broadly relates to a method for protecting cabling and centering a production string in a well bore or outer casing or production riser including attaching a plurality of centralizers of the present invention at intervals along the string to keep the string centered in the well bore or outer casing or riser and protected from contacting the well bore or outer casing or riser and running cabling through the cutaways in the centralizer.
The present invention also relates to a production string comprising sections of piping joined at joints each joint fitted with a joint protector and a plurality of centralizers of this invention fitted onto the string at space apart intervals sufficient to maintain the string substantially in the center of the well bore or inside an outer tubing or riser and a cable extending from the surface and running through the joint protectors and centralizer cutaways where the joint protectors and centralizers act to protect the cable as the string is inserted into or removed from the well bore or outer tubing.
The present invention also relates to a method for protecting a production string of tubing including the steps of opening a plurality of centralizer of this invention at each slit, pushing the centralizer over the tubing a spaced apart intervals sufficient to substantially center the string in a well bore or outer tubing and securing the centralizer onto the tubing at the intervals by tightening the fasteners.
The present invention also relates to a method for protecting a cable accompanying string of production tubing including the steps of attaching a joint protector to each joint in the string, attaching a plurality of centralizer of this invention to the string at spaced apart intervals sufficient to substantially center the string in a well bore or outer tubing or riser and threading the cabling through the protectors and the centralizers to protect the cable during insert into and removal from the well bore or outer tubing.
Suitable polymers for making the centralizers of the present invention include, without limitation, an engineering thermoplastic such as an acetal resins e.g., Delrin® from DuPont or other similar injection moldable polymers. The polymers should have a tensile strength between about 8,000 psi and about 14,000 psi at 73° F., a Tensile modulus of elasticity at 73 ° F. between about 400,000 psi and about 550,000 psi, an elongation of about at 73 ° F. between about 30% and 60%, a flexural strength at 73° F. between about 13,000 psi and about 16,000 psi, a flexural modulus of elasticity at 73° F. between about 350,000 psi and about 600,000 psi, a shear strength at 73° F. between about 7,000 psi to about 10,000 psi, a compressive strength at 10% deformation between about 15,000 psi and about 20,000 psi, dynamic coefficient of friction 0.25, Rockwell hardness at 73° F. between about 115 to about 125, coefficient of linear thermal expansion between about 5×10 −4 and about 7×10 −4 in/in/° F., deformation under load (122° F. and 2,000 psi) of about 0.7 to about 1.1%, deflection temperature at 264 psi between about 225 and about 260° F., melting point of crystalline part of composition between about 325 and about 350° F., continuous service temperature in air (max) of about 180° F., dielectric strength short time between about 350 and about 550 V/nul, volume resistivity between about 1×10 13 and about 1×10 16 OHM·cm, dielectric constant at 60Hz of about 3.7, dielectric constant at 10 5 Hz of about 3.7, dielectric constant at 10 6 Hz of about 3.7, and acceptable water, acid, base and solvent resistance. The thermoplastic is generally mixed with other ingredients to improve physical properties and lifetime such as fillers, antidegradants, or other common additives. The preferred thermoplastic composition is Celleprin 60 available for BJ Molding of Houston.
The centralizers of this invention are ideally suited for tubing having a dimension between about 3″ and about 6″, although centralizers can be fabricated for any other diameter tubing. The body thickness for 3.5″ id is between about 0.75″ and about 1.5″, preferably between about 1″ and about 1.5″ and particularly between about 1″ and about 1.25″. The blade thickness from the body is between about 0.75″ and about 1.25″ and preferably between about 1″ and about 1.2″. The distance between blades on the body is between about 1.2″ and about 1.4″, but the blades separation near the groove is slightly smaller. For a 3.5 i.d., the o.d. of the centralizer profile is between about 7.75″ and about 8.5″, but a larger and smaller o.d. is a matter of design choice. The groove depth should be sufficient to allow the centralizer to be opened at the slit through a blade opposite the groove, but not so deep that the centralizer is significantly weakened at the interior of the groove. If the body is about 1.25″ thick, then the groove depth is between about 0.6″ and 0.85″, but the depth is more a design consideration.
