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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of co-pending U.S. application Ser. No. 13/190,078 filed Jul. 25, 2011, which is a continuation-in-part of U.S. application Ser. No. 12/001,152 filed Dec. 10, 2007, now U.S. Pat. No. 8,006,756, issued Aug. 30, 2011, which applications are hereby incorporated by reference for all purposes in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
REFERENCE TO MICROFICHE APPENDIX
N/A
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to production systems and methods deployed in subterranean oil and gas wells.
2. Description of the Related Art
Many oil and gas wells will experience liquid loading at some point in their productive lives due to the reservoir's inability to provide sufficient energy to carry wellbore liquids to the surface. The liquids that accumulate in the wellbore may cause the well to cease flowing or flow at a reduced rate. To increase or re-establish the production, operators place the well on artificial lift, which is defined as a method of removing wellbore liquids to the surface by applying a form of energy into the wellbore. Currently, the most common artificial lift systems in the oil and gas' industry are down-hole pumping systems, plunger lift systems, and compressed gas systems.
The most popular form of down-hole pump is the sucker rod pump. It comprises a dual ball and seat assembly, and a pump barrel containing a plunger. A string of sucker rods connects the downhole pump to a pump jack at the surface. The pump jack at the surface provides the reciprocating motion to the rods which in turn provides the reciprocal motion to stroke the pump, which is a fluid displacement device. As the pump strokes, fluids above the pump are gravity fed into the pump chamber and are then pumped up the production tubing and out of the wellbore to the surface facilities. Other downhole pump systems include progressive cavity, jet, electric submersible pumps and others.
A plunger lift system utilizes compressed gas to lift a free piston traveling from the bottom of the tubing in the wellbore to the surface. Most plunger lift systems utilize the energy from a reservoir by closing in the well periodically in order to build up pressure in the wellbore. The well is then opened rapidly which creates a pressure differential, and as the plunger travels to the surface, it lifts reservoir liquids that have accumulated above the plunger. Like the pump, the plunger is also a fluid displacement device.
Compressed gas systems can be either continuous or intermittent. As their names imply, continuous systems continuously inject gas into the wellbore and intermittent systems inject gas intermittently. In both systems, compressed gas flows into the casing-tubing annulus of the well and travels down the wellbore to a gas lift valve contained in the tubing string. If the gas pressure in the casing-tubing annulus is sufficiently high compared to the pressure inside the tubing adjacent to the valve, the gas lift valve will be in the open position which subsequently allows gas in the casing-tubing annulus to enter the tubing and thus lift liquids in the tubing out of the wellbore. Continuous gas lift systems work effectively unless the reservoir has a depletion or partial depletion drive, which results in a pressure decline in the reservoir as fluids are removed. When the reservoir pressure depletes to a point that the gas lift pressure causes significant back pressure on the reservoir, continuous gas lift systems become inefficient and the flow rate from the well is reduced until it is uneconomic to operate the system. Intermittent gas lift systems apply this back pressure intermittently and therefore can operate economically for longer periods of time than continuous systems. Intermittent systems are not as common as continuous systems because of the difficulties and expense of operating surface equipment on an intermittent basis.
Horizontal drilling was developed to access irregular fossil energy deposits in order to enhance the recovery of hydrocarbons. Directional drilling was developed to access fossil energy deposits some distance from the surface location of the wellbore. Generally, both of these drilling methods begin with a vertical hole or well. At a certain point in this vertical well, a turn of the drilling tool is initiated which eventually brings the drilling tool into a deviated position with respect to the vertical position.
It is not practical to install most artificial lift systems in the deviated sections of directional or horizontal wells or deep into the perforated section of vertical wells since down-hole equipment installed in these regions may be inefficient or can undergo high maintenance costs due to wear and/or solids and gas entrained in the liquids interfering with the operation of the pump. Therefore, most operators only install down-hole artificial lift equipment in the vertical portion of the wellbore above the reservoir. In many vertical wells with relatively long perforated intervals, many operators choose to not install artificial lift equipment in the well due to the factors above. Downhole pump systems, plunger lift systems, and compressed gas lift systems are not designed to recover any liquids that exist below the downhole equipment. Therefore, in many vertical, directional, and horizontal wells, a column of liquid ranging from hundreds to many thousands of feet may exist below the down-hole artificial lift equipment. Because of the limitations with current artificial lift systems, considerable hydrocarbon reserves cannot be recovered using conventional methods in depletion or partial depletion drive directional or horizontally drilled wells, and vertical wells with relatively long perforated intervals. Thus, a major problem with the current technology is that reservoir liquids located below conventional down-hole artificial lift equipment cannot be lifted.
There is a need to provide an artificial lift system that will enable the recovery of liquids in the deviated sections of directional or horizontal wellbores, and in vertical wells with relatively long perforated intervals.
There is a need to provide an artificial lift system that will enable the recovery of liquids in vertical wells with relatively long perforated intervals and in the deviated sections of directional and horizontal wellbores with smaller casing diameters.
There is a need to lower the artificial lift point in vertical wells with relatively long perforated intervals and in wells with deviated or horizontal sections.
There is a need to provide a high velocity volume of injection gas to more efficiently sweep the reservoir liquids from the wellbore.
There is a need to provide a more efficient, less costly wellbore liquid removal process.
There is a need for a less costly artificial lift method for vertical wells with relatively long perforated intervals and for wells with deviated or horizontal sections.
There is a need for a less costly and more efficient artificial lift method for wells that still have sufficient reservoir energy and reservoir gas to lift liquids from below to above the downhole artificial lift equipment.
Finally, there is a need to provide a more efficient gas and solid separation method to lower the lift point in wells with deviated and horizontal sections and for vertical wells with relatively long perforated intervals.
BRIEF SUMMARY OF THE INVENTION
A gas assisted downhole system is disclosed, which is an artificial lift system designed to recover by-passed hydrocarbons in directional, vertical and horizontal wellbores by incorporating a dual tubing arrangement. In one embodiment, a first tubing string contains a gas lift system, and a second tubing string contains a downhole pumping system. In the first tubing string, the gas lift system, which is preferably intermittent, is utilized to lift reservoir fluids from below the downhole pump to above a packer assembly where the fluids become trapped. As more reservoir fluids are added above the packer, the fluid level rises in the casing annulus above the downhole pump installed in the adjacent second tubing string, and the trapped reservoir fluids are pumped to the surface by the downhole pump. In another embodiment, the second tubing string contains a downhole plunger system. As reservoir fluids are added above the packer, the fluid level rises in the casing annulus above the downhole plunger installed in the adjacent second tubing string, and the trapped reservoir fluids are lifted to the surface by the downhole plunger system.
A dual string anchor may be disposed with the first tubing string to limit the movement of the second tubing string. The second tubing string may be removably attached with the dual string anchor with an on-off tool without disturbing the first tubing string. A one-way valve may also be used to allow reservoir fluids to flow into the first tubing string in one direction only. The one way valve may be placed in the first tubing string below the packer to allow trapped pressure below the packer to be released into the first tubing string. The valve provides a pathway to the surface for the gas trapped below the packer. The resulting reduced back pressure on the reservoir may lead to production increases.
In another embodiment, the second tubing string may be within the first tubing string, and the injected gas may travel down the annulus between the first and second tubing strings. The second string may house a fluid displacement device, such as a downhole pumping system or a plunger lift system. A bi-flow connector may anchor the second string to the first string and allow reservoir liquids in the casing tubing annulus to pass through the anchor to the downhole pump. In one embodiment, the bi-flow connector may be a cylindrical body having a thickness, a first end, a second end, a central bore from the first end to said second end, and a side surface. A first channel may be disposed through the thickness from the first end to the second end. A second channel may be disposed through the thickness from the side surface to the central bore, with the first channel and second channel not intersecting. Injected gas may be allowed to pass vertically through the bi-flow connector to lift liquids from below the downhole pump to above the downhole pump. The bi-flow connector prevents the injected gas from contacting the reservoir liquids flowing through the bi-flow connector. Also contemplated are multiple channels in addition to the first channel and multiple channels in addition to the second channel.
In yet another embodiment, gas from the reservoir lifts reservoir liquids from below the fluid displacement device, such as a downhole pump or a plunger, to above the fluid displacement device. A first tubing string may contain the fluid displacement device above a packer assembly. A blank sub may be positioned between an upper perforated sub and a lower perforated sub in the first tubing string below the fluid displacement device. A second tubing string within the first tubing string and located below the lower perforated sub may lifts liquids using the gas from the reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference is had to the following figures in which like parts are given like reference numerals and wherein:
FIG. 1 depicts a directional or horizontal wellbore installed with a conventional rod pumping system of the prior art.
FIG. 2 depicts a conventional gas lift system in a directional or horizontal wellbore of the prior art.
FIG. 3 depicts an embodiment of the invention utilizing a rod pump and a gas lift system.
FIG. 4 depicts another embodiment of the invention similar to FIG. 3 except with no internal gas lift valve.
FIG. 5 depicts yet another embodiment of the invention having a Y block.
FIG. 6 depicts another embodiment of the invention similar to FIG. 5 except with no internal gas lift valve.
FIG. 7 depicts another embodiment similar to FIG. 3 , except with a dual string anchor and an on-off tool.
FIG. 8 depicts another embodiment similar to FIG. 7 , except with no internal gas lift valve.
FIG. 9 depicts another embodiment similar to FIG. 7 , except with a one-way valve.
FIG. 10 is the embodiment of FIG. 9 , except shown in a completely vertical wellbore.
FIG. 11 is an embodiment similar to FIG. 11 , except that an alternative embodiment plunger lift system is installed in place of the downhole pump system, and with no surface tank and no dual string anchor.
FIG. 12 depicts another embodiment in a vertical wellbore utilizing a bi-flow connector.
FIG. 13 is the embodiment of FIG. 12 except in a horizontal wellbore.
FIG. 13A is an isometric view of a bi-flow connector.
FIG. 13B is a section view along line 13 A- 13 A of FIG. 13 .
FIG. 13C is a top view of FIG. 13A .
FIG. 13D is a section view similar to FIG. 13B except with the bi-flow connector threadably attached at a first end with a first tubular and at a second end with a second tubular.
FIG. 14 is the embodiment of FIG. 13 except that an alternative embodiment plunger lift system is installed in place of the downhole pump system.
FIG. 15 depicts another embodiment that utilizes gas that emanates from the reservoir to lift liquids from the curved or horizontal section of the wellbore.
FIG. 16 is the embodiment of FIG. 15 except it is shown in a vertical wellbore.
FIG. 17 is the embodiment of FIG. 16 except that an alternative embodiment plunger lift system is installed in place of the downhole pump system.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows one example of a conventional rod pump system of the prior art in a directional or horizontal wellbore. As set out in FIG. 1 , tubing 1 , which contains pumped liquids 13 is mounted inside a casing 6 . A pump 5 is connected at the end of tubing 1 in a seating nipple 48 nearest the reservoir 9 . Sucker rods 11 are connected from the top of pump 5 and continue vertically to the surface 12 . Casing 6 , cylindrical in shape, surrounds and may be coaxial with tubing 1 and extends below tubing 1 and pump 5 on one end and extends vertically to surface 12 on the other end. Below casing 6 is curve 8 and lateral 10 which is drilled through reservoir 9 .
The process is as follows: reservoir fluids 7 are produced from reservoir 9 and enter lateral 10 , rise up curve 8 and casing 6 . Because reservoir fluids 7 are usually multiphase, they separate into annular gas 4 and liquids 17 . Annular gas 4 separates from reservoir fluids 7 and rises in annulus 2 , which is the void space formed between tubing 1 and casing 6 . The annular gas 4 continues to rise up annulus 2 and then flows out of the well to the surface 12 . Liquids 17 enter pump 5 by the force of gravity from the weight of liquids 17 above pump 5 and enter pump 5 to become pumped liquids 13 which travel up tubing 1 to the surface 12 . Pump 5 is not considered to be limiting, but may be any down-hole pump or pumping system, such as a progressive cavity, jet pump, or electric submersible, and the like.
FIG. 2 shows one example of a conventional gas lift system of the prior art in a directional or horizontal wellbore. Referring to FIG. 2 , inside the casing 6 , is tubing 1 connected to packer 14 and conventional gas lift valve 22 . Below casing 6 is curve 8 and lateral 10 which is drilled through reservoir 9 . The process is as follows: reservoir fluids 7 from reservoir 9 enter lateral 10 and rise up curve 8 and casing 6 and enter tubing 1 . The packer 14 provides pressure isolation which allows annulus 2 , which is formed by the void space between casing 6 and tubing 1 , to increase in pressure from the injection of injection gas 16 . Once the pressure increases sufficiently in annulus 2 , conventional gas lift valve 22 opens and allows injection gas 16 to pass from annulus 2 into tubing 1 , which then commingles with reservoir fluids 7 to become commingled fluids 18 . This lightens the fluid column and commingled fluids 18 rise up tubing 1 and then flow out of the well to surface 12 .
FIG. 3 shows an embodiment utilizing a downhole pump and a gas lift system in a horizontal or deviated wellbore. Referring to FIG. 3 , inside casing 6 , is tubing 1 which begins at surface 12 and contains internal gas lift valve 15 , bushing 25 , and inner tubing 21 . Inner tubing 21 may be within tubing 1 , such as concentric. Bushing 25 may be a section of pipe whose purpose is to threadingly connect pipe joints using both its outer diameter and its inner diameter. Bushing 25 may have pipe threads at one or both ends of its outer diameter, and pipe threads at one or both ends of its inner diameter. Other types of bushings and connection means are also contemplated. Tubing 1 is sealingly engaged to packer 14 . Tubing 1 and inner tubing 21 extend below packer 14 through curve 8 and into lateral 10 , which is drilled through reservoir 9 . Inside casing 6 and adjacent to tubing 1 is tubing 3 , which contains sucker rods 11 connected to pump 5 . Pump 5 is connected to the end of tubing 3 by seating nipple 4 . Tubing 3 is not sealingly engaged to packer 14 .
The process may be as follows: reservoir fluids 7 enter lateral 10 and enter tubing 1 . The reservoir fluids 7 are commingled with injection gas 16 to become commingled fluids 18 which rise up chamber annulus 19 , which is the void space formed between inner tubing 21 and tubing 1 . The commingled fluids 18 then exit through the holes in perforated sub 24 . Commingled gas 41 separates from commingled fluids 18 and rises in annulus 2 , which is formed by the void space between casing 6 and tubing 1 and tubing 3 . Commingled gas 41 then enters flow line 30 at the surface 12 and enters compressor 38 to become compressed gas 33 , and travels through flow line 31 to surface tank 34 . The compressor 38 is not considered to be limiting, in that it is not crucial to the design if another source of pressured gas is available, such as pressured gas from a pipeline.
Compressed gas 33 then travels through flow line 32 which is connected to actuated valve 35 . This actuated valve 35 opens and closes depending on either time or pressure realized in surface tank 34 . When actuated, valve 35 opens, compressed gas 33 flows through actuated valve 35 and travels through flow line 32 and into tubing 1 to become injection gas 16 . The injection gas 16 travels down tubing 1 to internal gas lift valve 15 , which is normally closed thereby preventing the flow of injection gas 16 down tubing 1 . A sufficiently high pressure in tubing 1 above internal gas lift valve 15 opens internal gas lift valve 15 and allows the passage of injection gas 16 through internal gas lift valve 15 . The injection gas 16 then enters the inner tubing 21 , and eventually commingles with reservoir fluids 7 to become commingled fluids 18 , and the process begins again. Liquids 17 and commingled gas 41 separate from the commingled fluids 18 and liquids 17 fall in annulus 2 and are trapped above packer 14 . Commingled gas 41 rises up annulus 2 as previously described. As more liquids 17 are added to annulus 2 , liquids 17 rise above and are gravity fed into pump 5 to become pumped liquids 13 which travel up tubing 3 to surface 12 .
FIG. 4 shows an alternate embodiment similar to the design in FIG. 3 except that it does not utilize the internal gas lift valve 15 .
FIG. 5 shows yet another alternate embodiment utilizing a downhole pump and a gas lift system in a horizontal or deviated wellbore with a different downhole configuration from FIG. 3 . Referring to FIG. 5 , inside the casing 6 is tubing 1 which contains an internal gas lift valve 15 and is sealingly engaged to packer 14 . Packer 14 is preferably a dual packer assembly and is connected to Y block 50 which in turn is connected to chamber outer tubing 55 . Chamber outer tubing 55 continues below casing 6 through curve 8 and into lateral 10 which is drilled through reservoir 9 . Inner tubing 21 is secured by chamber bushing 22 to one of the tubular members of Y Block 50 leading to lower tubing section 37 . Inner tubing 21 may be concentric with chamber outer tubing 55 . The inner tubing 21 extends inside of Y block 50 and chamber outer tubing 55 through the curve 8 and into the lateral 10 . The second tubing string arrangement comprises a lower section 37 and an upper section 36 . The lower section 37 comprises a perforated sub 24 connected above a one way valve 28 and is then sealingly engaged in the packer 14 .
Perforated sub 24 is closed at its upper end and is connected to the upper tubing section 36 . Upper tubing section 36 comprises a gas shroud 58 , a perforated inner tubular member 57 , a cross over sub 59 and tubing 3 which contains pump 5 and sucker rods 11 . The gas shroud 58 is tubular in shape and is closed at its lower end and open at its upper end. It surrounds perforated inner tubular member 57 , which extends above gas shroud 58 to crossover sub 59 and connects to the tubing 3 , which continues to the surface 12 . Above the crossover sub 59 , and contained inside of tubing 3 at its lower end, is pump 5 which is connected to sucker rods 11 , which continue to the surface 12 . Annular gas 4 travels up annulus 2 into flowline 30 which is connected to compressor 38 which compresses annular gas 4 to become compressed gas 33 . The compressor 38 is not considered to be limiting, in that it is not crucial to the design if another source of pressured gas is available, such as pressured gas from a pipeline.
Compressed gas 33 flows through flowline 31 to surface tank 34 which is connected to a second flowline 32 that is connected to actuated valve 35 . This actuated valve 35 opens and closes depending on either time or pressure realized in surface tank 34 . When actuated valve 35 opens, compressed gas 33 flows through actuated valve 35 and travels through flowline 32 and into tubing 1 to become injection gas 16 . The injection gas 16 travels down tubing 1 to internal gas lift valve 15 , which is normally closed thereby preventing the flow of injection gas 16 down tubing 1 . A sufficiently high pressure in tubing 1 above internal gas lift valve 15 opens internal gas lift valve 15 and allows the passage of injection gas 16 through internal gas lift valve 15 , through Y Block 50 and into chamber annulus 19 , which is the void space between inner concentric tubing 21 and chamber outer tubing 55 . Injection gas 16 is forced to flow down chamber annulus 19 since its upper end is isolated by chamber bushing 25 . Injection gas 16 displaces the reservoir fluids 7 to become commingled fluids 18 which travel up the inner concentric tubing 21 .
Commingled fluids 18 travel out of inner concentric tubing 21 into one of the tubular members of Y Block 50 , through packer 14 and standing valve 28 , and then through the perforated sub 24 into annulus 2 , where the gas separates and rises to become annular gas 4 to continue the cycle. The liquids 17 separate from the commingled fluids 18 and fall by the force of gravity and are trapped in annulus 2 above packer 14 and are prevented from flowing back into perforated sub 24 because of standing valve 28 . As liquids 17 accumulate in annulus 2 , they rise above pump 5 and are forced by gravity to enter inside of gas shroud 58 and into perforated tubular member 57 where they travel up cross-over sub 59 to enter pump 5 where they become pumped liquids 13 and are pumped up tubing 3 to the surface 12 .
FIG. 6 shows an alternate embodiment of the invention similar to the design in FIG. 5 except that it does not utilize the internal gas lift valve 15 .
FIG. 7 shows an alternate embodiment similar to FIG. 3 , except that there is a downhole anchor assembly or dual string anchor 20 disposed with first tubing string 1 and installed and attached with second tubing string with on-off tool 26 . Referring to FIG. 7 , first tubing string 1 is inside casing 6 . First tubing string 1 begins at the surface 12 and contains internal gas lift valve 15 , bushing 25 , perforated sub 24 , and inner tubing 21 . Perforated sub 24 is available from Weatherford International of Houston, Tex., among others. Tubing 1 is engaged to dual string anchor 20 and continues through it and is engaged to packer 14 and extends through it. Inner tubing 21 connects to bushing 25 and continues through perforated sub 24 , dual string anchor 20 , packer 14 and terminates prior to the end of tubing 1 . Dual string anchor 20 is available from Kline Oil Tools of Tulsa, Okla., among others. Other types of dual string anchors 20 are also contemplated. Inner tubing 21 may be within tubing 1 . Tubing 1 extends through and below dual string anchor 20 and through and below packer 14 through curve 8 and into lateral 10 , which is drilled through reservoir 9 . Second tubing string 3 is inside casing 6 and adjacent to first tubing string 1 . Second tubing string 3 contains perforated sub 23 , sucker rods 11 , pump 5 , seating nipple 48 , and on-off tool 26 . Second tubing string 3 may be selectively engaged to dual string anchor 20 with on-off tool 26 . On-off tool 26 is available from D&L Oil Tools of Tulsa, Okla. and from Weatherford International of Houston, Tex., among others. Other types of on-off tool 26 and attachment means are also contemplated. On-off tool 26 may be disposed with perforated sub 23 , which may be attached with second tubing string 3 .
The process for FIG. 7 is similar to that for FIG. 3 . The dual string anchor 20 functions to immobilize the second tubing string 3 by supporting it with first tubing string 1 . Immobilization is important, since in deeper pump applications, the mechanical pump 5 may induce movement to second tubing string 3 which may in turn cause wear on the tubulars. Movement may also cause the mechanical pump operation to cease or become inefficient. On-off tool 26 allows the second tubing string 3 to be selectively connected or disconnected from the dual string anchor 20 without disturbing the first tubing string 1 . The dual string anchor 20 minimizes inefficiencies in the pump and costly workovers to repair wear on the tubing strings. This movement is caused by the movement induced upon the second tubing string by the downhole pumping system.
FIG. 8 shows another alternate embodiment similar to the design in FIG. 7 except that it does not utilize internal gas lift valve 15 .
FIG. 9 shows another alternate embodiment similar to the design of FIG. 7 , except that FIG. 9 includes one-way valve 28 disposed on first tubing string 1 below packer 14 . Referring to FIG. 9 , when pressure conditions are favorable, one-way valve 28 opens to allow reservoir gas 27 to pass into chamber annulus 19 . One-way valve 28 may be a reverse flow check valve available from Weatherford International of Houston, Tex., among others. Other types of one-way valves 28 are also contemplated. Although only one one-valve 28 is shown, it is contemplated that there may be more than one one-way valve 28 for all embodiments. One-way valve 28 may be threadingly disposed with a carrier such as a conventional tubing retrievable mandrel or a gas lift mandrel. Other connection types, carriers, and mandrels are also contemplated.
One-way valve 28 functions to allow fluids to flow from outside to inside the device in one direction only. In FIGS. 9-14 , one-way valve 28 may be placed in the first tubing string 1 below the packer 14 to vent trapped pressure below the packer 14 into the first tubing string 1 . In a vertical well application, this venting may assist the optimum functioning of the artificial lift system. One-way valve 28 has at least two functions: (1) it provides a pathway to the surface for reservoir gas 27 trapped below packer 14 , and (2) it leads to production increases by reducing back pressure on the reservoir. As can now be understood, one-way valve 28 may be positioned at a location on first tubing string 1 such as below packer 14 , that is different than the location where injected gas 16 initially commingles with the reservoir fluids where inner tubing 21 ends. Injected gas 16 may initially commingle with reservoir fluids 7 at a first location, and one-way valve 28 may be disposed on first tubing string 1 at a second location. One-way valve 28 may be disposed above reservoir 9 , although other locations are contemplated. One-way valve 28 allows the venting of trapped fluids, and allows flow in only one direction.
FIG. 10 shows the embodiment of FIG. 9 in a completely vertical wellbore.
As can now be understood, dual string anchor or dual tubing anchor 20 with on-off tool 26 and one way-valve 28 may be used independently, together, or not at all. For all embodiments in deviated, horizontal, or vertical wellbore applications, there may be (1) gas lift valve 15 , dual string anchor 20 , and one-way valve 28 below packer 14 , (2) no gas lift valve 15 , no dual string anchor 20 , and no one-way valve 28 below packer 14 , or (3) any combination or permutation of the above. Surface tank 34 and actuated valve 35 are also optional in all the embodiments.
FIG. 11 is an embodiment similar to FIG. 10 in which pump 5 and sucker rods 11 have been replaced with an alternative embodiment plunger lift system, and there is no surface tank 34 and no one-way valve 28 . Referring to FIG. 11 , the process is as follows. Initially, actuated valve 37 is open at surface 12 , which allows flow from tubing 3 to surface 12 . Actuated valve 35 is open and actuated valve 36 is closed. Supply gas 46 , which may emanate from the well or a pipeline, is compressed by compressor 38 and compressed gas 33 flows through flow line 31 , through actuated valve 35 and flow line 32 , and into tubing 1 to become injection gas 16 , which then flows down tubing 1 , through gas lift valve 15 , and through inner tubing 21 . At the end of inner tubing 21 , injection gas 16 combines with reservoir fluids 7 to become commingled fluids 18 , which rise up chamber annulus 19 and flow through perforated sub 24 into annulus 2 . Liquids 17 fall to the bottom of annulus 2 .
As more liquids are added in annulus 2 , they eventually rise above plunger 5 and into tubing 3 and rise above perforated sub 24 , which may cause the injection pressure to rise which signals actuated valve 35 to close, actuated valve 39 to open, and actuated valve 37 to close. Compressed gas 33 then flows through actuated valve 36 and through flow line 30 , and into annulus 2 to become injection gas 16 . When a sufficient volume of injection gas 16 has been added to annulus 2 , the pressure in annulus 2 rises sufficiently to signal actuated valve 37 to open, actuated valve 36 to close, and actuated valve 35 to open. The pressure differential lifts plunger 45 off of seating nipple 48 and rises up tubing 3 and pushes liquids 17 to surface 12 . Some injection gas 16 also flows to surface 12 via tubing 3 . Once the pressure on tubing 3 drops sufficiently, plunger 45 falls back down to seating nipple 48 and the process begins again. Other sequences of the timing of the opening and closing of the actuated valves are contemplated. Surface tank 34 may also be utilized.
FIG. 12 is another embodiment and utilizes an outer and inner tubing arrangement, such as concentric, incorporating a novel bi-flow connector 43 in a vertical wellbore. The bi-flow connector 43 is shown in detail in FIGS. 13A-13D and discussed in detail below. FIGS. 13 is similar to FIG. 12 except in a horizontal wellbore. Although FIG. 13 is discussed below, the discussion applies equally to FIG. 12 . In FIG. 13 , first tubing string 1 begins at surface 12 and is installed inside casing 6 , contains bi-flow connector 43 , bushing 25 , one way valve 29 , and is sealingly engaged to packer 14 . Mud anchor 40 may be connected to bi-flow connector 43 to act as a reservoir for particulates that fall out of liquids 17 , and to isolate the injection gas 16 from liquids 17 . Mud anchor 40 is a tubing with one end closed and one end open, and is available from Weatherford International of Houston, Tex., among others. First tubing string 1 continues below packer 14 and contains one way valve 28 and continues until it terminates in curve 8 or lateral 10 , or for FIG. 12 in or below reservoir 9 . Within first tubing string 1 is second tubing string 21 , which is also sealingly engaged to bushing 25 and continues down through packer 14 and may terminate prior to the end of first tubing string 1 . Third tubing string 3 is within first tubing string, and begins at surface 12 and terminates in on-off tool 26 . On-off tool 26 allows third tubing string 3 to be selectively engaged to first tubing string 1 . On-off tool 26 is sealingly engaged to bi-flow connector 43 . Contained inside first tubing string 3 are sucker rods 11 , pump 5 and seating nipple 48 . Sucker rods 11 are connected to pump 5 which is selectively engaged into seating nipple 48 . Seating nipple 48 is available from Weatherford International of Houston, Tex., among others.
As shown in FIGS. 13A-13D , bi-flow connector 43 is a cylindrically shaped body with a central bore 112 extending from a first end 105 to a second end 107 and having a thickness 109 . Vertical or first channels 102 pass through the thickness 109 of the bi-flow connector 43 from the first end 105 to the second end 107 . Horizontal or second channels 100 pass from the side surface 111 through the thickness 109 of the bi-flow connector 43 to the central bore 112 . Although shown vertical and horizontal, it is also contemplated that first channels may not be vertical and second channels may not be horizontal. Different numbers and orientations of channels are contemplated. The first channels 102 and second channels 100 do not intersect. Threads 104 , 108 are on the side surface 111 of the bi-flow connector 43 adjacent its first and second ends 105 , 107 . There may also be inner threads 106 , 110 on the inner surface of the central bore 112 adjacent the first and second ends. As shown in FIGS. 12-13 , the mud anchor 40 is attached with the inner threads 110 , and the first tubing string 1 is attached with the outer threads 104 , 108 . In FIG. 13D , the threaded connection between the bi-flow connector 43 between upper tubular 114 and lower tubular 116 is similar to the connection in FIG. 13 between the bi-flow connector 43 and first tubing string 1 .
Returning to FIG. 13 , the process may be as follows. Injection gas 16 travels down annulus 47 and passes vertically through bi-flow connector 43 and continues down through bushing 25 , packer 14 , second tubing string 21 and out into first tubing string 1 where it commingles with reservoir fluids 7 to become commingled fluids 18 . Reservoir gas emanates from reservoir 9 and may travel through one way valve 28 and become part of commingled fluids 18 , which rise up annulus 19 and travel through one way valve 29 and then separate into liquids 17 and commingled gas 41 . Liquids 17 may enter horizontally through bi-flow connector 43 and up to pump 5 where they become pumped liquids 13 and are pumped to surface 12 . Commingled gas 41 rises up annulus 2 to surface 12 .
As can now be understood, the bi-flow connector 43 allows downward injection gas to pass vertically through the tool, while simultaneously allowing reservoir liquids to pass horizontally through the tool, without commingling the reservoir liquids with the downwardly flowing injection gas. The bi-flow connector 43 also allows the inner tubing string, such as third tubing string 3 , to be selectively engaged to the outer tubing string, such as first tubing string 1 . The bi-flow connector 43 may be used in small casing diameter wellbores in which the installation of two side by side or adjacent tubing strings is impractical or impossible. The bi-flow connector 43 is advantageous to wells that have a smaller diameter casing. Other non-concentric tubing arrangement embodiments may require larger casing sizes. A plunger system is also contemplated in place of the downhole pump.
FIG. 14 is the same embodiment as FIG. 13 except that an alternative embodiment plunger lift system is installed in place of the downhole pump system. A pump and a plunger are both fluid displacement devices.
FIG. 15 is another embodiment using only reservoir gas to lift the reservoir liquids from below the downhole pump to above the downhole pump. This embodiment is similar to FIG. 13 , but no inner tubing, such as third tubing string 3 , is needed to house the downhole pump and no external injection gas is needed. It may also incorporate a one way valve 28 in the tubing string to prevent wellbore liquids from falling back down the wellbore. The one way valve 28 allows the liquids to be trapped above the packer until the pump can lift them to the surface. The smaller diameter of the inner tubing efficiently lifts reservoir fluids by forcing the reservoir gas into a smaller cross-sectional area whereby the gas is not allowed to rise faster than the reservoir liquids. Due to the smaller tubing size, a relatively small amount of reservoir gas can lift reservoir liquids the relatively short distance from the end of the tubing to the one way valve.
Referring to FIG. 15 , first tubing string 1 begins at surface 12 and contains seating nipple 48 , upper perforated sub 23 , blank sub 42 , lower perforated sub 24 , one way valve 39 , on-off tool 26 , packer 14 , bushing 25 and terminates in curve 8 or lateral 10 . Seating nipple 48 , blank sub 42 , perforated subs 23 , 24 , on-off tool 26 , packer 14 , one way valve 39 , and bushing 25 are all available from Weatherford International of Houston, Tex., among others. Connected to seating nipple 48 is pump 5 which is connected to sucker rods 11 which continue up to surface 12 . Connected to bushing 25 is second tubing string 21 which is connected to one way valve 28 , and continues down the wellbore and may terminate prior to the end of tubing 1 .
The process may be as follows. Reservoir fluids 7 emanate from reservoir 9 and enter lateral 10 and then enter first tubing string 1 and second tubing string 21 . Gas in reservoir fluids 7 expand inside second tubing string 21 and lift reservoir fluids 7 up and out of second tubing string 21 into first tubing string 1 , through on-off tool 26 , through one way valve 39 and out of lower perforated sub 24 and into annulus 2 . Reservoir fluids 7 separate into liquids 17 and annular gas 4 . Liquids 17 enter into upper perforated sub 23 and then enter into pump 5 where they become pumped liquids 13 and are pumped to surface 12 via tubing 1 . Annular gas 4 rises up annulus 2 to surface 12 .
FIG. 16 is the embodiment of FIG. 15 except in a vertical wellbore.
FIG. 17 is the embodiment of FIG. 16 except that a plunger has been installed in place of the sucker rods and pump. The plunger may be operated merely by the periodic opening and closing of the first tubing string 1 to the surface or it may be operated by the periodic or continuous injection of gas down the annulus combined with the periodic opening and closing of the first tubing string 1 to the surface. Both methods will force the plunger and liquids above it to the surface. This embodiment is much less expensive than installing a downhole pump. This design is advantageous for wells that have sufficient reservoir energy and gas production to lift liquids from below the downhole pump to above the downhole pump, yet still require artificial lift equipment to lift these liquids to the surface. This embodiment is less costly to install since no injection gas from the surface is required. Subsequently there is no gas injection tubing, no surface tank, no actuated valve, no compressor, and no dual string anchor. It will also accommodate wellbores with smaller casing diameters.
The embodiment of FIGS. 15-16 is advantageous for wells that have sufficient reservoir energy and gas production to lift liquids from below the downhole pump to above the downhole pump, yet still require artificial lift equipment to lift these liquids to the surface. This embodiment is less costly to install since no injection gas from the surface is required. There does not have to be any gas injection tubing, surface tank, actuated valve, compressor, or dual string anchor. It will also accommodate wellbores with smaller casing diameters. The embodiment of FIG. 17 is even less expensive because there does not have to be any downhole pump and related equipment.
An advantages of all embodiments is a lower artificial lift point and better recovery of hydrocarbons. There is better gas and particulate separation in all embodiments. In FIGS. 3-11 , the entry point for the commingled fluids is above the intake of the pump or other fluid displacement device, which helps break out any gas in the fluids since gravity will segregate the gas from the liquids. The same is true for particulates since there is a large reservoir for them to collect in below the pump. In FIGS. 12-17 , the gas is discouraged from entering the perforated subs because of gravity separation.
Because many varying and different embodiments may be made within the scope of the invention concept taught herein which may involve many modifications in the embodiments herein detailed in accordance with the descriptive requirements 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 system and method for lifting reservoir fluids from reservoir to surface through a wellbore having a first tubing string extending through a packer in a wellbore casing. The system includes a bi-flow connector in the first tubing string, a second tubing string in the first tubing string below the bi-flow connector, and a third tubing string in the first tubing string above and connected with the bi-flow connector. A fluid displacement device in the third tubing string is configured to move reservoir fluids to the surface. The first tubing string allows pressured gas to move from the surface through the bi-flow connector to commingle with and lift reservoir fluids through annuli defined by the first and second tubing strings and defined by the casing and the first tubing string. The bi-flow connector is configured to allow simultaneous and non-contacting flow of the downward pressured gas and lifted reservoir fluid. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 USC §119(e) of a United States (US) provisional patent application filed on Apr. 26, 2002 under Ser. No. 60/375,619 whose contents are incorporated by reference.
TECHNICAL FIELD
This invention relates to the general subject of production of oil and gas and, in particular, to marine risers used in the production of oil and gas from the seabed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable.
BACKGROUND OF THE INVENTION
Marine riser technology and its development have been driven by two basic needs in the oil industry.
The first need has been to resolve the challenges that are related to using drilling risers during exploratory drilling. These risers bridge between the seabed and the surface when doing exploration drilling from a floating vessel, which is normally either a semi-submersible drilling rig, or a drill ship. These riser needs can be characterized as large diameter and relatively low pressure. They are designed for rapid disconnect from the seabed equipment, efficient running and retrieval via the drilling vessel, and relatively short design life. Basic floating drilling methods were established in the 1960's 1 (superscripts refer to “List of References” appearing before the Claims at the end of this specification) and these methods continue to be improved upon today 2 .
The second riser need occurs when exploration drilling is successful, leading to a field development. These field development risers bridge between the life-of-field development seabed and surface Host Facility. These risers have small diameters and large diameters, operate at relatively high pressures, and are designed in accordance with field development expectations for near-continuous hydrocarbon depletion that may require 20 years and more of uninterrupted service. These risers may include export and import riser systems that are related to the hydrocarbon production and sales. Also, if well drilling and completion is to be performed from the Host Facility, these riser needs have also to be addressed 3 .
The pace for deepwater developments in the Gulf of Mexico has been dramatic since the mid-1990's. A brief summary is presented in Appendix IV. The Industry has gone through a series of stages of riser technology development, resulting in the present preferred Steel Catenary Riser (SCR)/Flowline (FL) riser solutions for deepwater. SCR's have evolved in a natural way to replace the large, complex and costly top tensioning equipment that are required when vertical riser systems are used. Vertical risers with top tensioning are effective to water depths of about 4000 feet. However, top tensioning equipment, because of its size, weight, and tight clearances, is costly and difficult to manage. This geometric relationship becomes increasingly challenging when the Host Facility must support this equipment for riser strokes of more than 7–12 feet. For one project in the Gulf of Mexico in 6000 feet of water, riser top motions can approach about 20 feet. These motions represent major design challenge, even for the SCR/FL risers. The challenge is magnified due to the large number of risers that must bridge between the seabed and the Host Facility.
This stroke length is necessary to accommodate the change in riser system length as the Host Facility moves from its neutral position. Without this riser stroke, the riser would be subjected to either over-stressing or large stress level cycles. Riser failure can be manifested by either overstressing it, or by subjecting it to excessive stress cycling. The stress cycling can lead to riser failure due to accumulated fatigue damage, even though the allowable stress is not exceeded for the riser system.
The riser stroke length challenge is graphically represented in FIG. E-2 of a U.S. provisional patent application filed on Apr. 26, 2002 under Ser. No. 60/375,619. When a riser is attached to a fixed point on the seabed and directly to the Host Facility, the riser top must move along with the Host Facility. Considering the life of field possibilities, the range of motions that may occur is extensive. The solution to this changing riser length (stroke requirement) should be robust, as failure to do so is can lead to riser failure. Riser failure can be caused either by the immediate effect of over-stressing, or by diminished fatigue life due to excessive stress cycling. Riser failure due to collapse can also occur, but this tends to be a direct consequence of over-stressing it. In the case of Host Facilities that have very large motions, such as the FPSO systems that have been used outside the Gulf of Mexico, the riser stroke requirement can be met by using flexible pipe 16 .
A flexible pipe solution (See FIG. E-3(a) of the U.S. provisional patent application filed on Apr. 26, 2002 under Ser. No. 60/375,619), has been used successfully many times. However, for very deep water, this method can be costly. Also, flexible pipe technology for risers (i.e., ones that require a design combination of deepwater, high pressure, high temperature, or large size) remains under on-going development before flexible pipe will be ready for the long field life riser applications. Flexible pipe risers can provide good closing solutions when used in conjunction with a free-standing rigid riser (See FIG. E-3(b) of the U.S. provisional patent application filed on Apr. 26, 2002 under Ser. No. 60/375,619). This arrangement is sometimes referred to as a “hybrid riser” because it combines elements of both buoyancy for top tensioning of the steel risers and flexible pipe to complete the bridging from the top of the rigid risers to the Host Facility. This arrangement is commonly used for Spar well system jumpers that bridge between the well tree and the host manifold. The flexible pipe elements are comprised of a wall body that is made up of various combinations of metal and elastomers. The flexible pipe design is tailored to meet each specific application need. Although the resulting flexibility can help resolve the strokelength challenges that exist with rigid risers and they provide an efficient closing duty, their use for a life-of-field application for the entire riser system remains uncertain. Also, specialized installation methods are often used to ensure that the integrity of flexible pipe is maintained.
The fundamental need for a top-tensioning assembly is represented in FIG. E-4A of the U.S. provisional patent application filed on Apr. 26, 2002 under Ser. No. 60/375,619). In that example, no top-tensioning assembly with stroke length change is provided for the riser. Thus, it bridges directly between the seabed connection point and a point on the host facility. This is only shown as a hypothetical configuration. It assumes that the Host Facility could be designed such a way that the combination of hull and mooring would limit the hull motions so that this would be feasible. Also, it assumes that no over pull is applied to the riser at the neutral position. In an actual design, some over pull is necessary to ensure riser integrity for the range of environmental loads to which it will be subjected. However, as can be seen in this drawing, as the Host Facility moves laterally from its neutral position, the riser top-tensile stress begins to increase rapidly. In this example, an allowable material stress value of about 60,000 psi was assumed. Modern steels can be manufactured to provide material properties like this, including the direct requirement for suitable welding methods. Work to provide suitable commercial grade steels of higher stress values is continuing. But if it were possible to keep the Host Facility offset to within a very small percent of water depth, this type of rigid riser could be feasible today if cost realities related to the hull and mooring were not a consideration.
Given the recent pace of these developments, it is easy to understand why a deepwater field development would be based on the most proven riser systems that are available to the system designers. However, when subsea wells and equipment are located directly under the Host Facility, managing the seabed equipment, wells flowlines, and risers is costly and complex. The SCR/Flowline system requires that the SCR be routed in a straight line and away from the Host Facility. The flowline is routed around and back under the Host Facility, where it can then be connected to the subsea manifold using a jumper. Also, a flowline jumper arrangement is required to allow efficient transition between the SCR and the flowline. The drilling riser that is located on the Host Facility can be equipped with a conventional riser top-tensioning system. This is possible because it can be disconnected when Host Facility motions exceed a pre-determined limit. Since the production export and import risers cannot be disconnected this way, the use of a top tensioning assembly at the surface for these risers can only be obtained at the expense of space, weight, and clearance requirements on the topsides. The complexity and cost of doing this is high for deepwater applications. This is the fundamental reason why the SCR/Flowline method has been used. It represents a better solution than can be achieved by using a vertical riser with a top tensioning assembly. Top-tensioned risers continue to meet field development needs, and it is expected that they will continue to do so for many situations. Even so, the need for new approaches continues. Current riser design practices 15 recognize this need, and theses practices provide guidance on the approaches that can be used to qualify new riser designs.
In those cases that require vertical access into the riser system, a top tensioning assembly may continue to be a preferred solution, as this may be the only practical means for providing vertical riser access for well drilling and completion purposes. However, some types of risers do not require vertical access. These riser systems include the export and import risers that are used to move products away from and onto the Host Facility. The SCR/FL solution can also be used to meet these duties, especially for the larger riser sizes.
These problems have existed for some time. Considerable effort has been made, and significant amounts of money have been expended to resolve this problem. In spite of this, the problem still exists. Actually, the problem has become aggravated with the passage of time because the water depth requirements continue to rely on costly solutions, or solutions that are approaching their limits of practical application.
SUMMARY OF THE INVENTION
In accordance with the present invention, a bottom tensioned riser (BTR) assembly is disclosed comprising: a generally extendable coil section having an upper end adapted to be in flow communication with a generally vertical marine riser carried by a facility floating on the surface of a body of water, and having a lower end adapted to be in flow communication with a fluid source on the seafloor; and tensioning means, mechanically connecting the upper end of the marine riser with the lower end of the marine riser, for biasing said ends towards each other. The tensioning means comprises: a cylinder having one end open to sea pressure, having an opposite end sealed from sea pressure, and connected to the lower end of the vertical marine riser; a piston within the cylinder slidably and sealingly disposed for movement within the cylinder; and a piston rod sealingly and slidably moving through the opposite end of the cylinder having one end connected to the piston and having an opposite end connected to the upper end of the vertical marine riser.
The BTR can be designed to meet a wide range of Host Facility motions throughout the field development life, and it eliminates the need for disconnecting the vertical export/import riser. This is made possible by virtue of a coil section, which is located in the lower portion of the riser system. One unique aspect of the invention is that it solves a riser system application problem that has normally been approached from the surface/Host Facility (i.e., from the top down). The BTR concept, which approaches the top tension problem from the bottom up, provides a solution that has both technical and cost benefits.
The technical benefits include its use as a vertical riser system. The vertical riser system projection onto the seabed is low when compared to other methods. By virtue of this, it simplifies the seabed architecture. Simplicity in deepwater operations is directly related to the magnitude of risk of unplanned occurrences happening. The vertical riser design can be performed using analysis techniques and assumptions that are proven. The time required to do the analysis of a vertical riser is roughly one-half that of a SCR. The reason that the SCR requires so much more time is that it is a relatively new type of riser itself. Specialized and proprietary analysis methods are required for demonstrating riser fatigue life at the SCR touchdown point. The SCR touchdown point and lift-off modeling remains an area that is under research work to better resolve uncertainties about the models and their required assumptions. A SCR also requires proprietary modeling that is related to vortex-induced-vibrations (VIV). Since the riser shape is not vertical through the water column, VIV modeling cannot be performed in the traditional ways. Research work in this area of modeling is also continuing. The BTR concept can be designed to impose a relatively low top tensile load on the Host Facility. This tensile load change can be designed to be relatively small as the Host Facility goes through its full range of motions. This feature reduces the risks that are associated with predicting both the riser system maximum tensile stress and the fatigue design life that results from stress cycles. The BTR design can be configured to be forgiving without incurring excessive costs. If Host Facility motions are not identical to analytical predictions or model basin simulations, the BTR can be configured to provide a conservative design margin to allow for the differences from these predictions.
The BTR coil section can be designed so that it contains a minimum number of active components that require maintenance or repair. If it is necessary to replace any of these elements during field life, the coil section design lends itself to either replacement of individual components or the entire coil section, if this is necessary.
Cost efficiency of the BTR over present methods is summarized in FIG. D-3 of the U.S. provisional patent application filed on Apr. 26, 2002 under Serial No. 60/375,619. Riser sizes depend on specific application needs, but 8-inch through 12-inch sizes are common. Both smaller and larger sizes may be necessary in any particular application, but the trends that are identified in this Figure are representative. In comparison to the SCR/Flowline method, the BTR cost benefit is estimated to be about $2.9 million; $3.2 million; $3.5 million for each 8-inch, 10-inch, and 12-inch riser, respectively. This comparison assumes that a completely independent riser installation is used to install the BTR systems. When the Host Facility is equipped with a drilling rig, it is feasible to consider using the drilling rig to do the BTR running activities. If this BTR alternative is used, these same benefits are estimated to increase to $3.9 million, $4.3 million, and $4.8 million. Overall, the first set of benefits represent about a 33 percent cost reduction.
Most deepwater field developments will require site-specific numbers and sizes of risers. A representative example is provided in FIG. D-4 of the U.S. provisional patent application filed on Apr. 26, 2002 under Ser. No. 60/375,619). In this example, the BTR benefit represents a cost reduction of about $54 million, and the alternative BTR installation method represents about $75 million. These are cost benefits of about 32 percent and 44 percent, respectively.
Since the coil section diameter is relatively large, it is located a substantial vertical distance away from the Host Facility. By placing the coil section near the bottom of the riser, the required space is readily available. This location has the inherent and important advantage that it then only needs to support its own self-weight during installation and operation. If it were to be placed near the top of the riser, it would not only have to carry its own weight, but that of the riser suspended below it, both during installation and throughout its operating life.
In the case of export and import risers, the BTR invention may provide cost benefit over alternative riser solutions. And when compared to present methods, the technical benefits may also be significant, especially for deepwater configurations that use seabed equipment that is located under the Host Facility.
The BTR system is one way to simplify the deepwater challenge. Riser top tensile stresses for this new system are shown in FIG. E-4B of the U.S. provisional patent application filed on Apr. 26, 2002 under Ser. No. 60/375,619). That figure shows that the new rigid riser system can provide a relatively low top tensile stress level across the range of possible Host Facility motions.
Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention, the embodiments described therein, from the claims, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the overall environment of the invention;
FIG. 2 illustrates a side elevation view of a basic embodiment of the invention;
FIG. 3 depicts top, side elevation, and front views of the Coil Section;
FIG. 4 shows an enlarged elevation view of the invention with the Coil Section removed;
FIG. 5 depicts a top view of the apparatus shown in FIG. 4 ;
FIG. 6 shows the locking mechanism in its locked position;
FIG. 7 shows the locking mechanism in its un-locked position;
FIG. 8 depicts three optional arrangements of the BTR assembly;
FIG. 9 shows the basic global geometry of the BTR; and
FIG. 10 depicts minimum coil diameter consistent with 5Do pipe bends;
LIST OF TABLES
Table 1 BTR Advantages and Disadvantages
DETAILED DESCRIPTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawings, and will herein be described in detail, one specific embodiment of the invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to any specific embodiment so described.
Turning to FIG. 1 , the invention, and the overall environment of one embodiment of the invention is illustrated. At the upper half of the drawing is shown a Host Facility in the form of a semi-submersible platform and a floating production system 3 Production Drilling Quarters (PDQ). The PDQ comprises a drilling rig 4 , topsides 5 , crew quarters 6 , cranes 7 , and an emergency flare 8 . The superstructure of the PDQ is supported by columns 10 which are connected to pontoons 11 which are submerged below the surface 1 of the water. The PDQ is positioned by mooring lines 12 which extend to the seabed 2 . A drilling riser 13 is shown supported by the drilling rig 4 . Also shown are a production riser porch 14 and an export pipeline porch 15 . An export pipeline 16 sends oil to another facility.
Looking at the bottom of FIG. 1 , a clustered well manifold system 17 is shown on the seafloor 2 . The drilling riser 13 extends to a lower marine riser package 18 and a blowout preventer 19 to a subsea wellhead 20 . Flowline jumpers 23 join subsea Christmas Trees 21 to a subsea manifold 22 . Manifold jumpers 24 join the subsea manifold 22 to the Bottom Tension Riser (BTR) system 25 that is the subject of the present invention.
Turning to FIG. 2 and FIG. 3 , the BTR system 25 is located above the riser base 26 and below a generally long vertical section of main production riser 32 . The BTR comprises a Coil Section 27 , a lower connector 28 , flexing elements 29 , a tensioning assembly 30 , and an upper connector 31 . The riser base 26 has a jumper vertical connector hub 33 and a horizontal connector hub 34
FIG. 4 and FIG. 5 show the BTR system 25 with the Coil Section removed. There are four tensioning units 40 . A tensioning rod 39 extends from each unit and is mechanically connected to the upper structure and connector 38 . An auxiliary tensioning pressure unit 41 and a sea chest 42 are joined to the main body of the tensioning unit 40 . The main body of the tensioning unit is connected to the lower structure and connector 43 .
The locking mechanism 44 is shown in FIG. 6 and FIG. 7 . FIG. 6 shows the mechanism in the “locked” position. FIG. 7 shows the mechanism in the “open” position. The locking mechanism mechanically connects the main body of a tensioning unit 40 with the upper connector 31 . The mechanism comprises a fixed pawl 44 a is connected to the upper connector 31 . Another pawl 44 b is pivotally connected to the tensioning unit 40 . The free end of that pawl 44 b is moved towards and away from the free end of the fixed pawl 44 a by means of a locking screw 46 that is preferably configured to be operated by a Remotely Operated Vehicle (ROV). Thus, when the screw 46 is advanced toward the pivoted pawl 44 b , the two pawls separate. A clearance tolerance 49 allows the upper connector 31 to move away from the main body of the tensioning unit 40 .
The BTR system 25 is unique in at least four important ways:
First, it provides the means for providing top tension at the Host Facility in a way that tensile stresses remain relatively low throughout the range of Host Facility offsets. This is important because it ensures that riser integrity can be maintained as the Host Facility moves about.
Second, the stroke length requirement is provided via the Coil Section, which is contained within the lower section of the riser. Thus, the BTR system remains essentially transparent to the design of the hull and topsides. This is important because it simplifies hull and topsides designs.
Third, since this is a vertical riser system, it projects a relatively small footprint onto the seabed. This is important, particularly for those field developments that use of subsea wells and equipment that are located under the Host Facility. In these situations, the BTR approaches being an “enabling technology”. This is because there is only limited space at the seabed to accommodate the system and seabed equipment architecture needs.
Fourth, the BTR concept can be configured so that it is a “forgiving” arrangement, with minor cost increase to do so. Forgiving in this context refers to those situations in which the Host Facility could be displaced beyond its expected limits. The importance of the BTR system is that the Coil Section 27 can be provided with a conservative stroke length to account for this possibility. The reason that this is feasible is that unlike the topsides, where interface limits measure in inches between the riser and topsides equipment, ample headroom exists at the lower section of the riser. This feature allows many optimizing opportunities for the BTR system.
Moving on to the BTR rod and piston elements there are at least two basic approaches that can be used for this part of the system.
The first approach is to use a “closed” arrangement for the pressurized gas that is used in the cylinder and rod assembly. This method is represented in FIG. 8A . The gas is installed at a pre-determined pressure, and the pressure in the cylinder increases or decreases as the rod and piston move up or down, respectively. This approach has the advantage that it is cost efficient, but it may require occasional intervention to replenish the gas. In the event of component failure, removal and repair or replacement of the unit may be necessary. However, this design can provide an efficient solution. It is the basis that is used for developing the riser top tensile stress computations that are shown in FIG. E-4(b) of the U.S. Provisional Patent Application Ser. No. 60/375,619 filed on Apr. 26, 2002 This approach results in tensile stress increase, primarily as the Host Facility approaches maximum offset limits. Even so, the related maximum tensile stress remains well within acceptable limits. Most of the time, Host Facility offsets will be much less than the extreme offsets, and the tensile stress change is quite small.
The second approach is to use an “open” system for the pressurized gas that is used in the cylinder and rod assembly This method is represented in FIG. 8B . This approach has the advantage that a constant level of gas pressure can be applied via the Host Facility, resulting in the capability to maintain a near constant level of pressure on the cylinder and rod piston. This allows maintaining a more constant top tensile stress at the top of the riser throughout the range of Host Facility movements. However, this additional capability comes at considerable additional cost and complexity, with near certainty that the frequency of component failure, removal or replacement of the unit is expected to be little different than for the closed system approach. Due to the added complexity of this system, it could even require more frequent intervention than for the closed system approach. In any case, these are the reasons why the closed system approach is assumed for this BTR concept assessment.
FIG. 8C shows another variation of the “open system” approach wherein an auxiliary cylinder 41 is co-axial with the main cylinder 40 . Details of the comparison of different cylinder, rod, piston, and auxiliary cylinder configurations are provided in the Appendix II. The “piggy-back” auxiliary cylinder method is beloved to provide the most efficient solution for the cylinder volumes required for this type of application.
Dynamics
This invention has immediate application to situations where top tensioned risers have been used to transfer products between a floating Host Facility and the seabed for deepwater oil and gas field developments. Referring to FIG. 2 , there are two basic elements.
The first element is placement of the top tensioning equipment in the lower portion of the riser rather than at the top of the riser. By placing this equipment at the bottom of the riser system, the tensioning assembly is subjected to lower loads than when the tensioning assembly is placed at the top of the riser. This load reduction is roughly equal to the riser weight in water.
The second element is the use of a Coil Section 27 that lengthens and shortens to accommodate the Host Facility movements. In addition to this, it provides the required riser top tension to maintain riser integrity. By virtue of this invention, the need for large, complex, and costly top tensioning equipment at the interface with the Host Facility is eliminated. Since the Coil Section is placed at the bottom of the riser, it can accommodate most any Host Facility motions that fall within the practicalities of building, transporting and installing the Coil Section.
The BTR system global geometry is summarized in FIG. 9 . There are three important aspects of the riser system:
1. installation, 2. performance at the Host Facility neutral position, and 3. performance at Host Facility offset positions, including possible extreme events.
Turning to system installation, this is represented by FIG. 9A . The overall riser length is l to for a given water depth. The main riser section, which will make up most of the riser system, will have a riser section length, l r . As can be seen, it is the length of the riser system (excluding the height of the riser base and Coil Section above the seabed). This main part of the riser is commonly made from steel, but other materials, such as titanium, have been used. The weight of this riser during installation will include its weight in water during installation, and that of the Coil Section weight, W c . After installation, the weight of product carried within the riser will be also need to be included. These riser weights are represented by W r .
Before lowering the main riser section to the seafloor, the Coil Section of length l c and self-weight in water W c is attached to the riser. Since the Coil Section 27 is attached to the lower section of the main riser, the Coil Section carries only its own weight and that of the riser bottom connector and any special riser or subsea components that may be necessary for a specific application. This results in the riser system that is short of its final installed length by the value l o . The riser top tension at this point is T r . Once the riser system is landed and locked onto the riser base, the riser system is pre-tensioned to provide a pre-determined riser top tension, T ro . This is performed in conjunction with docking the riser top into the riser top connector that is provided on the Host Facility. At this point, the Coil Section is extended by the length l eo , resulting in the Coil Section tension load T co that causes the riser system top to increase to T ro . The connected and pre-tensioned riser system is represented by FIG. 9B . These riser system installation activities described herein are typical of those that are used when installing many types of deepwater equipment.
Performance at the Host Facility neutral position will now be addressed. At the Host Facility neutral, or no offset position, environmental responses and operational load changes will cause the need for riser length changes to occur. Also at this position, the riser top tension should be sufficient to ensure appropriate riser system behavior through the long water column. Maintaining the riser top tension to an amount that is somewhat more than the weight of the riser system does this. The pre-tensioning as described above causes the Coil Section length to increase from its original length l C by an amount l eo . This results in the Coil Section length l CO at the neutral position. This pre-tensioning load is transmitted directly through the main riser body and into the riser top connector, resulting in the total riser top tension, T ro . Thus, as Host Facility motions or operating loads change, the Coil Section length l eo also changes accordingly.
Performance at the Host Facility offset positions will now be addressed. The third set of conditions that the riser system should satisfy is represented in FIG. 9C . These conditions occur when the Host Facility moves laterally from it neutral position. During a possible extreme event, this offset can approach in excess of five percent of the water depth. From a riser system configuration standpoint, all motions are important. But of these motions, the most important is the Host Facility extreme offset conditions. In an area like the Gulf of Mexico, hurricanes normally define the extreme events, which in turn determine the Host Facility maximum offset. However, in some situations, the Host Facility may be offset even more than this for system operating purposes. If this is so, this need should also be accounted for in the riser system configuration. During hurricane events, Host Facilities are commonly de-manned. During these periods, the riser system should continue to perform without any requirement for man-machine interaction. The offset x, as shown in FIG. 9C , is used to represent all Host Facility and the connected riser system lateral displacements. Since a moored, floating body experiences six degrees of motion, and not just the single degree of freedom motion (x offset) that is represented in this drawing, additional allowance for the other five degrees of motion is necessary in actual practice. However, since x is the most significant single item, a first approximation of the change in riser system length can be defined using equations (1), (2) and (3):
tan −1 ( x/l to )=θ (1)
cos(θ)= l to /l tx (2)
l tx =l to /cos(θ) (3)
l ex =l tx −( l r +l c ) (4)
The main riser body length l r is essentially unchanged as the Host Facility offsets from its neutral position. The Coil Section length extends beyond its neutral position length l eo to satisfy the extreme event Coil Section extension length l ex , as shown in equation (4). This results in a total Coil Section extended length of l cx and riser system length of l tx for the extreme offset conditions. These same relationships can be used to characterize the riser system throughout the range of Host Facility offset positions between the neutral and maximum positions. The Coil Section is a key part of the BTR system. It is now described in more detail.
The export and import riser duty of the BTR system should satisfy specific Industry Practice design features. The overall Coil Section assembly is shown in FIG. 2 . It consists of the upper and lower connectors 31 and 28 , the Coil Section 27 , and the tensioning unit 40 . The connectors are commercially available components today, so they are not be described in detail. However, the way in which the connectors are configured to meet the specific requirements of the BTR Coil Section is unique, and their use in this way is included in this application. The main Coil Section is described first, followed by the tensioning unit and the complete assembly.
The Coil Assembly is shown in FIG. 3 . As shown in the plan and elevation views, it consists of six components.
The first two components are the upper connector 31 and lower connector 28 . Each connector is required to provide the structural strength that is needed to transmit loads and provide pressure isolation for the riser production as it is moved from the main riser body into the riser base. These connectors are commercially available today, so no further description is necessary.
The next component is the Pipe Section 35 for the Tensioning Assembly 30 . The Pipe Section 35 is an engineered segment of pipe that provides the attachment to the bottom of the upper connector 31 and the top of the Upper Coil Transition Section 36 (described later). The Pipe Section 35 serves two purposes. The first purpose is to provide a length of pipe that reduces the number of individual coils to the minimum number of coils that are needed in the Coil Section 27 . For most situations, excluding Pipe Section 35 would result in the need for using more coils than is required to meet the Coil Section maximum stroke length. The Pipe Section 35 provides design efficiency for each application. The second purpose for Pipe Section 35 is to provide the strength that is needed to expand the coils while providing pressure isolation for the riser products.
The next component of the Coil Section 27 is the Upper Coil Transition Section 36 . It is connected to the bottom of the Pipe Section 35 and the uppermost coil. The Upper Coil Transition Section 36 has two purposes. The first is to provide the strength that is required to expand the uppermost of the coils while providing pressure isolation for the riser products. The second purpose is to provide this transition in accordance with Industry Practices for export and import pipelines. Basically, this means that the Upper Coil Transition Section 36 will have a minimum pipe bend limit throughout its own shape and as it makes the tangential transition into the connection with the uppermost of the coils. FIG. 10 shows one way in which the Industry Practice for minimum bend radius criteria determines the geometry of both the Upper Coil Transition Section 36 and the main coils.
The engineered coils are the next components of the Coil Assembly. These coils have two purposes: The first purpose is to provide the flexibility that will satisfy the stroke length changes that will be required by the riser system as the Host Facility moves. The second purpose is to provide pressure isolation for the riser products between the Upper Coil Transition Section 36 and the Lower Coil Transition Section 37 .
The last component of the Coil Assembly is the Lower Coil Transition Section 27 . It bridges between the coils and directly to the Lower Connector 28 . The purposes for the Lower Transition Section 5 and the Lower Connector 28 are the same as those described for the Upper Connector 31 and the Upper Coil Transition Section 36 . As an assembled unit, the six components of the Coil Assembly will have a structural stiffness modulus as the assembly length changes. This Coil Assembly stiffness modulus is to be considered in conjunction with the Tensioning Assembly that is shown in FIG. 4 .
Referring to FIGS. 4 and 5 , the Tensioning Assembly the main body of a Riser Pipe 32 is attached to the Upper Connector 31 . Also, an engineered Upper Structure and Connector 38 is attached to the Upper Connector 31 . The Upper Structure and Connector 38 has two functions: The first function is to transmit the forces from a Tensioning Rod 39 to the Upper Connector 31 . The second function is to provide a proper connection for the Tensioning Rod 39 .
In one embodiment, this connection has a gimble configuration so that the Tensioning Rod 39 can perform properly. The displacement that occurs at the top of the overall Coil Section is expected to be more than the displacement that occurs at the bottom. This occurs because the base of the Coil Section is fixed by the Lower Connector 28 attachment to the riser base 26 , while the top of the Coil Section 27 responds to main riser length changes and offsets. This gimble arrangement can also be configured so that the Tensioning Rod 39 can be disconnected using subsea intervention practice. The reason for this is so that individual Tensioning Units 40 can be recovered for repair or replacement without having to recover and replace the entire Tensioning Assembly 30 . As will be explained later, the force that is developed by the Tensioning Rod 39 is provided by compression of gas that is acting on the piston 55 that is attached to the lower end of it, and confined within the Tensioning Unit 40 .
Each Tensioning Unit 40 is configured so that it is long enough to satisfy the particular application stroke needs, including additional length that may be considered appropriate by the system designers. The diameter of this cylinder is determined by the combination of contained gas compression pressure that is acting on the Tensioning Rod 39 piston's net area and the Tensioning Rod's tensile force that is required for the application. It is this Tensioning Rod tensile force, working in unison with the rods of the other Tensioning Units' rods' tensile forces that provides a significant portion of the Coil Section 27 stiffness modulus that is required as the system stroke length changes take place.
The Tensioning Auxiliary Pressure Unit 41 is an integral element to the Tensioning Unit 40 . This unit provides additional compressed gas volume that is in direct communication with that of the Tensioning Unit's compressed gas volume. This configuration permits the Tensioning Rod 39 to make the long stroke length changes without causing excessive compressed gas pressure changes. If this were not performed in this way, the rod load changes could be excessive, resulting in excessive changes in the riser top tension, which could lead to riser fatigue failure. The positioning of the individual Tensioning Units 40 around the Upper and Lower Connectors 31 and 28 is important. As a minimum, they should be placed so that they work in unison. This will prevent any excessive unbalanced loads on these two connectors 31 and 28 . Since the Host Facility lateral movements can occur in any direction, the number of Tensioning Units 40 and their placement should preferably satisfy this requirement. Evaluation of each application will reveal the appropriate arrangement.
FIG. 5 shows a representative plan view of an assembled Coil Section 27 that uses four Tensioning Units 40 . As shown in FIG. 4 and FIG. 8 , the Tensioning Unit 40 is also provided with a Sea Chest 42 . It is connected to the underside of the rod piston element that is contained within the Tensioning Unit 40 . The Sea Chest 42 provides the important function of pressure balancing the Tensioning Unit 40 . Local seawater pressure will be allowed to act on the underside of the rod piston and on the top of the rod. By using this pressure compensation method, the compressed gas pressure that is required to charge the cylinder of Tensioning Unit 40 and the cylinder of Tensioning Auxiliary Pressure Unit 41 is reduced roughly by the equivalent seawater pressure at the application depth. This provides important design and system performance efficiency. The Sea Chest 42 can be used to provide an inhibited fluid that is displaced into and out of the underside of the Tensioning Rod 39 and its connected piston as it moves in and out of the cylinder of the Tensioning Unit 40 in response to the Host Facility movements. This arrangement not only serves to eliminate the possibility for hydraulic block of the mechanism, but it reduces the possibility for unwanted corrosion or debris from affecting performance of the Tensioning Unit. At the base of the Tensioning Unit, the Lower Structure Connector 43 is provided. This item transmits Tensioning Unit 40 loads into the Lower Connector 28 . Preferably, it will have a gimble feature and disconnect capability for the same reasons as described previously for the Upper Structure 38 .
Operation
Referring to FIG. 1 through FIG. 5 , the way in which the Coil Section 27 works will now be summarized. The lower connector 28 is attached to a mating connector that is contained within a riser base. The riser base is structurally attached to the seabed, resulting in the lower connector 28 being a fixed point that is near the seabed. The bottom of the main riser pipe contains a mating connector for the upper connector 31 .
As the Host Facility moves, the top of the main riser pipe, which is connected directly to the Host Facility, moves with it. This movement is transmitted immediately via the main riser pipe into the Upper Connector 31 . This causes the spacing of the Coil Section coils to increase for Host Facility motions that tend to make the riser system length increase. As this coil spacing increases, coils provide a resisting force to the movement that is transmitted into the upper Connector 31 . Also, the tensile force of the tensioning rod 39 of the Tensioning Unit 40 is maintained, increasing somewhat as coil spacing increases. This action maintains a near constant load that also resists this Main Riser pipe movement, as the load is transmitted into the upper connector 31 . The load of the combined coils and Tensioning Units' 40 are transmitted into the Upper Connector 31 , and are in turn transmitted into the main body of the riser pipe. This Coil Section and main riser pipe loading increase results in an increasing tension load at both the bottom and the top of the riser that is predictable for the riser system. This helps ensure riser system design integrity. Since the fundamental purpose for the riser system is to provide pressure isolation for the fluid that is transmitted through it, maintaining this riser integrity is important. For Host Facility movements that tend to shorten the riser system length, the changes that occur are exactly the opposite of those changes that were just described for movements that tend to lengthen the riser system.
This concludes the detailed description of the Bottom Tensioned Riser system. By placing the top tensioning equipment in the lower section of a deepwater riser, the loads that are carried by the Tensioning System are reduced by an amount that is roughly equal to the weight of the riser in water. Moreover, a Coil Section 27 , which is placed in the lower part of a riser, can be used to efficiently control riser top tension loads while accommodating the Host Facility motions.
Representative BTR System examples are further discussed in Appendix I and Appendix II. The results of Model Experiments are provided in Appendix III. A rudimentary description of the installation of a BTR System is presented in Appendix VI.
Scope
From the foregoing description, it will be observed that numerous variations, alternatives and modifications will be apparent to those skilled in the art. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. Various changes may be made in the shape, materials, size and arrangement of parts. Deepwater production risers range in pipe diameters from 3-inch through 36-inch. They are used in water depths (length) ranging from a few thousand feet to more than ten thousand feet. Carried fluid internal pressure may range from 1,000 psi to more than 20,000 psi.
Moreover, equivalent elements may be substituted for those illustrated and described. Parts may be reversed and certain features of the invention may be used independently of other features of the invention. For example, the common application for the BTR System will be steel and steel alloy materials. Other metallic materials, such as titanium, can be used. Composite type materials, such as those that are based on high strength, lightweight strands like Kevlar, also may be used in the future. The invention may also have applicability to the Ocean Thermal Research Program. It may ultimately lead to the need for long life and deep risers that are suspended from a surface facility. These risers also need be to be stabilized against lateral current forces, while managing riser top tensioning loads. This is just what the BTR System does. However, as presently configured, the BTR System is for high pressures and relatively low rates. Energy recovery that is based on the temperature differences between shallow water and deepwater will likely require very high seawater throughput rates at low pressures. The BTR System configuration may look different, but the principles would be the same. Thus, it will be appreciated that various modifications, alternatives, variations, and changes may be made without departing from the spirit and scope of the invention as defined in the appended claims. It is, of course, intended to cover by the appended claims all such modifications involved within the scope of the claims.
Appendix I
Worked Examples of Bottom Tensioned Riser (BTR) System
Referring to Appendix FIG. 1 , the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619, the BTR System and its key relationships are shown. These relationships are used in Appendix Table 1. All subsequent references to figures and tables in this appendix will be with respect to the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619. The examples provide simple static solutions for 4-inch through 14-inch riser and Coil Section pipe sizes in 6000 feet of water. This type of global, static solution information is representative for the initial riser approximations. Thus, the solutions are only indicative of the first step forward for doing a full riser analysis and design. These subsequent steps, which are beyond the scope of concept feasibility assessment, should include appropriate riser dynamic analysis in the frequency and time domains, use the predicted hull motions at the Host Facility attachment point, and apply appropriate hydrodynamic and modeling for the riser system. Also, static and transient multiphase product hydraulic simulations, and inclusion of the riser changes that will occur as a result of related thermal effects—especially for high temperature and pressure conditions will require analysis. However, based on previous experience, it is believed that these simple initial static results are sufficiently representative to reach conclusions about this new riser concept based on the results of these worked examples.
Referring to Appendix Table 1, this initial information results in the wall thickness estimate for a given grade of material, which is steel of Grade X60 in this case. The pipe code that is used is B31.4, with the wall thickness shown for each of the line sizes. For convenience, it is assumed that the riser pipe and coil pipe is made using the same material. It is feasible to use different materials for each, and this could result in optimized solutions. The single coil properties are defined, and items are specified or calculated as shown in the Table. Where applicable, the specific figure number and equation that is used to do each calculation is provided for reference. The global system parameters are then specified for the particular case. This provides an estimate for the number of individual coils that are required to satisfy these global conditions, and the Stiffness Modulus for the number of pipe coils that are used in the Coil Section. As described earlier, these are approximate solutions only. The reason is that engineering solutions for this type of system are not yet matured for detailed design purposes. The next section provides the calculations for the Tensioning Units that are used with the Coil Section 27 . This case assumes that a “closed system” is used for the cylinder and rod piston elements, along with an auxiliary cylinder. This is performed to efficiently manage the gas compression. Further discussion about this is provided in Appendix II.
The focus on this work has been primarily on the 12-inch riser size, so the tensioning assembly sizes and rod forces are best suited to using four of these tensioning units. As can be seen in Appendix Table 1, the number of units is artificially reduced for the smaller sizes. If this were not performed, riser top tension loads would be too high because the tensioning unit rod loads would be too high. In actual practice, smaller tensioning units would be configured so that a minimum of three units, perhaps four would be used. The larger number of units is necessary to ensure that the rod loads are properly distributed around the Coil Section top connector. For this work, it is assumed that the rod piston cylinders are completely efficient. This is rarely a good assumption, and it is common engineering practice to handle this matter during detailed design of equipment. With the Tensioning Unit Stiffness Modulus determined, the overall Coil Section Stiffness Modulus is then established, accounting for the stiffness of both the coils and the tensioning units. The Stiffness Modulus for the Riser Pipe itself is then calculated as referenced in the Table. The combined Stiffness Modulus for the Riser Pipe and the Coil Section 27 is also calculated as shown in the Table.
The weights that are represented in this Table are essentially solutions in air. In actual practice, a very wide range of weights will be possible in a given situation. This is because individual pipes will displace a volume of seawater, and buoyant forces will partially offset the pipe weight in air. However, the product in the riser will add weight, while coatings added to the pipe usually decrease the pipe weight in water. Experience has shown that for initial approximations, just using the pipe weight in air is a reasonable initial assumption pending availability of detailed information. It is believed that this weight in air assumption will provide reasonable first approximations for assessing the BTR System.
With the riser system stiffness modulus established, the conditions for the riser when the Host Facility is in the neutral, or no offset position are satisfied. The means for doing this is to apply an initial top tension in the riser that exceeds the weight of the riser itself. This allows the Host Facility to move around in its neutral position, and it provides a top tension load that exceeds the riser self weight. This additional tension is needed to structurally stabilize the riser during the wide range of environmental loadings to which it will be subjected, even when the Host Facility as at or near its no offset position. For this case, it is assumed that one third of the Coil Section 27 extension capability is used to provide this pre-tensioning. This fixes the top tensile stress in the riser at the level at which it will be for the predominant time period of its useful life. These calculations are shown in Appendix Table 1. Similarly, the next condition that should be satisfied is when the Host Facility is offset to its predicted extreme offset position. These calculations, including the resulting riser top tensile stress, are shown in the Table.
Maintaining a consistent set of assumptions, these calculations can be repeated for a wide range of possible water depths. An example for a 12-inch BTR System is provided in Appendix FIG. 2 . This is performed to demonstrate that the BTR concept is suitable for a wide range of water depths. Use of the closed system Tensioning Unit method causes the riser top tensile stress to increase as the Host Facility moves from the no offset position to the maximum offset position. This appears to be a manageable level of stress increase. However, if detailed riser design determines that this is not acceptable, an open system Tensioning Unit can be used to maintain a near constant riser top tensile stress across the range of Host Facility movements. However, this open system Tensioning Unit design is expected to add complexity and cost to the BTR System.
A few final comments are provided about the loads that will occur at the lower end of the BTR System. The Coil Section 27 will be subjected to a wide range of loads. Since it is located under the main riser body, these loads will be relatively small. This is why the focus of this discussion is the riser top loads, which are quite large in deep water. Even so, the Coil Section loads should be properly identified and detailed designs provided to meet these load conditions. When these bottom-located Coil Section loads are compared to those of a comparable surface located, stroke-providing tensioning unit, where the surface unit carries the riser weight and its over pull, the true value of a BTR riser system and the Coil Section design becomes immediately apparent. Since the Coil Section is located at the bottom of the riser, the impact of providing a long stroke unit is minimal. Providing a long stroke unit at the surface is costly, and interfacing a unit like this with the topsides can become complex to the extent that it may not be feasible to do it.
Appendix II
Tensioning Assembly Cylinder and Rod Piston Configurations and Comparisons
This is a summary of the work that was performed to select one preferred configuration for a Coil Section 27 closed system Tensioning Unit. There are three fundamental ways in which a subsea cylinder and rod piston unit can be configured. These three methods are represented in Appendix FIG. 3 and FIG. 8 herein. Unless otherwise indicated, all references to figures and tables in this appendix will be with respect to the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619.
A basic cylinder and piston rod option is shown in FIG. 8A . The work that was performed previously in conjunction with the Coil Section 27 load determination established representative types of rod loads and stroke lengths that would be needed for a Tensioning Unit. The focus of this effort was on a 12-inch riser pipe size for 6000 feet of water. This provided first approximations of a required rod force of between 100,000 pounds and 130,000 pounds (when combined with coil properties and four tensioning units, this will result in top tension loads (over pull) up to about 500,000 pounds. At 6000 feet, the required stroke length is about 360 inches. For the purposes of this work, a minimum stroke length of 480 inches was assumed.
In a perfectly pressure compensated system (i.e., frictionless), gas pre-charge at the surface can be performed so that the cylinder pressure at subsea application depth is exactly the same as it is at the surface (See FIG. D-13, equations (1) through (3)). Thus, cylinder wall thickness requirements can be determined for the application. In an actual design, a higher gas pre-charge than the “perfect” pressure would be used. This is performed because some extra pressure is required subsea for two reasons: First, the rod lubricator that is located at the top of the cylinder, and the rod piston element, where it contacts the cylinder wall, exhibit real world friction that must be overcome. Second, the rod is long and slender. Thus, the piston force should be kept high enough that it ensures that the rod will be “pulled” into the cylinder, and not “pushed” into it as the Tensioning Unit stroke is decreasing. If the rod were pushed, it could easily buckle. This could lead to failure of the Rod and Cylinder. For this comparison, the perfect gas pre-charge pressure is assumed for all options, recognizing that all configurations will require a pressure greater than this for actual design.
As can be seen in Appendix FIG. 3 and FIG. 8 herein, as the piston rod is stroked out, the gas in the cylinder is compressed. The solution to this problem is easily determined using the compressed gas pressure that will not over pressure the cylinder or over stress the rod as it develops the required tension load as it approaches the required rod stroke length.
Appendix FIG. 4 provides the results of this solution for the basic cylinder and piston rod option of FIG. 8A herein. However, as shown in Appendix FIG. 4 , the cylinder length is twice as long as the stroke length objective of 480 inches to prevent over pressuring the cylinder.
The auxiliary cylinder option uses an auxiliary cylinder and is shown in the middle of Appendix FIG. 3 and FIG. 8B herein. This configuration achieves the same purpose as the first option, but because the added gas compression volume is provided in parallel, the cylinder pressure increases more slowly. The results of this solution are shown in Appendix FIG. 5 . The configuration length remains within the stroke length objective of 480 inches.
A “carrier pipe” option, which is basically placing the main cylinder within another cylinder to provide the added gas compression volume in parallel to the main cylinder, is shown on the right side of Appendix FIG. 3 and FIG. 8C herein. The results for this solution are provided in Appendix FIG. 6 . The configuration length remains within the stroke length objective of 480 inches.
An overall summary comparison of the “attributes” for these three Tensioning Unit options is provided in Appendix FIG. 7 . It is clear that the configuration that is represented in the middle of Appendix FIG. 3 is the preferred way to approach the design for the Tensioning Unit assemblies.
In closing on this topic, it should be noted that no allowance has been made for the weight of these Tensioning Units in the Coil Section 27 weight estimate. The reason for this is the possibility that these units will be of very low weight in water, perhaps even buoyant (tendency to float). At this point, it is thought conservative to exclude their weight from the example calculations.
Appendix III
Summary of Model Experiments
A series of simple, but representative, experiments were performed to assess the BTR concept. The experimental set-up is shown in FIG. C-1 of the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619. All subsequent references to figures and tables in this Appendix will be with respect to the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619. Each Experiment is characterized by investigating the physical deflection of the Coil Section 27 with different weights attached to the apparatus. The primary difference between each of the experiments is a change in the Coil Section diameter. For each Test Condition, engineering calculations were performed based on representative materials and the model geometry. These measured and calculated results were then compared to one another. Results of the Experiments are summarized in Appendix FIG. C-2 through Appendix FIG. C-22. The following conclusions may be made:
First, the calculated deflection values (Coil Section stretch) were consistently over-predicted. By direct inference, this resulted in consistent under-prediction of the Coil Section Modulus K. Second, at very low loadings on the model, the Coil Section Modulus values demonstrated significant high variations. Some of this can be readily explained by limitations of the model apparatus, such as friction on the weight/pulley assembly being inconsistent. Regardless, low-load measurements are suspect. Third, at higher end loadings, the convergence of Coil Section Modulus measured and calculated value seems to be more consistent. However, the Coil Section tends to retain more of its stretched length with the higher loads. Even so, the Coil Section appears to retain its basic modulus value. This aspect warrants further investigation before any full-scale application is considered. Fourth, the agreement between measured and calculated deflections across Coil Section diameters supports the basic analytical procedures. Given that general engineering handbook properties are assumed representative for hardware store supplied materials, confidence in the methods that were used is bolstered.
At the end of Experiment 1, an attempt was made to “fail” the Coil Section at the maximum offset position of the model. This model offset is much more than would occur in actual practice. It is noteworthy that although this was quite a severe condition, and the Coil Section was permanently extended, nothing came apart. Although this should not be construed as a design attribute, it indicates that the Concept does provide some forgiveness for conditions that may exceed design expectations.
Much was learned about the model apparatus and its limitations during the set-up for Experiment 1. Since this work was performed solely for purposes of simple assessment of a concept, no costly effort was made to overcome observed deficiencies.
Appendix IV
Brief Summary of Recent Deepwater Developments
Riser concepts and designs have evolved along with the various types of offshore field developments. Field development configurations are dependent on water depth, reservoir size and properties, fluids properties and the environmental conditions. A summary of Gulf of Mexico representative field development methods is provided in FIG. E-1 of the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619. All subsequent references to figures and tables in this Appendix will be with respect to the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619. Given the nature of well development drilling, completion, production and well work over operations, the field developments that use Conventional Platforms have established a long and proven track record for water depths approaching 1500 feet of water. These platforms are rigid structures that are designed not only to support topsides equipment, but they also fully resist the large environmental loads. The well risers, consisting of the surface conductor, drill casings, production casing and production tubing are supported by the surface conductor, which is anchored, usually by pile-driving it, into the seabed. Conductor guides, which are imbedded within the platform structure, are spaced to prevent the conductor from buckling due to its self and supported weights 4 . This arrangement provides the desirable hands-on access to the surface wellhead equipment. This “dry” well equipment access exists throughout the field life. In the relatively shallow water, export and import risers can be “stalked-on” to the platform with the assistance of divers. However, as water depths increase, the J-tube pull-in riser is generally preferred. This is because the need for diving support is eliminated. As water depths increase, commercial diving support is feasible to a little more than 1000 feet of water. However, saturation diving, which is necessary beyond 180 feet of water, is costly and there can be safety issues to consider as well. Even so, the stalk-on riser method can be used when necessary, with water depth limitations as noted.
As water depths continue to increase, the Compliant Tower Jacket (CTJ) 5 can be an alternative field development method. This name is used because it is a flexible structure. This flexibility reduces the environmental loads that would need to be accommodated if it were of the more rigid conventional platform design. Thus, for a given water depth, the CTJ contains less steel, resulting in cost advantages when compared to conventional platforms. Above the water line, the CTJ looks much like the conventional platform, providing the “dry” well equipment features, with support to this equipment still being provided by the surface conductors. As the water depth increases, the depth to which the surface conductor is anchored into the seabed increases. Due to soft bottom conditions that prevail to several hundred feet below the seabed in many parts of the Gulf of Mexico, proper placement of these conductors using pile-driving technology can be a challenge. J-Tube risers can be used for export and import risers for many cases, but stalk-on or steel catenary risers are also viable alternatives.
The Tension Leg Platform field development method originated in the early 1970's. This concept introduced the floating hull method as a way to keep the Host Facility cost from escalating due the large quantities of steel that are required by bottom-founded structures as the water depth increases. A bottom-founded structure requires that the amount of steel that is needed just to support its own weight will increase geometrically with water depth. The TLP, combined with highly tensioned mooring tendons, reduces the amount of heave (up-and-down) motions to a much smaller amount than would exist if the hull were spread-moored. This feature makes it feasible to attach the well system equipment to the TLP, retaining “dry” equipment features. However, even though the heave motions are small, the TLP will still move laterally due to its response to environmental loadings. Thus, the riser top-tensioning equipment is designed to provide a strokelength to accommodate the small up and down motions as well as the riser length change that occurs as the TLP moves laterally. This top tensioning assembly stroke length capability prevents the riser from being over-stressed as the TLP moves in response to the environment and load changes on the TLP itself. Also, the riser top tensioning assembly should maintain a relatively constant tension along with the stroke length changes. This is performed to prevent the large stress cycles that could otherwise limit fatigue life of the riser. The riser tensioning systems add complexity and weight to the Host Facility, but allow retaining the “dry” features. Several TLP's have been installed since the 1980's, and their design methodologies have matured accordingly 7 .