The present invention is more fully described in reference to the following Figures and their description which are presented for illustration and not for limitation. It should be recognized that the implementation represented by the Figures is only one implementation of many that would function equivalently.
Referring now to FIGS. 1 to 3 , one embodiment of a centralizer, generally 100 , of the present invention is shown to include a body 102 , a plurality of blades 104 extending longitudinally along a length of the body 102 , a slit 106 through the blade 105 opposite a groove 108 and oppositely disposed holes 110 for receiving fasteners 112 shown here as nuts and bolts, but any fastener means can be used as well. The centralizer 100 also includes a plurality of arcuate cutaways 114 for receiving and protecting cabling extending from the surface along a length of a string of pipe onto which the centralizer 100 is fitted. The slit 106 and the groove 108 are designed so that the centralizer 100 can be put in an opened condition for fitting over a pipe as shown in FIG. 4 .
Referring now to FIG. 5, another embodiment of a centralizer, generally 120 , of the present invention is shown to include a body 122 , a plurality of blades 124 extending longitudinally along a length of the body 122 , a slit 126 through the blade 125 opposite a groove 128 and oppositely disposed holes 130 for receiving fasteners 132 shown here as nuts and bolts, but any fastener means can be used as well. The centralizer 120 also includes a channel cutaway 134 for receiving and protecting cabling extending from the surface along a length of a string of pipe onto which the centralizer 120 is fitted.
Referring now to FIG. 6, another embodiment of a centralizer, generally 140 , of the present invention is shown to include a body 142 , a plurality of blades 144 extending longitudinally along a length of the body 142 , a slit 146 through the blade 145 opposite a groove 148 and oppositely disposed holes 150 for receiving fasteners 152 shown here as nuts and bolts, but any fastener means can be used as well. The centralizer 140 also includes holes 154 for receiving and protecting cabling extending from the surface along a length of a string of pipe onto which the centralizer 140 is fitted.
Referring now to FIG. 7, another embodiment of a centralizer, generally 160 , of the present invention is shown to include a body 162 , a plurality of blades 164 extending longitudinally along a length of the body 162 , a slit 166 through the blade 165 opposite a groove 168 and oppositely disposed holes 170 for receiving fasteners 172 shown here as nuts and bolts, but any fastener means can be used as well. The centralizer 160 also includes a slot 174 for receiving and protecting cabling extending from the surface along a length of a string of pipe onto which the centralizer 160 is fitted.
Referring now to FIG. 8, a centralizer 100 of FIG. 1 secured to a section of pipe 180 by nuts and bolts 182 .
Referring now to FIG. 9, a plurality of centralizers 100 of FIG. 1 positioned at intervals 190 along a pipe string 192 including a joint 194 protected by a joint protector 196 and a cable 198 running along the string 192 through one of the cutaways 114 and into and through the joint protector 196 .
It can be seen from the preceding description that a polymeric centralizer for centering a string of pipe within a well bore or another string of pipe which provides ease of attachment after string make-up having a slit through a blade and oppositely disposed groove and structural strength capable of withstanding the forces exerted by a string of pipe contacting a well bore or an outer string of pipe, is non-sparking when contacting metal pipe strings, does not promote electrolysis when in contact with a pipe string and provides cathodic protection between strings of pipe, and is resistant to acid has been provided.
All references cited herein are incorporated by reference. While this invention has been described fully and completely, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. Although the invention has been disclosed with reference to its preferred embodiments, from reading this description those of skill in the art may appreciate changes and modification that may be made which do not depart from the scope and spirit of the invention as described above and claimed hereafter. | A polymeric centralizer for casing having a body adapted to fit closely about the casing, a plurality of blades extending substantially longitudinally along an outer surface of body, a slit through a blade and opposing groove to allow the centralizer to be spread apart and a fastener to pulling the slit together and tightening the centralizer about the casing. The polymeric centralizer having strength characteristics capable of withstanding the forces encountered in casing operations. The polymeric centralizer is non-sparking for use in hazardous environments, abrasion and wear resistant, and provides protection from electrolysis between adjacent casing strings. The polymeric centralizer is light weight, allowing increased transportation capacity at a economical cost and allows easy attachment to broken down or made-up piping, production string or casing and including hole or cutaways for receiving surface cabling. |
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