The pace at which the need for field developments in deepwater has increased rapidly. In the early 1990's, it was thought that commercial viability of field developments would probably be in the range of 3000–4000 feet of water in the Gulf of Mexico. Since TLP technology was viable to these water depths, it was thought that the TLP, top-tensioned risers, and steel catenary risers could meet most, if not all, of these needs. Even so, there remained concerns about the high cost of these systems, primarily due to the way that tendon size and weights escalate beyond 3000 feet of water. New technology approaches to address these TLP needs were initiated. Some of the most notable include the use of new materials to reduce topsides weight and consideration for the use of new materials for tendons, production, and drilling risers 8,9 . In the interim, exploration drilling has continued to identify field development opportunities well beyond 4000 feet. Thus, while the TLP well and export and import riser needs can be met efficiently using top-tensioning methods to about 4000 feet, the TLP approach remains challenged for the deeper water applications.
During the mid-1980's, a new type of riser system was conceived to address some of the disadvantages that exist with the top-tensioned export and import risers. It was called the Steel Catenary Riser (SCR). This name is based on the shape that the riser takes as it bridges between its connection point on the Host Facility to an offset position that is located on the seabed. It offers technical and cost advantages for those top-tensioned riser applications that do not require vertical access. Since vertical access is needed for drilling and completion risers, the SCR approach is limited to the export and import riser applications. First commercial use of the SCR risers was for the Auger TLP export pipelines 6,10 . Following this success, SCR's continue to meet many deepwater field development needs.
Also, during the mid-1980's, a new type of hull system that can be used for the Host Facility was conceived 11 . It is referred to as a Deep Draft Caisson Vessel (DDCV). It is also called a “Spar”, which refers to its up-right appearance when it is installed, but before the topsides have been installed. The DDCV has been used for some field developments that are in water depths for which the TLP or other methods are too costly. The riser systems for a DDCV can use buoyancy in the upper riser section, which is guided through the central section of the hull. This method not only meets the requirements for top tensioning of each well riser, but it reduces the load that the hull carries. The Spar drilling riser may be top-tensioned using an approach that is similar to the one that is used for the TLP. The Spar surface well equipment retains “dry” access to the wells. Export and import SCR's, which do not require the vertical access, are commonly attached to the hull. In some circumstances, even the well equipment may be provided with top-tensioning equipment rather than using buoyancy in the riser. The Spar hull, which may be either spread moored or taut moored, provides heave motions that are somewhat similar to those of the TLP, but the Spar can handle topsides weight increases more efficiently than a comparable TLP. Thus, the Spar mooring system cost does not increase geometrically as the water depth increases. The Spar riser stroke length is considerable for the extreme design events, but topsides can be configured to accommodate these clearance, or headroom, needs. It is thought that the DDCV/Spar approach may continue to be cost efficient as exploration success in ultra-deep water continues.
With continuing increase of the water depth and additional topsides payload capacity requirements, a Host Facility called a Semi-submersible-shaped Floating Production System (FPS) 12 can provide cost advantage over a DDCV. Although FPS's have been used many times for field developments in other areas, especially offshore Brazil, they have not yet seen frequent application in the Gulf of Mexico. The spread-moored FPS provides favorable motions for producing operations, but these motions are not compatible with the use of “dry” well equipment due to the riser stroke challenge. Thus, they are most often used with subsea equipment and “wet” wells as represented in this drawing. Mobile Offshore Drilling Units (MODU's) are used to drill and complete the subsea wells that are laterally offset from the FPS. Since the FPS is offset from the subsea wells, the SCR's can be routed directly to the Host Facility and connected to the hull. Another variation on the FPS is to locate the subsea wells directly under the FPS. In this configuration, the FPS can be equipped with a drilling rig that can meet these “wet” subsea well needs. Floating well drilling and completion methods are used for these wells. SCR's that are needed for export are connected directly to the hull. However, seabed manifold equipment is commonly used to commingle production so that a reduced number of SCR's can be used for the import riser duty. A flowline is run outward and away from the Host Facility. It is then routed through a 180-degree turn so that the SCR approach to the FPS is provided in a straight line.
Another type of floating system, referred to as a Floating Production Storage and Offloading (FPSO) system, has been used elsewhere, with application area environments ranging from quite benign to extremely harsh 13 . This particular configuration includes a new large diameter export riser concept 14 called a Helical-base Riser. It provides a means to meet the very long stroke requirements for a large diameter rigid riser (steel) that might be used with an FPSO system. The use of FPSO-based developments in the Gulf of Mexico has only recently been approved by the Minerals Management Service (MMS). Since the FPSO type system and its risers may be applied at some undefined time in the future, further discussion is premature.
Each of the previous field development methods are based on technology that is relatively mature, but ultimate field development costs remain high. A significant cost element remains the cost of meeting the riser system needs. Table E-1 of the U.S. Provisional Patent Application Ser. No. 60/375,619 filed on Apr. 26, 2002 provides a summary for the types of risers that have been discussed above.
Appendix V
BTR Performance
Overall BTR system relationships are shown in FIG. E-5, of the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619. All subsequent references to figures and tables in this Appendix will be with respect to the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619. Typical results for the riser top tensile stress that are provided in FIG. E-4B, indicate that the BTR system can provide efficient vertical riser solutions for deepwater applications. FIG. E-5 represents a summary of pertinent information that is individually developed as shown FIG. E-6 and FIG. E-7. The BTR system is directed to those deepwater riser duties that do not require vertical access. These duties are generally regarded as export and import risers.
The BTR concept could be used for some export and import riser applications with considerable benefit over present methods. The combinations of very deep water and the deep reservoirs can result in the need for handling very high pressure and temperature fluids. The BTR system provides a solution that is all metal. This is a very important advantage for the high pressure and temperature situations. Table E-2 (reproduced below) provides a summary list of advantages and disadvantages for the BTR concept.
TABLE 1
BTR Advantages & Disadvantages
Advantages
Disadvantages
Low Cost
New
Minimum impact on Host Facility Design
Requires New Design
Small Seabed Footprint
Methodologies
All Steel, Vertical Riser Design
New Challenges for
Small Top Tensile Loads for Full Range
Manufacturing,
of Host Facility Offsets
Transportation and
Coil Section can be Changed (if
Installation
necessary) Throughout Field Life
Demonstration of Life-of-
“Forgiving” Design if Host Facility
Field Materials behavior in
Motions are Different from those
Coil Section will need to be
Predicted
evaluated
Minimum number of Active Components
to Maintain or Repair
As can be observed from FIG. E-5 and FIG. 2 herein, the top tensioning assembly, including provision for accommodating basic riser length changes as the Host Facility moves, is placed in the lower part of the riser. By doing this, the top tension load is limited to that of the riser self weight, external environment loads on the riser, and the tension that is developed by the Coil Section 27 to provide structural integrity of the riser for these external loads. The really large differences between this approach and traditional top tensioning assemblies is that the BTR tensioning assembly does not need to carry the riser self weight and by virtue of the Coil Section 27 location, riser stroke length needs can be easily accommodated. This Coil Section 27 includes a combination of pipe coils and rod/gas pressurized cylinder assemblies.
As shown in FIG. E-6 and FIG. 10 herein, the Coil Section 27 includes a series of pipe coils. The purposes of these coils are primarily twofold: First, they provide product pressure containment and continuity from the main riser pipe to the riser base connection. Second, they provide the riser flexibility that allows the main riser body to move along with the Host Facility without incurring excessive riser top tensile stresses. The coil behavior is assumed to be similar to that of a spring coil that is made from a solid rod of a particular material 17 .
These relationships are recognized for their intended purpose, which is to provide reasonable first approximations for the evaluation of this new riser concept To account for this difference between a solid rod and a tube, an equivalent tube diameter is estimated using the cross-section moment of inertia equivalency as the means for approximating a solid rod diameter. Determination of appropriate tube coil relationships that can be used with confidence for Coil Section 27 design purposes will be necessary as a first step forward to mature this concept. Regardless, application of these solid rod principles is straight forward, and the first approximations should provide reasonable results.
The coil design boundaries are determined by the combination of application duties and manufacturing limitations. It is desirable to make the coil diameter as small as possible for at least two reasons:
First, the coil stiffness modulus is an inverse exponential relationship to the coil diameter. The smallest possible diameter provides the largest stiffness modulus. And the larger the stiffness modulus, the closer the Coil Section system modulus is to that of the main riser itself. Also, the smaller the coil radius is, the smaller the resulting seabed footprint. As discussed previously, this is desirable to simplify subsea architecture. The smallest feasible diameter can ease manufacturing, transportation, and installation requirements, which are directly related to costs and risks.
Second, the coil diameter needs to keep the pipe strain within acceptable design practice limits 18, 9 . This requirement is best met by increasing the coil diameter. Since application duty will also require accommodating pigging operations, the Industry criteria for minimum pipe bend radius, which is the same as that required for maximum strain, has to be followed.
FIG. E-6, FIG. E-7 and FIG. 10 herein summarize what the assembled coils, including the upper and lower transition sections, can look like to meet these objectives. Although there are many ways that can be used to solve the underlying geometry, the method that is provided in these drawings is straightforward and suitable for first approximations. Based on these relationships, single coil solutions vs. coil pipe outside diameter for the minimum pipe bend criteria are provided in FIG. E-7, FIG. E-9, FIG. E-10, and FIG. 10 herein This information is representative of maximum conditions.
The relationships for the closed system cylinder and rod assembly that are provided in FIG. E-11 can be used to determine this assembly Stiffness Modulus. Summary results are provided in FIG. E-14.
The Coil Section 27 components, as described earlier, result in the configuration and relationships that are shown on FIG. E-15. Although numerous possible solutions exist, it is assumed for this concept assessment work that four cylinder and rod assemblies are used. Also, the equipment design is based on the use of a sea chest to pressure balance the equipment at its subsea operating depth. This result provides efficient use of gas pressure that can be readily accommodated at both surface and subsea conditions and controlled and clean fluid displacement from the underside of the piston elements.
Appendix VI
BTR Installation
A representative description of the BTR system installation activities will not be given. The objective is to provide information about one way in which the BTR System could be installed. The method that is described should result in little interference with other activities that may be taking place on the Host Facility. Other installation methods may be preferred for other specific installation equipment and site-specific situations. The activities that are described are based on the use of installation equipment that reduces the amount of Host Facility assistance as much as is practical under the circumstances.
Modern deepwater installation equipment comes with fully equipped facilities that are needed for this sort of work. Such facilities include high capability dynamic positioning and station keeping systems. Even so, deepwater riser installation activities, including those described below, are often weather and water column current sensitive. Thus, the riser installation activities are progressed as the environment is determined to be in accordance with the pre-determined limits for each activity.
Initial Conditions
As shown in FIG. I-1 of the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619, the Host Facility is spread moored at its permanent location. All subsequent references to figures in this Appendix will be with respect to the U.S. Provisional Patent Application filed on Apr. 26, 2002 under Ser. No. 60/375,619.
1. The seabed riser base connector is pre-installed, 2. The riser top connector is pre-installed on the Host Facility, and 3. The riser installation aids are installed.
The riser top connector placement is shown on an out-board pontoon, but it could also be placed on the in-board side of the pontoon. This connector placement is shown below the water line, but it could also be placed at other locations, including a suitable connection point on the Host Facility that may be above the water line.
Coil Section
FIG. I-2 represents how the BTR Coil Section is transported from a land fabrication site to the field location on a cargo barge.
1. The Coil Section 27 is transported in a transportation frame. This frame is used to secure the Coil Section during transportation. It also provides structural strength to the Coil Section as it is lifted from the horizontal position into the vertical position. 2. The cargo barge is brought alongside a construction vessel that is equipped with a lifting crane. 3. The crane lifts the Coil Section into the vertical position (see FIG. I-3) until it is free of the cargo barge. 4. An auxiliary crane (not shown for clarity) on the construction vessel is used to assist with removal of the transportation frame. All materials having no further need in the field are loaded onto the cargo barge, and it is returned to port. 5. An installation vessel that is equipped to install the Main Riser and the Coil Section is brought to a location that is near the construction vessel, which continues to suspend the Coil Section in its vertical position. This is shown in the upper part of FIG. I-3. In this case, a reel-type vessel is used to install the Main Riser. The Main Riser and Coil Section could also be installed using a vessel that is outfitted for J-Laying pipe. It is also possible to use the Host Facility drilling rig to assist the Main Riser installation, but as previously mentioned, this assumed case is based on conducting the riser installation work with minimum interference with any other activities that may be taking place on the Host Facility. 6. As shown in the lower part of FIG. I-3, keelhaul rigging lines are run from the Riser Installation vessel to the top of the Coil Section. These activities can be performed using hard-hat diving because the water depth is relatively shallow, but it is also possible to use a remotely operated vehicle (ROV) to make the necessary connections as well. 7. The mating connector attaches to the bottom of the Main Riser and the top of the Coil Section is attached to the end of the Main Riser, which is suspended below the installation vessel. 8. Once the rigging is in place, the construction vessel crane lowers the Coil Section 27 , and the riser installation vessel begins picking up the weight of the Coil Section, resulting in the Coil Section being located beneath the Main Riser and its Mating Connector 9. The Main Riser is lowered to engage the Coil Section Upper Connector, and this connection is made using ROV assist techniques. As can be seen in the upper portion of FIG. I-4, the Coil Section 27 , Main Riser, keelhaul rigging lines, and construction vessel lowering lines are attached near the top of the Coil Section upper connector. Riser loads are now carried by way of the Main Riser body. 10. The connector is tested to confirm integrity. 11. Then, each of the handling lines is disconnected from the Main Riser using ROV methods. This results in the arrangement that is shown in the lower part of FIG. I-4. 12. The riser and Coil Section 27 can be lowered towards the seabed and the Construction Vessel released. 13. As the Main Riser reaches a pre-determined water depth and riser length, it is “hung-off” on the installation vessel. 14. In this reel-type installation vessel example, the Main Riser pipe is continuous, so it is cut off just above the hang-off point. 15. The Riser Top Connection Assembly is then attached to the Main Rise, pipe. This length of the Main Riser pipe and the Coil Section 27 , including consideration for pipe stretch due to self-weight and contraction of the pipe due to the cold water column, is shorter than the connection length between the riser base and the Host Facility riser top connection point.
Thus, after the Coil Section 27 is locked onto the seabed riser base as described further below, it will require an over pull at the top of the riser that is in excess of the weight of the Main Riser and Coil Section as it is landed at the Main Riser to the Host Facility connection point. This over pull, which is performed once the Coil Section 27 is readied for extension provides the Main Riser pre-tensioning that is required for the Main Riser structural stability when the Host Facility is located in its neutral, or no-offset position. Once the BTR is connected to both the Riser Base and the Host Facility, the Coil Section 27 extension and retraction accommodates Host Facility motions at its neutral position. At the same time, it maintains the riser top tension at the appropriate level as these motions take place. Although a separate handling line could be used for remaining Installation vessel activities, it is efficient to use the excess riser pipe that is still on the installation vessel.
As described above, the Main Riser is cut off above the Main Riser hang-off point. Thus, a riser handing assembly, which is robust, flexible, and capable of handling the weight of the riser, is attached to the end of the pipe that is still on the installation vessel. The flexibility is necessary to ensure that the Main Riser pipe is not over stressed or otherwise damaged during any of these handling operations.
16. This riser handling assembly is connected to the Riser Top Connection Assembly, 17. The installation vessel pipe tensioning equipment and excess riser pipe is used to lower the top of the Main Riser as necessary. If required for any reason, this equipment can also be used to raise the Main Riser. As mentioned previously, there are other methods for doing these activities. The preferred method is determined based on vessel specific information and installation engineering design. 18. Continuing with this example, the riser is in its suspended position and the Main Riser Installation vessel is maneuvered close to the Host Facility as shown in FIG. I-5. 19. The riser handling equipment and riser installation line that is located on the Host Facility is hauled over to the riser top and attached to the riser top connection assembly. Since this is usually a very heavy chain, appropriate rigging and handling equipment is used to assist making this connection. The connection activities may be aided by the use of hard-hat diving and ROV equipment. 20. This connected equipment is then used to take up the riser weight using a sequence of coordinated steps. These steps include: moving the installation vessel toward the Host Facility; and as this is being performed, reducing the riser weight that is carried by the installation vessel and increasing the riser weight that is carried by the Host Facility riser installation line is increased. The steps are complete when the Host Facility Riser Installation Line carries all of the riser weight as represented on the left side of FIG. I-6. 21. The Main Riser installation vessel Line and any related installation aids are disconnected from the Main Riser. 22. The Riser Installation vessel can then be released. 23. The Host Facility is positioned on its mooring so that the Main Riser and Coil Section 27 are located above and directly over the Riser Base Connector. 24. The Coil Section 27 , which contains the upper portion of the Riser Base Connector, and the Main Riser are lowered onto the riser base connector, locked, and tested. These guideline-less connection methods are commonly used to install well and subsea equipment in deepwater. Since these connection activities occur in deepwater, ROV and related tooling methods are used exclusively to assist these Riser Base connection activities. An ROV is then used to perform additional duties after the BTR System is connected to the Riser Base. These may include:
disabling Coil Section locking mechanisms, removing various installation aids, and confirming readiness of the Coil Section Tensioning Units for the riser pre-tensioning activity.
25. For example, it may be determined that more or less Tensioning Unit cylinder gas pressure may be required to meet the actual Main Riser weight in water top tensioning objectives. The reason for this is that the actual riser weight in water may not be exactly as estimated. Any differences are usually due to the combination of engineering assumptions, manufacturing tolerances, and other minor deviations that may be unique to the installation site. 26. Once final adjustments are finished, the conditions that are represented on the left side of FIG. I-6 exist. 27. The Host Facility Riser Installation Line is used to pre-tension the Main Riser and the Coil Section 27 . Lifting the Riser Top Connection to the appropriate level does this. 28. The Riser Top Connection is then landed into the docking receptacle as represented on the right side of FIG. I-6. 29. Auxiliary handling lines from the Host Facility may be used to assist landing the Riser Top Connection Assembly in the Host Facility docking receptacle. 30. Once the Main Riser is docked in the receptacle and the Riser handling equipment is removed, the BTR installation activities are essentially complete. Any remaining Host Facility piping bridging between the top of the riser and Host Facility piping is installed and tested as appropriate. Once all risers that are to be installed are completed, related Host Facility Installation Aids would typically be removed.
LIST OF REFERENCES
All of Which are Hereby Incorporated by Reference
1—Moran, K.:“Deepwater Technology in the International Ocean Drilling Program”, Offshore Technology Conference (1–4 May, 2000), OTC 12179
2—Moyer, M.C., Barry, M.D., Tears, N.C.: “Hoover-Diana Deepwater Drilling and Completions”, Offshore Technology Conference (Apr. 30–May 3, 2001), OTC 13081
3—Bates, John B., Kan, Wan C., Allegra, Allen P., Yu, Allen: “Dry Tree and Drilling Riser System for Hoover DDCV”, Offshore Technology Conference (Apr. 30–May 3, 2001), OTC 13084
4—Stahl, B., Baur, M. P.: “Design Methodology For Offshore Platform Conductors”, Offshore Technology Conference (May 5–8, 1980), OTC 3902
5—Simon, J. V., Edel, James C., Melancon, Charles: “An Overview of the Baldplate Project”;, Offshore Technology Conference (May 3–6, 1999), OTC 10914
6—Enze, C. R., Brasted, L. K., Arnold, Pete, Smith, J. S., Luyties, W. H.: “Auger TLP Design, Fabrication, and Installation Overview”, Offshore Technology Conference (May 2–5, 1994), OTC 7615
7—Recommended Practice for Planning, Designing, and Constructing Tension Leg Platforms, API Recommenced Practicee 2T, Second Edition, August 1997
8—Hanna, Shaddy Y., Salama, Mamdough M.: “New Tendon and Riser Technologies Improve TLP Competitiveness in Ultra-Deepwater”, Offshore Technology Conference (Apr. 30–May 3, 2001), OTC 12963
9—Botker, Stig, Storhaugh,Turid, Salama, Mamdough M.: “Composite Tethers and Risers in Deepwater Field Development: Step Change Technology”, Offshore Technology Conference (Apr. 30–May 3, 2001, OTC 13183
10—Hays, P. R.: “Steel Catenary Risers for Semisubmersible Based Floating Production Systems”, Offshore Technology Conference (May 6–9, 1996), OTC 8245
11—Halkyard, John, Horton, Edward H.: “Spar Platforms for Deep Water Oil and Gas Fields”, MTS Journal, Vol. 30, No. 3, 3–12
12—Blincow, R. M., Whittenburg, L. A., Pickard, R. D.: “GB 388—An Independent's Approach to Deepwater Development”, Offshore Technology Conference (May 1–4, 1995), OTC 7842
13—Leghorn, J., Brookes, D. A., Shearman, M. G.: “The Foinaven and Schiellion Developments”, Offshore Technology Conference (May 6–9, 1996), OTC 8033
14—McShane, Brian M., Bruton, David A. S., Palmer, Andrew C.: “Rigid risers for floating production systems in deepwater field developments”, Pipes & Pipelines International, January–February 2000
15—Design of Risers for Floating Production Systems (FPS's) and Tension Leg Platforms (TLP's), API Recommended Practice 2RD First Edition, June 1998
16—Serta, Otavio B., Longo, Carlos E. V., Roveri, Francisco E.: “Riser Systems for Deep and Ultra-Deepwaters”, Offshore Technology Conference (Apr. 30–May 3, 2001), OTC 13185
17—Baumeister, Theodore, Avallone, Eugene A., Baumeister III, Theodore: “Marks'Handbook for Mechanical Engineers”, Eighth Edition, 1978, pages 8–76/8–77
18—Design, Construction, Operation, and Maintenance of Offshore Hydrocarbon Pipelines (Limit State Design), API Recommended Practice 1111, Third Edition, July 1999
19—Kopp, F., Peek, R.: “Determination of Wall Thickness and Allowable Bending Strain of Deepwater Pipelines and Flowlines”, Offshore Technology Conference (Apr. 30–May 3, 2001), OTC 13013
20—Byle, Steven M.: “Tension control device for tensile elements”, U.S. Pat. No. 6,190,091, Feb. 20, 2001
21—Davies, Richard; Finn, Lyle D., Pokladnik, Roger: “Riser tensioning device”, U.S. Pat. No. 5,758,990, Jun. 2, 1998 | A new marine oil production riser system for use in deepwater applications is disclosed. An efficient means for accommodating movements of the host facility, while maintaining riser top tension within the limits for long-term riser performance. Long riser stroke lengths can be accommodated without requiring complex interfacing with the topsides. The riser assembly comprises: a generally extendable substantially non-vertical section having an upper end adapted to be in flow communication with a generally vertical marine riser carried by a facility floating on the surface of a body of water, and having a lower end adapted to be in flow communication with a fluid source on the seafloor; and tensioning means, mechanically connecting the upper end of the marine riser with the lower end of the marine riser, for biasing said ends towards each other. The tensioning means comprises: a cylinder having one end open to sea pressure, having an opposite end sealed from sea pressure, and connected to one end of the marine riser; a piston within the cylinder disposed for movement within the cylinder; and a piston rod passing through the opposite end of the cylinder and having one end connected to the other end of the marine riser. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
This invention relates to a novel drilling device and method of drilling a well. More particularly, but not by way of limitation, this invention relates to a non-reactive torque device that contains an inner bit and a counter-rotating outer bit. This invention also describes a method of drilling the well. The novel device will significantly reduce the reactive torque generated during the drilling phase.
In the search for oil and gas, operators have utilized various types of devices in order to drill wells. Operators are continually searching for ways to drill the wells faster and more economically. Traditionally, a specifically designed drill string was used to drill wells. The drill string would have attached thereto a drill bit. In order to drill the well, the driller would cause the drill string to rotate which would in turn cause the bit to rotate, and hence, drill the well. Over the years, various types of drill strings have been developed in order to drill directional, or inclined, well bores.
Further, different types of bottom hole assemblies have also been developed in order to drill these wells. Thus, a typical directional drill string may contain a bottom hole assembly which includes: a bit, bent sub, drilling motor, and measurement-while-drilling surveying and logging tools. With this type of bottom hole assembly, the drill string ideally is held stationary with respect to down hole rotation. The drilling motor generates rotation of the bit via circulation of the drilling fluid through the drilling motor as is well understood by those of ordinary skill in the art. With the drill string held stationary with respect to rotation, the well is drilled in the desired, controlled direction of the bend in the bent sub.
A common problem with this type of drilling assembly is the torque generated by the bit. The bit torque generates an equal and opposite reactive torque that is transferred from the motor into the bottom hole assembly and drill string, causing it to counter-rotate, relative to the bit. Further, the reactive torque, and hence the drill sting counter-rotation, varies due to drilling conditions, such as the weight applied to the bit, properties of the rock being drilled, and hole condition, which all vary independently of each other. As the bent sub is part of the bottom hole assembly being counter-rotated, the direction in which the well is being drilled changes with the changes in reactive torque.
As a result, the directional driller is required to make numerous surface adjustments of the drill string, and hence the bent sub, to maintain drilling in the desired direction. These numerous adjustments cost valuable rig time and reduce the efficiency of the drilling operation. By eliminating, or greatly reducing, the reactive torque in the bottom hole assembly and drill string, drilling can proceed unabated in the desired direction, saving valuable rig time. Other benefits of eliminating, or reducing, reactive torque include the ability to use more powerful motors and more weight on bit to increase drilling rates and drilling a smoother, less tortuous borehole for running logging tools and setting casing. A non-reactive bit apparatus and method were disclosed in U.S. Pat. No. 5,845,721 entitled “Drilling Device And Method Of Drilling Wells”, which is incorporated herein by express reference.
As those of ordinary skill in the art will appreciate, daily rig cost are substantial. In many cases after a well is drilled, the well is prepared for running and cementing a casing string into the well. Hence, any time saved cleaning, running and cementing the casing converts to significant cost savings. Prior art tools have not allowed an operator to effectively drill with a casing string forming a part of the work string due to structural limitations of the casing string and the casing string thread connections. In other words, the casing strings and casing string connections are not structurally designed to handle the stress and strain applied by the numerous torquing requirements for a drill string. However, with the advent of the non-reactive torque drilling device herein described, drilling with an attached casing string is possible. Numerous advantages and features flow from the non-reactive torque drilling device.
Therefore, there is a need for a drilling device that will allow the drilling of a well with a casing string attached thereto. There is also a need for a non-reactive drilling tool with dual bits, and wherein the casing string is left within the well after cessation of drilling operations. Under this scenario, the casing string can be cemented in place and other remedial well work can be performed, wherein the remedial well work includes perforating the casing in order to produce hydrocarbon from a subterranean reservoir.
SUMMARY OF THE INVENTION
An apparatus for drilling a well bore with a down hole motor is disclosed. The down hole motor contains a power shaft for imparting rotational movement. In one preferred embodiment, the apparatus comprises a driver operatively connected to the power shaft, with the driver having a cylindrical body, and wherein an outer portion of the cylindrical body contains a plurality of cogs. The apparatus further contains a first bit having a first end, and wherein the first end is connected to the driver so that rotational movement of the driver is imparted to the first bit, and a sleeve disposed about a portion of the power shaft, with the sleeve having a plurality of openings therein for placement of a plurality of pinions. The pinions have a pin disposed there through, and wherein the sleeve has a radial shoulder for attaching the plurality of pins. A housing is included, and wherein a second bit is formed on a first end, and wherein the housing has an internal portion that contains internal cogs, and wherein said internal cogs engage said pinions so that as said driver rotates in a first direction, rotation is imparted to said pinions which in turn imparts a counter rotation to said second bit.
In one most preferred embodiment, the driver contains an outer radial surface that is disposed within the sleeve, and wherein the outer radial surface contains an outer coating material for preventing wear with the sleeve during rotation. The apparatus further comprises thrust bearing means, operatively positioned within the housing, for transferring the axial and lateral loads of the apparatus during drilling. The thrust bearing means generally comprises a thrust mandrel disposed between the housing and the driver, and a plurality of roller bearings operatively associated with the thrust mandrel. A trim spacer may also be included, and wherein the trim spacer is disposed within the housing and abutting the thrust mandrel, for engaging with the thrust mandrel. In the most preferred embodiment, the first bit is offset relative to the second bit so that the first bit extends further into the well bore relative to the second bit.
In one embodiment, the sleeve is attached to a coiled tubing string. In another embodiment, the downhole motor and planetary bit driver is attached to a work string. And, in the most preferred embodiment, the sleeve is attached to a casing string.
A method of drilling a well with a motor having a power shaft is also disclosed. The method comprises providing a drilling apparatus, with the drilling apparatus comprising a driver operatively connected to the power shaft, with the driver having a cylindrical body containing a plurality of cogs. The drilling apparatus also includes: a first bit having a first end connected to the driver so that rotational movement of the driver is imparted to the first bit; a sleeve disposed about a portion of the power shaft, with the sleeve having a plurality of openings therein for placement of a plurality of pinions, with the pinions having a pin disposed there through, and wherein the sleeve has a radial shoulder for attaching the plurality of pins. The drilling apparatus further includes a housing having a second bit formed thereon, and wherein the housing has an internal portion that contains a plurality of internal cogs engaging the pinions.
The method further comprises providing a casing string concentrically placed within the well, with the casing string being operatively connected to the sleeve, rotating the power shaft via a fluid flow down an internal portion of the casing string and the drilling apparatus, and rotating the first bit in a first direction. The method further includes drilling the well with the first bit, rotating the cogs on the driver, engaging the pinions with the cogs on the driver, and engaging the internal cogs on the housing. The method then comprises rotating the housing in a counter direction relative to the first bit, rotating the second bit in the counter direction, and drilling the well with the second bit. In one embodiment, the first bit is offset relative to the second bit so that the first bit extends further into the well relative to the second bit.
In the preferred embodiment, the method further includes terminating the flow of the fluid down the internal portion of the casing string and the drilling apparatus, and terminating the drilling of the well with the first bit and the second bit. Next, the internal portion of the drilling apparatus, including the first bit, is retrieved from the well. The casing string can then be cemented in place within the well. The method further includes perforating the casing sting so that the inner portion of the casing string is in communication with a subterranean reservoir.
In yet another preferred embodiment, a device for boring a well is disclosed. In this most preferred embodiment, the device is attached to a motor and wherein the motor has a power shaft for imparting rotational movement. The apparatus comprising a driver mandrel operatively connected to the power shaft, with the driver mandrel containing a cylindrical body. Also included is a first bit member having a first end and a second end, and wherein the first end is connected to the driver mandrel so that rotational movement of the driver mandrel is imparted to the first bit member, and wherein the first bit member has an inner bore. A sleeve is disposed about a portion of the power shaft, and wherein the sleeve has a radial shoulder. In this preferred embodiment, a casing string is attached to the sleeve, and wherein the casing string is designed to be permanently placed within the well once the boring is completed, and wherein the inner bore of the casing string is in fluid communication with the inner bore of the first bit. The device further includes a housing disposed about the driver mandrel, a second bit member attached to the housing, and a planetary gear anchored to the radial shoulder and disposed between the driver mandrel and the housing, and wherein the planetary gear is adapted for imparting rotation from the driver mandrel to the housing in a counter radial direction.
The device may further comprise thrust bearing means, operatively placed between the housing and the driver mandrel, for transferring the axial and lateral loads generated during boring. The thrust bearing means comprises a thrust mandrel and a plurality of ball bearings operatively associated with the thrust mandrel. A bearing assembly may also be included, wherein the bearing assembly having a first end and a second end, with the second end of the motor housing being rotatably associated with the first end of the bearing assembly so that rotation of the first bit member and the second bit member is facilitated. Additionally, the first bit includes a first set of cutter teeth positioned to drill the well in the first rotational direction and the second bit includes a second set of cutter teeth positioned to drill the well in the counter rotational direction. Also, in the most preferred embodiment, the first bit member is offset relative to the second bit member so that the first bit member extends further into the well relative to the second bit member.
ADVANTAGES
An advantage of the present invention is the ability to drill with non-reactive torque utilizing a first bit and a second concentric bit. An advantage of the present system is that wells can be drilled and completed faster. Another advantage is that the work string used with the dual bit is a casing string. Yet another advantage is that the casing string can be left in the hole after the intended total depth of the well is reached.
Still yet another advantage is that after drilling the well, the well can be cemented. By cementing the well quicker than prior art methods, the well will experience less skin damage to potential hydrocarbon bearing reservoirs. Another advantage is that operators will realize significant cost savings due to significantly faster completion times. Another feature is that the drilling apparatus can utilize coiled tubing string as a work string, and wherein drilling is possible utilizing the coiled tubing string due to the non-reactive torque produced by the disclosed drilling apparatus.
A feature of the present invention includes the ability to drill-in with the casing string without the need to pull the entire length of casing string from the well. Yet another feature is that the casing string can be cemented into the well. Yet another feature is the option to perforate the casing string to produce hydrocarbon reservoir. Another feature is that the drill-in casing string can employ the same thread connection means used on commercially available casing strings. In other words, commercially available thread means can be used with the drill-in casing. Yet another feature is the pinions are mounted about pins, and wherein the pins are mounted on a radial shoulder of the sleeve, and therefore, the pinions are capable of rotation. Still yet another feature is that the down hole motors used with the disclosed system are commercially available.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the drilling apparatus of the present disclosure.
FIGS. 2A , 2 B and 2 C are a cross-sectional view of the drilling apparatus of the present disclosure.
FIG. 3 is a cross-sectional view of the drilling apparatus taken from the line 3 - 3 in FIG. 2A .
FIG. 4 is a cross-sectional view of the drilling apparatus taken from the line 4 - 4 in FIG. 2A .
FIG. 5 is a schematic of the drilling apparatus system of the present disclosure disposed within a well.
FIG. 6 is a schematic of the drilling apparatus system cemented within the well with perforations to a hydrocarbon reservoir.
FIG. 7 is a schematic of the drilling apparatus system with the inner bit having been removed.
FIG. 8 is a schematic of the drilling apparatus system drilling a well from a rig.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , a perspective view of the drilling apparatus 2 of the present disclosure will now be described. The power shaft 4 has a first end with external threads 6 and a second end with internal threads 8 . A driver 10 will threadedly connect with the power shaft 4 . The driver 10 has a first end having external threads 12 that will engage with the internal threads 8 and a second end having external threads 14 . As seen in FIG. 1 , driver 10 has a cylindrical body having a plurality of cogs 16 (sometimes referred to as splines 16 ) as well as the raised shoulder 18 . A sleeve 20 is included, and wherein the sleeve 20 has internal thread means 22 on one end and a second end having a plurality of openings, such as seen at 24 . Also, on the radial end, a plurality of indentations have been formed, such as seen at 26 .
FIG. 1 also depicts the pinions 28 , 30 , 32 , and wherein the pins will be disposed therethrough for rotation. Hence, the pin 34 a will be disposed through pinion 32 as well as the bushings 36 , 38 . The pins (for instance pin 34 a ) will cooperate to engage with a radial shoulder located within the openings of the housing 20 . FIG. 1 also illustrates the housing 40 which will have a first end 42 that will abut the ledge 44 of the sleeve 20 . The housing 40 also contains the external threads 46 on the second end.
FIG. 1 also depicts the thrust pack cylindrical assembly 48 which comprises a plurality of ball bearings (not seen in this view), and wherein the thrust pack assembly 48 (the thrust pack assembly 48 is commercially available) will be disposed about the thrust mandrel 50 . As seen in FIG. 1 , the thrust mandrel 50 has a first end having external threads 52 and a second end having a lip 54 . The trim spacer 56 is included, and wherein the trim spacer 56 is a ring member that cooperates with the thrust mandrel 50 as well as the thrust pack 48 , as seen in FIG. 2A . Returning to FIG. 1 , the outer bit 58 is depicted, and wherein the outer bit 58 has a first end having internal threads 60 and a second end that contains the bit face 62 . As seen in FIG. 1 , bit face 62 contains indentations for allowing fluid and debris circulation, as well understood by those of ordinary skill in the art. The cross-over 64 contains a generally cylindrical body having internal threads 66 that will engage with the external threads 14 . The cross-over 64 will also have internal threads 68 . FIG. 1 also depicts the inner bit 70 , and wherein the inner bit 70 has a first end including external threads 72 that will mate with the internal threads 68 . The second end of the inner bit 70 contains the cutting face 74 for boring the well, as understood by those of ordinary skill in the art.
Referring now to FIGS. 2A , 2 B and 2 C, a cross-sectional view of the drilling apparatus 2 of the present disclosure will now be described. It should be noted that like numbers appearing in the various figures refer to like components. The outer bit 58 is disposed about the cross-over 64 , and wherein the inner bit 70 is threadedly connected to the cross-over 64 . The outer bit 58 is threadedly connected to the housing 40 via the external threads 46 and the internal threads 60 . The driver 10 is threadedly connected to the cross-over 64 on one end and the driver 10 is also connected to the power shaft 4 via internal threads 8 and external threads 12 . The sleeve 20 has a radial shoulder 80 within the previously described openings, . . . and wherein the pin 34 a and pin 34 b are connected to the radial shoulders of the openings so that the pins 34 a , 34 b are held in place as the pinions rotate as per the teachings of this description. Additionally, an indented bottom portion 82 of sleeve 20 is included (which includes the indentation 26 seen in FIG. 1 ), with the indented bottom portion 82 being threadedly attached to the thrust mandrel 50 , and wherein the pins 34 a and 34 b are attached to the indented bottom portion 82 in order to fix the pins 34 a and 34 b in place during operation of the down hole motor.
The power shaft 4 is connected to the down hole motor 84 (also referred to as a mud motor). Down hole motors are commercially available from Robbins and Meyers Inc. under the name positive displacement motors. As seen in FIGS. 2A , 2 B and 2 C, the power shaft 4 is connected to the rotor 86 of the motor 84 . The rotor 86 cooperates with a stator of the motor 84 and the fluid flow in order to impart a rotational movement to the power shaft 4 , as understood by those of ordinary skill in the art. As seen specifically in FIG. 2C , the motor 84 is connected to a cross-over 88 , and cross-over 88 is connected to the casing string 90 as per the teachings of this disclosure.
FIG. 3 is a cross-sectional view of the drilling apparatus 2 taken from the line 3 - 3 in FIG. 2A . Hence, FIG. 3 shows the external cogs 16 of the driver 10 . The pinion 32 is shown with the pin 34 a disposed there through; the pinion 30 is shown with the pin 34 b disposed there though; the pinion 91 is shown with the pin 34 c disposed there through; the pinion 92 is shown with the pin 34 d disposed there through; the pinion 94 is shown with the pin 34 e disposed there through; the pinion 96 is shown with the pin 34 f disposed there through. In operation, as the driver 10 rotates (due to its connection to the rotor), which in turn causes the pinions 28 , 30 , 32 , 91 , 92 , 94 and 96 (due to the engagement of the cogs), which in turn imparts a counter rotation movement to the housing 40 via the engagement of the pinion cogs with the internal cogs 98 located on the housing 40 .
Referring now to FIG. 4 , a cross-sectional view of the drilling apparatus 2 taken from the line 4 - 4 in FIG. 2A will now be described. In this view, the end of pins 34 a , 34 b , 34 c , 34 d , 34 e , 34 f are configured to engage with the indented bottom portion 82 of sleeve 20 , and in particular with a slot within the indented bottom portion 82 . A set screw is used to attach the pin ends to the indented bottom portion 82 . More specifically, the set screw 102 is configured to be inserted into the slot 104 , and wherein the end of pin 34 a is engaged with the set screw 102 so that the pin 34 a is attached to the indented bottom portion 82 . The other set screws include 106 , 108 , 110 , 112 , 114 and their engagement with the pin ends are the same as described with reference to set screw 102 .
Referring now to FIG. 5 , a schematic of the drilling apparatus system of the present disclosure disposed within a well 120 will now be described. The down hole motor 84 is threadedly attached to the cross-over sub 88 as previously mentioned. Fluid flow through the inner bore of the casing string 90 , and into the down hole motor 84 (through the rotor-stator), will produce the rotation of the inner bit 70 in a first direction, which in turn will impart a counter rotational movement to the outer bit 58 , and wherein the action of the two bits in counter directions will produce a non-reactive force. As shown, the bits 70 , 58 will be boring through the subterranean reservoirs. Hence, this non-reactive force allows the drilling of the well 120 with the attached casing string 90 , which heretofore has not been possible due to the extreme torque applied to the casing string thread connections during prior art drilling operations.
As those of ordinary skill in the art will appreciate, many times a well progresses in a series of hole sections which are drilled in progressively smaller hole sizes. Casings are run to consolidate the current progress, to protect some zones from contamination as the well progresses (such as freshwater sources) and to give the well the ability to hold higher pressures. FIG. 6 is a schematic of the drilling apparatus system cemented within the well 120 with perforations 122 to a hydrocarbon reservoir 124 . The cement is denoted by the numeral 126 and has been applied using known techniques to the annulus, wherein the annulus is the area between the outer portion of the apparatus 2 and casing 90 and the inner portion of the well 120 .
Referring now to FIG. 7 , a schematic of the drilling apparatus system with the inner bit (bit 70 ) having been removed is shown. In the position seen in FIG. 7 , the casing string has been cemented in place. As per the teachings of the present invention, a second drilling apparatus system may be run into the hole, down the casing string and through the open end so that drilling may continue. This second drilling apparatus system can also have a casing string as the work string. Note that as seen in FIG. 7 , the casing string 90 may be referred to as intermediate casing. In FIG. 8 , a schematic of the drilling apparatus 2 drilling the well 127 from a rig 128 . The rig is positioned on a drilling platform 130 , and wherein the drilling platform 130 is located in water. FIG. 8 shows an intermediate casing string 132 . The work string is the casing string 134 , and wherein the well 127 can be drilled and subsequently cemented in place as per the teachings of this disclosure. It should be noted that a coiled tubing string can be used as the work string i.e. in place of the casing string. Due to the continuous nature of the tubular of the coiled tubing string, having a non-reactive torque system herein disclosed, allows operators the option of drilling wells utilizing coiled tubing as the work string.
Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appended claims and any equivalents thereof. | A device for boring a well with casing. The device is attached to a motor that has a power shaft for imparting rotational movement. The device comprises a driver operatively connected to the power shaft, with the driver containing a cylindrical body, a first bit having a first end connected to the driver so that rotational movement of the driver is imparted to the first bit, and a sleeve disposed about the power shaft, and wherein the sleeve has a radial shoulder. The device further includes casing attached to the sleeve, and wherein the casing is designed to be permanently placed within the well once the boring is completed. The device further comprises a housing disposed about the driver, a second bit attached to the housing, and a planetary gear anchored to the radial shoulder, and wherein the planetary gear is adapted for imparting rotation from the driver to the housing in a counter radial direction. |
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FIELD OF THE INVENTION
[0001] This invention relates to improved methods for subsurface exploration, and more particularly to an automated apparatus and methods for performing the standard penetration test.
BACKGROUND OF THE INVENTION
[0002] The Standard Penetration Test (SPT) is an in-situ testing technique that drives a sampler into the ground at the bottom end of a drill hole (or borehole) during subsurface exploration. The test can yield a measure of the soil resistance to the penetration of the sampler under the impact of a free drop hammer from a constant height.
[0003] There are two operators to conduct the test operations. As shown in FIGS. 1 and 2 , the primary operator uses the power of the drilling rig and the steel wireline above the derrick to lift or drop the hoist hook. The secondary operator couples or decouples the hoist hook either with the top of a drill rod ( FIG. 1 ) or with the steel chain of a impact hammer apparatus ( FIG. 2 ). The impact hammer apparatus includes the steel chain, a X-clamp, the hammer and the guide rod. The guide rod has a lower anvil at its bottom, an upper anvil at its top, and a steel chain. The hammer has a cap for clamping by the X-clamp. The testing at a drill hole depth follows the following three processes in a real time sequence.
[0004] At first, the sampler coupled to a drill rod in series has to be inserted into the drill hole ( FIG. 1 ). The sampler has to reach the bottom of the drill hole. If the length of the drill rod whose bottom end is coupled with the sampler cannot make the sampler tip to reach the bottom of the drill hole, a second drill rod will be added to the top of the first drill rod to make the sampler tip to reach the drill hole bottom. Similarly, a third drill rod will be added and coupled if the sampler tip still cannot reach the drill hole bottom. This adding, coupling and inserting process will be repeated until the sampler tip reaches the drill hole bottom. This process is the first process of sampler inserting.
[0005] Next, once the sampler is placed at the test depth, the impact hammer apparatus will be added to the top of the coupled drill rods and the sampler system. The hammer impact apparatus will be used to make the sampler penetrate into the ground at the drill hole bottom ( FIG. 2 ). The hoist hook will lift the X-clamp upward through the steel chain. The X-clamp will clamp the hammer cap and carry the hammer upward along the guide rod. Once the X-clamp impacts the upper anvil, the clamping at the hammer cap will be forced to open and release the hammer automatically. The hammer will drop freely along the guide rod. The flat bottom surface of the hammer will hit the lower anvil at its flat top surface. The lower anvil bottom is coupled to the drill rods. The induced shock force in the drill rods will make the sampler penetrate into the ground below the drill hole bottom. Once the hammer becomes stable on the lower anvil, the primary operator will drop the hoist hook to make the X-clamp drop onto the hammer cap along the guide rod. Then the operator will tighten the steel chain to make the X-clamp couple the hammer cap again. The operator will then lift the hammer quickly. Again, the hammer will drop freely once the X-clamp impacts the upper anvil. The hammer will hit the lower anvil to make the sampler to penetrate the soil again. The above operation process will be repeated several times until a test criterion is satisfied. This process is the second process of hammer impact and sampler penetrating.
[0006] Third, once the penetrating stage is completed, the operators will remove the hammer impact apparatus from the drill rods. The operators will then retrieve the drill rods from the drill hole one by one ( FIG. 1 ). The drill rods and the sampler will be lifted up. The top drill rod will then be decoupled from the remaining drill rods in the drill hole, and it will be placed on the ground nearby. Then the remaining drill rods will be removed from the drill hole. The second top drill rod will be decoupled and placed on the ground nearby. This lifting, decoupling and placing process will be repeated until the first drill rod with the sampler is retrieved from the drill hole. This process is the third process of sampler retrieving. Further drilling work will be then carried out until the bottom end of the drill hole reaches the subsequent test depth. Then the subsequent test will be conducted following the above three processes.
[0007] The hammer is made of steel and weighs 63.5 kg. The free drop height is 760 mm. The blow counts of the hammer falling on the anvil are recorded for each of 75 mm penetration between 0 and 450 mm penetrations. The first 150 mm penetration is regarded as a seating drive. The number of blows necessary to drive the sampler to penetrate 300 mm into the ground is known as the penetration resistance or N-value. A specification on how to determine the N-value is normally adopted by authorities for determining the soil shear strength and bearing capacity. A hammer efficiency can be further defined as the percentage ratio of a rod dynamic energy over the total potential energy of the hammer drop height (473 Joule). The rod dynamic energy is calculated from the axial shock force in the drill rod generated by the hammer blowing according to a specific equation such as the equation in ASTM (1995).
[0008] The SPT has been widely used and is a tool of choice in Hong Kong housing and infrastructure development as well as landslip preventive measures project. The SPT is included for most ground investigation contracts. The SPT has the following advantages: a) the test apparatus is simple and rugged; b) the test can be carried out in many different types of soils; c) the test has been widely adopted as a routine in-situ testing method throughout the world; and d) tremendous experience and empirical correlations have been obtained for geotechnical design and construction.
[0009] The SPT results, and more particularly the N-value and the test depth, however, have been obtained completely from manual measurements. Usually, two contractors conduct the manual measurements. For most tests, there is no full-time independent supervision or inspection. Furthermore, the testing and the drilling are destructive, non-repeatable and time consuming. More importantly, the test is often carried out in colluvium and weathered rock soils in Hong Kong. Gravel, cobbles, and boulders of high strengths and stiffness can appear randomly in the soil. They can substantially alternate the N-values. As a result, the N-values at a construction site can have a large range of variations in Hong Kong.
[0010] Therefore, the accuracy and quality of the manual test results have always been the main concern of many geotechnical engineers and contractors in Hong Kong. At present, there is no tool independently to check and verify the accuracy and quality of the manual test results. Therefore, it is believed that automation of the measurement monitoring and recording for SPT can solve the pressing issues and offer additional data for independently checking and verification of the manual test results.
SUMMARY OF THE INVENTION
[0011] The field observation and issue of the manual operations and measurements of the conventional standard penetration test have led to the present invention for automation of the test measurements. The inserting process, the impact hammer and sampler penetrating process, and retrieval process are carried out sequentially in time sequence. A first object of the present invention is to provide an automatic digital SPT monitor for recording and evaluating the inserting process of the rods and sampler into a drill hole in real time, which enables the assessment and verification of the test depth and its commencement time. A second object of the present invention is to provide an automatic digital SPT monitor for recording and evaluating the impact hammer and sampler penetration process in real time, which is able to assess the soil resistance and more particularly the N-value and the associated hammer efficiency in accordance with a specification [in the present configuration, the specification is the Hong Kong Housing Authority specification]. A third object of the present invention is to provide an automatic digital SPT monitor for recording and evaluating the retrieval process of the rods and sampler from a drill hole in real time, which enables the assessment and verification of the test depth and its completion time.
[0012] In order to accomplish the foregoing objects, the present invention provides an in situ digital SPT monitor for the standard penetration tests in association with an existing SPT apparatus and operation procedures. The digital SPT monitor comprises a tip depth transducer, a shock force transducer, a shock penetration transducer, and a micro-process controller for data acquisition and processing. The micro-process controller comprises a notebook computer, a data logger, and a battery. The data logger connects with the tip depth transducer, the shock force transducer and the shock penetration transducer with a first signal cable, a second signal cable and a third signal cable for transmission of a first electrical signal, a second electrical signal and a third electrical signal, respectively. The first and third electrical signals are digital signals. The second electrical signal is an analog signal.
[0013] Immediately before the commencement of the insertion process, the tip depth transducer is mounted onto the top of a drill hole casing and unlocked. The tip depth transducer senses the vertical movement (or non-movement) of the sampler and each of the coupled drill rods with respect to a fixed position (i.e., the casing) on the ground during the insertion process, and transmits the first electrical signal into the micro-process controller for storage and display at a first pre-selected sampling rate in real time. At the completion of the insertion process, the tip depth transducer is locked and dismounted from the casing and placed on the ground nearby. The lock makes the first electrical signal have no change with time.
[0014] Subsequently, the impact hammer apparatus together with the shock force transducer and the shock penetration transducer are mounted onto the top of the drill rod in series for the second process of impact hammer and sampler penetration. The shock force transducer senses the axial force in the rod and the shock penetration transducer senses the rod displacement with respect to a fixed position on the ground. They transmit the second and the third electrical signals to the micro-processor controller with the second and the third electric cables simultaneously and in real time. A triggering method is adopted for data acquisition and storage for a pre-selected duration of time in the micro-processor controller at a second pre-selected sampling rate. The criterion for triggering is that the shock force is equal or greater than a pre-selected magnitude in compression. The pre-selected interval of data acquisition is less than the time interval for hammer lifting and drop and is greater than the time interval for hammer rebound. At the same time, the micro-process controller counts and records one hammer blow. This auto-monitoring and data acquisition process is repeated for each hammer blow until the micro-processor controller finds that the test has reached one of the predetermined criteria for the N-value. At this moment, the computer of the micro-process controller alerts the operators. After the completion of the second process, the impact hammer apparatus, the shock force transducer, and the shock penetration transducer are removed from the drill rod.
[0015] At the beginning of the retrieval process, the tip depth transducer is re-mounted onto the casing and unlocked. The tip depth transducer senses the vertical movement or non-movement of the sampler and each of the coupled drill rods with respect to a fixed position (i.e., the casing) on the ground during the retrieval process and continues the transmission of the first electrical signal into the micro-process controller for storage and display at the first pre-selected sampling rate in real time. At the completion of the retrieval process, the tip depth transducer is again locked and dismounted from the casing and placed on the ground nearby.
[0016] In the present configuration, the pre-selected first sampling rate is 100 Hz for the first electrical signal and 50 kHz for the second and third electrical signals; the pre-selected magnitude of the triggering axial force is 50 kN; and the pre-selected duration of data acquisition for the second and third electrical signals is one second.
[0017] The present invention is portable and is applicable to any existing SPT apparatus. It monitors the three testing processes in real time. It further evaluates the SPT measurements and reports a summary of the test results from the monitored digital data in real time sequence. It is applicable to various ground conditions including extreme hard (N>200), normal (1<N<200) and extreme soft (e.g., N<1) ground conditions at any test depths.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The foregoing and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0019] FIG. 1 is a prior art manual apparatus for the first process of inserting (or the third process of retrieving) a sample coupled with drill rods in series into and from a drill hole for SPT at a given test depth at field;
[0020] FIG. 2 is a prior art apparatus for hammer and sampler penetrating at the bottom of a drill hole to determine the soil N value at field;
[0021] FIG. 3 is a general schematic view of the measurement, automation, and recording of the first process of the sampler insertion or the third process of the sample retrieval of the prevent invention;
[0022] FIG. 4 is a general schematic view of the measurement, automation, and recording apparatus of the second process of the impact hammer and sample penetration in accordance with the present invention;
[0023] FIG. 5 is a detailed schematic view of the present invention for measurement, automation, and recording of the first process of the sampler insertion or the third process of the sample retrieval;
[0024] FIG. 6 is a detailed schematic view of the tip depth transducer of the present invention;
[0025] FIG. 7 is an example of actual measurement results of the present invention from the tip depth transducer for the first process of sample insertion and the third process of sample retrieval in real time series;
[0026] FIG. 8 is a detailed schematic view of the present invention for the measurement, automation, and recording of the second process of the impact hammer and sample penetration;
[0027] FIG. 9 is the axial shock force measurement with the shock force transducer in the drill rod for one second due to the impact of hammer drop at field;
[0028] FIG. 10 is a detailed view of the result of the shock force in FIG. 9 during its initial 0.05 second duration;
[0029] FIG. 11 is a detailed schematic view of the shock penetration transducer of the present invention;
[0030] FIG. 12 is a detailed schematic view of the gear box on the rack and along the two guide rods of the shock penetration transducer of the present invention;
[0031] FIG. 13 is a graph of the shock penetration transducer for the change of the gear box position on the rack with the time simultaneous to that for the shock force in FIG.9 ;
[0032] FIG. 14 is a detailed view of the typical result of the shock penetration transducer in FIG. 13 during its initial 0.05 second duration; and
[0033] FIG. 15 is a summary report for the measurement automation of the second process of hammer blow and sample penetration at the test depth showing in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The present invention will be described in further detail by way of example with reference to the accompanying drawings. As shown in FIGS. 3 to 8 , a digital SPT monitor 10 for measurement automation of standard penetration test according to the present invention comprises a micro-process controller 30 , a tip depth transducer 40 , a shock force transducer 60 , and a shock penetration transducer 70 . The micro-process controller 30 comprises a data logger 32 , a battery 33 , and a notebook computer 31 . The data logger 32 uses a power supply cable 34 to attach the battery 33 and uses a firewall cable 35 to communicate with the computer 31 . The battery 33 is used to supply the small amount of power required for the data logger 32 and the notebook computer 31 . The micro-process controller 30 further uses the first signal cable 36 to communicate with the tip depth transducer 40 , the second signal cable 37 to communicate with the shock force transducer 50 , and the third signal cable 38 with the shock penetration transducer 60 .
[0035] Referring to FIGS. 5 and 6 , the tip depth transducer 40 has the following components: a first circular wheel 41 with a first rotation sensor 42 and a lock, a second circular wheel 41 and a third circular wheel 44 , a hollow cylinder 43 , a footing plate 44 with a circular hole at the center, four screw blots 45 , four columns 46 , an inner cylinder 47 , a podium plate 48 with a circular hole, two springs 49 , and a travel shaft 50 . The first wheel 41 , the second wheel 41 and the third wheel 44 are vertically placed above the podium plate 48 and surround a common center at a spacing of 120° on horizontal plane. The footing of the travel shaft 50 is also welded on the podium plate 48 . The podium plate 48 has its bottom surface welded with the hollow cylinder 43 below. The hollow cylinder 43 has its base welded with the footing plate 44 . The footing plate 44 is welded above and with the inner cylinder 47 and the four columns 46 . The diameters of the circular holes in the podium plate and the footing plate are larger than the diameters of the drill rod 22 and sampler. The inner diameter of the hollow cylinder 43 is larger than the diameter of the casing. The inner diameter of the inner cylinder 47 is larger than the diameters of the drill rod and sampler and less than the diameter of the casing.
[0036] The tip depth transducer 40 uses the footing plate 44 to seat on the casing and the four screw bolts 45 to clamp the four columns onto the casing. Therefore, the tip depth transducer 40 can be firmly mounted onto or completely removed from the top of a casing in a drill hole. The coupled sampler and drill rods can be inserted into or retrieved from the tip depth transducer 40 as shown in FIGS. 5 and 6 . In the present configuration, the casing is used to support the tip depth transducer. Other means to support the tip depth transducer 40 can also be developed.
[0037] During insertion or retrieval, the sampler or a drill rod 22 frictionally contacts with the three wheels and causes them to rotate about their rotational axes. The rotational axis of the first wheel 42 is bolted to the travel shaft 50 . The first wheel 42 and the travel shaft 50 together can move horizontally above the podium plate. The two springs 49 urge the travel shaft and the first wheel against the drill rod 22 or the sample. When it is switched off, the lock stops the rotation of the first wheel 42 about its axis. When it is switched on, the first wheel can freely rotate about its axis.
[0038] The first electrical signal measures the degree of the rotation of the first wheel 42 about its axis. The first rotation sensor 42 captures the first electrical signal and transfers it into the micro-process controller through the first signal cable 36 in real time at a first pre-selected sampling frequency. The micro-process controller 30 further changes the first electrical signal into the amount of the length of the sampler coupled with the rods passing through the first wheel position in real time and displays it on the screen of the notebook.
[0039] FIG. 7 shows the first graph for an actual result of the present invention from the first digital signal, where the first pre-selected sampling frequency was 100 Hz. The first graph represents the first process of sampler inserting and the third process of sampler retrieving. The test was carried out between 15:14 and 15:29 in the afternoon of Jun. 29, 2005. The first process was between 15:14 and 15:17. Its graph has a down-staircase shape with the actual time, representing that four rods were being coupled with the sampler for inserting the sampler into the drill hole one by one. The total length of the four rods and the sampler inserting through the tip depth transducer was 10.625 m. Between 15:17 and 15:25, the graph is a horizontal line, representing that the first electrical signal had no change during the second process, when the first wheel of the tip depth transducer was locked. The third process was between 15:25 and 15:29. Its graph has an up-staircase shape with the actual time, representing that the four rods and the sampler were being lifted up and decoupled out of the drill hole one by one. The total length of the four rods and the sampler lifting up through the tip depth transducer was 11.033 m.
[0040] Referring to FIGS. 4 and 8 , the shock force transducer 60 is connected to the lower anvil 28 with the upper coupling 52 and the drill rod 22 with the lower coupling 52 at the bearing arm 81 . The shock force transducer 60 captures the second electrical signal and transfers it into the micro-process controller through the second signal cable 37 in real time at a second pre-selected sampling frequency. The second electrical signal is a voltage output. The micro-process controller 30 further changes the second electrical signal into the amount of the axial force due to the hammer impact in the drill rod 22 and displays it on the screen of the personal computer 31 in real time.
[0041] FIG. 9 shows the second graph for an actual result of the present invention from the second digital signal, where the second pre-selected sampling frequency was 50 kHz and the total sampling period was one second. The second graph represents the time variation of the shock force in the drill rod immediately after the hammer impact on the lower anvil. A third graph in FIG. 10 details the axial shock force within the first 0.05 second of the second graph in FIG. 9 . From the second and third graphs in FIGS. 9 and 10 , the following observations can be made: (a) the axial shock force increased quickly at the beginning and reached its maximum at a time less than 0.001 second; (b) the axial shock force vanished to zero at about 0.05 second; and (c) the axial shock force had the maximum value about 230 kN.
[0042] Referring to FIGS. 8, 11 and 12 , the shock penetration transducer 70 has the following main components: a right triangle steel frame 71 with four pulleys 72 , 73 , 74 , and 75 , a steel wire loop 76 , a gear box with a second rotation sensor 77 , an inclined rack 78 , two inclined guide rods 79 , a bearing arm 80 and other accessories. During monitoring, the shock penetration transducer 60 is coupled to the drill rod 22 with the bearing portion of the bearing arm 81 , as shown in FIGS. 8 and 11 . The shock penetration transducer 60 rests on a supporting beam 82 clamped on the two sleepers of the drilling rig, as shown in FIG. 4 .
[0043] The bearing arm 81 is tied to the steel loop wire 76 with a bolt 80 and transfers the rod's longitudinal movement to the steel loop wire 76 . The steel loop wire 76 is supported by the first pulley 72 , the second pulley 73 , the third pulley 74 and the fourth pulley 75 , and can smoothly slide on the four pulleys. The four pulleys are supported by the right triangle steel frame 71 . The steel loop wire 76 is also connected with the gear box 77 on the inclined rack 78 . The gear of the gear box 72 matches the rack gear. The two steel guide rods 79 guide the upward or downward movement of the gear box 77 on the rack 78 . The rack 78 and the two steel guide rods 79 are fixed with the right triangle steel frame 71 .
[0044] As it moves between the first pulley 72 and the fourth pulley 75 , the bearing arm 81 uses the steel loop wire 76 to bring the gear box 77 to slide correspondingly on the rack between the second pulley 73 and the third pulley 74 . The upper portion of the steel loop wire 76 on the first 72 and second 73 pulleys between the bearing arm 81 and the gear box 77 is always straight and in tension because it prevents the gear box 77 from sliding down on the rack 78 due to the weight of the gear box 77 . The gear box 77 typically weighs one to two kilograms. The lower portion of the steel loop wire 76 on the third pulley 74 and the fourth pulley 75 and between the gear box 77 and the bearing arm 81 is used to quickly damp and eliminate the free vibration of the gear box 77 on the rack 78 from the impact of the hammer.
[0045] The second rotation sensor associated with the gear box 77 obtains the third electrical signal and transfers it into the micro-process controller 30 through the third signal cable 38 in real time at the second pre-selected sampling frequency. The third electrical signal is the degree of the rotation of the gear of the gear box 77 on the rack 78 . The micro-process controller 30 further changes the third electrical signal into the position of the gear box on the rack and displays it on the screen of the notebook in real time. The gear box upward movement at its stable condition is equal to the permanent penetration of the sampler due to one blow from a hammer drop.
[0046] FIG. 13 shows the fourth graph for a typical result of the present invention from the third digital signal, where the second pre-selected sampling frequency was 50 kHz and the total sampling period was one second. This fourth graph represents the time variation of the gear box position on the rack immediately after the hammer blow onto the lower anvil. A fifth graph in FIG. 14 details the gear box position within the first 0.05 second of the fourth graph in FIG. 13 . From the fourth graph in FIG. 13 and the fifth graph in FIG. 14 , the following observations can be made: (i) the change of the gear box position due to the hammer blow vanished within 0.2 second; (ii) initially, the gear box monotonically moved upward to a maximum at a time between 0.045 and 0.005 second; (iii) subsequently, the gear box had its first downward movement; (iv) then, the gear box experienced small vibrations with magnitude less than 2 mm; and (v) after about 0.2 second, the gear box position had no change with time and stayed at a position 22 mm above the initial position.
[0047] The time in the second graph in FIG. 9 was exactly the same at that in the fourth graph in FIG. 13 . The time in the third graph in FIG. 10 was exactly the same at that in the fifth graph in FIG. 14 . The micro-process controller 30 collected the second and third electrical signals simultaneously at the second pre-selected time-sampling frequency in real-time sequence. The micro-process controller 30 also recorded the actual commencement time (i.e., the time 0) of the graphs in FIGS. 9, 10 , 13 and 14 in the form of year, date, hours, minutes and seconds, which are omitted in these figures.
[0048] Furthermore, the micro-process controller 30 of the present invention has a triggering mechanism for data acquisition and storage of the second and third electrical signals in real time. The criterion for the triggering mechanism is that the shock force from the shock force transducer 60 is equal or greater than a pre-selected magnitude in compression (50 kN at the present configuration). Once the shock force reaches a pre-selected or predetermined the criterion, the micro-process controller 30 acquires, stores and displays the second and third signals at the second pre-selected sampling frequency (50 kN at the present configuration) for a pre-selected period of time (one second at the present configuration). At the same time, the micro-process controller 30 records one hammer blow and the actual commencement time of the data acquisition, and checks the accumulated permanent penetration and the accumulated hammer blow number with the predetermined specification for alerting the completion of the testing. This automonitoring and data acquisition process is repeated for each hammer blow until the micro-process controller 30 finds that the test has reached the pre-determined specification. At this point, the micro-process controller 30 alerts the operators of the completion of the testing.
[0049] FIG. 15 shows a summary report of the present invention for the measurement automation of the second process of hammer blows and sampler penetration at the test depth showing in FIG. 7 . The micro-process controller 30 produced and displayed this summary report once the test was completed. In FIG. 15 , the actual date, the beginning and the ending time for the second process of the testing are reported. The numbers of the hammer blow for the 150 mm seating drive and each of the subsequent 75 mm main drives are shown in the table. The N value, the total blows and the total penetration depth are listed.
[0050] FIG. 15 also shows the sixth graph, the seventh graph and the eighth graph. The results shown in the sixth graph and the seventh graph were acquired simultaneously from the second electrical signal and the third electrical signal, respectively. The micro-process controller 30 was triggered 27 times for the data acquisition and evaluation at this test depth. Each triggering represents a hammer blow on the lower anvil in FIG. 4 . The total time for the data acquisition is 27 seconds, which is the abscissa of the sixth and seventh graphs. Accordingly, there were 27 hammer blows in total in FIG. 15 .
[0051] The actual commencement time of each of the one second sampling period was recorded but not shown in the sixth and seventh graphs. The portion of the sixth graph in FIG. 15 between any two nearby integers of the time seconds (say, [0,1], [1,2], . . . , [26,27]) represents the time variation of the axial shock force during the pre-selected sampling period of one second for each of the 27 hammer blows. Similarly, the portion of the seventh graph in FIG. 15 between any two nearby integers of the time seconds (say, [0,1], [1,2], . . . , [26,27]) represents the corresponding time variation of the gear box position during the pre-selected sampling period of one second for each of the 27 hammer blows. The time variation of the axial shock force during each of the 27 one-second data acquisition periods can be presented as those shown in the second and third graphs in FIGS. 9 and 10 . The time variation of the corresponding gear box position during each of the 27 one second data acquisition periods can also be presented as those shown in the fourth and fifth graphs in FIGS. 13 and 14 , respectively. All those graphs can be produced in the micro-process controller.
[0052] The micro-process controller also calculated the energy efficiency (%) from the acquired shock force in the sixth graph for each hammer blow, presented it in the eighth graph with respect to its corresponding blow number and displayed on the computer screen.
REFERENCES
[0000]
The following references are incorporated by reference as illustrative of the state of the art.
1. ASTM, 1995. Soil and Rock (1), Vol. 04.08: Standard Test Method for Penetration Test and Split - Barrel Sampling of Soils , D 1586-84, 1916 Race Street, Philadelphia, U.S.A., 129-133
2. ASTM, 1995. Soil and Rock (1), Vol. 04.08: Standard Test Method for Stress Wave Energy Measurement for Dynamic Penetrometer Testing Systems , D 4633-86, 1916 Race Street, Philadelphia, U.S.A., 775-778.
3. GEO, 1996. Section 21.2 Standard Penetration Test, in Guide to Site Investigation, Geoguide 2, Geotechnical Engineering Office (GEO) Civil Engineering Department, Hong Kong, pp. 111-113.
4. HKHA, 2003. HKHA General Specifications for Ground Investigation Contracts, 2003 Edition ( Revision A ), Hong Kong Housing Authority (HKHA), Hong Kong. p. 2.
5. Yue, Z. Q., Lee, C. F., Law, K. T. and Tham, L. G., 2004. Automatic monitoring of rotary-percussive drilling for ground characterization—illustrated by a case example in Hong Kong, International Joumal of Rock Mechanics & Mining Science, 41: 573-612.
6. U.S. Pat. No. 6,637,523 B2 (Lee) | An apparatus is used with an impact hammer penetration assemble such as standard penetration test (SPT) in geotechnical engineering. The impact hammer penetration assembly comprises a penetration sample, a series of rods coupled together and an impact hammer apparatus. The drop of the hammer from a constant height hits the coupled rods and sampler in series and forces the sampler deeper into the ground. The apparatus includes a tip depth transducer and sampler to output a first electrical signal that is a function of the sampler tip position. A shock force transducer communicates the axial shock force in the rod to output a second electrical signal that is a function of the rod shock force and hammer blows. A shock penetration transducer communicates the movement of the coupled rods and sampler to output a third electrical signal that is a function of the sampler penetration due to the hammer blows. A micro-process controller monitors and processes the first, second and third signals in real time. |
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BACKGROUND OF THE INVENTION
1. Field Of The Invention
This invention relates to systems for obtaining access to the annulus between a well bore and a drill string herein, and particularly to a system with a plurality of valves installed in, and forming a part of, the drill string including the drill collar, whereby fluid may be pumped into the annulus as desired and which is useful for such purposes as controlling a high pressure area in the well bore resulting from the entry of high pressure formation fluid, such as a liquid or gas, into the well, a situation commonly referred to as a "kick". The valve configuration is designed for use in the drill string, but is not limited to such usage.
2. Description Of The Prior Art
Most previous downhole valves relate to cementing procedures and are not part of the drill string. An example is the apparatus of Burt, U.S. Pat. No. 2,380,022. In Burt, a plurality of valves are mounted in a conduit string such as casing or production tubing. A single manipulative device is utilized for controlling said valves. Another valve assembly usable for cementing purposes is that of Pitts, U.S. Pat. No. 3,848,670 which also utilizes a sliding valve. Still another cementing apparatus installed in the casing is shown in U.S. Pat. No. 2,249,511 to Westall.
U.S. Pat. No. 2,855,952 to Tausch et al. discloses a valve used for well stimulation and workover operations. Tausch et al. has a sliding valve member which is returned to its original position by a spring, but has a totally different opening arrangement from the valve system of the present invention.
The valve of Middleton et al., U.S. Pat. No. 2,723,677, is installed in a well string, unlike the drill string installation of the present invention, and is used for control of fluids through the well string.
SUMMARY OF THE INVENTION
The present invention is a system for providing access to the annulus between a well bore and a drill string therein whereby fluid may be pumped into the annulus as desired. The system includes a plurality of valves spaced along the drill string including the drill collar, forming a portion thereof, with each of the valve providing means for access to the annulus by fluids pumped down a central opening of the drill string. The system also includes means for actuating the valves either individually or in combination.
Each valve includes a valve body which is connected to the drill string and which has a longitudinal opening therethrough with at least one transverse port interconnecting the longitudinal opening and the annulus. A longitudinally slidable valve sleeve is positioned in the valve body and has a conical upper surface thereon. A replaceable seat is threaded into the valve body in a position above the valve sleeve and has a conical surface at the lower end thereof which conforms to the conical surface of the valve sleeve to sealingly close the transverse port when the valve sleeve is in a closed position. Packing is used to seal between the valve sleeve and an inner surface of the valve body.
Positioned below the valve sleeve is a valve plunger held in contact with the valve sleeve by a spring. The spring biases the plunger and sleeve upwardly toward a closed position of the valve sleeve.
An actuator is used to move the valve sleeve from its closed position to an open position so that fluid may be pumped downwardly through the central opening of the drill string and through the transverse port of the valve into the annulus. The actuator seats on the valve sleeve and forces it downwardly to an open position by hydraulic pressure. A plurality of actuators are used in the system, each actuator uniquely sized so that it will actuate a single valve in the drill string. The minimum central opening of each valve is progressively smaller from the uppermost valve to the lowermost. The actuator for a specific valve will pass through each valve in the drill string above the specific valve, but will engage the valve sleeve of the specific valve so that the valve will be opened.
Each actuator has an actuator body and an actuator cap defining a cavity therein in which is positioned a flow control valve. When the flow control valve is in a closed position, no fluid will be pumped below the actuator when it engages its corresponding valve, thus directing all fluid out the transverse port in the valve. When the flow control valve is in a variably open position, some fluid will be directed through a longitudinal passage in the actuator.
While the valve and actuator are disclosed herein for usage in a drill string, the configuration of the valve and actuator is adaptable to other usages, such as in the well production string.
The annulus access valve system of the present invention is ideally suited for preventing blowouts when there has been an entry of high pressure formation fluids into the well bore. The operator may open the desired valve in the drill string and pump an appropriate drilling fluid through the valve to contain the high pressure fluid. The high pressure fluid may then be circulated out of the well by conventional methods.
An important object of the invention is to provide a system for providing access to the annulus between a well bore and a drill string therein at selected depths along the drill string.
Another object of the invention is to provide a plurality of valves spaced along a drill string such that the valves are openable individually or in combination so that appropriate fluids may be pumped therethrough into the annulus.
A further object of the invention is to provide a valve which may be installed in a drill string and which has a longitudinally slidable valve sleeve for opeing and closing a transverse port therethrough.
Still another object of the invention is to provide a plurality of unique actuators for opening specific valves spaced along a drill string.
An additional object of the invention is to provide a method of quickly preventing blowouts in wells without removing or damaging the drill string therein.
Additional objects and advantages of the invention will become apparent as the following detailed description of the preferred embodiment is read in conjunction with the accompanying drawings which illustrate such preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the annulus access valve system of the present invention having a valve, shown in a closed position, forming a part of the drill string with an actuator for opening the valve.
FIG. 2 illustrates the apparatus in which the actuator has engaged the valve and moved it to an open position.
FIG. 3 shows the valve system in place in a drill string positioned in a well bore where a kick and packoff have occurred.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIG. 1, the annulus access valve system of the present invention is shown in an open position and has a valve generally designated by the numeral 10 and an actuator generally designated by the numeral 12.
Valve 10 of the apparatus includes a valve body 14 having a central longitudinal opening 16 therethrough. Upper end 18 of valve body 14 is threadingly engaged to an upper portion 20 of the drill string in a manner known in the art. Similarly, a lower end 22 of valve body 14 is threadingly engaged with a lower portion 24 of the drill string.
Upper end 18 of valve body 14 defines an inner cylindrical surface 26. A straight, internal thread 28 is located immediately below cylindrical surface 26 and defines a diameter substantially less than that of cylindrical surface 26. A substantially cylindrical seal bore 30, having a diameter less than that of threaded surface 28, is disposed below the threaded surface. An inwardly extending shoulder 32, defining an inner cylindrical surface 34 and having an inner chamfer 35 on an upper surface thereof, separates seal surface 30 from another substantially cylindrical surface 36.
Replaceable seat 38, having a threaded outer surface, is threadingly engaged with threaded surface 28 of valve body 14. Seat 38 defines an inner cylindrical surface 40 at an upper end thereof and a conical surface 42 extending outwardly from cylindrical surface 40. In cross section, conical surface 42 preferably defines an acute angle from a longitudinal axis of valve body 14, but is not limited to such construction. Seat 38 further defines an outer recess 44 therearound. A plurality of transversely disposed holes 46 extend from conical surface 42 to outer recess 44.
A transverse hole 48 in valve body 14 extends radially outwardly from threaded surface 28 in alignment with recess 44 of seat 38. A counterbore 50, substantially concentric with transverse hole 48, is also located in valve body 14. Extending from counterbore 50 is an angularly disposed hole 52. An orifice 54 of a kind commonly known in the art is positioned in counterbore 50 adjacent transverse hole 48. A holddown cage 56 bears against orifice 54 and is held in place by threaded plug 58. Holddown cage 56 has a plurality of holes 60 therethrough such that at least one hole 60 is always in substantial alignment with angular hole 52 in valve body 14. Thus, holes 46, recess 44, hole 48, orifice 54, cage 56 and hole 52 define a substantially transverse port in valve 10 which provides communication between longitudinal opening 16 and annulus 62 formed between valve body 14 and well bore 64.
A valve sleeve 66 is longitudinally slidably received in seal surface 30 of valve body 14. Valve sleeve 66 has a conical, upper outer surface 68 which is dimensioned to conform to conical surface 42 of seal 38 and to sealingly close transverse holes 46 when valve sleeve 66 is in a closed position as shown in FIG. 1. Thus, seat 38 provides a seating means against which valve sleeve 66 seats and seals. Valve sleeve 66 also defines a central bore 70 therethrough with an inwardly chamfered surface 72. Further, valve sleeve 66 has an outwardly chamfered lower end 73. Outer surface 74 of valve sleeve 66 is dimensioned to be in close spaced relationship with seal surface 30 of valve body 14. Outer surface 74 has an annular recess 76 therein. Packing 78 of a kind known in the art is disposed in annular recess 76 for sealing between the recess and seal surface 30.
In one embodiment, a retainer ring groove 80 extends outwardly from cylindrical surface 36 adjacent lower end 22 of valve body 14, and a retainer ring 82 is positioned in the retainer ring groove. Located on retainer ring 82 is a spring seat 84. The apparatus is not limited to such construction; for example, retainer ring 82 and spring seat 84 could be replaced by a shoulder extending inwardly from cylindrical surface 36.
Positioned immediately below valve sleeve 66 in longitudinal opening 16 is a valve plunger 86 held in contact with the valve sleeve by a spring 88. Spring 88 bears against an upper surface 90 of spring seat 84 and against a lower surface 92 of an outwardly extending shoulder 94 of valve plunger 86. Spring 88 is always in compression such that valve plunger 86 is upwardly biased which in turn upwardly biases valve sleeve 66 toward its closed position. Cylindrical outer surface 96 of valve plunger 86 is dimensioned to be longitudinally slidingly received in cylindrical surface 34 of shoulder 32. Shoulder 94 of valve plunger 86 is positioned below shoulder 32. Valve sleeve 66 and valve plunger 86 are dimensioned such that shoulder 94 of the plunger never contacts the lower surface of shoulder 32 of valve body 14.
Actuator 12 of the present invention includes an actuator body 98 and an actuator cap 100 threadingly engaged thereto as indicated by reference number 102. Actuator body 98 defines a counterbored inner surface 104 and actuator cap 100 defines counterbored inner surface 106, such that the assembly of the actuator body and cap defines a cavity 108 therein.
At the lower end of cavity 108 is a small counterbore 110 in actuator body 98. An orifice seat 112 having a central opening 114 therethrough is disposed in counterbore 110 and held in place by retainer ring 116. Orifice 112 is positioned such that central opening 114 therein is aligned with a central longitudinal opening 118 in actuator body 98.
Actuator cap 100 has a central longitudinal opening 120 therein at an upper end thereof. A control rod 122 has an intermediate portion 124 disposed through opening 120 and a lower threaded portion 126. A flange 128 extends outwardly from intermediate portion 124 of control rod 122 above upper surface 130 of actuator cap 100, and flange 128 is dimensioned such that it cannot pass through opening 120. Control rod 122 has an upper portion 132 which forms a conventional fishing neck as commonly known in the art. Threaded portion 126 of control rod 122 is threadingly engaged with a threaded central opening 134 of adjusting nut 136 at an upper end thereof. A flow control valve 138 has a threaded upper end 140 threadingly engaged to a lower end of adjusting nut 136. Lock nut 141 holds flow control valve 138 in the desired position. Flow control valve 138 has a tapered lower end 142 which is dimensioned to seat in orifice seat 112 for sealing central opening 114 when the flow control valve is in a closed position.
Actuator cap 100 has a plurality of angularly disposed holes 144 through an upper end thereof in communication with cavity 108. Thus, it can be seen that angular holes 144 are placed in communication with central longitudinal opening 118 of actuator body 98 when flow control valve 138 is in an open position wherein its lower portion 142 is not seated on orifice seat 112. It will be seen that this open position is variable depending on the threaded position of control rod 122 and flow control valve 138 in adjusting nut 136.
As viewed in FIG. 1, valve sleeve 66 of valve 10 is in a closed position sealing transverse ports 46 in seat 38 from longitudinal opening 16. It will be obvious to those skilled in the art that when valve sleeve 66 is in this closed position, the exposed upper area of the top of the valve sleeve, essentially the exposed area of chamfered surface 72, is less than that of the exposed lower area. Thus, when pressurized fluid is present, the upwardly directed static pressure acting on valve sleeve 66 is greater than the downwardly directed static pressure which tends to keep the valve sleeve seated against seat 38. Preferably, the upper and lower exposed areas are sized such that the upward static pressure differential is greater than any downwardly directed dynamic pressure acting on valve sleeve 66 by fluid flowing down the drill string. Thus, intermittent unseating of the valve, known as "chatter", is avoided.
In FIG. 1, actuator 12 is positioned in longitudinal opening 16 as it would be when being lowered or dropped into the drill string for the purposes of opening the valve by downwardly displacing valve sleeve 66. Outer cylindrical surface 146 of actuator body 98 is dimensioned to fit within central bore 70 of valve sleeve 66. Chamfer 148 extends outwardly from surface 146 and is designed to engage and substantially seal against chamfered surface 72 of valve sleeve 66.
FIG. 2 shows the apparatus of the present invention in an open position in which valve sleeve 66 is moved downwardly from conical surface 42 of seat 38 exposing transverse holes 46. Valve sleeve 66 stops against shoulder 32 with chamfer 73 of the sleeve being in substantially sealing contact with chamfer 35 of the shoulder. An open volume 150 is formed adjacent transverse holes 46 when the valve is opened. Thus, valve sleeve 66 provides annulus access means for allowing fluid pumped down the drill string into longitudinal opening 16 to pass through the substantially transverse port formed by holes 46, recess 44, hole 48, orifice 54, cage 56 and holes 52 into annulus 62 between valve portion 10 and well bore 64.
Prior to lowering or dropping actuator 12 into the drill string, the position of flow control valve 138 is preset by adjusting nut 136 and locked into position by lock nut 141. As shown in FIG. 2, flow control valve 138 is set in an open position so that it will never seat on orifice seat 112 allowing a portion of the fluid pumped down longitudinal opening 16 to pass through angular openings 144, into cavity 108, thence through openings 114 and 118 and on down the drill string as desired. This procedure will be further described hereinafter.
When actuator 12 contacts valve sleeve 66, valve plunger 86 is downwardly displaced to compress spring 88. When actuator 12 is removed, spring 88 will exert an upward force on valve plunger 86 to act as a valve return means for returning valve sleeve 66 to the original, closed position.
A plurality of annulus access valves of the present invention may be installed in a drill string at any desired point. When this is done, the central bore 70 of each valve sleeve 66 is progressively smaller from the uppermost valve 10 to the lowermost. A plurality of actuators 12 are sized such that a single, unique actuator is utilized to open a corresponding valve 10 in the drill string. In other words, outer surface 152 of actuator 12 designed for actuating valve sleeve 66 in the lowermost valve 10 in the drill string is sized to pass through central bore 70 of the valve 10 located above the desired valve. Therefore, the operator of the apparatus may select which specific valve 10 or which specific combination of such valves to open.
Although the valve 10 and actuator 12 are shown for usage in the annulus access sytem of the present invention, it will be obvious to those skilled in the art that the configuration of valve and actuator is adaptable to other usages, such as in the well production string.
OPERATION OF THE APPARATUS
The annulus access control of the present invention is ideally suited for blowout prevention. As is well known, a blowout occurs when there is an uncontrolled flow of well fluids into the atmosphere or when there is such an uncontrolled flow into a low pressure formation in the well bore. Either of these is an extremely dangerous and undesirable situation, particularly when gas is involved, and accordingly, well operators make every effort to prevent a blowout from happening.
Generally, the first step that may possibly lead to a blowout is when the drill bit enters a high pressure formation and there is an entry of water, gas, oil, or other formation fluids into the well bore, commonly referred to as a "kick". This occurs because the pressure exerted by the column of drilling fluid in the annulus between the drill string and well bore is not great enough to overcome the pressure exerted by the fluids in the high pressure formation. If prompt action is not taken to control the kick, a blowout will occur. A typical example of such a situation is illustrated at FIG. 3. A drill string 152 has a larger diameter drill collar portion 153 with a bit 154 at the lower end thereof, and the drill string is in a well bore 156. Casing 158 is shown at the upper portion of well bore 156. The lower end of casing 158 defines a casing shoe 159. As shown in FIG. 3, drill bit 154 has entered a high pressure formation 160. Gas in the formation has blown sand and rock into the well bore as indicated by numeral 162, locking the drill string and preventing rotation thereof. This is commonly referred to as a "packoff". The danger of such a situation arises when a high pressure gas bubble 164 enters the well bore from high pressure formation 160. Such a gas bubble 164 will eventually migrate up the well bore through drilling mud 166. A blowout can occur when gas bubble 164 reaches a low pressure formation, such as that indicated by numeral 168, and spreads uncontrollably therethrough or when the gas bubble reaches casing shoe 159 or the top of the well and uncontrollably escapes to the atmosphere.
When a packoff occurs, this is immediately known at the surface, because the drill string ceases to rotate and the pressure of the mud pumps increases dramatically. The object of blowout prevention is to control and contain the gas bubble so that it may be gradually expanded to a low pressure, at which point it is no longer a danger. In normal blowout prevention procedures, it is first necessary to perforate the drill string as near to the bit as possible, or back off the drill string as near the bit as possible. After this is done, heavy mud is pumped down the drill string into the well bore to help control the formation pressure which caused the "kick". The heavy mud forms a column of fluid exerting hydrostatic pressure on formation 160. This hydrostatic pressure plus pressure from the mud pumps and back pressure from a choke at the top of the well exert sufficient total pressure at the bottom of well bore 156 to prevent further entry of gas from formation 160. The disadvantage of these conventional techniques is that it takes time to lower a perforation charge into the drill string or to back off the drill string near the bit. Also, perforation destroys part of the drill string.
FIG. 3 shows drill string 152 as having five valves 10 of the present invention installed therein. These valves are identified from top to bottom by reference numerals 170, 172 and 174 in the upper portion of drill string 152 and valves 176 and 178 in drill collar portion 153. Although five valves are illustrated, the system is not limited to such a number, and any number of valves may be installed as desired and as conditions dictate. The advantage of the system over prior blowout prevention techniques is that a valve is already present in the drill string through which mud may be pumped to control the kick and work it out of well bore 156 when drill bit 154 is plugged. For the example of FIG. 3, the appropriate actuator 12 sized for valve 178 is lowered into the hole, and fluid is pumped down the drill string to hydraulically force that actuator against valve sleeve 66 in valve 178 to move the valve sleeve downwardly to its open position, exposing transverse holes 46 as hereinbefore described. The pressure on the fluid then causes the fluid to be pumped through hole 52 and out into the annulus between drill string 152 and well bore 156 wherein it acts to contain the formation pressure so gas bubble 164 may be worked out. Thus, the operator is able to take action to prevent a blowout much more quickly than with conventional techniques. Also, there is no destruction of the drill string as when a perforation technique is utilized. After the operator has controlled the formation pressure, gas bubble 164 may be expanded and circulated out of the well in any conventional manner previously known in the art.
The quickness of controlling formation pressures with the present invention may be of particular importance in offshore installation where reaction time is much shorter.
In cases where lowermost valve 178 is also covered by the packoff, the operator can lower the appropriate actuator 12 for valve 176 and pump fluid therethrough to control the formation pressure. Again, with this access to the annulus, high pressure gas bubble 164 may then be circulated out of the well by conventional methods.
Once high pressure gas bubble 164 has been circulated out of the well, and the well is safe, the various actuation portions 12 may be fished out of the well. At this time, the packoff or plugged bit is corrected by conventional methods known in the art.
Normally, in the above-described procedures of the use of the annulus access valve system, flow control valve 138 is adjusted so that it will close hole 114 in seat 112. In other words, no fluid pumped down the hole to force the actuator to open valve sleeve 66 will be allowed to continue further down the central opening of the drill string.
However, sometimes the bit will not be totally packed off and rotation of the drill bit will still be possible. By preadjusting flow control valve 138 to remain in an open position as shown in FIG. 2, a portion of the fluid may still be pumped down drill string 152 below actuator 12 to bit 154. Thus, the system includes a selectable fluid flow control means for allowing some fluid to continue down the drill string while diverting the remainder of the fluid through the transverse port of the valve. Although there is obviously a reduced volume of fluid pumped to the bit, it will still be possible to rotate the drill string and continue drilling. At a convenient time, actuator 12 may be fished out of the well in a manner commonly known in the art. When the pressure above actuator 12 is relieved, the corresponding valve sleeve 66 is automatically returned to its closed position by spring 88 as hereinbefore described.
The apparatus also provides the operator with the ability to inject different fluids known in the art into annulus 62 adjacent the gas bubble formed by a kick for the purpose of chemically and/or physically changing the natural gas.
Because the operator may select which valve in the drill string to open, different fluids may be pumped through different valves as desired. For example, but not by way of limitation, a heavy fluid might be pumped through valve 178 in FIG. 3 to fill a portion of the annulus between drill string 152 and well bore 156. A lighter fluid might be then added through valve 174 so that the heavy fluid is not adjacent, and thus could not enter, low pressure formation 168.
The flexibility of the annulus access valve system of the present invention also may be used for a variety of other purposes. For example, the valves are useful in tripping pipe wherein they may be used as an aid to clear an obstruction in the hole so that the bit may be passed therethrough. Abrasive materials of a kind known in the art may be pumped through the valves to cut out a key seat so that the drill bit may be removed. It can be seen that such flexibility will many times eliminate partial removal of the drill string and a fishing operation.
It can be seen, therefore, that the annulus access valve system of the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as those inherent therein. While a presently preferred embodiment of the apparatus of the invention and several preferred methods of use have been described for the purposes of this disclosure, numerous changes in the construction and arrangement of parts in the apparatus, and variations in method of use, can be made by those skilled in the art. All such changes and variations are encompassed within the scope and spirit of this invention as defined by the appended claims. | An annulus access valve system having a plurality of valves installed in, and forming a part of, a drill string in a well bore whereby fluid may be pumped into the annulus through the valves individually or in combination as desired. Each valve has a valve body connected to the drill string in which defines a longitudinal opening therethrough and a transverse port therein interconnecting the longitudinal opening with the annulus. A longitudinally slidable valve seats on a replaceable valve seat defining a closed position of the transverse port in the valve. The valve sleeve is biased in the closed position by a spring. An actuator, uniquely sized for a specific valve in the drill string, is utilized to engage the valve sleeve and move it to an open position by hydraulic pressure applied thereabove so that fluids may be pumped down the drill string through the transverse port into the annulus. A flow control valve is positioned in the actuator so that some fluid may be directed therebelow as desired. A method of utilizing the annulus access valve system for preventing blowouts in wells is disclosed, along with other methods of use. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a Continuation-in-Part application of U.S. application Ser. No. 11/079,806 filed Mar. 14, 2005, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to an improved apparatus and method for constructing pole buildings. Specifically, this invention relates to an improved concrete post anchor.
Pole buildings have been in use for many years. The popularity of these buildings has risen due to their economical nature in manufacturing.
Typically, pole buildings are constructed with large wooden poles extending upward from the ground which are connected together with stringers and then sided with a sheet metal siding. In addition, roof beams or trusses are put across the top of the wooden poles and a roof is then applied to the building. As mentioned, this type of building is economical to construct. However, one problem with this type of building is that when the wooden poles are in contact with the earth, the wooden poles invariably rot off and shorten the life of the building.
Many people have tried to remedy this problem. One such remedy is using pretreated or pressure treated lumber. Pressure treated lumber is treated with poisonous chemicals which prevents bugs and worms from tunneling into the wood, thus reducing premature failure of the pole. However, eventually the acids in the soils of the earth decompose the wood and the building still has a premature failure.
Thus, it is desirable to have a method and apparatus for allowing construction of pole buildings where the wall support poles are not in direct contact with the soil.
The primary objective of the present invention is to provide an improved concrete post anchor.
Another objective of the present invention is to provide a concrete post anchor which can be imbedded into concrete at the building site.
Another objective of the present invention is a concrete post anchor which can easily be set to level and plumb so that uniform length posts can be fastened to the anchors and do not have to be trimmed once installed.
Another objective of the present invention is to reduce freight costs since the anchor itself has little weight and the concrete is brought and poured on site.
Another objective of the present invention is to create a safe concrete post anchor by not having to handle very heavy pre-made concrete post anchors.
A further objective of the present invention is to create a post anchor which is configured to reduce risks of cracking of concrete that it is embedded into.
A further objective of the present invention is to reduce chances of the concrete post anchor sinking in uncured concrete.
A further objective of the present invention is to create a pole building in which wooden poles do not directly contact the soil.
A further objective of the present invention is a concrete post anchor in which concrete piers, upon which concrete anchors are embedded into, are constructed with a reduced risk of shearing off.
A further objective of the present invention is to provide a concrete post anchor in which the chances are reduced for splitting out a wooden post fastened to the post anchor.
A further objective of the present invention is to create a post anchor with stronger anchor rods.
A still further objective of the present invention is a provision of a concrete post anchor which is economical to manufacture, durable in use, and efficient in operation.
A still further objective of the present invention is an improved post building.
A still further objective of the present invention is an improved method of constructing a post building.
A further objective of the present invention is to provide a concrete post anchor with improved load handling ability.
A still further objective of the present invention is to provide a concrete post anchor capable of supporting a longer and taller span of sidewall.
Another objective of the present invention is to provide a concrete post anchor having load handling capabilities that exceed the load handling capabilities of the wall post.
Another further objective of the present invention is to provide a pair of front brackets for tightly securing the post within the concrete post anchor.
One or more of these or other objectives of the invention will be apparent from the specification and claims that follow.
A still further objective of the present invention is to provide a U-shaped concrete post anchor where the open back side is partially enclosed by a back bracket and the open front side is partially enclosed by the front brackets.
SUMMARY OF THE INVENTION
The foregoing objects may be achieved by a concrete post anchor comprising a pair of substantially vertical side brackets, the side brackets operatively connected opposite one another and spaced apart with a base bracket and a back bracket to thereby form a U-shaped bracket with a partially enclosed back side, at least one front bracket removably attached to the side brackets, an anchor and a portion of the side brackets extend below the base bracket to form an anchor tab and a side bracket tab, and a pair of anchor rods operatively connected to each side bracket tab and extending away from the base bracket in a direction opposite the U-shaped bracket.
A further feature of the present invention wherein the anchor tab and side bracket tabs extend away from the base bracket in a direction opposite the U-shaped bracket.
A further feature of the present invention involves a concrete post anchor wherein the side brackets are welded or fastened to a base bracket and the back bracket.
A further feature of the present invention wherein the at least one front bracket is bolted to the side brackets.
A further feature of the present invention wherein a plurality of lugs are operatively attached to the side brackets for anchoring the at least one front bracket to the side brackets.
A further feature of the present invention involves a concrete post anchor wherein the anchor is formed from a single piece.
A further feature of the present invention is a concrete post anchor wherein side brackets are substantially parallel to one another.
A further feature of the present invention involves a concrete post anchor wherein side brackets are configured with a plurality of apertures to allow for fastening a wall post to the concrete post anchor.
A further feature of the present invention involves a concrete post anchor configured with a first aperture is located in a diagonal relationship to a second aperture to thereby resist splitting of a wood post when fasteners are inserted into the post through the plurality of apertures.
A further feature of the present invention is a concrete post anchor wherein an anchor rod is welded with a lap joint to the side bracket tabs.
A further feature of the present invention involves a concrete post anchor wherein the anchor tab, the side bracket tab and the anchor rod extend from the post anchor into a concrete pier so the concrete pier may be formed at a building site where the anchor is being used for constructing a building.
The foregoing objects may also be achieved by a pole building on a building site comprising a floor, side walls, and a roof; the roof supported by roof supports, the roof supports supported by wall posts, and the wall posts supported by a concrete post anchor. The concrete post anchor comprising a pair of substantially vertical side brackets; the side brackets operatively connected opposite one another and spaced apart with a base bracket and a back bracket to thereby form a U-shaped bracket having a partially enclosed back side. A pair of front brackets is removably attached to the side brackets. A portion of the side brackets extend below the base bracket forming a side bracket tab. And, at least one anchor rod is operatively connected to each side bracket tab so as to extend away from the base bracket in a direction opposite the U-shaped bracket.
A further feature of the present invention wherein an anchor tab is connected to the base bracket on the partially enclosed back side so as to extend away from the base bracket in a direction opposite the U-shaped bracket.
A further feature of the present invention involves a building wherein the concrete post anchor extends upward from and is embedded into a concrete pier.
A further feature of the present invention involves a building wherein concrete is poured and formed in the concrete piers on the building site for supporting the concrete post anchors.
The foregoing objects may also be achieved by a method of constructing a building on a building site comprising the steps of assembling a baseboard frame substantially around a perimeter of a desired building location on the building site, creating holes in the ground at locations where a wall post is desired to support a wall and a roof, affixing concrete pier forms to the baseboard above the holes in the ground, pouring concrete into the holes and forms, inserting at least one shear rod into the concrete before the concrete cures, inserting a post anchor into the concrete before the concrete cures, leveling the post anchors to approximately plumb before the concrete cures, positioning the wall post within the post anchor after the concrete cures, securing the wall post to the post anchor by attaching at least one front bracket to the post anchor, leveling the posts to approximately plumb, attaching roof supports between two wall posts across the desired building location, and attaching roofing to the roof supports and siding to the wall supports to substantially enclose the building.
A further feature of the present invention involves a method of constructing a building comprising the step of attaching an anchor height bracket to a baseboard above holes in the ground to keep a post anchor from sinking in uncured concrete which is poured into the post holes.
A further feature of the present invention involves a method of constructing a building comprising a step of attaching baseboard mounting screws to a baseboard above holes in the ground so that the screws will be located within concrete which is poured into the post holes and hold the baseboard to the concrete.
A further feature of the present invention involves a method of constructing a building comprising a step of removing forms from a concrete post pier once the concrete cures so that the forms can be reused.
Another feature of the present invention involves a method of constructing a building wherein the at least one front bracket is bolted to a pair of lugs on the post anchor for compressing and securing the wall post within the post anchor.
A still further feature of the present invention involves a method of constructing a building comprising the step of fastening the wall post to the post anchor with lag screws using a plurality of apertures in the post anchor.
This invention discusses a building wall post. It is contemplated that the building wall post can be a solid wooden post, a laminated post from solid boards, a laminated post from laminated boards, a metal post, or other similar building material rigid posts suitable for use to post buildings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is one embodiment of the structural framework of a pole building using the current invention.
FIG. 2 is a perspective view of an exemplary embodiment of the present invention.
FIG. 3 shows another perspective view of an exemplary embodiment of the present invention.
FIG. 4 shows the beginning stages of construction for one embodiment of a pole building using the current invention.
FIG. 5 is one embodiment of assembly using a pier form and baseboard mounting screws attached to the baseboard.
FIG. 5A is one embodiment of a concrete form tube.
FIG. 6 is an elevation view of one embodiment of the concrete form detail.
FIG. 7 is a plan view of one embodiment of the concrete form detail.
FIG. 8 is a front elevation view of one embodiment of a completed post/pier detail.
FIG. 9 is a side elevation view of one embodiment of a completed post/pier detail.
FIG. 10 is a plan view of one embodiment of a completed post/pier detail.
FIG. 11 is a perspective view of one embodiment of a pole building constructed using a current invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The current invention is an improved concrete post anchor and method of constructing a pole building using the same.
As with any building process, the first step is selecting a building site, clearing the building site, and leveling or grading the site to a substantially level grade. The grade on the site should be packed sufficiently so as to minimize settling of the ground after construction of the building.
FIG. 1 shows one embodiment of a building frame assembly 40 for the current invention. Once the building site is prepared, construction on the building can begin. This process will be described later.
FIG. 2 shows the preferred embodiment of the concrete post anchor 10 of the current invention. Similarly, FIG. 3 shows another view of the preferred embodiment of the concrete post anchor assembly 10 of the current invention. Additionally, other configurations may be used for this invention.
As seen in FIGS. 2 and 3 , it is preferred that the concrete post anchor assembly 10 is constructed with two side brackets 18 oriented substantially parallel to one another and spaced apart with the use of a base bracket 24 and back bracket 25 . It is preferred that the side brackets 18 , the base bracket 24 and back bracket 25 be constructed from quarter-inch sheet steel. However, any other rigid material suitable for building can be used. It is preferred that the base bracket 24 and back bracket 25 be welded to the side brackets 18 . However, the base bracket 24 and back bracket 25 can be bolted or otherwise fastened to the side brackets 18 . Similarly, it is contemplated that the base bracket 24 , side brackets 18 and back brackets 25 can be created from a single piece and formed to a shape. The side brackets 18 are preferred to be substantially parallel to one another to hold a building wall post 46 . The base bracket 24 and back bracket 25 are preferred to be substantially perpendicular to one another to hold a building wall post 46 . The back bracket 25 can fully or partially enclose the parallel space defined by the side brackets 18 and the base bracket 24 .
The side brackets 18 are preferred to be configured with a side bracket tab 20 . The side bracket tab 20 extends below the base bracket 24 . The side bracket tab 20 and the side bracket 18 are preferred to be made from a single piece of quarter-inch sheet steel. However, the side bracket tab 20 can be welded on or otherwise affixed to the side bracket 18 . Additionally, if the U-shaped bracket formed with two side brackets 18 , one base bracket 24 and back bracket 25 are formed from a single piece, then the side bracket tab 20 can be welded near the point where the side bracket and the base bracket meet. Furthermore, if the U-shaped bracket is created from a single piece, the side bracket tab 20 can be created by laminating an entire second side bracket 18 which includes the side bracket tab 20 with the original side bracket 18 . Other types, shapes and materials of side brackets 18 , base bracket 24 , back bracket 25 and side bracket tabs 20 and their assembly can be used for this invention.
The side brackets 18 are preferred to be configured having lugs 19 . The lugs 19 are connected to the side brackets 18 by a weld, unitary construction or fastener. The lugs 19 are mounted on the outside of the side brackets. Lugs 19 are mounted to the side brackets 18 so that their forward-most face is collinear with the side bracket edge 30 . In the preferred embodiment, a pair of lugs 19 are spaced apart and mounted on the outer surface of the two side brackets 18 . Moreover, the lugs 19 are mounted on the same plane opposite one another on side brackets 18 . For example, one lug 19 is connected on the outer surface near the top of one side bracket 18 and another lug 19 is mounted in the same position on the opposite side bracket 18 . Alternatively, several lugs 19 may be mounted on each side bracket 18 and mirrored in position on the opposite side bracket 18 . The lugs 19 may be constructed in such a way to support or hold a front bracket 23 . For example, the front brackets 23 may be welded, fastened or hooked to the lugs 19 . In the preferred form, the lugs 19 would be a nut for attaching the front brackets 23 to the side brackets 18 using a bolt.
An anchor tab 21 is attached to the base bracket 24 . The anchor tab 21 extends perpendicularly away from the base bracket 24 in a direction opposite the U-shaped bracket. The anchor tab 21 may be a unitary piece with the U-shaped bracket, fastened or welded to the base bracket 24 . The anchor tab 21 helps to stabilize the U-shaped bracket when embedded in concrete. The width of the anchor tab 21 may be constructed to traverse the total distance between the side brackets 18 or only a portion there between. By increasing the length of the anchor tab 21 or the distance the tab 21 extends away from the base bracket 24 , helps increase the stability of the anchor 10 . For example, the anchor tab 21 may extend a shorter distance, the same distance or a greater distance than the distance of the side bracket tabs 20 from the base bracket 24 . In the preferred form, the anchor tab 21 is attached to the bottom and centered in the middle of the base bracket 24 and has a width less than the distance between the side brackets 18 . The tab anchor 21 is preferably constructed of quarter-inch sheet steel.
When the concrete post anchor assembly 10 is used for building a building, the side bracket tabs 20 and tab anchor 21 should be embedded within a concrete pier 82 . In the preferred configuration, side bracket edge 30 of the side bracket 18 are collinear with side bracket tab edge 32 of the side bracket tab 20 , such that side bracket tab edges 32 extend away from the base bracket 24 ending in straight edges parallel to the base bracket 24 . Similarly, the tab anchor 21 has edges extending in a perpendicular direction away from the base bracket 24 ending a straight edge parallel to the base bracket 24 .
Other configurations, including angled or narrowing edges, may be used with this invention. For example, in order to reduce risk of the concrete pier 82 cracking, the side bracket tab 20 may have a side bracket tab edge 32 which is angled inward or narrowing with respect to the side bracket edge 30 of the side bracket 18 .
The concrete post anchor assembly 10 also preferably has anchor rods 26 extending away from the base bracket 24 . These anchor rods 26 are also to be embedded within a concrete pier 82 (shown in FIGS. 1 and 6 - 11 ) for use in constructing a building. The anchor rod 26 helps to hold the concrete post anchor assembly 10 securely within the concrete. To help to secure a concrete post anchor assembly 10 , into the concrete, it is preferred that anchor tab 21 and side bracket tabs 20 also be embedded in the concrete pier 82 . It is preferred that anchor rods 26 be constructed from one-half inch rebar (#4 bar size); however, other similar material can be used.
The anchor rods 26 can extend from either the base bracket 24 , the anchor tab 21 or the side bracket tab 20 , or from each. It is preferred, however, that the anchor rod 26 be welded with a lap-weld joint 28 to the side bracket tab 20 . A lap-weld joint 28 creates a stronger connection with the anchor rod 26 over a standard butt-weld joint, which is commonly known in the art. However, any type of welding joint can be used for this invention as well as any other type of connecting means, thread joint, fasteners, etc., can be used for holding the anchor rod 26 to either the side bracket tab 20 or the base bracket 24 .
The purpose of the concrete post anchor assembly 10 is to hold a building wall post 46 . This is accomplished by tightening the front brackets 23 to the lugs 19 , thereby enclosing and securing the building wall post 46 within the U-shaped bracket, as best illustrated in FIG. 3 . FIG. 3 shows the front brackets 23 being securely bolted to the lugs 19 putting the building wall post 46 in compression against the back bracket 25 . For example, the depth of the U-shaped bracket may be shallower than the building wall post 46 such that the building wall post 46 is not flush with the side bracket edge 30 or the front surface of each lug 19 . Thus, when the front brackets are tightened down, the building wall post 46 is compressed against the back bracket 25 . The building wall post 46 may be further secured in the post anchor assembly 10 using the side bracket apertures 22 shown in the side brackets 18 . Any number of side bracket apertures 22 can be used. The side bracket apertures 22 are used to further fasten and secure the building wall post 46 to the concrete post anchor assembly 10 . Generally, a building wall post 46 is inserted between the side brackets 18 , and the front brackets 23 are secured to the side brackets 18 to secure the building wall post 46 in the U-shaped bracket. Then, if further securement is desired, a hole is preferably predrilled in the building wall post 46 in line with the side bracket apertures 22 to permit insertion of fasteners to hold the building wall post 46 to the anchor assembly 10 . As shown in FIGS. 2 and 3 , the side brackets 18 are configured with several apertures 22 on each side bracket 18 . The placement of the apertures 22 create holes in opposing positions which are not in line with the grain of the lumber of the building wall post, thereby reducing chances for the building wall post 46 to split.
It is preferred that the building wall post 46 be a three-ply column wood laminate, such as 3-2×8 laminated #2 South Yellow Pine (SYP) boards. It is also preferred that lag screws be used as the fastener for further securing the post 46 to the anchor assembly 10 through side bracket apertures 22 . Additionally, it is preferred that the lag screws or fasteners penetrate the center member of the laminate for maximum strength.
Other configurations to hold the building wall posts 46 can be used. One example, is using a through-bolt with apertures located opposite one another and a hole drilled through the building wall post 46 . The through-bolts should be inserted through the holes and tightened with a nut, thereby connecting the side brackets 18 with the building wall post 46 . However, this is not as strong as the fasteners being fastened part way into the building wall post 46 . In fact, holes drilled through the building wall posts 46 may increase chances of splitting the posts 46 . If this happens, the strength of the connection between the building wall posts 46 and the concrete post anchor assembly 10 depends on the tightness of the front brackets 23 and bolt or fastener and the friction on the side walls of the U-shaped socket for strength.
FIG. 4 shows the beginning steps of construction of a pole building. Once the building site is prepared, a baseboard frame 42 is constructed, preferably of treated 2×8 lumber, substantially around the perimeter of where the building is to be located. This baseboard frame 42 is generally a permanent part of the structure and should be leveled as is commonly known in the art. The baseboard frame 42 can be located and leveled with removable stakes or other similar method. Then, ground holes 44 are to be drilled in the ground. The holes 44 are preferably 12 inches in diameter and 48 inches deep, in the locations where building wall posts 46 are desired for supporting the building. Other size and depth of holes can be used as building size increases or decreases.
FIGS. 5 , 6 and 7 show a preferred set-up for a concrete pier form 70 . Once the ground holes 44 are created, it is preferred that baseboard mounting screws 74 be screwed into the baseboard 42 but not clear through the baseboard 42 . These baseboard mounting screws 74 hold the baseboard 42 to the concrete pier 82 once the pier 82 is created, and are a permanent part of the building. Next, an anchor height bracket 76 can be fastened to the baseboard 42 . The anchor height bracket 76 should be mounted level with the desired top of the concrete pier 82 . Then, once concrete is poured, and the concrete post anchor assembly 10 is inserted into the concrete, the anchor height bracket 76 keeps the concrete post anchor assembly 10 from sinking in the uncured concrete. Finally, a concrete pier form 70 should be temporarily fastened with pier form fasteners 72 to the baseboard 42 in the locations where the concrete post anchor assemblies 10 are desired to support the building wall posts 46 . The pier form 70 can be in any shape. Additionally, the pier form 70 can remain in place permanently or can be removed and reused, once the concrete is formed and cured. The top of the pier form 70 should also be located where the top of the concrete pier 82 is desired to be.
If the level of the soil is below the concrete pier form 70 , a concrete form tube 78 shown in FIG. 5A can be used to essentially extend the ground hole 44 up to the base of the pier form 70 so as to create a continuous form with the pier form 70 , the concrete form tube 78 , and the ground hole 44 for the concrete to be poured into. There may be relatively horizontal openings where the form is not covered such that the uncured concrete will still cure properly. For instance, in FIG. 5 , the ground hole 44 is located below the pier form 70 . Therefore, the concrete form tube 78 can be placed below the pier form 70 and above the ground hole 44 , thereby leaving a little bit of opening between forms since in this example, the pier form 70 is square shaped and the concrete form tube 78 is round.
Once all of the pier forms 70 are in place in the locations where the concrete post anchor assemblies 10 are to be used, concrete is to be poured into the ground hole 44 , any necessary concrete form tube 78 , and the pier forms 70 . After the concrete has been poured, at least one sheer rod 80 is to be inserted into the uncured concrete and down through the pier form 70 and into the ground hole 44 . The sheer rod 80 is preferred to be 32 inch long, half-inch diameter rebar. The purpose of the sheer rod 80 is to reduce chances of the concrete pier 82 sheering, should the concrete pier 82 receive a side impact, therefore, any size and length of similar material can be used.
After the concrete is poured, but before the concrete cures, the concrete post anchor assemblies 10 are to be inserted, anchor rods 26 and anchor tab 21 first, into the uncured concrete. The concrete post anchor assemblies 10 should be inserted in the concrete down to the level desired for the building wall post 46 . This is aided by the anchor height bracket 76 . Once the anchor assembly 10 is inserted, preferably with the base bracket 24 contacting the anchor height bracket 76 , thereby imbedding the anchor rods 26 , the side bracket tab 20 and the anchor tab 21 in the uncured concrete. Next, the concrete post anchor assembly 10 should be leveled to substantially plumb so that when a building wall post 46 is inserted into the concrete post anchor assembly 10 , the building wall post 46 will be relatively plumb. However, the building wall post 46 can be leveled to substantially plumb even if the concrete post anchor assembly 10 is not leveled to plumb.
After all necessary concrete post anchor assemblies 10 are installed in the uncured concrete and preferably leveled to plumb, they are then to be left until concrete has sufficiently cured.
Once the concrete pier 82 has cured, the pier forms 70 can be removed, if desired, by removing the pier form fasteners 72 . As seen in FIGS. 8 , 9 and 10 , the baseboard mounting screws 74 should now be embedded securely into the cured concrete pier 82 and thus hold the baseboard 42 securely in place and any temporary stakes holding the baseboard 42 can be removed. Now, any desired building wall post 46 can be inserted substantially vertically into the U-shaped bracket of the concrete post anchor assembly 10 and fastened thereto using the front brackets 23 and fasteners inserted through apertures 22 . As discussed previously, it is preferred that a three-board laminate building wall post 46 be used for added strength to the building.
Since the concrete pier 82 , the concrete post anchor assembly 10 and the building wall post 46 are all assembled separately on site, and the concrete post anchors 10 are leveled with the baseboard 42 , the building wall posts 46 can be cut to length before installation. In other words, some other concrete post anchors which come with preformed concrete and post anchor assemblies are extremely heavy and hard to work with, and therefore are very difficult to get set on a uniform level grade for the building. Thus, on that type of assembly, the building wall posts 46 must be individually trimmed depending on how high they are with respect to level grade.
One benefit of having the laminated building wall post 46 precut is that the laminate boards can be cut with a wall post miter 48 as necessary to match the roof line of the building. Similarly, an advantage is the building wall post 46 with a laminate construction can have a wall post groove 50 for the roof support structure 60 to fit into for added support and strength. The building roof supports 60 can be beams, joists, trusses, or other similar type support devices.
As is known in the art, laminated building wall posts 46 are stronger than conventional solid wall posts. Part of what adds to the strength of the laminated wall posts 46 is the fact that multiple layers of material are layered and held securely together. It is preferred that these laminated layers be held together with multiple laminate fasteners 52 embedded on one side of the layer through a first layer and preferably into one or more other layers of the laminate. It is also preferred that this be done from both sides of the laminate layers. The laminate fasteners 52 can be nails, screws, or any other similar type device. In addition, the laminate layers can be held together with an adhesive for added strength.
Once the building wall posts 46 are put into place and leveled to substantially plumb, the building roof support beams 60 can be stretched across the desired building location between the building wall posts 46 as is customary in construction. Once this part is completed, the building frame assembly 40 should appear substantially as in FIG. 1 .
Once the building frame assembly 40 is completed, the roof and building walls can be sheeted and sided as necessary. One embodiment of a completed building assembly 38 is shown in FIG. 11 .
The advantages of the current invention over the prior art are many. However, some notable advantages will be detailed below. Prior art pole buildings generally have wooden building wall posts directly in contact with the soil which causes a relatively short building life. On the other hand, the current invention does not have a building wall post 46 directly contact the soil therefore creating a substantially longer life building.
Other types of concrete post anchors are manufactured with large, preformed concrete bases attached to post anchors. These are extremely heavy, difficult to handle, expensive to ship, and nearly impossible to get set level and at the proper height without need for trimming the building wall posts. Conversely, the current invention has each step of construction done separately on the building site so that once the baseboard 42 is set level and at the proper height, the concrete post anchor assembly 10 can be embedded into uncured concrete to relatively the same level on baseboard 42 at each ground hole 44 , thereby creating all of the concrete post anchor assemblies 10 at substantially the same level with respect to the grade for the building site. Thus, building wall posts 46 can be precut before installing, and therefore save time and money by having all of the building wall posts cut to the same height along the same wall of the building.
The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives. | The current invention is a concrete post anchor and method of using comprising two substantially vertical side brackets, side brackets operatively connected opposite one another and spaced apart with a base bracket and a back bracket forming a U-shaped bracket. A pair of front brackets is removably attached to the side brackets. An anchor and a portion of the side brackets extend below the base bracket forming an anchor tab and a side bracket tab. A pair of anchor rods is operatively connected to each side bracket tab. The anchor can be embedded in a concrete pier and then a post can be secured within the concrete post anchor with the front brackets and fastened to the anchor. The concrete post anchor withstands increased loads and forces associated with post built-type buildings without permitting the wood post to directly contact the soil, thereby creating substantially stronger and longer-lasting post buildings. |
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This is a divisional of application Ser. No. 631,108, filed Nov. 12, 1975, and now U.S. Pat. No. 4,018,279.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention lies in the field of energy recovery. More particularly, it is concerned with the in situ combustion in shallow thin beds of coal, at shallow depths below the surface of the earth. Still more particularly, the invention lies in the field of the combustion of the coal by supplying air to the coal seam from the surface and utilizing the heat generated by the coal combustion to generate steam which is utilized at the surface of the ground, utilizing the earth (coal and surrounding rocks) as the furnace in the same manner as if it were geothermal.
In one application, this invention lies in the field of outcropping seams of coal where horizontal conduits can be drilled and placed within the coal seam to a specific point, where they join a vertical pipe. Water supplied to the horizontal pipes at the outcrop is heated within the pipes by the combustion of the coal around the pipes, and steam thus formed is carried up the vertical pipe to be used to drive a turbine generator system.
A still further application lies in the field of utilizing coal seams thin or thick, shallow or deep overlain by water sands or by hydrocarbon bearing formations whereby fires are started within the coal seam, and the heat of combustion is then communicated to the overlying aquifer or oil formation. If the overlying bed is an aquifer then steam will be formed which can be carried to the surface to drive an electric generator system. If the overlying bed contains viscous oil, then the heat will cause the oil to be reduced in viscosity sufficiently so that it can be driven by a steam drive, or by pumping water into the seam, which in view of the fire in the coal seam will turn to steam, which will drive the oil to the surface to be collected.
Still a further application involves the burning of coal in situ and carrying the hot gaseous products of combustion up a vertical borehole past a coiled pipe carrying water. Heat is transferred to the water by convection, forming steam which is carried to a turbine, etc.
2. Description of the Prior Art
Subsurface combustion of coal has been carried on in nature, by fires of unknown origin which were started many years ago and are burning continuously to the present date. Also oil companies, coal companies and government research laboratories have investigated many ways of underground combustion of coal, so as to utilize the products of combustion directly, as a coal gasification system. However, none of these methods have become practical as of the present date because of one or more basic difficulties.
SUMMARY OF THE INVENTION
It is a primary object of this invention to provide a rather specialized system for the utilization of the heat of in situ combustion of coal in shallow, thin, veins, seams or formations. The situations are specialized in that they are not generally applicable, but are applicable and are particularly useful in specialized areas, such as, for example, where the thin, shallow coal beds outcrop. The beds can be drilled and pipes inserted into the coal bed, in a more or less horizontal direction. Air holes can be supplied from the surface of the coal bed, on both sides of the horizontal pipes, so that combustion can be carried on along the position of the horizontal pipes. The horizontal pipes are supplied with water at the outcrop. The water will be heated and converted to steam, and can be carried to the surface through a vertical pipe drilled from the surface, and adapted to intersect the horizontal pipe or pipes. A plurality of such horizontal pipes can be directed in different directions, from the outcrop to a central vertical pipe, or the use of several vertical pipes can be used.
Another object of this invention is to provide a means for utilizing the heat resulting from the combustion of coal in situ in normally unminable coal veins, at a shallow depth below the surface. This is particularly useful where there is a water bearing formation directly above, and in contact with, the coal seam, or where there is a hydrocarbon bearing formation, where the oil is of such high viscosity that it cannot be produced by ordinary means. Here, by causing an artificial combustion, in situ, in the coal seam, the heat of combustion passes upward into the overlying aquafer and the water is heated and converted to steam, and is produced by one or more vertical pipes drilled into the water sand from the surface. The natural flow of water in the aquafer can replenish the water lost by steam, or additional vertical boreholes can be provided for the introduction of water under pressure into the aquafer.
If the overlying bed above the coal seam carries a very viscous oil, then the heat of combustion, after due course of time for the transmission of the heat vertically into the overlying formation, will cause the viscosity to be reduced to a point where it can be produced by gas drive or water drive. If water is used then there will be a combination of water and steam drive to force the oil, now of reduced viscosity, out through appropriate producing wells.
In a third embodiment, the hot gaseous products of combustion are carried to a vertical borehole in which is installed a coiled pipe, through which water is passed from the surface. The water is heated by heat transfer to the pipe from the hot gases as they flow up the borehole. The water is converted to steam which flows to a turbine, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of this invention and a better understanding of the principles and details of the invention will be evident from the following description taken in conjunction with the appended drawings, in which:
FIGS. 1 and 2 illustrate in vertical cross-section and plan views, one embodiment of this invention.
FIGS. 3 and 4 illustrate two views, in vertical section and in plan view, of a second embodiment of this invention.
FIGS. 5 and 6 illustrate two views of a third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and in particular to FIGS. 1 and 2, there are shown two views of one embodiment of this invention. In FIG. 1 there is a vertical cross-section through the earth, showing the surface of the earth 10, an upper portion of the earth 12, resting on a thin, more or less horizontal seam or vein, of coal 14. Because of the surface topography, and the hillside 16, there will be an outcropping at 18 of the coal seam 14. Because of the availability of the outcrop 18, one or more horizontal boreholes 20 are drilled into the coal seam, parallel to the plane of the coal seam, to a selected point. There is a vertical borehole 22 drilled at said selected point, and a vertical pipe 26 is inserted into that borehole, and is cemented into place around the inner end of pipe 20, inserted into the horizontal borehole. This makes a continuous conduit from the outcrop 18, by means of the pipe or conduit 20 into the portion 28 of the borehole 22, and a pipe or casing 26 cemented around the inner end of the pipe 20 and around the vertical pipe 26.
The cementing of the joints between the horizontal and vertical pipes 20 and 26 in the region 28 permits the flow of water into the pipe 20 by means of a flow line 40 and arrows 42, for example, and the conversion of the water in the pipe 20 into steam in the region of the burning coal in the areas 46. The steam then flows along the pipe 20 and up the pipe 26 in accordance with arrows 44 to the surface where the steam is supplied to a turbine electric system 34, 36 and the power output of the generator goes by power line 38 to a point of application.
A plurality of vertical boreholes 30 are drilled from the surface down to, and into, the coal seam 14 in the vicinity of the horizontal pipes 20. As indicated by arrows 19 air is supplied under pressure to pipes within the boreholes 30, and the air passing down through the pipes into the coal seam maintain the combustion of the coal. The heat of combustion of the coal serves to convert the water in the pipe 20 into steam. The borehole 30 will generally be lined with casing which passes into and through the coal seam. The lower part of the casing will generally be perforated, or slotted, so as to permit the air to pass out into the coal area, but to prevent clinker and other products of the combustion of the coal, from stopping up the cross-section of the casing.
As shown in FIG. 2, plurality of horizontal bores 20A, 20B, 20C etc. and corresponding pipes in these bores, can be formed from different directions into or from the common vertical borehole 22 shown in FIG. 1. However, it is possible also to have a separate vertical borehole 22 and casing 26 for each of the horizontal pipes 20A, 20B, and 20C. The vertical air holes 30 are shown clustered around the position of the pipes 20 so as to completely burn all of the coal in the vicinity of the pipes.
When all of the coal has been burned in the region around one of the pipes, an additional bore 20, and corresponding pipe would be made in another portion of the coal seam where the coal has not yet been burned, so that the combustion can be carried out in the new area, to keep pace with the advance of the burning front. Of course, the original air holes can be used and/or additional air holes drilled as needed.
As shown in FIG. 1 no provision has been made for the passage out of the coal seam, of the products of combustion. If this becomes necessary, it may be desirable to drill one or more additional boreholes, for the passage of the products of combustion from the fires in the regions 46 to pass through the porosity of the coal into the outlet boreholes, to the surface, where the hot gases can be utilized in heat recovery devices, or boilers. If there are any unburned combustibles in the exit gases, they may be supplied, with the combustion air, in a boiler so as to utilize the further heat value of the products of combustion.
Referring now to FIGS. 3 and 4, there is shown a second embodiment of this invention which comprises a portion of the shallow surface of the earth containing a more or less horizontal coal seam 14 overlain by a porous water formation 13, and a portion of the earth 12 up to the surface 10. If the porous zone 13 contains water, then the combustion of the coal in bed 14 can serve to heat the water in the zone 13 to form steam, which can be utilized in a turbine, etc. For example, boreholes 30 are drilled from the surface down to, and into, the coal seam. The lower parts of the casing of these holes would be perforated or slotted for the passage of air down the casing and into the coal seam. The coal would be ignited by methods well-known in the art and combustion would be carried out within the coal seam 14. The heat of combustion would be communicated vertically to the overlying porous zone 13, which is filled with water. Because of the heat transmitted, the water would be converted to steam and steam would pass in accordance with arrows 58 from the porous sand 13, up one or more casings 56 drilled from the surface of the earth down into the water sand, and appropriately cased, so that the steam would pass upward and into a turbine 34 driving a generator 36 to provide power for delivery by the power line 38.
It may be desirable to provide additional cased holes 54 drilled from the surface down into the zone 13, to supply water under pressure, in accordance with arrows 56. This water would provide sufficient pressure in the water zone 13, to create enough back pressure to maintain a high pressure and steam, for efficient turbine operation. No detail is supplied as to the turbine generator and power system, since that art forms no part of this invention.
In FIG. 4 is shown a plan view of the surface 10 indicating a plurality of pipes 56 representing the pipes through which steam is supplied from the subsurface, to the turbine. Also shown are a plurality of spaced air bore holes 30 through which is supplied air for the combustion of the coal. In addition, pipes 54 are provided from the surface, to introduce water into the zone 13 to replenish the water supplied as steam to the turbine if necessary. Although not shown, it is possible to condense the steam issuing from the turbine and pump it back down into the formation 13 with the resulting conservation of water.
In FIG. 3, it is further considered that if an oil zone or an oil bearing formation 13 overlies the coal seam, and if the oil is of a viscous nature, which is not normally produceable, it is possible, where there is coal below the oil formation, to burn the coal, and by means of the heat of combustion, to heat the oil, and thereby reduce its viscosity, so that it can be pumped to the surface. One way of getting more fluid oil to the surface would be by means of pumping a gas down the pipes 54 to create a flow pressure on the oil toward the center of the field. The oil would then flow up the pipes 56. Of course, in the case of an oil formation the vertical pipes 56 would carry oil and would not be connected to a turbine generator system as shown.
It is also possible to force the flow of thinned oil to the producing pipes 56 by flowing water into the pipes 46 at the surface, and causing the water to convert to steam due to the heat provided by the burning coal. This steam would then provide a very effective sweeping or driving fluid to carry the oil into the central portion of the field and to the outlet pipes 56. In this type of situation, it may be desirable to surround the plurality of oil pipes 56 with a ring of input wells 54 arranged in a circle around the pipes 56, for the flow of drive fluid into the oil formation to drive the oil toward the center of the field.
Referring now to FIGS. 5 and 6, there is shown a third embodiment of this invention in which there is a coal seam 14 at a selected depth in the earth. There are a plurality of vertical boreholes to which air is supplied under pressure 30 and which boreholes intersect the coal seam and the air flows in accordance with arrows 82 so that after the coal is ignited it will continue to burn and the hot products of combustion will pass through the pores of the coal seam and possibly through radial bores 70 to a central relatively large diameter vertical borehole 72. This will be cased or lined with concrete with cement as is customary. There is a continuous conduit which consists of pipe 75 which passes condensed steam from the turbine 34 in accordance with arrows 79 downward through a first pipe 76 which joins a second vertical pipe 78 at the bottom of the borehole. The condensed steam goes down as hot water through pipe 76 and is heated and passes upward in accordance with arrows 80 through the second pipe 78 in which the water is heated to steam and the steam then goes into the turbine 34 where it drives the turbine and the steam is then condensed and passes as hot water through the pipe 75 and back down into the borehole.
The hot product of combustion 84 pass up the borehole in accordance with arrows 84 and 86 and by convection heat the pipes 76 and 78 and thereby heat the liquid water inside the pipes turning the water into steam so as to drive the turbine.
The products of combustion 86 then vent at the surface end of the borehole and are utilized in any way that may be desired such as for example passing to a waste heat boiler for further utilization of the heat content of the products of combustion.
The down going pipe 76 is shown as a sinuous pipe. It will undoubtedly be advantageous to coil that pipe 76 possibly as helix surrounding the vertical pipe 78 thus providing a greater surface area of pipe for heat transfer from the upwardly flowing gases to the pipe and to the water inside the pipe. No further detail of the construction of these pipes is needed since this is a common type of situation where such as in the convection section of a heater where hot gases are passed over a plurality of pipes for heating a liquid in the pipe thereby recovering the waste heat that still remains in the products combustion just prior to their issuance through a stack to the atmosphere.
This embodiment as shown in FIGS. 5 and 6 is different from either of the other two body embodiments shown in FIGS. 1 and 2 and in FIGS. 3 and 4. In the former the pipe containing the water passes through the zone where the coal is actually being burned and is therefore in a hotter environment and therefore there is a greater rate of heat transfer. In the embodiment shown in FIGS. 3 and 4, the water is in a planar contact over the surface of the coal seam and heat is transferred from the hot coal into the water sand and from there to the water where it is converted to steam which passes to the turbine. Here in this embodiment the combustion of the coal provides a continuous stream of products combustion which flows from the points of air inlet 82 through the burning zone and through a volume either drilled or otherwise formed 70 or through porous regions which have previously been burned. The hot products of hot gases which are products of the combustion then pass out through the borehole and deliver their heat to the pipes 76 and 78 by convection and then pass out to the atmosphere or to some other heat recovery means such as is well known in the art.
FIG. 6 shows in planned view the spacial arrangement of the air holes in a pattern surrounding the central bore holes 72.
Other elements of FIG. 5, which have not been specifically described, are similar to the corresponding elements having the same numbers in FIGS. 1 and 3 and therefore need no further description.
No detail has been provided on the methods or apparatus required for drilling the horizontal and vertical boreholes, and for setting casing, etc. since all of this art is well-known in the oil industry. While we have talked of "more or less" horizontal coal seams, it will be clear that the coal seams can be tilted to any angle of dip in which they may be found. It may be valuable in that case to design the drilling of the pipes and the air holes in such a direction as to take advantage of the dip of the coal seam.
While it is old in the art, to generally burn coal in situ in the earth, and to recover its products of combustion, we have invented particular embodiments which utilize the geological environments in which:
(a) the coal seam crops out, and
(b) where the coal seam is overlain by either a water formation or a formation containing very viscous oil, which normally cannot be produced except by being heated and then driven through the formation.
Although the physical requirements of these two embodiments are rather specific, they do have considerable advantage in that:
(a) they eliminate the mining of the coal which would be unprofitable, particularly for thin seams;
(b) they eliminate waste in the mining of coal;
(c) they eliminate the dust pollution, etc.;
(d) they eliminate the transportation of coal;
(e) they can recover all available energy and usuable gases;
(f) the methods are applicable to any depth of the coal seam, although the economics would indicate that they are best for relatively shallow coal seams;
(g) they can utilize thin coal seams that would never be mined;
(h) the burning of the coal can be regulated by the amount of air pumped to obtain all the energy that can be captured with the described facilities;
(i) the energy can be transmitted as electrical energy, the cheapest form of energy transportation.
While the invention has been described with a certain degree of particularity it is manifest that many changes may be made in the details of construction and the arrangement of components. It is understood that the invention is not to be limited to the specific embodiments set forth herein by way of exemplifying the invention, but the invention is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element or step thereof is entitled. | A method for recovery of heat generated by the combustion of coal in situ within coal seams in the earth. Three embodiments are described: one, in which the coal seam crops out and into which can be drilled and inserted a pipe, through the coal seam, to a central point, where it is joined with a vertical pipe drilled from the surface. Water is supplied to the pipe at the point of outcrop. Fires are started within the coal seam and supplied with air from the surface by means of drilled boreholes. The heat of combustion converts the water in the pipe to steam which travels up the vertical pipe and is used to drive a turbine generator system. A second embodiment is used where there is an overlying aquifer above the coal seam. Fires are started by means of air supplied through boreholes leading from the surface into the coal seam. The heat of combustion converts the water in the aquifer to steam, which then is circulated out of the aquifer and up to the surface where it drives a turbine generator system. A third embodiment uses the hot combustion gases to heat water to steam in pipes in a vertical borehole. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 61/005,710, filed Dec. 7, 2007. Said U.S. Provisional Application Ser. No. 61/005,710 is herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The disclosure generally relates to the field of tilt-up concrete construction, and more particularly to temporary floor joint filler.
BACKGROUND
[0003] A smooth surface is the primary objective when producing concrete wall panels. To make concrete wall panels, construction workers use a method commonly referred to as “tilt-up” construction. When using this method, the concrete used to make the wall panel is placed over an already cured concrete floor slab. Oftentimes, this floor slab has joints which have been cut into the slab, creating deep cuts in the otherwise smooth and clean surface. A liquid applied bond breaker is usually placed atop the cured concrete to prevent the two pieces from sticking together. After the concrete has developed sufficient strength, the wall panel may be tilted vertically into the appropriate place, creating a wall. Because the wall panel was cast over the concrete floor slab, the wall panel may include large ridges running across the wall panel corresponding to where the wall panel concrete seeped into the pre-cut floor joints. Workers are then required to spend a substantial amount of time fixing the wall panel's imperfections created by pre-cut floor joints by grinding the ridges down until the wall panel is smooth.
[0004] Consequently, it is desirable to provide a filler which would be capable of covering pre-cut floor joints in concrete floor slabs.
SUMMARY OF THE INVENTION
[0005] Accordingly, the present invention is directed to a method and apparatus for covering and sealing pre-cut joints in concrete floor slabs. A temporary floor joint filler may be comprised of a flexible, reusable material, creating a support member for longitudinally inserting into pre-cut floor joints. The support member may include a plurality of longitudinally oriented fins for securing the support member within the floor joint. The support member may further include a cap for preventing wall panel concrete from seeping into the pre-cut joint, such as when the concrete shrinks during curing, increasing the size of the pre-cut floor joint.
[0006] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the present disclosure. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate subject matter of the disclosure. Together, the descriptions and the drawings serve to explain the principles of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The numerous advantages of the disclosure may be better understood by those skilled in the art by reference to the accompanying figures in which:
[0008] FIG. 1 is a partial isometric view illustrating temporary floor joint filler;
[0009] FIG. 2 is an end view illustrating temporary floor joint filler, wherein the temporary floor joint filler comprises a cap and four fins oriented substantially perpendicular to the base member;
[0010] FIG. 3 is an end view illustrating temporary floor joint filler, wherein the temporary floor joint filler comprises a cap and two fins oriented at an angle from the base member;
[0011] FIG. 4 is an end view illustrating temporary floor joint filler, wherein the temporary floor joint filler comprises a cap and six ridged fins coupled to the base member;
[0012] FIG. 5 is an end view illustrating temporary floor joint filler, wherein the temporary floor joint filler comprises a cap and two elongated fins coupled to the base member;
[0013] FIG. 6 is an isometric view illustrating insertion of a temporary floor joint filler into a sawcut joint;
[0014] FIG. 7 is an exploded view illustrating placement of liquid applied bond breaker over a concrete floor slab and temporary floor joint fillers;
[0015] FIG. 8 is a partial cross-sectional end elevation view illustrating a concrete floor slab, a sawcut floor joint and a temporary floor joint filler covered with bond breaker, and a wall panel; and
[0016] FIG. 9 is an isometric view illustrating a wall panel being moved to a vertical orientation from a concrete floor slab.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Reference will now be made in detail to the subject matter disclosed, which is illustrated in the accompanying drawings.
[0018] Referring generally to FIGS. 1 and 2 , a temporary, reusable floor joint filler 100 is described in accordance with an exemplary embodiment of the present invention. The temporary floor joint filler 100 may include a cap 102 , a base member 104 , one or more fins 106 , 108 , 110 and 112 , a first set of opposing sides 114 and 116 , and a second set of opposing sides 118 and 120 . The cap 102 may be coupled to the first side 114 of the first set of opposing sides 114 and 116 . The first fin 106 may be coupled to the first side 118 of the second set of opposing sides 118 and 120 . The second fin 108 may be coupled to the second side of the second set of opposing sides 118 and 120 . In this embodiment, the cap 102 and one or more fins 106 , 108 , 110 and 112 are included for securing temporary floor joint filler 100 into a joint 122 (as illustrated in FIGS. 1 through 2 and 6 through 8 ). In another embodiment, a cap 102 and one or more fins 106 , 108 , 110 and 112 are included for sealing the joint 122 (as illustrated in FIGS. 1 through 2 and 6 through 8 ).
[0019] In some embodiments, the temporary floor joint filler 100 may be constructed from a flexible (and possibly reusable) material, such as rubber. It is contemplated that any type of rubber may be employed for temporary floor joint filler 100 . In one specific embodiment, an American Society for Testing and Materials (ASTM) rubber with a Shore A hardness of a range 20-100 may be utilized. For example, the temporary floor joint filler 100 may be constructed from a material selected to provide flexibility for inserting the temporary floor joint filler 100 into a pre-cut concrete joint 122 , while still providing adequate strength for supporting concrete. Further, it will be appreciated that certain materials may be selected according to other design considerations, including reusability and/or disposability. For instance, in one embodiment, silicon and/or another non-stick material may be selected for reusability; while in another embodiment, a biodegradable material may be selected for disposability.
[0020] Referring now to FIGS. 3 through 5 , a temporary floor joint filler 100 is described in accordance with the present invention. For example, in one embodiment a temporary floor joint filler 100 may include a cap 102 and one or more fins 124 and 126 oriented at an angle from a base member 104 for securing temporary floor joint filler 100 into a joint 122 (as illustrated in FIGS. 3 and 6 through 8 ). In another embodiment, a temporary floor joint filler 100 may include a cap 102 and one or more ridged fins 128 and 130 coupled to the base member 104 for securing temporary floor joint filler 100 into a joint 122 (as illustrated in FIGS. 4 and 6 through 8 ). In still a further embodiment, a temporary floor joint filler 100 may include a cap 102 and one or more elongated fins 132 and 134 coupled to the base member 104 for securing temporary floor joint filler 100 into a joint 122 (as illustrated in FIGS. 5 and 6 through 8 ). It will be appreciated that the orientation and design of the fins may be varied according to other design considerations, including flexibility and/or retention within a joint 122 .
[0021] In some embodiments, a temporary floor joint filler 100 may include a base member 104 coupled to the center of the cap 102 for securing temporary floor joint filler 100 into a joint 122 . In other embodiments, a temporary floor joint filler 100 may include a base member 104 coupled to the side of the cap 102 for securing temporary floor joint filler 100 into a joint 122 . It will be appreciated that the orientation and design of the cap and/or the base member may be varied according to other design considerations, including flexibility and/or retention within a joint 122 .
[0022] Referring now to FIG. 6 , a technique for inserting temporary floor joint filler 100 into a joint 122 is shown. The temporary floor joint filler 100 may be pressed into a joint 122 using an individual's foot 136 . Installing the temporary floor joint filler 100 in this fashion may allow for simple and efficient preparation of a concrete slab 138 for subsequent construction activities.
[0023] In some embodiments, a tool may be used for inserting temporary floor joint filler 100 into a joint 122 . For example, in one embodiment, temporary floor joint filler 100 may be pressed into joint 122 using a hand-held roller. In another embodiment, temporary floor joint filler 100 may be extruded into joint 122 using an extruding device. In still a further embodiment, temporary floor joint filler 100 may be threaded through joint 122 . It is understood that a number of methods may be employed for inserting temporary floor joint filler 100 into joint 122 without departing from the scope and intent of the disclosure.
[0024] In some embodiments, various techniques may be employed to ensure temporary floor joint filler 100 is secured in joint 122 . For example, in one embodiment, temporary floor joint filler 100 may be affixed into joint 122 with a temporary adhesive. In another embodiment, joint filler 100 may be anchored to at least one end of the concrete slab 138 . These examples are meant to illustrate specific embodiments of the present invention and are not meant to be restrictive of the invention. Thus, it is understood that a number of methods may be employed for securing temporary floor joint filler 100 into joint 122 without departing from the scope and intent of the disclosure.
[0025] Referring now to FIGS. 7 through 9 , a method for creating a wall panel 142 is shown. For example, the temporary floor joint filler 100 may be installed into a joint 122 , bond breaker 140 may be applied over the temporary floor joint filler 100 and the concrete slab 138 . A wall panel 142 may be fashioned by pouring concrete over the concrete slab 138 . Once the wall panel 142 has developed sufficient strength, a crane 144 may be used to move the wall panel 142 into a vertical orientation from the concrete slab 138 .
[0026] In some embodiments, multiple wall panels 142 may be fashioned by placing concrete over the concrete floor slab 138 . For example, the temporary floor joint filler 100 may be installed into a sawcut joint 122 , bond breaker 140 may be applied over the temporary floor joint filler 100 and the concrete floor slab 138 . A wall panel 142 may be fashioned by placing concrete over the concrete floor slab 138 . Once the wall panel 142 has developed sufficient strength, a crane 144 may be used to move the wall panel 142 into a vertical orientation from the concrete floor slab 138 . The process may then repeat in order to produce the number of wall panels 142 desired.
[0027] It is believed that the temporary floor joint filler of the present disclosure and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components without departing from the disclosed subject matter or without sacrificing all of its material advantages. The form described is merely explanatory, and it is the intention of the following claims to encompass and include such changes. | A temporary floor joint filler may include a base member having a cross-sectional profile including a first set of opposing sides and a second set of opposing sides, a cap coupled to the base member, a first fin coupled with a first side of the second set of opposing sides of the base member, and/or a second fin coupled with a second side of the second set of opposing sides of the base member. The base member may be configured for insertion into a floor joint, the first fin and the second fin may be configured for retaining the base member in the floor joint, and the cap may be configured for covering the floor joint. |
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CROSS-REFERENCE TO RELATED APPLICATION
The instant application is a national phase of PCT International Patent Application Serial No. PCT/MY2014/000018, filed Feb. 19, 2014, and claims priority to Malaysian Patent Application Serial No. PI 2013701893, filed Aug. 21, 2013, the entire specifications of both of which are expressly incorporated herein by reference.
FIELD OF INVENTION
The present invention relates to an interlocking end plate connector attached to the ends of a concrete pile for joining the end of one concrete pile to the end of another adjoining concrete pile. The tapered square pin is rotated 45 degrees to the vertical axis of the pile for maximum engagement of the tapered square pin with the tapered square passageway formed by the mated end plates. The interlocked end plates have a safe bending moment and tension capacity that exceeds the reinforced concrete pile section. In addition this invention is adapt to suit heavy pile driving using heavy drop hammer impact onto the top of the end plate without damaging the interlocking grooves.
BACKGROUND OF THE INVENTION
Reinforced concrete (RC) pile and prestressed high tensioned concrete spun (PHC) pile are capped at the ends with normal steel end plates that do not have a mechanical means to joint to each other except by site welding. It is cumbersome to use mechanical pile splices or connectors that consist of many small and fragile parts such as bolts, pins, washers, shear keys etc. In addition, these fragile parts of the connectors as mentioned above will require additional opened accesses such as grooves or holes that reduces the contact surface of the end plate for load transfer, and therefore the pile connectors must be fortified with flanges or wedges. Of recent, there are many patents filed in Korea that teach the use of various intermediate steel connectors that are used like adaptors placed in between the end plates of the spun piles. The use of an additional steel intermediate connector incurs extra cost. Further, these intermediate connectors are usually welded from smaller parts which tend to introduce additional weakness. Whereas in this invention, the end plate is hot forged from steel and precasted into ends of the spun pile
A pending patent PI2012700742 is filed in Malaysia by the same inventor that relates to an article for joining concrete piles which has overcame several drawbacks in the prior arts as referred to above. However in this present invention, many further improvements has been made as compared to PI2012700742; 1) The present end plate is designed to take heavy hammer impact without sustaining damages to the end plate's interlocking dovetail grooves. 2) In PI2012700742, thicker end plates are necessary to accommodate the prestressed steel tendon button head such that it is placed at least flush or below the top surface of the end plate and yet provide sufficient remaining depth in the end plate for the prestressed steel tendon seating to avoiding material punching failure through the base of the end plate. However in this invention, material savings is achieved by reducing the overall thickness of the steel end plate through creating segmental protrusions and segmental recesses of generally similar thickness, and in addition to this feature each segments have localised hot forged indentations that creates deeper sections for the prestressed steel tendon button head and seating. As a result of reducing the overall thickness, there is a material saving of at least 30% to 45% as compared to PI2012700742. 3) Another crucial feature lies in the 45 degrees rotation of the square openings to the vertical axis of the pile resulting in the edges of the segmental protrusion and recesses having like dovetail grooves when viewed from the side elevation. This 45 degrees orientation gives maximum contact surface between the tapered square pin and tapered square passageway. Further with this 45 degrees rotation, the tapered square opening can accommodate a tapered square pin that is 40% larger in size as compared to the prior art if the square pin is placed in the horizontal position. This is advantageous because by jamming and forcing the tapered square pins into the tapered square passageway of the mated end plates, it has higher axial compression force of 283% as that for the square pin placed in the horizontal position. The prior patent PI2012700742 specified a tapered passageway of a square shape but did not teach about the rotation angle in the axis of the pile. 4) The transfer of tension in the prestressed steel tendons across the connected piles is also improved by placing the vertical prestressed tendons in close proximity to horizontal interlocked tapered square pins instead of being located at the centre of the segmental protrusions or segmental recesses as in PI2012700742. Thus, when the pile is resisting a bending moment, the resulting additional tension in the vertical prestressed steel tendons will pull the end plate along the axis of the tendons and thereby bends the end plate, but this bending effect is considerably reduced by the close distance of the top and bottom vertical prestressed steel tendons to the horizontal interlocked tapered square pins. 5) To avoid seepage of grout through the end plate and the sides of the spun pile's mould during spinning, there is a provision to secure a circular steel skirt to the end plate by means of providing outer segmental side edges on the underside of the segmental protrusions so that there is sufficient thickness for a deep rectangular groove to traverse the circumference of the end plate such that it can embed the proximal lipped edge of the circular steel skirt. 6) In another adaptation of the present invention for use in a solid square concrete piles which is more common as compared to square hollow concrete piles, the alignment of the dovetail groove in the plan view of the end plate has been altered to avoid a sharp kink angle. A problem is encountered in the side milling process of a dovetail groove because a length of about half a diameter of the dovetail cutter to a sharp kink angle is obstructed. It is impossible to side mill the dovetail groove throughout its entire length unless there is a central opening in the end plate which is bigger than the diameter of the side mill cutter as in PI2012700742. Alternatively, this problem may be alleviated by using localised electrical induction to heat the interlocking edge of the end plate to about 1000° C. and hot forged the edge into a dovetail groove shape with specialised conforming die with the corresponding sharp kink angle, but this process is expensive as many specialised dies needs to be customised for different sizes of end plate.
In the CN 201120356388, this utility model claims a pre-stressing force concrete pipe pile machine fast connector is composed of tubular pile connected with the inclined plate in clamping block clamping block bolt and screw cap. Pipe pile is set in the connecting plate is symmetrically distributed with 3-8 radial locking groove each which is set on the bolt radial through hole at the inner ring of the groove with inner inclined clamping block the axial direction of the square hole. Outer clamping piece of inner surface of the gear shape of the outer surface of the clamping block is set in the centre of which is set on the bolt through hole. This utility teaches that the force derived from the clamping bolts is acting perpendicular to the vertical axis of the pile, and the horizontal clamping force is to grip the lateral edges of the pile into place by friction. Whereas in the present invention, the axial clamping force is derived not by tightening bolts but by jamming the tapered square pin which creates a expansionary force inside the tapered square passageway on the opposing contact surfaces along the grooves of the top segmental protrusion and the bottom segmental recess which finally presses the mated flat surfaces of the end plates very tightly together hence giving a stiffer performance under a pile bending moment.
An example of such pile connector is known in U.S. Pat. No. 4,157,230, whereby a nut is constructed within the joining ends of the two pile sections for a threaded bolt to be fastened to the nuts. The nut is provided with an annular groove having radially directed locking notches in the bottom. A locking disk is inserted into the groove. The disk has resilient locking tongues with radial edges which are directed against the unscrewing direction and which engage with the notches in the nut. One specific drawback is the dimensional accuracy required by this mechanical bolted splice as specified by the author is that the end surfaces of the abutting pile sections must be extremely plane in order to obtain as strong a connection between the sections as possible. Whereas in reality, under heavy hammer impact, the end surface be stressed and distorted.
In the EP0891454B1, the object of the invention is a stiff adjoining piece for joining concrete piles, particularly reinforced piles, end to end so that those ends of the concrete piles which are joined together comprise base plates that is provided with a cavity that receives the locking bar, and the groove extending as a toroid around the cavity, and with a hole extending from this groove at least approximately in a tangential direction; and of an insert pin which, when the pile joint is made, is driven into the hole so that it rums around the locking bar in the cavity, guided by the circumferential face of the groove, whereby it is simultaneously locked permanently in place because of plastically deformation. This invention specifically uses a round bar as a deformable lock pin whereas the present invention teaches the use of stiff tapered square pin.
In EP1403436A2, it concerns a pile connecting structure for connecting upper pile and lower pile to each other, at the connecting portion between the upper pile and the lower pile, by screwing bolts inserted in circular-shaped bolt inserting holes formed in the connecting to the bolt hole in the end plate of the pile on one side, where the head of the bolts screwed to the end plate of the pile on the other side is inserted in the large diameter portion of heteromorphic bolt insertion holes communicating between a large diameter portion which the head of the bolts formed on the connecting plate can pass through making the other pile and the connecting plate move relatively so that the bolts may shift from the large diameter portion of the heteromorphic bolt insertion holes to the small diameter portion. The drawback lies in that twice as many bolt insertion holes is required which weakens the pile connector and demands precision in manufacturing and also leads to difficulty in manipulating the bolts into the smaller diameter heteromorphic bolt insertion holes through twisting heavy piles. The current invention overcomes these problems during mating of the end plates with the tapered edges of the interlocking end plates and generous tolerance provided in the gaps to easily lower the segmental protrusions vertically into the segmental recesses. The tapered square pins can then be easily inserted and jammed into the tapered square passageway created by the mating of the end plates.
SUMMARY OF INVENTION
The main aspect of the present invention is to provide to an interlocking end plate connector attached to the ends of a concrete pile for joining the end of one concrete pile to the end of another adjoining concrete pile having a safe bending moment and tension capacity that exceeds the reinforced concrete pile section.
Another aspect of the present invention is to suit heavy pile driving using drop hammer impact onto the top of the end plate without damaging the interlocking grooves.
Another aspect of the present invention is the 45 degrees rotation of the square openings having a width of “d” to the vertical axis of the pile gives the maximum contact surface and compression force between the tapered square pin and tapered square passageway, and requires a minimum depth of 1.4d for the tapered square passageway when mating the tapered dovetail groove of the segmental protrusion with segmental recess. Otherwise it would require a end plate thickness of at least 2d for the square pin passageway using the horizontal square pin.
Another aspect of the present invention is that the 45 degrees rotation of the square openings of the vertical axis of the pile provide a axial clamping force that is derived by jamming the tapered square pin into the square opening which creates a vertical clamping force in the axis of the pile that presses the surfaces of the end plates into contact very tightly together hence giving a stiffer performance under a pile bending moment.
Another aspect of the present invention is to provide an end plate for joining concrete spun piles that do not require a male and female locking mechanism or use of intermediate connectors or adaptors.
Another aspect of the present invention is to reduce weight of the end plate without sacrificing the strength by reducing the overall thickness of the steel end plate through creating segmental protrusions and segmental recesses of generally similar thickness with each segments having localised hot forged indentations that creates deeper sections for the prestressed steel tendon button head and seating.
Another aspect of the present invention is a provision to secure a circular steel skirt to the end plate.
Another aspect of the present invention is providing outer segmental side edges on the underside of the segmental protrusions so that there is sufficient thickness for a deep rectangular groove to traverse the circumference of the end plate such that it can embed the proximal lipped edge of the circular steel skirt
Another aspect of the present invention provides a method of attaching the circular skirt to the end plate to avoid seepage of grout through the end plate and the sides of the spun pile mould during spinning.
Another aspect of the present invention is to suit the manufacturing of the end plate made from a single piece of forged steel and milling of the rough forged end plate.
Still another aspect of the present invention is to provide an article for joining concrete piles that has a sufficient tolerance to mate the end plates easily.
At least one of the preceding aspects is met, in whole or in part, by the present invention is best described consisting of a top end plate ( 1 a ) and bottom end plate ( 1 b ) for joining two separate spun piles by interlocking together at the top end plate ( 1 a ) located at the bottom end of the first spun pile ( 16 a ) to the bottom end plate ( 1 b ) located at the top end of the second spun pile ( 16 b ). The end plates ( 1 a , 1 b ) are identical and similar except in the orientation where the flat surfaces of the end plates ( 1 a , 1 b ) is the exposed outwards and rotated by the interposing angle such that the proximal end plate's segmental protrusion ( 8 a , 8 b ) is in line matching to the distal end plate's segmental recess ( 7 a , 7 b ). As a result equal length of steel tendons can be placed between the end plates. During manufacturing of the steel tendon cage for production of the spun piles, it is important that the equal cut lengths can be placed into a circular steel tendons ribbed cage for automatic welding machine to suit the client's machines. A 45 degrees rotation of the square openings ( 4 ) is formed from matching the tapered dovetail groove ( 14 ) of the top segmental protrusion ( 8 a ) with the bottom segmental recess ( 7 b ) and top segmental recess ( 7 a ) with the bottom segmental protrusion ( 8 b ) wherein a corresponding tapered square pin ( 3 ) can be jammed therethrough an opening ( 4 ) to securely interlocked the end plates together.
The preceding aspects of the invention also covers the manufacturing of the spun pile using the end plates ( 1 a , 1 b ); one proximal edge of the circular steel skirting ( 11 a , 11 b ) is pressed into a “L-shaped” lip and forced into the deep rectangular circumferential grooves ( 6 a , 6 a ) of the end plates ( 1 a , 1 b ) by using a rolled formed machine such that the inner sides of the circular steel skirting ( 11 a , 11 b ) is in very close contact with the sides of the end plates ( 1 a , 1 b ). In this way a tight enclosure is formed so that the cement grout cannot escape through the gaps between the steel skirting ( 11 a , 11 b ) and the end plates ( 1 a , 1 b ) when the infilled concrete is poured into the spun pile mould containing the two end plates ( 1 a , 1 b ) at each end of the spun pile ( 16 a , 16 b ) and spun to densify the concrete.
A second preferred embodiment of the present invention comprises a square end plate ( 22 a , 22 b ) which is mounted at the ends of a solid square concrete pile ( 26 a , 26 d ) with steel bars ( 25 a , 25 b ) welded flush to the top of the square end plate ( 22 a , 22 b ). The top end plate ( 22 a ) has segmental protrusion ( 29 a ) and segmental recess ( 28 a ) with a dovetail grooves ( 24 ), and the bottom end plate ( 22 b ) has segmental protrusion ( 29 b ) and segmental recess ( 28 b ) with a dovetail grooves ( 24 ). The end plates ( 22 a , 22 b ) are not identical and can only be mated in two orientation by rotating 180 degrees around the vertical axis. The top square end plate ( 22 a ) of the top section concrete square pile ( 26 a ) is mated with the bottom square end plate ( 22 b ) of the bottom section concrete square pile ( 26 b ), a tapered square passageway is formed in each side edge of the segments. By jamming and forcing the tapered square pins ( 23 ) into the tapered square passageway ( 24 ) of the mated end plates ( 22 a , 22 b ), the two end plate presses against each other and bindingly interlocked as an integral squared solid concrete pile ( 21 ). So this invention can be used for a solid square concrete piles without the use of indentations to increase the thickness of the square end plate ( 22 a , 22 b ) because the steel bars ( 25 a , 25 b ) is welded to the square end plate ( 22 a , 22 b ).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the separated upper first spun pile and lower second spun pile with the attached top end plate attached to the base of the first spun pile and the bottom end plate attached to the top of the second spun pile.
FIG. 2 shows the mated top and bottom spun piles with the tapered square pins inserted through the openings into the tapered square passageway.
FIG. 3 shows the dissected components in the preferred embodiment of the present invention with the mated top and bottom end plates, top and bottom vertical steel tendons and top and bottom circular skirt exposed without the concrete.
FIG. 4 shows the separated top and bottom end plates and top and bottom circular skirt exposed without the concrete and circular skirt.
FIG. 5 shows the side view of the mated top and bottom end plates with the tapered square pins, the top and bottom indentations to the top and bottom end plates, and the top and bottom circumferential grooves to the top and bottom end plates respectively.
FIG. 6 shows the detailed side view of the 45 degrees rotation of the square openings to the tapered square passageway of the mated top and bottom end plates.
FIG. 7 shows the detailed side view of the square pin inserted to the opening of the square passageway created by mating of the top and bottom end plates.
FIG. 8 shows the overall plan view the tapering alignment of the square passageway from 0-5 degrees towards the center of the annulus end plate
FIG. 9 shows the detailed plan view the tapering alignment of the square passageway from 0-5 degrees towards the center of the annulus end plate
FIG. 10 shows the detailed side view of the vertical alignment of the square passageway at 0-5 degrees to the axis of the pile with a parallel gap of 0.1d to 0.4d between the sides of top segmental protrusion and the bottom segmental recess.
FIG. 11 shows the detailed side view of the gap tolerance opening of 0.5d to 1.5d between the sides of top segmental protrusion and the bottom segmental recess for ease of mating the end plates
FIG. 12 shows the partial cut away 3D view of the mated the top and bottom indentations to the top and bottom end plates, the top and bottom steel tendons to the top and bottom end plates, and attachment of the top and bottom circular skirt to the top and bottom end plates respectively.
FIG. 13 shows the position of section A-A and section B-B cut of the partial cut away plan view of the mated the top and bottom end plates.
FIG. 14 shows the position of section A-A ( FIG. 13 ) of the partial cut away plan view of the mated the top and bottom end plates with the inserted tapered square pins.
FIG. 15 is a of section B-B ( FIG. 13 ) showing partial cut away plan view of the mated end plates and the steel tendons with the top indentations to the top segmental recesses and protrusions, and the bottom indentations to the bottom segmental recesses and protrusions.
FIG. 16 shows the finite element analysis of a mated top and bottom end plates with the inserted tapered square pins before subjecting to a tension force induced by resistance to the pile bending moment.
FIG. 17 shows the finite element analysis of a mated top and bottom end plates that has opened up at the contact surface under ultimate failure due to a tension force induced by the steel tendons on to the end plates.
FIG. 18 shows the compression forces derived from a horizontal square pin with a interlocking depth of 2d.
FIG. 19 shows the compression forces derived from a rotated 45 degrees square pin with an interlocking depth of 1.4d, and the formula to compare the compression forces between the horizontal and rotated square pin.
FIG. 20 shows the 3D view of the bottom end plates where there is a sloping edge above the tapered square pin to avoid contact with impact hammer during pile driving thus avoid compressing the dovetail groove.
FIG. 21 shows the side view of the sloping edge above the tapered square pin varies from 20 to 45 degrees to the plane of the end plate.
FIG. 22 shows the side view of the dimension of the dovetail groove opening in terms fraction of “d” which is the cross-section width of the square openings ( 4 ).
FIG. 23 shows the top and bottom circular skirt and its embedment of one proximal end of the “L-shaped” lip into the circumferential groove in the top and bottom end plate respectively.
FIG. 24 shows the mated top and bottom square end plates for a solid square piles with the tapered square pins inserted through the openings into the tapered square passageway.
FIG. 25 shows the side view of the mated top and bottom square end plates with the tapered square pins, the top and bottom segmental recesses, the top and bottom segmental protrusions.
FIG. 26 shows the separated top and bottom solid square piles with the tapered square pins located at the dovetail grooves of the segmental recess of the bottom end plate.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the present invention discloses a pair of identical top end plate ( 1 a ) and bottom end plate ( 1 b ) for joining two separate spun piles by interlocking together at the top end plate ( 1 a ) located at the bottom end of the first spun pile ( 16 a ) to the bottom end plate ( 1 b ) located at the top end of the second spun pile ( 16 b ). The top annulus spun concrete ( 15 a ) and bottom annulus spun concrete ( 15 b ) is cast in place in a factory with the steel tendons ( 5 a , 5 b ) placed as a welded ribbed cage inside the mould, after which wet concrete poured into it and the mould is closed, following which the tendons are prestressed against the ends of the strong mould and spun to compact the concrete and allowed to cure before removing the spun pile from steel mould.
As seen in FIG. 5 , FIG. 12 and FIG. 23 , there is a thickening at the outer segmental side edges ( 10 a , 10 b ) on the underside of the segmental protrusions ( 8 a , 8 b ) in order to create a continuous width all around the end plate whereby a deep rectangular groove ( 6 a , 6 b ) can traverses the circumference of the end plate ( 1 a , 1 b ) such that it can embed the proximal lipped edge of the circular steel skirt ( 11 a , 11 b ). Alternative it the edge of the circular skirt ( 11 a , 11 b ) must be corrugated and complex lipped edges must be formed to fit into the rectangular groove made into the sides of the end plate. Another method would be to cut the corrugated edges of the circular steel skirt ( 11 a , 11 b ) and fully weld to the outer side of the end plate ( 1 a , 1 b ) but this cumbersome and wasteful. The function of providing a circular skirt ( 11 a , 11 b ) around the perimeter of the end plate ( 1 a , 1 b ) is to prevent grout loss and acts as additional confining circumferential stress to prevent the concrete from spalling at the top of the spun pile under explosive impact of the drop hammer.
In a competitive market, it will be necessary to reduce the weight of the end plates ( 1 a , 1 b ) as there are dead zones in the plates where it is lightly stressed, however the concentrated high prestress tendons ( 5 a , 5 b ) of 1100 MPa acting on the seat ( 9 a , 9 b ) causes high localised shear stress leading punching failure which the plate material is likely mild steel. However in this invention, the end plates ( 1 a , 1 b ) are hot forged in a closed die under high hydraulic force to create the segmental protrusion ( 8 a , 8 b ) and recesses ( 7 a , 7 b ) with indentations ( 2 a , 2 b ) that is drawn at about 30 degrees to 45 degrees to the horizontal plane whereby it create a localised deep profile to overcome the highly stressed zones in tendon seat ( 9 a , 9 b ) thus allowing weight savings as shown in FIG. 5 and FIG. 23 .
It is common that the contact surface of the hammer may not be completely flat and when pounding on the flat top surface of the end plate ( 1 a , 1 b ), certain asperities in the hammer surface can damage and compress the edges above the tapered square groove ( 14 ) thereby making the tapered square groove ( 14 ) to be irregular as seen in FIG. 1 , FIG. 20 and FIG. 22 . This problem is overcome by cutting a top sloping edge ( 12 a , 12 b ) on the exposed flat surface to avoid contact with the asperities at the underside of the drop hammer. In addition the angle of the top sloping edge ( 12 a , 12 b ) is generously angled at 20-45 degrees to the horizontal plane as seen in FIG. 22 .
It is normal in most of the mechanical joints in the prior art that the locking pin is likely to be a solid rod which may be tapered, some are solid tabular but placed squarely in a horizontal position into the passageway. From comparing FIG. 18 and FIG. 19 , in the present invention differs in the rotating the square pin ( 3 ) by 45 degrees to the vertical axis, the edges of the segmental protrusion ( 8 a , 8 b ) and segmental recesses ( 7 a , 7 b ) have like dovetail grooves when viewed from the side elevation. This dovetail groove is formed from a concave 90 degrees edge that is rotated by 45 degrees to the axis of the spun pile ( 16 a , 16 b ) such that the enclosure formed by the two concave 90 degrees edge on one side by the segmental protrusion and the other side by the segmental recess, it results in a 45 degrees rotated square opening ( 4 ) on the side elevation of the end plate ( 1 a , 1 b ). This 45 degrees orientation gives twice the contact surface between the tapered square pin and tapered square passageway and that the critical shear cracking zone is longer and deeper into the endplate ( 1 a , 1 b ) therefore giving greater shear resistance to avoid the pin from dislodging from the square passageway as seen the FIG. 17 . Further for a square opening ( 4 ) of width “d”, comparing FIG. 19 with the 45 degrees rotated square pin, it is noted that the depth for the segmental protrusion ( 8 a , 8 b ) and segmental recess ( 7 a , 7 b ) required is only 1.4d as compared to a minimum of 2d for the normal horizontal square pin in FIG. 18 . In addition, the current invention has higher axial compression force of 283% as that for the square pin placed in the horizontal position due to the increase area of contacts between the square pin ( 3 ) and the dovetail groove ( 14 ). It is also noted that the tapering of the square pin should be about 0.5 to 2 degrees only and when the pin is jammed it, it will not be released as the friction has exceed the sliding of vertical pile under a axial load transmitted to the square pin ( 3 ). This jamming of the square pin ( 3 ) creates a large expansionary force due to the small taper angle into the tapered square passageway on the opposing contact surfaces along the dovetail grooves ( 14 ) of the top segmental protrusion ( 8 a , 8 b ) and the bottom segmental recess ( 7 a , 7 b ) which finally presses the mated flat surfaces of the end plates very tightly together hence giving a stiffer performance under a pile bending moment. This effect of this jamming force of the square pin creates a continuous prestressing across the mated end plates ( 1 a , 1 b ) thus preserving a continuous prestress force along the entire length of the spun pile such that the joint is invisible and can maintain bending moment and tension without initial large rotational displacements.
Another key feature of the present invention is to enhanced shear transfer and reduced bending in the end plate ( 1 a , 2 a ) when mated and undergoing severe bending moments. The transfer of tension in the prestressed steel tendons across the connected piles is improved by placing the vertical prestressed tendons ( 5 a , 5 b ) in close proximity to horizontal interlocked tapered square pins ( 3 ) instead of being located at the centre of the segmental protrusions ( 8 a , 8 b ) or segmental recesses ( 7 a , 7 b ) as seen in FIG. 15 and unlike as in PI2012700742. As seen in the 5× deformed simulation of the end plate under ultimate bending stress in FIG. 17 , the resulting additional tension in the vertical prestressed steel tendons will bends the end plate and open the contact between the end plates ( 1 a , 1 b ). In the present invention the vertical tendons ( 5 a , 5 b ) is placed as close to the edge of the dovetail groove ( 14 ) at about 2d-3d from the centreline of the vertical tendons ( 5 a , 5 b ) to the centreline of the square pins as seen in FIG. 15 .
Another important aspect of the invention is to make provision for sufficient tolerance during mating of the end plate ( 1 a , 1 b ) at the site, this is due to manufacturing inaccuracies and for ease of installation. As seen in FIG. 10 , there is a large parallel gap width of about 0.1d to 0.4d on each side of the mated dovetail groove ( 14 ) when the segmental protrusion ( 8 a ) adjoins to the segmental recess ( 7 b ). In addition in FIG. 10 , there is a flaring angle of about 0-5 degrees in the segmental recess ( 7 b ) to receive the segmental protrusion ( 8 a ). Thus when bringing the top end plate ( 1 a ) into the mating position with bottom end plate ( 1 a ) there is a tolerance of 0.5d to 1.5d which makes installation easy.
In another adaptation of the present invention for use in a solid square concrete piles which is more common as compared to square hollow concrete piles. For a square pile without a hollow core, the dovetail groove ( 14 ) cannot be arranged to radiate out from a point as there would be congestion. In fact, the alignment of the dovetail groove ( 14 ) must avoid a sharp kink angle due to diameter of the dovetail side milling cutter otherwise a length of about half a diameter of the dovetail cutter to a sharp kink angle is obstructed.
The square end plate ( 22 a , 22 b ) which is mounted at the ends of a solid square concrete pile ( 26 a , 26 b ) with steel bars ( 25 a , 25 b ) welded flush to the top of the square end plate ( 22 a , 22 b ) does not encounter the problem of the lowered tendon seat ( 9 a , 9 b ) in the end plate ( 1 a , 1 b ) for spun pile, moreover the yield stress in the reinforced concrete pile is about 355 MPa to 460 MPa which is less than half of the prestressed tendons, therefore less prone to local punching failure and there is no need for indentations in the square end plate ( 22 a , 22 b ). This simplifies the manufacturing of the square end plate in that it can be cold formed along straight lines. In FIG. 25 and FIG. 26 , the fold lines that form the segmental protrusions ( 29 a , 29 b ) and segmental recesses ( 28 a , 28 b ) are nearly straight lines with a kink of not more than 5 degrees. The tapering of the dovetail groove ( 24 ) by 0-5 degrees is adopted similarly as illustrated in FIG. 9 . One drawback is that the end plates ( 22 a , 22 b ) are not identical, therefore a male and female end plate must be attached to each ends of the RC pile, and it can only be mated in two orientation by rotating 180 degrees around the vertical axis. The top male square end plate ( 22 a ) of the top section concrete square pile ( 26 a ) is mated with the bottom female square end plate ( 22 b ) of the bottom section concrete square pile ( 26 b ), a tapered square passageway is formed in each side edge of the segments for insertion of the tapered square pin ( 23 ). The square skirt to surround the perimeter of the end cap can be formed from a thin plate and one proximal edge of the inner sides of the square skirt is welded to the outer side of the square end plate ( 22 a , 22 b ), in this way this welding it is more economical for square piles which is much smaller than spun piles. | A system for joining two separate spun piles by interlocking together a top end plate located at a bottom end of a first spun pile to a bottom end plate located at a top end of a second spun pile, wherein the end plates each have a plurality of segments comprising an equal number of segmental protrusions and segmental recesses. |
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FIELD OF THE INVENTION
[0001] The present invention relates to an interlocking waney edge glue system for utilizing waney lumber to produce composite wood products and thereby reduce waste. In particular, the present invention relates to profiled wood articles made from waney lumber and a system for using the profiled wood articles to manufacture composite edge-glued wood products.
BACKGROUND OF THE INVENTION
[0002] The production of standard lumber inevitably results in waste in the form of waney lumber, or boards or pieces of lumber that, instead of being cut square, show the original curve of the log from which they are cut. Due to the curvature and irregular shape of waney lumber, it is difficult to use in the manufacture of wood products. Its low cost, on the other hand, makes it a potentially useful raw material. Many composite wood products are made by gluing and pressing pieces of lumber together. To carry out such a lamination of lumber, each of the pieces of lumber used must have complementary surfaces that provide a good joining surface. As waney lumber has irregular surfaces that do not facilitate lamination, waney lumber must be further processed to provide complementary uniform surfaces before it can be used to produce composite wood products. A typical approach to utilizing waney lumber has been to simply saw off the waney portion of the board. Such an approach results in a great deal of waste of waney fiber.
[0003] As forests are a precious resource, and as there is a need to conserve forests, the minimization of waste is desirable. Consequently, there is a need in the art for a means of utilizing waney lumber to obtain composite wood products with a minimum of waste.
[0004] Previously disclosed methods of utilizing waney lumber have further deficiencies and limitations that negatively impact the efficiency of making composite products from waney lumber, or the durability of such products. Known methods often do not produce strong joints between adjacent pieces of waney lumber due to insufficient contact area for the joint, and non-uniform contact between profiled edges. Profiling refers to the reshaping of waney lumber to remove the irregular rounded surfaces. In addition, the edge profiles of the prior art are such that complex pressing machinery (e.g. two-dimensional presses) is required. Such presses significantly increase the cost of the final composite product due to the cost and complexity of the press itself, a more complex manufacturing process and the relatively low throughput.
[0005] Key to producing waney wood composite products that are commercially feasible is that the products must be durable as well as easy to produce. Ideally, the profiled edges between adjacent pieces of lumber are shaped such that they provide a strong joint, permit the use of conventional pressing equipment, and allow a standard manufacturing process.
[0006] U.S. Pat. No. 5,870,876, issued to Deiter, discloses a composite wood product made from a plurality of identical profiled pieces of lumber having identical and complementary profiled edges. However, the profile used in Deiter is such that a two dimensional press is required because the profiled edges do not interlock in a manner that prevents lateral movement of adjacent pieces of profiled lumber. Therefore, if a one dimensional press is used, the glue lines perpendicular to the press plates don't receive any pressure and the profiled pieces of lumber are likely to shift during the pressing process.
[0007] Accordingly, it is an object of the present invention to provide a composite wood product and means for the manufacture thereof, that makes efficient use of waney lumber (i.e. cost effective use resulting in a minimum of fiber waste) and that requires only a conventional one dimensional edge glue press during the manufacturing process.
SUMMARY OF THE INVENTION
[0008] A composite edge-glued wood product, comprising profiled pieces of lumber bonded and pressed together. The profiled pieces of lumber are made from waney lumber, which has been profiled such that the waney edges thereof have been removed to reveal profiled edges. The profiled edges each have at least one protrusion and one indentation, and each of the profiled edges extends from the top surface and the bottom surface of the respective profiled piece of lumber.
[0009] The profiled pieces of lumber are arranged side by side in parallel relation and adjacent profiled pieces are inverted with respect to one another such that the top and bottom surfaces of the composite wood product are formed by alternating top and bottom surfaces of the profiled pieces.
[0010] Each of the profiled edges is complementary to and engageable with adjacent profiled edges on adjacent and inverted profiled pieces of lumber such that adjacent profiled pieces of lumber are in close-fitting and interlocking engagement with one another by mutual interlocking engagement of their respective profiled edges.
[0011] The interlocking engagement of the profiled pieces of lumber prevents lateral movement of adjacent profiled pieces of lumber relative to one another when the composite wood product is pressed. During manufacture, adjacent profiled edges are bonded to one another by adhesive, and the composite wood product is pressed in one dimension in a manner operative to force adjacent profiled edges against one another. Accordingly, in the preferred embodiments the profiled edges do not have portions or faces parallel to the top and bottom surfaces because such portions or faces would not receive pressure when the profiled pieces of lumber are pressed in a conventional edge gluing press. In addition, depending on the precise configuration of the profiled edges in question, it may be more difficult to apply glue to such portions or faces.
[0012] The present invention additionally contemplates a method of making the composite wood product. The first step in the method is to provide elongated pieces of waney lumber which are then profiled by removing the waney edges thereof to reveal profiled pieces of lumber having profiled edges. Each of the profiled edges has at least one protrusion and one indentation, and each of the profiled edges extends from the top to the bottom surface of a respective profiled piece of lumber. Adhesive is then applied to the profiled edges, and the profiled pieces of lumber are arranged side by side in parallel relation such that adjacent profiled pieces of lumber are inverted with respect to one another and such that adjacent profiled edges come into close-fitting interlocking engagement. The profiled pieces are arranged such the top and bottom surfaces of the composite wood product are formed by alternating top and bottom surfaces of the profiled pieces of lumber.
[0013] The close fitting interlocking engagement the adjacent profiled pieces is operative to prevent lateral movement of adjacent profiled pieces of lumber relative to one another.
[0014] The interlocked profiled pieces of lumber are then pressed together in one dimension such that the adjacent profiled edges are forced against one another.
[0015] The invention makes use of waney lumber, which is a presently underutilized and readily available raw material, to make composite wood products. Further, the invention makes use of waney fiber in an economical way. The use of a one-dimensional edge glue press takes advantage of inexpensive conventional technology.
[0016] The invention also enables the manufacture of edge-glued composite products from material with wane only on one side as well as square-edge material.
[0017] Other objects and advantages of the invention will become clear from the following detailed description of the preferred embodiment, which is presented by way of illustration only and without limiting the scope of the invention to the details thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further features and advantages will be apparent from the following Detailed Description of the Invention, given by way of example, of a preferred embodiment taken in conjunction with the accompanying drawings, wherein:
[0019] FIG. 1 is a cross section of waney lumber having two waney edges;
[0020] FIG. 2 is a cross section of profiled lumber having both edges profiled;
[0021] FIG. 3 is a cross section of a composite wood product formed from profiled lumber;
[0022] FIG. 4 is a cross section of a prior art composite wood product formed by combining prior art profiled lumber;
[0023] FIG. 5 is a cross section of a prior art composite wood product formed using square-edged lumber;
[0024] FIG. 6 is a cross section of a prior art composite wood product formed by combining prior art profiled lumber;
[0025] FIG. 7 is a cross section of waney lumber having one waney edge;
[0026] FIG. 8 is a cross section of profiled lumber having one profiled edge;
[0027] FIG. 9 is a cross section of a composite wood product formed by combining profiled lumber having one profiled edge;
[0028] FIG. 10 is a cross section of a log showing waney lumber produced as a byproduct when producing standard lumber;
[0029] FIGS. 11 to 14 are illustrations of various additional profiled edges; and
[0030] FIG. 15 is a flow chart of the method of manufacturing the composite wood products of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIGS. 1 and 2 illustrate an elongated piece of waney lumber 10 , having an upper surface 60 , a lower surface 62 , and waney edges 16 , and a profiled piece of lumber 12 made therefrom. The elongated piece of waney lumber 10 and the profiled piece of lumber 12 are shown in cross-section (i.e. the longitudinal axes of the piece of waney lumber 10 and the profiled piece of lumber 12 extend perpendicularly out of the page). Waney lumber usually results as a byproduct from the production of standard lumber as a consequence of the curvature of the tree from which the lumber is produced. By way of example, the elongated piece of waney lumber 10 is illustrated as being a waney byproduct from the production of standard 2×6 lumber; the dotted outline 14 indicates the shape that a standard 2×6 piece would have.
[0032] The rounded, irregular surface of the waney edge 16 makes the elongated piece of waney lumber 10 unsuitable for use in the manufacture of composite wood products because it is not possible to achieve a strong and uniform bond between the waney edge 16 and other components of composite wood products. Cutting off the entire waney portion to produce a lumber product with a rectangular cross section would result in much waste. It is desirable to utilize a maximum of the waney fiber for purposes of manufacturing composite wood products.
[0033] FIG. 2 shows a profiled piece of lumber 12 obtained by profiling the elongated piece of waney lumber 10 of FIG. 1 . The dotted line in FIG. 2 indicates the waney edge 16 of the original waney lumber 10 . The process of profiling amounts to the removal of the waney portions 30 from the original waney lumber 10 to form profiled edges 18 .
[0034] Profiled lumber 12 is shaped such that the profiled edge 18 has protrusions 28 and indentations 38 , and so as to be complementary to a profiled edge of an adjacent piece of profiled lumber. Referring to FIG. 3 , two or more pieces of profiled lumber 12 may be combined to produce a composite wood product 20 . Adjacent pieces of profiled lumber 12 are inverted with respect to one another such that the top and bottom surfaces of the composite wood product 20 are comprised of alternating top 60 and bottom 62 surfaces of the profiled pieces of lumber 12 .
[0035] FIG. 4 shows prior art (see U.S. Pat. No. 5,870,876) in which a profiled piece of lumber 70 has a profiled edge 72 , which profiled edge 72 contacts a similar profiled edge 72 of an adjacent profiled piece 70 to form a composite wood product 74 . During the manufacture of the prior art composite wood product 74 , the profiled pieces 70 must be pressed simultaneously in two dimensions. Pressing in the first dimension is achieved by applying equal and opposite forces to the upper 78 and lower surfaces 80 such that the horizontal portions 82 of the profiled edges 72 of adjacent profiled pieces 70 are forced against one another. The second dimension is orthogonal to the first and pressing in the second dimension is achieved by applying equal and opposite forces to the left and right sides of the composite product 74 such that the vertical portions 76 of adjacent ones of the profiled pieces 70 are forced against one another. If pressing is performed in only one dimension the. profiled pieces 70 may shift relative to one another along either the vertical portions 76 or horizontal portions 82 , whichever are perpendicular to the pressing force and the glue line (i.e. vertical portions 76 or horizontal portions 82 ) parallel to the pressing force will not receive any pressure at all, creating no bond.
[0036] Referring to FIGS. 2 and 3 , profiled edges 18 are shaped such that protrusions 28 and indentations 38 of each piece of profiled lumber 12 engage the protrusions 28 and indentations 38 of an adjacent piece of profiled lumber 12 when two or more pieces of profiled lumber 12 are joined together to form composite wood product 20 . During the manufacturing process the profiled pieces of lumber 12 are pressed together along one dimension (in contrast with the prior art as discussed above in relation to FIG. 4 ). The pressing step is achieved by applying equal and opposite forces to either side of the composite wood product 20 along an axis parallel to the upper and lower surfaces 60 , 62 such that the profiled edges 18 of adjacent profiled pieces of lumber 12 are forced together (i.e. the profiled pieces 12 are pressed together from the left and right as viewed in FIG. 3 ). The mutual engagement of the protrusions 28 and indentations 38 during the pressing process prevents movement of the profiled pieces of lumber 12 relative to one another in a direction perpendicular to the upper and lower surfaces 60 , 62 and to the longitudinal axes of the profiled pieces of lumber 12 , and allows for pressure being applied to all glue lines while being pressed. In other words, protrusions 28 and indentations 38 are so shaped as to make a composite wood product 20 resistant to lateral movement at joint 64 during the pressing process and to create a strong durable glue line.
[0037] Preferably, the profiled edges 18 do not have portions or faces parallel to the upper and lower surfaces 60 , 62 because such portions or faces would not receive pressure when the pieces of lumber 12 are pressed in a conventional edge gluing press, and because, depending on the precise configuration of the profiled edges 18 in question, it may be more difficult to apply glue to such portions or faces.
[0038] The profiled pieces of lumber 12 in FIG. 3 have identical profiled edges 18 . A less complex and more efficient process of manufacturing composite wood products results from this as the same milling head may be used on each piece of waney lumber 10 , and, furthermore, on each waney edge 16 of each piece of waney lumber 10 . In addition, any two adjacent profiled pieces of lumber 12 selected from a plurality of such pieces 12 can be fit together.
[0039] As a consequence of the shape of profiled edges 18 , pieces of profiled lumber 12 mate precisely, thereby reducing, if not eliminating, any need for planing the surfaces of composite wood product 20 . As illustrated in FIG. 5 , in the prior art there arises the problem of alignment of the component pieces of lumber 92 as the flat profile does not prevent lateral movement of the pieces of lumber 92 during the process of gluing and pressing. As illustrated in FIG. 6 , a similar problem is encountered in the manufacture of prior art composite wood products. If a one dimensional press is used, the wood products 70 can shift during the pressing step (the adhesive applied between the wood products 70 can act as a lubricant) resulting in a loss of alignment. As a result of such shifting, the integrity of the joints between adjacent pieces of prior art profiled pieces of lumber 70 is compromised, and the surface of the resulting composite product is uneven.
[0040] As stated above, and with reference to FIG. 3 , the present invention makes use of profiled lumber 12 having profiled edges 18 shaped so as to: (a) allow precision mating of adjacent pieces of profiled lumber 12 ; (b) resist lateral movement of adjacent pieces of profiled lumber 12 such that composite products may be made by pressing in only one dimension; and (c) create a strong durable glue line. Adjacent pieces of profiled lumber 12 automatically interlock for a precision fit upon the exertion of pressure from either side in the direction of joint 64 (i.e. pressed in one-dimension so as to force profiled edges 18 of adjacent pieces of profiled lumber 12 together).
[0041] FIGS. 7 to 9 illustrate a piece of waney lumber 24 having one waney edge 16 , a piece of profiled lumber 26 made therefrom having one profiled edge 18 , and a composite wood product 40 made from such profiled pieces of lumber. The square edge 42 of profiled lumber 26 may be joined with square edge 42 of another piece of profiled lumber 26 or standard lumber (having a rectangular cross section) in order to form a composite wood product. FIG. 9 shows a composite wood product 40 made of a plurality of profiled pieces of lumber 26 . The embodiment of FIG. 9 serves to demonstrate that the present invention is compatible with prior art edge gluing systems.
[0042] A further aspect of the present invention is that one single profile is used on all the profiled edges 18 of all the profiled pieces of wood 12 , 26 so that the process of milling waney lumber into profiled lumber, and the process of assembling the profiled lumber into composite wood products is simplified. In order for a single profile to be used on all of the profiled pieces of lumber 12 , 26 , the profile must have a certain degree of symmetry, such that any one profiled edge will mate with an identical profiled edge that is inverted with respect thereto. FIGS. 11 to 19 illustrate several alternative profiles 18 that exhibit such symmetry, while also exhibiting the characteristics of preventing lateral movement of adjacent profiled pieces of lumber and minimizing waste of waney fiber.
[0043] In a preferred embodiment, the choice of profile of the profiled edges 18 is made so as to maximize the utilization of waney lumber through the selection of a profile that most closely follows the original waney edge 16 . In general, waney edges will have a surface that, in cross section, resembles an arc (as illustrated in FIG. 1 ).
[0044] Referring to FIGS. 1, 2 and 11 - 14 , several examples are shown of profiled edges 18 demonstrating the necessary symmetry about line 36 such that, given two pieces of profiled lumber 12 , each having the same profiled edges 18 selected from FIGS. 1, 2 and 11 - 14 , the profiled edges are complementary to one another and interlockingly fit together in a manner that prevents lateral movement of the two profiled pieces of lumber relative to one another.
[0045] In addition, in the preferred embodiment of the invention the configuration of the profiled edges 18 is selected such that a maximum of waney fiber is retained (i.e. fiber waste is minimized).
[0046] The profile chosen for the profiled edge 18 of any given embodiment of the present invention can be chosen according to several criteria such as, for example, the degree of wane, the quality of the lumber, the machinery and/or tools available, the application for which the composite wood product is intended to be used, etc.
[0047] The present invention additionally contemplates a method for manufacturing composite wood products, as is shown in FIG. 15 . The process of fabricating composite wood products begins with conventional lumber, running it through a moisture meter 140 and sorting it in the chop line 150 into different lumber sorts 160 . Wet lumber 170 is kiln dried 180 when required. The sorting 150 produces both square-edged lumber 192 and waney lumber 194 . Although the present invention is particularly advantageous in that it maximizes utilization of waney lumber, it is applicable to square-edged lumber as well. As discussed above, waney lumber is lumber cut from near the outside of the log and one or two edges are rounded off and irregular. At step 200 , the shorter lumber pieces may be finger jointed to achieve the requisite length.
[0048] After finger jointing 200 the lumber is profiled 210 to provide profiled edges 18 , (see FIGS. 2, 3 and 11 - 14 ). The profiling step 210 also makes it possible to utilize waney lumber that previously was not useable in composite construction. The profiling step 210 removes the waney portions of the waney lumber or square edges in the case of square edged lumber.
[0049] The profiled lumber is then trimmed, laid up, glued and pressed 220 together to form a composite wood product. This step involves the application of adhesive in the interfaces joints 64 between the profiled edges of adjacent profiled pieces of lumber 12 , 26 (see FIGS. 2, 3 , 8 and 9 ). Once the adhesive has been applied the profiled pieces of lumber 12 , 26 are processed 220 in a conventional edge-gluing press. No pressing is required in a second dimension because the profiling of the lumber prevents lateral movement of the lumber during the pressing process. Once the glue has set, the product is finished 230 and packaged for shipping 240 or further processed 250 .
[0050] Preferably, the adhesive or bonding material is applied to substantially all surfaces of profiled edge 18 . The present invention provides an additional advantage over the prior art method of producing composite wood products, which method utilizes square-edged lumber (whether originally waney lumber or not), as the profiled edge 18 has a greater surface area than the square edge for adhesion, and thereby allows for a stronger joint between adjacent profiled pieces of lumber 12 , 26 .
[0051] Composite wood products formed from the profiled lumber provide significant improvements in resistance to shearing and impact forces and improved load bearing capacity. Composite wood products further avoid many of the complex reinforcing requirements of the prior art. In addition, the significant resistance to shearing and impact forces achieved in the composite wood products above permits the use of wood pieces from old growth and stagnant growth timber as well as younger generation timber for a much broader application of use in the lumber industry.
[0052] Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention. | A composite edge-glued wood product, comprising profiled pieces of lumber bonded and pressed together. The profiled pieces of lumber are made from waney lumber, which has been profiled such that the waney edges thereof have been removed to reveal profiled edges. The profiled edges each have at least one protrusion and one indentation. Interlocking engagement of the profiled pieces of lumber prevents lateral movement of adjacent profiled pieces of lumber relative to one another when the composite wood product is pressed. The invention makes use of waney lumber to make composite edge-glued wood products. The use of a standard edge glue press takes advantage of inexpensive conventional technology. |
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This is a continuation of application Ser. No. 09/604,839 filed Jun. 27, 2000, and now abandoned.
BACKGROUND OF THE INVENTION
The invention deals generally with underground structures such as manholes, utility vaults, and pump stations, and more specifically with a method and apparatus to attach an impermeable continuous liner to prevent corrosion by the effects of sewer gas and to prevent fluid leaking into the underground structure.
Underground structures such as manholes serve to connect pipes, transfer sewage, and provide maintenance access. When they permit ground water to leak in, they contribute to unnecessary sewage treatment costs or damage the sewer lines or other utility services which pass through the underground structures. Furthermore, microorganisms that consume sewer gas form sulfuric acid, and this acid dissolves the underground structure walls which may lead to deterioration, collapse, service interruption, or accidents.
This deterioration is caused mainly because of the nature of the original structure. Underground structures such as manholes are essentially chambers in the ground, sometimes large vertical shafts, which extend to the depth at which sewer pipes or utility services are located. The older chambers are usually built of bricks or cement blocks, with the bricks or blocks assembled with mortar joints. These materials, and particularly the joints, deteriorate with time because of such factors as traffic loads, ground water, soil pressure, and septic gases. Even cast concrete underground structures can be damaged by such causes, particularly from the acids septic gases create and which attack most materials.
Once an underground structure is damaged and leaking, it is very difficult to repair it so that it is watertight and gas tight, and completely rebuilding it is costly and time consuming because it requires excavating all around the underground structure.
Several patents have been issued on a newer approach to repairing underground structure chambers. The technique involves attaching a liner to the inside wall surface of the underground structure chamber. As described in U.S. Pat. Nos. 5,490,744 and 5,265,981 by McNeil, the liner is typically a long fiberglass bag covered with an epoxy resin. This bag is lowered into the underground chamber, inflated by the use of a removable interior inflatable bladder until it presses against the inside walls of the underground chamber, and the resin is cured in place. The result is the formation of a new chamber which conforms to the original underground structure regardless of whether the chamber is a straight cylinder or it has an irregular shape. However, this type of additional internal chamber still has problems.
The structure of the McNeil liners, which have fiberglass and resins on the exposed surfaces, are themselves attacked by septic gases. This causes erosion of the exposed fiberglass layers which deteriorate over time and ultimately weaken the rehabilitation structure. Furthermore, at liner termination points such as junctions where the liner is joined to pipes and flow channels, gas infiltration leads to corrosion of the underground structure walls and destruction of the liner bond.
It would be very beneficial to have a underground structure liner which was chemically stable, allows gas-tight joints with pipe lining, and prevents fluid leakage into the underground chamber.
SUMMARY OF THE INVENTION
The present invention solves the problems with crumbling of fiberglass epoxy layers that are exposed to sewer gas and of joint adhesion with pipe linings by constructing the liner in a different fashion. The liner of the present invention includes two essential layers. The first layer is an acid resistant layer which is the innermost layer, the layer exposed to the environment of the underground structure. The second layer is located on the outside and is the layer in contact with the wall of the underground structure. This layer is a fleece layer, a continuous layer of fibers protruding from the acid resistant layer. The fleece layer is integrated into the acid resistant material and serves to capture and retain the epoxy resin applied to the liner. Furthermore, the fibers of the fleece layer function as multiple anchors as they contact the wall of the underground structure and form a continuous layer which conforms to irregularities and crevices in the underground structure wall surface. Reinforcing material can also be added to the fleece layer. Typically this reinforcing material is a cloth layer which is also saturated with resin, and it can be added to the outside of the fleece layer. However, the reinforcing material can also be integrated into the epoxy resin by applying a mixture of epoxy resin and fibers directly onto the fleece layer.
In the preferred embodiment the material of the acid resistant layer is polyvinyl chloride (PVC), the fleece layer is polyester, and the cloth layer is fiberglass. The thicknesses of the layers can be adjusted for the specific application to yield, for instance, greater strength or acid resistance.
Several methods of applying the epoxy resin are available. A two part resin can be applied to the fleece layer or to the fiberglass layer at the installation site just before insertion into the underground structure. A delayed reaction epoxy can also be applied to the liner before it arrives at the installation site, in which case the epoxy is cured by subjecting the assembly to elevated temperature or to some other activating agent such as light or other radiation.
The present invention also affords a means to create a superior seal between the liner installed within the underground structure and the pipes entering into the underground structure. To accomplish this, a PVC cap is formed which is inserted into the end of the pipe at the underground structure. This cap is held in the pipe with an expansion ring, and the cap extends out of the pipe end and is bonded to the liner and to a fiberglass disc which is attached to the bottom of the underground structure.
The liner of the present invention and the pipe seal together completely protect the original underground structure walls from any further contact with acid products from within the underground structure while also strengthening the walls and preventing ground water from leaking into the underground structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified cross section view of an underground structure with the liner of the preferred embodiment installed in the interior of the underground structure.
FIG. 2 is an enlarged cross section view of a portion of the liner of the preferred embodiment of the invention.
FIG. 3 is a simplified cross section of a seam used to attach the bottom of the liner to the wall and to attach flat side panels to each other to form the wall and the bottom of the liner.
FIG. 4 is a simplified cross section view of the preferred embodiment of a seal between the liner of the invention and a pipe entering the underground structure.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a simplified cross section view of underground structure 10 with liner 12 of the preferred embodiment installed in the interior of underground structure 10 . Underground structure 10 has vertical walls 14 and bottom slab 16 , and although underground structure 10 is shown in FIG. 1 as constructed of concrete, older underground structures are sometimes constructed of bricks or concrete blocks. Liner 12 is installed to seal cracks within underground structure walls 14 and to reinforce walls 14 to prevent continuing damage.
Pipes 18 penetrate walls 14 as they do in most underground structures to move sewage or to give access to other utilities, and pipes 18 must also be sealed to liner 12 . The description of this seal follows with the discussion of FIG. 4 .
FIG. 2 is an enlarged cross section view of a portion of liner 12 of the preferred embodiment of the invention when it is attached to underground structure wall 14 .
Liner 12 of the present invention includes two essential layers. Interior layer 20 , which is exposed to the interior environment of underground structure 10 , is an acid resistant layer. The second layer is fleece layer 22 , a continuous layer of fibers protruding from acid resistant interior layer 20 . Fleece layer 22 is integrated into acid resistant interior layer 20 and is impregnated with an epoxy resin which it captures and retains. When fleece layer 22 is in contact with underground structure wall 14 , the fibers of fleece layer 22 function as multiple anchors as they contact underground structure wall 14 and form a continuous layer which conforms to irregularities and crevices in the underground structure wall surface.
In the preferred embodiment the material of the acid resistant layer is 0.018 inch thick polyvinyl chloride (PVC), thermally bonded to a 10 oz. polyester fleece layer. The product is manufactured by Ferland Industries. A liner made to this specification will resist acids such as sulfuric acid. The thicknesses of all of these layers can be adjusted for the specific application to yield, for instance, greater strength and superior acid resistance.
Several methods of applying the epoxy resin are available. A two part resin can be applied to fleece layer 22 or to the fiberglass layer 24 (FIG. 3) at the installation site just before insertion into underground structure 10 . The resin used for the preferred embodiment is a mixture of 60% part A and 40% part B, with part A being 90% PEP 6128 and 10% PEP 6748 and part B being 30% PEP 9140 and 70% PEP 9254. All the PEP products are sold by Pacific Epoxy Polymers, Inc. of Richmond, Mo.
A delayed reaction epoxy can also be applied to liner 12 before it arrives at the installation site, in which case the epoxy is cured by subjecting the assembly to elevated temperature or to some other activating agent such as light or other radiation.
FIG. 3 is a simplified cross section of seam 26 which is used to attach bottom panel 28 of liner 12 . The same seam 26 is used to attach individual flat side panels to each other to form walls 14 or bottom panel 28 of liner 12 . The seam between flat side panels can be better understood if bottom panel 28 of FIG. 3 and panel 12 ′, shown in phantom lines, are visualized as adjacent side panels viewed from the top. All of seams 26 are formed by bonding together impervious layers 20 and 30 of adjacent panels. Such bonds are made by conventional methods such as by the use of fusion welding of the materials, by sewing, or by the use of an intermediate bonding material such as epoxy or glue. Such materials are available on the market as HH-66 PVC glue sold by R-H Products Co. Inc. of Acton, Mass.
It is important that seam 26 be formed by joining together impervious interior layers 20 and 30 as opposed to the more traditional technique of simply overlaying adjacent panels. Overlaying the adjacent panels attaches an impervious layer to a fleece layer 22 , and although the joint would probably be structurally sound, there is little assurance that it would be leak tight.
The use of seams 26 to form an entirely enclosed liner 12 provides an added benefit over the prior art. Existing underground structure liners have all been installed by the use of a separate removable air tight bladder which is placed within the liner when the liner is inserted into the underground structure. The separate bladder is then inflated to hold the liner against the underground structure wall as the epoxy resin cures and the bladder is removed after curing.
Seams 26 and bottom 28 produce a liner which is itself completely leak tight, and it therefore does not require the use of an inflation bladder. A liner such as liner 12 is directly inflated in the same manner as previous bladders, with hot air or a mixture of air and steam, but does not require the cost, time, and extra labor of installing the additional inflatable bladders
As also shown in FIG. 3, reinforcing material can also be added on top of or within fleece layer 22 . Typically this reinforcing material is cloth layer 24 which is also saturated with resin, and it can be added to the outside of fleece layer 22 . However, the reinforcing material can also be integrated into the epoxy resin by spraying a mixture of epoxy resin and fibers directly onto the fleece layer. The cloth layer of the preferred embodiment is 18 or 24 oz. fiberglass cloth sold by Vetrotex America of Wichita Falls, Tex.
FIG. 4 is a simplified cross section view of the preferred embodiment of a seal between underground structure liner 12 and pipe 18 entering underground structure 10 . When properly prepared, such a seal can be made after liner 12 has been inflated and attached to underground structure wall 14 . In preparation for the seal, capping strip 32 is placed into pipe 18 and held tightly in place with conventional expansion ring 34 . Capping strip 32 is then expanded and bonded to underground structure wall 14 at end 36 , and also bonded at edge 38 to fiberglass leveling disc 40 . Temporary plywood disc 42 is then set against the end of pipe 18 to prevent liner 12 from expanding into pipe 18 . Later, after liner 12 is bonded to underground structure wall 14 and to fiberglass disc 40 , temporary plywood disk 42 and the portion of liner 12 bonded to it are removed to open up pipe 18 again.
The present invention thereby furnishes a underground structure liner with improved bonding to the underground structure wall and also eliminates the need for an additional inflation bladder.
It is to be understood that the form of this invention as shown is merely a preferred embodiment. Various changes may be made in the function and arrangement of parts; equivalent means may be substituted for those illustrated and described; and certain features may be used independently from others without departing from the spirit and scope of the invention as defined in the following claims. | The apparatus is an underground structure liner based upon an inflatable liner structure. An acid resistant layer is the innermost layer of an inflatable liner, and the liner is coated with epoxy resin on its outermost surface, the surface which contacts the existing walls of the underground structure. The outermost coated surface of the liner is constructed with a fibrous fleece layer for retention of the epoxy and adhesion of the epoxy to the walls of the underground structure. An added feature of the liner is a structure which also seals the liner to pipes entering the underground structure. |
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to an operating mechanism for movable parts for the selective closing or exposing of openings, especially for sliding roofs and sliding/lifting roofs of motor vehicles, having a motor drive for the movable part and an actuating member for starting the drive when required.
In the known mechanisms of this type (DE-PS No. 21 00 336 corresponding to U.S. Pat. No. 3,702,430, and DE-PS No. 19 06 084), the actuating member is a switch or a group of switches by means of which the drive can be switched on or off in the desired operating direction. In the case of sliding roofs and sliding/lifting roofs, additional limit switches are provided, as a rule, which stop the movable part (the cover) in the closed position, in the fully retracted position or in a fully tilted-out position. Nevertheless, the operation is awkward. Especially the stopping of the cover in intermediate positions presents problems. For example, in order to bring the cover of a sliding roof from the closed position to a partially opened position, the actuating switch must be pressed and be held in the pressed position until the cover has reached the desired intermediate position. When and whether this is the case, can only be determined by the driver by directly observing the cover, which requires that the driver look away from the road.
The invention is based on the objective of constructing an operating mechanism of the initially described type which can be operated more easily and which permits a precise movement into desired intermediate positions without the requirement of observing the movable part.
According to the invention, this objective is achieved by the fact that the actuating member is formed as a desired-value transmitter for the position of the movable part, and the drive is part of a control circuit which compares the position chosen at the desired-value transmitter with the actual position of the movable part and adjusts the movable part until the deviation has become zero. In the case of the operating mechanism according to invention, the actuating member must only be brought into a position that corresponds to the desired position of the movable part. Via the control circuit, the drive will then automatically be caused to bring the movable part into the desired position and arrest it there. The movable part itself does not have to be observed in this case. A repeated actuating is not necessary, such as was required in the known mechanism, when the switch was released before the desired intermediate position had been reached or after this position had been exceeded. In the case of sliding roofs of motor vehicles or similar devices, any distraction of the driver is avoided.
In order to further facilitate the adjustment, the actuating member advantageously has a selector lever located in the normal field of vision of the operating person to which an indicating device is expediently related so as to show the adjusting range of the movable part. A mechanical catch is also provided, advantageously, that interacts with the desired-value transmitter of its selector lever in order to enable the driver to locate at least one indicated position, such as the closed position of the movable part, without having to look away from the roadway.
The movable part can be given the ability to carry out at least two different types of adjusting movements, such as, in the case of a sliding/lifting roof, to carry out a sliding movement and a pivoting or tilting-out movement. In the case of such a design, a selector switch may be provided for the preselection of the type of adjusting movement and, by means of a single selector lever, the desired position can be selected in the course of all forms of the adjusting movement. Corresponding to a modified embodiment, the design may be such that the type of adjusting movement of the movable part can be selected by the direction of the adjustment of the selector lever with respect to a predetermined starting position. The indicating device is preferably provided with additional elements for indicating the selected type of adjusting movement, and the selector lever may expediently itself, at the same time, form a part of the indicating device. An especially clear indication will be received when the selector lever can be adjusted with respect to one or several fixed wedge representations symbolizing the desired positions.
In accordance with a further feature of the invention, the control circuit has a three-point transfer characteristic with a hysteresis for avoiding an undesired response of the control circuit in the case of slight actual-value/desired-value deviations. The control circuit may have a coarsely regulating and a precisely regulating circuit which may, for example, interact with a motor that can be switched to two different speeds, where the switching from the coarsely regulating to the precisely regulating circuit takes place automatically in order to, among other things, carry out precise positioning.
In this manner, wind forces may be counterbalanced, for example, in the case of a sliding or sliding/lifting roof. A coarse or precise regulating with respect to the position may also take place in connection with a regulating of the motor speed. The desired-value selection and the actual-value detection may basically be selected to be analog or digital. An analog actual-value detection has the advantage that the actual position remains stored, without additional expenditures, even in the case of power failure. Especially suited for an analog desired-value selection and/or actual-value detection are rotary or sliding potentiometers. For a digital actual-value detection, a digital-position transmitter having a count-up/count-down device at the output side is suitable. The control circuit also may be developed to be analog, digital or mixed: analog/digital. Digital-to-analog converters or analog-to-digital converters may possibly be provided in order to permit digital data transmitters to work with an analog control circuit or, vice versa, to permit analog data transmitters to work with a digital control circuit.
In a further development according to the invention, at least one additional transmitter is provided for determining a fixed desired-value, as well as a logic circuit that responds to predetermined conditions for switching from the adjustable desired-value transmitter to the fixed-value/desired-value transmitter. The logic circuit may, for example, respond to the turning-off of the ignition or to a rain sensor in order to automatically bring a sliding or sliding/lifting roof into the closed position. Vice versa, the logic circuit may be actuated by a jamming-protection sensor in order to bring the cover of a sliding or sliding/lifting roof into the end positions of the opening or into one of the end positions of the opening, as soon as, during a cover-adjusting movement, a counterforce is experienced that exceeds the adjusting force that is to be expected normally.
In the case of an arrangement with analog transmitters and a digital signal evaluation, a single analog-to-digital converter may expediently be associated jointly with the transmitters, and the transmitters may be connected to the joint analog-to-digital converter in time-division multiplex operation.
The desired-value transmitter potentiometer may be provided with an additional fixed tap for a signal corresponding to the predetermined starting position. A voltage divider with a resistance that is low in comparison to the combined resistance of the potentiometer may be connected in parallel to such a potentiometer, while the fixed tap of the potentiometer is connected with a voltage-divider tap for the starting-position signal in an electrically conductive manner. Such a design results in a particularly simple mounting and permits a simple adaptation of the characteristic adjusting line to the respective requirements.
These and further objects, features and advantages of the present invention will become more obvious from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, several embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a sliding/lifting roof of a motor vehicle with the cover being retracted;
FIG. 2 shows the sliding/lifting roof according to FIG. 1, in the closed position;
FIG. 3 shows the sliding/lifting roof according to FIG. 1, with the cover being tilted out;
FIG. 4 is a perspective view of the dashboard of a motor vehicle with the desired-value transmitter for the sliding/lifting roof according to FIGS. 1 to 3;
FIG. 5 is a larger-scale diagrammatic view of the desired-value transmitter according to FIG. 4;
FIGS. 6 and 7 show modified embodiments of the desired-value transmitter;
FIG. 8 shows a diagrammatic view of the operating mechanism provided for the sliding/lifting roof;
FIG. 9 shows a schematic diagram of an analog control circuit;
FIG. 10 shows a schematic diagram for an analog control circuit with a digital actual-value detection;
FIG. 11 shows a schematic diagram of an embodiment with analog transmitters and digital transmitter-signal evaluation;
FIG. 12 shows a preferred embodiment of an analog desired-value transmitter; and
FIG. 13 shows a characteristic adjusting line of the desired-value transmitter according to FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sliding/lifting roof shown in diagrammatic form in FIGS. 1 to 3 had a cover 1 which is adjustable by means of an electric motor 2 that can be reversed with respect to the direction of its rotation, via one or several transfer elements 3, expediently in the form of pressure-resistant cables, via a transport bridge 4 and a tilt-out mechanism 5. In the operating condition according to FIG. 1, the cover 1 is retracted under a stationary part 6 of the roof in order to expose an opening 7 in the roof. In the position according to FIG. 2, the cover 1 closes the opening 7 in the roof. By means of a further advancing of the transport bridge 4, starting from the closed position according to FIG. 2, the tilt-out mechanism 5 is caused to lift the rear edge of the cover 1 above the stationary part 6 of the roof, while swivelling the cover 1 around an axis located near the front edge of the cover. Means for achieving the described sliding and lifting motions are known and do not, per se, form part of this invention.
The motor 2 is disposed in a control circuit described in detail below, and the desired position of the cover can be indicated by means of a desired-value transmitter of the type shown in FIGS. 4 and 5. In the case of this embodiment, the desired-value transmitter is integrated into the dashboard 10 of the motor vehicle in such a way that it is located within the field of vision of the driver. It has a flip switch 11, by means of which it may be selected whether the cover 1 should be tilted out or slid. Symbols 12, 13 (FIG. 5) are associated with the movement directions of the flip switch 11, with said symbols 12, 13 showing clearly how said flip switch 11 must be operated for changing over from a tilting-out mode of operation to a sliding mode of operation and vice versa.
Also, part of the desired-value transmitter is a selector lever 14, which, in this case, can be moved in a horizontal direction, for selecting the desired displacement position of the cover 1, in the case of both types of cover movements that can be selected by means of the flip switch 11. The selector lever 14 can be adjusted with respect to a fixed wedge representation symbolizing the desired-position range and, thus, itself, also forms a part of the indicating device for the desired position. In FIG. 5, the left end position of the selector lever 14 corresponds to the closed position according to FIG. 2, while the right end position, depending on the position of the flip switch 11, indicates either the fully tilted-out position (FIG. 3) or the fully retracted position (FIG. 1) of the cover 1. The position of the selector lever 14 shown in FIG. 5 corresponds to approximately a 40% opening of the cover 1 in the sliding or the tilting-out direction.
While, in the case of the embodiment according to FIG. 5, the selector lever 14 is formed as a slide and the additional flip switch 11 is provided, FIG. 6 shows a modified embodiment where the selector lever is actuated via a turning knob 17. The turning knob 17, starting from the position according to FIG. 6, may selectively be turned clockwise and counterclockwise. The indicating symbols 12, 13 show that, by means of a counterclockwise turning, a tilting-out movement is selected, and that, by means of a clockwise turning, on the other hand, a sliding movement of the cover is selected. The extent of these movements is indicated by the position of an arrow-shaped symbol 18 on the turning knob 17 with respect to the actuate wedge representations 19 and 20. In this manner, the additional flip switch 11 of FIG. 5 will not be necessary.
Another embodiment of the desired-value transmitter, which also does not require the flip switch 11, is shown in FIG. 7. There a selector lever 14, like that of FIG. 5, is provided which, however, has a starting position, corresponding to the closed position of the cover, from which it may be moved selectively to the left and to the right. A sliding of the lever 14 to the left, as represented by the symbol 12, causes a tilting-out of the cover 1 by a distance that is indicated by a wedge 21, whereas, by a sliding of the selector lever 14 to the right, in the manner indicated by the symbol 13, the cover 1 can be retracted by a distance indicated by a wedge 22. The selector lever 14 protrudes through a slot 25 of the dashboard 10, and, in order to enable the driver to recognize the starting position of the selector lever 14, that corresponds to the closed position of the cover 1, without having to look at the selector lever and/or in order to precisely identify this position, a spring catch 23 is provided having a ball 24 that is spring biased into a recess 26 in the selector lever 14 when said selector lever 14 reaches its starting position (FIG. 7). The spring catch 23 can be adjusted in the sliding direction of the selector lever 14. For this purpose, a guide rod 27, for example, is provided that extends in parallel to the slot 25, with said spring catch 23 being able to be slid on said guide rod 27 and being able to be fixed on said guide rod 27 by means of a clamping screw 27a. Naturally, other indicated positions may be shown in the same or a similar manner.
The manner in which selector lever 14 produces the noted operation of the cover will now be described with reference to FIG. 8. As can be seen, the end of lever 14, which passes through the dashboard slot 25, is coupled to the slide-type potentiometer 28. The potentiometer 28 converts the position of the selector lever 14, as adjusted by the driver, into an electrical desired-value signal which is fed to a regulator 30 via a line 29. The transfer element 3 is driven by an electric motor 2 via a sliding clutch 31 and a pinion 32. A toothed wheel 34 is disposed on the pinion shaft 33, with said toothed wheel 34 mating with a toothed wheel 35 on a control shaft of a multiple-turn potentiometer 36. The potentiometer 36 converts the actual position of the cover 1 into an electrical actual-value signal which is directed to the regulator 30 via a line 37.
The desired position of the cover 1 is adjusted at the selector lever 14. In this case, the selector lever 14 adjusts the potentiometer 28. If the desired-value signal transmitted by the potentiometer 28 to the regulator 30 deviates from the actual-value signal delivered by the potentiometer 36, the regulator 30, via a line 38, furnishes a drive signal to the motor 2. The motor 2 will drive the cover 1 via the sliding clutch 31 and the pinion 32. On the basis of the adjustment of the cover, the actual-value signal delivered by the potentiometer 36 to the line 37 will change. As soon as the latter is made to conform with the desired-value signal of the potentiometer 28, the drive signal on the line 38 becomes zero and the motor 2 stops, so that the cover 1 is arrested in the position indicated by means of a selector lever 14. The FIGS. 5 and 6 embodiments function in an analogous manner; in FIG. 5, switch 11 being connected so as to reverse the direction in which motor 2 drives element 3, relative to the closed position, and FIG. 6 using a rotary-type potentiometer instead of slide-type 28. The driver can easily read the position of the cover by looking at the wedges 15 or 19, 20 or 21, 22. He does not have to turn his head and view the cover in order to be certain of the intermediate position or end position of the cover 1.
FIG. 9 shows a preferred embodiment of an analog control circuit. A circuit of this type is known (Elektronik, Volume 2, 1982, pages 67 and 68), so that a short explanation will be sufficient. The desired-value signal goes from the potentiometer 28, via a line 29 and a resistor 40, to an inverting inlet of an operation amplifier 41, at the non-inverting inlet of which the actual-value signal from potentiometer 36 is applied via a resistor 42. A voltage divider having resistors 43, 44 is disposed between the outlet of the operational amplifier 41 and the ground. The coupling point of the resistors 43, 44, via a feedback resistor 45, is connected to the inverting input of the operational amplifier 41. The deviation that is amplified by the operational amplifier 41 reaches a three-point element which includes, especially, two oppositely poled Zener diodes 46, 47 that are connected in series and an operational amplifier 48. The Zener diodes are diposed between the outlet of the operational amplifier 41 and the inverting inlet of the operational amplifier 48, which is countercoupled via a resistor 49. A voltage divider having the resistors 51, 52 is disposed between the outlet of the operational amplifier 48 and the ground. The coupling point of the resistors 51, 52 is connected at the non-inverting inlet of the operational amplifier 48 which supplies a positive feedback. A condenser 53 is disposed between the non-inverting inlet of the operational amplifier 48 and the ground, with said condenser 53 preventing oscillations at the switch-over points of the three-point element. The three-point element, as known, has a three-point characteristic with a hysteresis as the transfer characteristic, in which case, the hysteresis, via the divisor relationship of the resistors 51, 52, can be adjusted arbitrarily. The switch-on points, on the other hand, are determined by the Zener voltage of the Zener diodes 46, 47. If the desired value and the actual value are the same, the control signal at the outlet of the operational amplifier becomes zero.
In the case of a positive control signal, a power transistor 56 is energized via a driving transistor 55, with a relay 57 being disposed in the collector-emitter circuit of said power transistor 56. Relay contact 58 is switched over. At the same time, a driving transistor 59 and a power transistor 60, assigned to said driving transistor 59, remain currentless. The relay contact 61 of the relay 62, located in the collector-emitter circuit of the transistor 60, remains in the switching position shown in FIG. 9. In this operational condition, positive potential is applied at one terminal 63 of the motor 2, while negative potential is located at the other terminal 64 of the motor 2. The motor 2 will run until the control signal at the output of the operational amplifier 48 becomes zero, and the relay 57 falls off. On the other hand, if the control signal exceeds a predetermined negative value, the transistors 59, 60 are energized, reversing the polarity of the voltage of the motor with respect to the operational condition explained above. The motor 2 will run in the opposite rotating direction until the deviation becomes zero again.
FIG. 10 shows a modified embodiment of the control circuit that utilizes digital actual-value detection. In this case, a digital position transmitter 67 is connected to the motor 2. Transmitter 67 may be designed as a mechanical, optical or magnetic position transmitter. FIG. 10 shows a graduated disk or a diaphragm disk 68 having two light barriers 69, 70, said disk being driven by the motor 2. The light barriers 69, 70 are connected to a direction discriminator 71 which determines the rotating direction of the motor 2 on the basis of the phase relation of the outlet signals of the light barriers 69, 70. A count-up/count-down device 72 is connected at the outlet side of the direction discriminator 71, with said device 72 counting the position signals of the position transmitter 67 in one rotating direction of the motor 2, e.g., the forward direction, and subtracting therefrom in the other rotating direction of the motor 2, i.e., the return direction. The counting device 72 is followed by a digital-to-analog converter 73 for converting the digital actual-value signal to an analog actual-value signal. In a window comparator 74, the analog actual-value signal is compared with the desired-value signal coming from the potentiometer 28. In the case of a deviation in one or the other direction that is outside the gate width of the comparator 74, a control signal, via a line 75 and a switching contact 76, goes to an electronic output stage 77 causing the motor 2 to rotate in one or the other direction. When the control signal of the comparator 74 becomes zero, the contact 76, via a line 78, is switched over to the outlet of a differential amplifier 79, which is also acted upon by the actual-value and the desired-value signal, but forms a precisely positioning circuit in order to, in the case of inadequate holding forces, counterbalance windforces affecting the cover 1. In this case, an electric motor 2 may, for example, be provided which, through the switching of motor windings, may be switched betweeen two speeds, the high speed step being connected to the coarsely positioning circuit having the comparator 74, and the low speed step being connected to the precisely positioning circuit having the differential amplifier 79, in order to carry out, in this manner, a coarse positioning with a high adjusting speed, as well as a precise positioning with a slow adjusting speed. A speed-regulating circuit may also be assigned to the motor 2, and the desired speed can be made a function of the extent of the deviation in the position-regulating circuit. In this manner, in the case of a large deviation of the desired position from the actual position of the cover 1, the cover can rapidly be brought into the proximity of the desired position, in order to then move into the desired position relatively slowly and with a correspondingly increased precision.
In the case of the embodiment according to FIG. 11, the evaluation of the desired- and actual-position signals coming from the potentiometers 28 and 36, as well as from additional potentiometers 83, 84, is digital. For this purpose, the output sides of the potentiometers 28, 36, 83, 84, via electronic switches 85, 86, 87, 88 in a time-division multiplex operation, can be connected to an analog-to-digital converter 89, which converts the analog position signals into digital signals. Said digital position signals are admitted to a microcomputer 90. The microcomputer 90, which is fed from main power via a power-supply and clock stage 91, carries out the above-mentioned comparison of the desired and the actual position, and, in the case of corresponding deviations, supplies control signals, via control lines 92 or 93, to the power transistors 56 or 60. If necessary, the motor 2, via the contacts 58, 61 of the relays 57, 62, is made alive. The drive of the switches 85 to 88 takes place via control lines 94, 96, 96, or 97 by the microcomputer 90. By means of the potentiometers 83 and 84, <-> corresponding to predetermined cover positions, such as the closed position or the fully open position of the cover 1, are supplied. <desired-value signals>
At the input sides of the microcomputer 90, a logic circuit 98 and coding switches 99 are connected in order to trigger especially preprogrammed moving processes. For example, the logic circuit 98 may be actuated as a function of the ignition lock of the motor vehicle via a sensor 104 in order to, when the ignition lock is actuated, switch the input side of the analog-to-digital converter 89 from the potentiometer 28 to the fixed potentiometer 83, and, thus, irrespective of the user set adjusting position of the potentiometer 28, will transfer the cover 1, under the influence of the fixed desired-value signal of the potentiometer 83, automatically into the closed position. Such an automatic closing of the cover 1 may, for example, also be triggered by the logic circuit 98 on the basis of a rain sensor 105 that is connected with it so that the cover will close when it starts to rain. The logic circuit 98 may also be coupled with a jammingprotection sensor 106, which responds when movement of the cover 1 encounters excessive resistance. In this case, the microcomputer 90 causes a switching of the analog-to-digital converter 89 from the potentiometer 28 to the potentiometer 84 in order to move the cover 1 in the direction toward the fully opened position. The coding switches 99 permit an adaptation of the system to the various client demands regarding the individual operational sequences. The illustrated relay drive of the motor 2 can be replaced by any other suitable electronic power circuit.
In practice, the individual structural components of the described operating mechanism are, as a rule, furnished separately for assembly in series. This requires a modulation or adaption of the control circuit, especially the desired-value and the actual-value transmitters, and the part (cover 1) to be positioned. This adaption, in the case of the embodiment according to FIGS. 8 to 11, can expediently be achieved by electrically connecting the regulator 30 with the actual-value transmitter 36, the desired-value transmitter 28 and the motor 2. The desired-value transmitter 28 is brought into the desired starting position (zero-position). Then the supply voltage is applied and switched on. The motor 2 and the actual-value transmitter 36 will automatically go to the zero-position. Then, instead of the motor 2, a voltmeter is connected with the regulator, and the desired-value transmitter 28, which is still in zero-position, will be connected instead of the actual-value transmitter 36. Now the selector lever 14, together with the locked spring catch 23, is mechanically adjusted until there is no more voltage at the motor connections. The spring catch 23 will be fixed in this position. The original connections are restored. Finally, the drive is installed in the sliding-roof mechanism 3, 4, 5, which is in zero-position. After the coupling of the thus modulated control circuit with the roof mechanism, the installation is completed.
The explained coordination can be simplified further when, instead of the potentiometer 28, a desired-value potentiometer 100, with a zero-position fixed tap 100a, is used and with which, according to FIG. 12, a voltage divider consisting of the resistors 101 and 102 is connected in parallel. The combined resistance R1+R2 of the voltage divider 101, 102 is low in comparison to the combined resistance P1 of the potentiometer 100. The tap 100a is connected with the voltage divider tap 103 in an electrically conductive manner, and the mechanical catch position (spring catch 23) is preadjusted in coordination with the tap 100a. Thus, the above-described adjusting of the control mechanism is not necessary. By means of a suitable selection of the values of resistance R1 and R2 of the resistors 101 and 102, the zero-position, in adaptation to the respective type of the roof, can be placed at any desired value of the control range of the desired-value transmitter, for example, in the center of this control range. The latter is indicated in the control characteristic according to FIG. 13. There, standardized with respect to the applied supply voltage U B of the potentiometer 100, the variable desired-position signal U S and the zero-position signal U N , as a function of the percentage of the control range, are indicated. Provided that R1, R2<<P1, then ##EQU1##
The illustrated parallel connection of the potentiometer 100 and the voltage divider 101, 102, at the same time, provides an advantageous linearization of the control characteristic.
The tap 101a may, for example, be vacuum-metallized onto the potentiometer 100. However, it is also possible to make the arrangement such that the fixed tap 101a can be placed arbitrarily in the control range. In this case, an adjustment of the characteristic can be provided in the whole displayable range.
Naturally, numerous modifications are possible within the framework of the invention. The arrangement may, for example, be completely digital. In such a case, instead of the potentiometer 28, a coding switch, for example, may be provided as the desired-value transmitter. The motor 2 may be designed as an impulse-controlled step motor. The sliding clutch 31 represents a protection against jamming, which has the effect that the cover 1 stops when exceeding an indicated operational resistance. In this case, the actual value will not be lost because the actual-value transmitter is connected with the part of the sliding clutch 31 that is on the power take-off side. In addition to, or instead of, the sliding clutch 31, an electrical switch-off device may also be provided in order to discontinue the supply of power to the motor 2 in the case of excessive operational resistance. The described operating mechanism is also suitable for the adjusting of ventilating flaps and similar movable parts which selectively are to be brought into intermediate positions. Also included are lifting roofs, side windows that can be operated by window lifts, and lateral tilt-out windows.
While we have shown and described various embodiments in accordance with the present invention, it is understood that the same is not limited thereto, but is susceptible of numerous changes and modifications as known to those skilled in the art, and we, therefore, do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications as are encompassed by the scope of the appended claims. | An operating system for movable parts for the selective closing or exposing of openings, especially for sliding roofs and sliding/lifting roofs of motor vehicles. The operating mechanism has a motor drive for the movable part and an actuating member for starting the drive, if required. In order to facilitate, especially, the bringing of the movable part into intermediate positions, the actuating member is developed as a desired-value transmitter for the position of the movable part, and the drive is part of a control circuit which compares the position selected at the desired-value transmitter with the actual position of the movable part and adjusts the movable part until the deviation has become zero. |
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BACKGROUND OF THE INVENTION
When passing through a doorway, where the door is hinged to the frame on one side and has a latch handle mechanism, for example, on the other side to keep it closed, a pedestrian tends to divert from a straight line direction of travel after unlatching the door and moving it off center. When the door swings away from the individual, he tends to veer off to the side rather than pushing the door fully open to be able to stay on a straight-line path. In the case when the door swings toward the person, he must back-step and then circle around the side of the door. Certainly, extra steps are required, but usually these steps are taken without a moment's hesitation or any extra effort.
This is not the normal procedure for a wheelchair-bound person, though. In the case where a door opens toward an individual in a wheelchair, that person must first maneuver up to the door in order to reach and unlatch the handle. Now that the handle is unlatched, the person must keep a grasp on the handle while backing the wheelchair away from the doorway in order to sufficiently swing the door open wide enough to pass the wheelchair through. Backing away from the doorway in a manual, i.e. nonpowered, wheelchair causes an asymmetric force on the wheelchair due to the use of one arm. Since a person's reach in a wheelchair is approximately at the location of their footrests, the opened door will always tend to "hug" the chair, thus limiting space to maneuver in.
When the door must be opened away from a person in a wheelchair, the task can be equally as difficult. Again, the first step is for the individual to maneuver up to the door to unlatch the handle. Now they must simultaneously push the door open while maneuvering the wheelchair through the door. For one thing, as the door opens, the corner of the wheelchair closest to the hinged edge of the door will be repeatedly blocked by the door until the door is fully opened. Also, as the door opens, the latch edge moves out of reach of the individual thus requiring more and more "stretch" to make the reach or that the person must push on the door nearer and nearer to the hinged edge. Pushing near the hinged edge or stile of the door requires a significantly greater force than pushing on the latch edge or stile due to the shorter moment arm. And, again, whenever the person is in a manual wheelchair, he or she must operate the wheelchair with one arm, again putting an asymmetric load on the operation, something which requires correction for the wheelchair to move along a desired path through the doorway.
For the wheelchair-bound person, the solution would be a device that not only assists in unlatching the door, but also allows the user to maintain a relatively straight pathway through the doorway. It would allow the user to minimize unbalanced loads on the wheelchair while simultaneously minimizing the movement of the wheelchair while it is worked through the doorway.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a device which assists a wheelchair-bound person in unlatching a latch handle, hinged door.
It is another object of the present invention to provide a device that will simultaneously assist a wheelchair-bound person in unlatching a door and moving it out of the path of the wheelchair.
It is a still further object of the present invention to provide such a device that may be retrofitted to existing latch-handle doors or installed on new doors.
It is a still further object of the present invention to provide such a device that when retrofitted to existing latch-handle doors or installed on new doors will not interfere with the operation of the door by pedestrians.
These and other objects and advantages will become apparent with the door opening device for wheelchair-bound persons.
The device comprises a substantially L-shaped grasping bar hingedly attached to the hinge stile and the latch stile of the door and adjacent the latch handle. In the unused position, the grasping bar will merely hang in a substantially vertical position alongside the face of the door. When it is to be used, the wheelchair-bound person lifts up the grasping bar and forces an upper edge of the attachment portion to activate the latch handle. Once the latch handle has been unlatched, the person uses the outward-extending and angled grasping bar to manipulate the door accordingly. As an alternate embodiment, an extension pin may be fastened to the handle, on the opposite side from the latch. With this embodiment, the latch stile stanchion, or hinge arrangement, is placed on the opposite side of the handle.
The novel features which are believed to be characteristics of the invention, both as to its organization and methods of operation, together with further objects and advantages thereof, will be better understood from the following descriptions in connection with the accompanying drawings in which the presently preferred embodiments of the invention are illustrated by way of examples. It is to be expressly understood, however, that the drawings are for purposes of illustration and description only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of one face of a door having a lever-action latch with the instant invention installed and with the bar shown in the raised position by phantom lines;
FIG. 2 shows a perspective view of the opposite face of the door of FIG. 1 with the instant invention installed and with the bar shown in the raised position by phantom lines;
FIG. 3 shows a cross-sectional view of the door and invention taken along lines III--III of FIG. 1 showing the invention with the bar in the raised position;
FIG. 4 shows a partially broken away cross-sectional view taken along lines IV--IV of FIG. 3 showing the bar in the down, or hanging, position;
FIG. 5 shows a cross-sectional view taken along lines V--V of FIG. 1;
FIG. 6 shows an exploded view of the door latch actuating bar of the instant invention;
FIG. 7 shows a cross-sectional view, similar to that of FIG. 3, of another embodiment of the invention;
FIG. 8 shows a partially broken away cross-sectional view taken along lines VIII--VIII of FIG. 7 showing the bar in the down, or hanging, position;
FIG. 9 shows a cross-sectional view taken along lines IX--IX of FIG. 8; and
FIG. 10 shows an exploded view of the door latch actuating bar of the other embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, where like reference characters designate like or corresponding parts throughout the several views, there is illustrated in FIG. 1 a perspective view of one face, for example, the inside, of a door 13 hingedly fixed in a doorway 11 with the instant invention attached. FIG. 2 shows a perspective view of the opposite face, for example, the outside, of door 13 with the instant invention attached, To simplify the description of the parts of the door and the invention, for purposes of this section, the letter "a" will be used to designate parts on the inside of the door and the letter "b" will be used to designate corresponding parts on the outside of the door. The latch stile 16 on the inside of the door is shown to the right side of FIG. 1 and the hinge stile 18 on the inside of door 13 is shown to the left side (hinges, as normally known in the art, not shown in FIGS. 1 or 2). In like manner, a lever-action latch mechanism 20, as is known in the industry, is shown attached on latch stile 16, at a standard position on door 13 and has a lever latch handle 22 extending therefrom. The instant invention, a door opening device for wheelchair-bound persons, is referred to generally as 25 in the drawings.
FIG. 3 shows a cross-sectional view of door 13, as taken along lines III--III of FIG. 1 and gives a plan view of the instant invention. As can be seen clearly in FIGS. 4, 5 and 6, partially broken away and enlarged views of specific portions of the instant invention, in one embodiment, latch mechanism 20 can have an extension bar 23 affixed thereto on the opposite side from latch handle 22, substantially diametrically opposite from handle 22. As will be explained below, in another embodiment of the invention, no latch handle extension is used. Bar 23 can be a steel pin of approximately 1/2 inch diameter, of a length of between 2 to 2 and 1/2 inches long, and can optionally have a plastic, or similar type material, protective sleeve 24 around it. Pin 23 can be journalled into latch mechanism 20 to fix it against movement.
As shown in FIGS. 4 and 6, a latch stanchion, or bracket, 26 is fixed to the face of the door, as for instance with wood screws 27 or other similar fasteners, at a predetermined location adjacent latch mechanism 20 and the edge of door 13. Bracket 26 can be a substantially U-shaped piece with flattened legs 28, or any other convenient solid base, for pivot pin 29. As seen, pin 29 is inserted through the aperture in one leg 28, through the aperture 31 in the tip end of a latch actuator 37, and through the aperture in the second leg 28 where it is then secured against removal by means known in the art.
Latch actuator 37, through its pivoting movement about pin 29, uses a load-bearing surface 39 to move latch handle extension 23, as will be explained. Actuator 37 is formed from a 3 inch long section of flat bar stock with an aperture 31 drilled through the tip end. It then has a preselected radius machined into one side, with excess material at the drilled end removed to make that end narrower than free end 40. Finally, the edges near aperture 31 are rounded off to provide adequate clearance from the face of door 13
A hinge stanchion, or bracket, 27 similar to bracket 26 is affixed to the face of door 13 in a predetermined location on hinge stile 18 opposite from bracket 26. Bracket 27 also uses a pin 29 to restrict movement of a bar attachment 44. Bar attachment 44 is also made from a 3 inch long section of flat bar stock, or similar material, and has, at about its lengthwise midpoint, an angle in the range of approximately 45 to 60 degrees therein to form a pivoting end 45 and a free end 46. As with actuator 37, free end 46 remains squared off. Further details of this design and construction can be clearly seen in FIGS. 4 and 5.
One of the features of door opening device 25 is angled grasping bar 30. Bar 30, used for opening door 13, is formed out of tubular material as a generally L-shaped section with its end sections 35 being swaged to compress the outline of their peripheries to conform to free end 40 of actuator 37 and to free end 46 of bar attachment 44. Bar 30a has a substantially straight section 51 that turns in to an elbow of approximately 60 degrees. On the other end of elbow 39a, an elongated portion 41 continues away and connects with swaged end 35. For better holding purposes, bar 30a may optionally have a knurled surface, as is known.
Bar 30b, on the outside of door 11, has a slightly different design, as can be seen in FIG. 3. Instead of a relatively straight portion, as with 51, bar 30b uses a slightly curved portion 52. The radius of curvature of portion 52 will depend on the width of door 13 and the thickness of sash 14, as sufficient clearance is required to push portion 52 through the doorway while it is held in a relatively horizontal position. In either case, grasping bar 30 will simply hang from brackets 26 and 27 in a relatively vertical position alongside the face of door 13 when not in use.
FIGS. 7 to 10 illustrate a slightly different embodiment, that will now be described. FIG. 7 shows a cross-sectional view, similar to FIG. 3, of this embodiment. As can be seen, door 13 has an inside, or "a" face, and an outside, or "b", face. The door opening device 65 consists of a latch stanchion, or bracket, 76 positioned adjacent a lever-action latch mechanism 66 and a hinge stanchion, or bracket, 77 fixed to the hinge stile 18 as have been earlier described. With this embodiment, latch bracket 76 is fixed to latch stile 16 adjacent latch mechanism 66 and immediately adjacent lever latch handle 72. As can be seen by comparing the two embodiments of FIGS. 3 and 7, grasping bar 65a and 65b are designed with a slight "S" bend in the portion of bar 65 that joins to latch actuator 87. Swaged end 85b is formed as has been previously described and is fixedly attached to free end 90. In this embodiment, load-bearing section 89 contacts the underside of lever latch handle 72 directly. With either embodiment, the load-bearing section and the underside of latch handle 72 or of bar 23 both can be covered with a known PTFE coating, or other similar slippery type material to minimize friction.
Operation:
In the case where door 13 opens in toward a person in a wheelchair, the person first rolls in close enough to the door to grasp bar 25a or 65a. The person lifts bar 25a or 65a high enough, generally to approximately a horizontal position, to disengage latch mechanism 20 or 66 and cause door 13 to be free to swing on its hinges (not shown). As bar 25 is lifted and door 13 unlatched, the person backs away from the door so that the door will clear the wheelchair as opening proceeds. Once the person is sufficiently clear of the door, the wheelchair is braked and opening is commenced. The person pulls on bar 25a adjacent elbow 39 and pulls in a direction perpendicular to portion 41. A person pulling on the bar at this portion is provided with a greater moment arm than would be attained by simply pulling on latch 22 or 72. This greater moment arm results in a smaller force required to continue door movement. As the door is pulled open, the person alternately grasps and pulls the portion 41 which is perpendicular to the door until the door is in reach. At this point bar 25a is left to drop back to the vertical position, the door is pushed aside and the person passes the wheelchair through.
An alternate method can be utilized to simutaneously back away from and open the door. As bar 30 is lifted and door 13 unlatched, the person can alternately push on bar 30 along the axis of portion 41 and pull on bar 30 in a direction perpendicular to portion 41. Pushing along the axis of portion 41 drives the wheelchair away from the door which will allow the door to partially clear the wheelchair. Pulling perpendicular to portion 41 will open the door until it contacts the wheelchair. Such actions are alternately performed until the wheelchair has fully moved away from the door and the door is fully open.
In the case where door 13 opens away from the wheelchair, the person reaches in and grasps bar 25b or 65b and lifts it to an approximately horizontal position, as before. Once latch mechanism 20b or 66b is opened, bar 25b or 65b is positioned approximately horizontal. In this position, the bar allows the person to utilize a greater moment arm, and consequently smaller force, in opening the door than would be obtained by merely pushing against the door. In addition, since the bar acts as an extension of the door, the wheelchair-bound person can keep the door away from the wheelchair as it is passing through the doorway.
Finally, while the door opening device for wheelchair-bound persons has been described with reference to particular embodiments, it should be understood that these embodiments are merely illustrative as there are numerous variations and modifications which may be made by those skilled in the art. Thus, the invention is to be construed as being limited only by the spirit and scope of the appended claims. | A substantially L-shaped grasping bar is hingedly attached to the hinge stile and the latch stile of a door. An upper surface of the latch stile attachment is placed adjacent the underside of the latch handle so that upon lifting the grasping bar, the latch is activated and the door can be easily manipulated by a wheelchair-bound person. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to a skid (or sliding) road surface capable of providing a stable, low skid resistance value and a method for constructing the same.
Recently, also in driving schools, there has been an increasing necessity of providing a skid road surface in driving test roads, driving schools and the like. For example, some driving schools have a skid experiencing road to let the students acquire a careful driving technique.
Heretofore, cement concrete type and asphalt concrete type skid road surfaces have been used practically. In many of asphalt concrete type skid road surfaces, an asphalt mixture using limestone as a coarse aggregate is used to pave a road surface and the thus-paved surface is then ground for smoothing.
In using the resultant skid road surface, water is sprinkled over the road surface so as to give a uniform thickness of water layer throughout the road surface and in this wet state the skidding road surface is used for running of an automobile thereon. Thus, during vehicular running, the asphalt concrete pavement is kept soaked in water, so that the surface of the limestone exposed to the surface of the pavement is covered with the sprinkled water and the surface lime of the limestone is dissolved out with the water.
Further, the dust between the vehicular tires and the road surface causes wear of the surface limestone of the pavement.
Due to these matters, the limestone surface which was initially ground smooth becomes more and more uneven and the skid resistance increases with the lapse of time. According to the prior art, for maintaining a certain resistance value, grinding is repeated periodically or is performed upon increase of the skid resistance value, but these maintenance works require much labor and expenses.
It is the object of the present invention to eliminate the aforementioned conventional drawbacks of an asphalt concrete type skid road surface using an asphalt mixture and provide a pavement surface having a stable, low skid resistance value and not causing a secular change, as well as a method for constructing the same and an asphalt mixture suitable for the same.
SUMMARY OF THE INVENTION
As asphalt concrete type skid road surface according to the present invention employs a substantially spherical coarse aggregate as a coarse aggregate contained in an asphalt mixture which is used for constructing the said skid road surface, and the pavement surface formed according to the present invention is characterized by having a randomly continuous shape based on the upper surface shape of the coarse aggregate.
DETAILED DESCRIPTION OF THE INVENTION
The coarse aggregate used in the present invention can be considered substantially spherical in practical use and is essentially not limited if only the surface thereof is difficult to be flawed and has a hardness not causing wear and flattening during the use thereof as a skid road surface and during vehicular running thereon. For example, artificial or natural gravel is used as the coarse aggregate. Natural pebbles are particularly preferred. Characteristics which such spherical coarse aggregate should possess will now be described in more particular terms. When the tires of an automobile come into contact with the skidding road surface during running of the automobile thereon, the surface of the spherical coarse aggregate should be difficult to be flawed, have a hardness of 6% or less, preferably 3% or less, in terms of abrasion loss as measured by a Dobal tester, also should have an indoor PSV of 45 BPN or less, preferably 40 BPN or less, as measured by an aggregate accelerated abrasion test according to the BS standard which value indicates easier skidding of automobile tires during running of the automobile, further should have a difference of 4 or less between the value obtained before the aggregate accelerated abrasion test according to the BS standard and the value obtained after the same test which difference indicates the difficulty of change in skid during continuous running of an automobile on the skidding road surface, and preferably it is difficult to change according to weather conditions and has a skid resistance value of ±4 BPN (as measured using a portable skid resistance tester) after a weathering test (conducted 400 hours using a sunshine weather meter) involving repeated radiation of ultraviolet ray and sprinkling of water, with respect to a skid resistance value obtained before the same test.
Although the size of the coarse aggregate is not specially limited, the diameter thereof in the paved surfaces formed preferably corresponds to a large coarse aggregate diameter of 20 to 5 mm in the paved asphalt concrete surface course of a general road. There may be used only one kind, or two or more kinds in combination, out of those classified within the above range.
It is preferable that the coarse aggregate grains be present adjacent to each other without interruption when the asphalt mixture is used for pavement. The coarse aggregate is used in an amount of usually 50 to 90 wt %, preferably 60 to 80 wt %, based on the weight of the entire asphalt mixture.
In the asphalt mixture there also is contained a fine aggregate together with the above coarse aggregate. As the fine aggregate, sand is used at least as a main portion thereof. Both natural sand and screenings are employable if only they can be converted to asphalt mortar in the asphalt mixture. Particularly when the proportion of screenings is sand is in the range of 25 to 75 wt %, the resulting asphalt mixture is easily compacted and stable and grasps the spherical coarse aggregate well. It is necessary to keep the amount of sand within range in which the shape of the resulting pavement surface is not flat and there appear random protuberanes (partially spherical) based on the spherical coarse aggregate. Preferably, sand is used in an amount such that an average texture depth is about 1/10 to 1/20 of the maximum grain diameter of the coarse aggregate. Usually, sand is used in an amount of 15 to 30 wt %, preferably 20 to 25 wt %, based on the weight of the entire asphalt mixture. Further, stone dust is used as a filler. Preferably, stone dust is used in an amount of 1 to 8 wt %. Particularly, when a portion thereof is replaced with slaked lime, there is obtained a more outstanding effect. It is preferable that slaked lime be used in an amount of 1 to 3 wt %. As the asphalt component there is used asphalt which is commonly used for pavement. Particularly preferred is one containing an elastomer such as SBR. The elastomer content of the asphalt is preferably in the range of 1 to 10 wt %. Usually, the proportion of the asphalt component is in the range of 3 to 6 wt % of the entire mixture.
For example, the surface course of an existing road cut out and the asphalt mixture is applied for pavement to form a skid road surface. The pavement surface thus obtained is employable as a skid road surface if it assumes a shape comprising random protuberances (partially spherical) which are continuous and based on the spherical coarse aggregate. It is more desirable to remove the asphalt mortar from the pavement surface to expose the coarse aggregate surface now free of the asphalt coating.
Thus, the present invention is also concerned with a method for constructing a skid road surface characterized in that, in asphalt concrete pavement, a substantially spherical coarse aggregate is used as a coarse aggregate contained in an asphalt mixture of the surface course, and an asphalt coating on the coarse aggregate present in the pavement surface portion is removed.
It is also possible to use a coarse aggregate having a dihedral angle, as will be described later, then remove the asphalt mortar from the resulting pavement surface and at the same time grind the exposed dihedral angle portion of the coarse aggregate to round it. This mode of embodiment is also included in the present invention.
By thus removing the asphalt mortar from the resulting pavement surface, the coarse aggregate surface now free of the asphalt coating is exposed to obtain a surface shape comprising random protuberances (partially spherical) which are continuous and based on the spherical coarse aggregate.
Usually, if the thus-paved road is allowed to stand or seldom used, the asphalt mixture exhibits an increase in skid resistance with the lapse of time. This is an aging phenomenon of asphalt concrete pavement. As a result of a weathering test it turned out that this phenomenon was caused by the loss of oil component from the asphalt contained in the asphalt mortar present in the pavement surface under such weather conditions as dry-wet repetition, repetition of shining, and hot-cold repetition. On the other hand, by exposing the coarse aggregate surface as described above it is made possible to prevent the increase of skid resistance and obtain a skidding road surface superior in performance. Further, by grinding this coarse aggregate surface it is made possible to obtain a lower skid resistance and maintain it.
The method for removing the asphalt coating is not specially limited.
For example, there may be adopted a method of heating the pavement surface to soften and remove the asphalt mortar, a method of spraying a gas oil or a solvent over the pavement surface to cut back the asphalt mortar and removing the softened asphalt mortars, or a method using water jet, shot blasting or sand blasting. The method using water jet will now be described as an example. The pressure of water to be jetted is not specially limited only it permits removing of the asphalt mortar from the pavement surface. But since a distance is needed between the road surface and the discharge port, it is preferable that the said pressure be not lower than 300 kg/cm 2 . Further, the asphalt mortar removing operation can be done more efficiently by rotating plural discharge ports. Usually, the asphalt coating slightly remains on the coarse aggregate surface after removal of the asphalt mortar, but it can be removed easily with running of an automobile thereon, whereby there can be attained a low skid resistance. Where a low skid resistance value is to be obtained simultaneously with completion of the execution of work, this can be attained, for example, by dissolving an abrasive powder 4 to 10 μm in diameter in water, then applying it to the road surface after removal of the asphalt mortar and grinding the road surface with a nylon pad or the like.
In the case of shot blasting for removal of the asphalt mortar, the steel shot diameter is not specially limited if only it permits removal of the asphalt mortar from the pavement surface, but preferably it is in the range of 0.3 to 2.5 mm.
The shape thereof may be spherical or a shape having a dihedral angle provided it permits removal of the asphalt mortar. The quantity of steel shots to be used is not specially limited if only the asphalt mortar can be removed without influence of the machine moving speed upon the grinding work of the next step; for example, it is preferably in the range of 150 to 240 kg per minute at a machine moving speed of 5 to 15 m per minute.
In the case of sand blasting, the sand diameter is not specially limited if only the asphalt mortar can be removed from the pavement surface, but preferably it is in the range of 0.6 to 2 mm. The shape of sand to be used may be spherical or one having a dihedral angle provided it permits removal of the asphalt mortar. Preferably, a shape having a dihedral angle is used. The quantity of sand to be used is not specially limited if only it permits removal of the asphalt mortar, but a quantity thereof which permits efficient recovery of the sand after use is preferred, e.g. 20-30 kg/m 2 .
In the case where shot blasting is applied to an asphalt concrete pavement surface using a coarse aggregate having a hardness of 15% or less as measured in a Los Angeles abrasion loss test for evaluating the hardness of crushed stone for road, the coarse aggregate surface exposed is rough and a considerable time is required for grinding to obtain a low skid resistance. For efficient execution of the said method, for example, shot blasting is again performed using steel shots of 0.3 to 0.6 mm in diameter, or sand blasting is conducted again.
The method for grinding after removal of the asphalt mortar is not specially limited if only a low skid resistance value is obtained thereby. For example, according to a method which is often adopted, an abrasive powder 4 to 10 μm in diameter is dissolved in water, then applied to the road surface after removal of the asphalt mortar, followed by grinding using a nylon pad.
According to the present invention, the conventional drawbacks of a skid road surface constructed of asphalt concrete using an asphalt mixture can be eliminated and it becomes possible to provide a stable skidding road surface not causing a secular change of a skid resistance value under any conditions of use or weather conditions, whereby the maintenance work for maintaining the skid resistance value or properties after pavement is not required, thus permitting a great contribution to economy.
EXAMPLE
Asphalt mixtures shown in Table 1 were prepared each using asphalt, coarse aggregate, sand and stone dust (with about 30% of slaked lime incorporated therein). An existing road surface was cut out over a width of 3 m and three kinds of asphalt mixtures for skid road surface were each applied to the thus-cut road surface portion at a thickness of 4 cm in section to construct skid road surfaces of asphalt concrete.
The three kinds of the asphalt mixtures for skid road surface are of such compositions as shown in Table 1.
Table 2 shows the results of measurements made using a portable skid resistance tester after completion of the skid road surfaces. From the same table it is seen that there were obtained remarkably low skid resistance values in comparison with the value of a conventional pavement, which values little change even after the lapse of about a half year from summer to winter, thus ensuring a stable skid. Further, since the pavement furfaces obtained according to the present invention each have an uneven shape based on the coarse aggregate, a slight error in the amount of water sprinkled onto the road surface is also cancelled and thus the pavement surfaces could be used in the automobile running test without causing a hydroplaning phenomenon.
TABLE 1__________________________________________________________________________Item Kind of Mixture Mixture A Mixture B Mixture C__________________________________________________________________________Aggregate Gravel 3 57 -- --(%) Gravel 2 19 38 -- Crushed -- -- 76 stone No. 6 Crushed -- 36 -- stone No. 7 Screenings 10 11 -- Sand 10 11 19 Stone dust 4 4 5Amount of Asphalt (%) 4.3 5.1 4.5How to remove water jet water jet shot blasting +Asphalt Mortar sand blastingGrinding 1 4 μm 1 4 μm, 1 4 μm, 2 nylon pad 10 μm 10 μm 2 nylon pad 2 nylon pad__________________________________________________________________________ Note) In the item "Grinding" 1 represents the diameter of the abrasive powder used and 2 represents an abrasive material.
TABLE 2__________________________________________________________________________(Unit: BPN) Kind of Mixture A Mixture B Mixture C ExistingItem Pavement Road Surface Road Surface Road Surface Surface Course__________________________________________________________________________Skid Just after 34 41 42 61Resistance pavingValue After the 34 39 44 58 lapse of half a year__________________________________________________________________________ | A road surface specially designed to enhance skidding includes an asphalt mixture containing a plurality of substantially spherical coarse aggregates, said aggregates having a randomly continuous shape on their upper surface. A method to provide this surface involves replacing a road having an asphalt coating with the road surface of the present invention. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to supports for signs and similar structures, and more particularly to improvements in breakaway bases and connections for highway signs and the like. The present sign support utilizes set screws to lock the sign support pipe within the breakaway base or connector component, thereby precluding twisting or turning of the pipe within the base and corresponding misalignment of the sign.
[0003] 2. Description of the Related Art
[0004] It has been recognized for some time that it is not desirable to construct highway sign supports and similar structures, of extremely durable and damage resistant materials. Generally, the impact forces from a motor vehicle hitting such a sign, result in severe damage to the vehicle and possible injury to the occupant(s) as well as destruction of the sign support structure. Moreover, the additional cost of the sign structure for such relatively strong and massive sign supports, results in considerably greater costs in labor and materials to replace such a sign when it is damaged.
[0005] As a result, a number of different assemblies have been developed to provide an intentionally weak highway sign structure which will flex, break, and/or disassemble upon impact by a vehicle. It is of course desirable to provide a structure which will disassemble upon impact without damage to components, in order to allow the previously used components to be reassembled without requiring replacement of any significant or costly components (other than perhaps small fasteners, etc.).
[0006] One such sign support system which has been developed, is the Texas Universal Triangular Slipbase System (TUTSS). This system utilizes mating triangular plates having notched apices, with bolts installed at each apex to clamp the apices of the plates together. Shear forces caused by an impact, result in the two plates moving apart from one another in shear and dislodging the bolts from their apex notches in the triangular plates. Most, if not all, of the structure is reusable and may be reassembled after an impact, with the impact possibly resulting in the need to replace the readily available and inexpensive post or pipe, bolts, nuts, etc.
[0007] The TUTSS assembly utilizes a specially configured slipbase component, having a relatively large diameter relief area formed within the base of the pipe attachment collar at its juncture with the triangular plate. This relief area is provided for clearance for a split ring collar, which is tightened around the base of the pipe after passing the slipbase component over the end of the pipe. The split ring collar is captured by the slipbase component and prevents the pipe from being pulled from the slipbase.
[0008] The problem with the split ring collar support pipe retention structure, is that the cylindrical pipe can turn within the collar unless an excessive amount of force is used to tighten the pinch bolt of the collar in place on the pipe. While this may not be so critical for signs utilizing multiple support columns, a sign having a single support pipe or column, may turn or rotate within the slipbase collar. This is particularly a problem in areas of high winds, where aerodynamic forces can cause the relatively large plate area of the sign to flutter or work back and forth in the wind. This produces a torsion on the pipe or post holding the sign, which torsional force is transmitted down the pipe to the slipbase and collar contained therein. The collar may turn on the pipe, and/or the collar may turn relative to the slipbase, unless the various bolts holding the assembly together are extremely tight.
[0009] Standards call for the pinch bolt on the collar to be tightened to a torque of sixty foot-pounds, with the three apex bolts securing the slipbase components together being tightened to forty foot-pounds of torque. Even these high torque values still fail to prevent a sign on a single support pipe, from gradually rotating or twisting the pipe relative to the slipbase assembly. It has been found that in areas of high wind, that maintenance crews sometimes have to realign signs using this system, as often as once a week. The costs of this frequent maintenance can result in the cost of the sign being many times the initial purchase and installation cost, over the life of the sign.
[0010] It will be appreciated that the realignment of signs using the TUTSS assembly is not a trivial task, as it requires the mechanic to loosen the three apex bolts securing the slip base components together, slide the upper slipbase up the pipe to access the split collar and its pinch bolt, retorque the pinch bolt as required, realign the sign, and tighten the three slipbase apex bolts to the proper torque. This procedure requires at least a few minutes, in addition to the travel time and costs of operating a vehicle to travel to the site where the sign is located.
[0011] The present invention responds to this problem by locking the base of the post or pipe into the slipbase by means of a series of set screws, which penetrate the side walls of the slipbase collar and engage the walls of the pipe. The point compression of the setscrews into the side wall of the pipe, prevents rotation of the pipe within the slipbase collar. Thus, once the sign post assembly of the present invention has been assembled, no further periodic maintenance is required in order to maintain the alignment of the sign and post relative to the mounting base. The present system thus provides significant cost savings in terms of maintenance, over the life of the sign.
[0012] A discussion of the related art of which the present inventors are aware, and its differences and distinctions from the present invention, is provided below.
[0013] U.S. Pat. No. 1,575,040 issued on Mar. 2, 1926 to Rufus M. Crum, titled “Flagpole,” describes a hinged pole assembly in which the upper portion of the pole is pivotally secured to the upper end of the stationary lower portion. The bottom end of the pivoting upper portion extends downwardly past the pivot hinge to seat within the stationary lower portion of the pole, where it is pinned in an upright position by a removable bolt. This arrangement allows the upper portion of the pole to be lowered for installation or removal of a flag to or from its upper end. Crum does not provide any form of shear plates which are secured together by bolts to allow the upper and lower portions to separate from one another, as is the case with the present sign support invention.
[0014] U.S. Pat. No. 3,451,319 issued on Jun. 24, 1969 to Hans E. Gubela, titled “Road Guidepost,” describes a sign post comprising a wood core with a plastic shell or cover. A tapered attachment flange is provided at the top of the base which is installed in the ground, with a tapered shoe being secured to the bottom end of the post and engaging the flange of the base. Impact with the post dislodges the shoe from the flange, allowing the post to be reinstalled to the base. However, the Gubela assembly is unidirectional, due to the taper of the components, and can only be assembled in one orientation. Moreover, the manufacture of the wood core with its plastic cover is relatively labor intensive, thus resulting in considerably higher manufacturing costs than the present sign post formed of a length of stock pipe material.
[0015] U.S. Pat. No. 3,521,917 issued on Jul. 28, 1970 to Charles E. King, titled “Positive Action Clamp,” describes a sign having a permanently installed base with a breakaway upper column or post. Two opposed cheek plates are attached to the bottom end of the upper portion by spring compression bolts and nuts which pass through the post and cheek plates. Lateral force on the upper portion of the sign causes the cheek plates to spread against the compression of the springs, thereby allowing the upper portion of the sign to break loose from its attachment to the lower portion. Longitudinal force causes the upper portion of the sign to pivot about its lower end which rests upon the fixed bottom column, again allowing the upper portion to break loose from the lower portion. However, the King sign assembly with its opposed cheek plates is only adaptable to square or rectangular section posts, and no mating, horizontally shearing plates are provided by King for connecting cylindrical sign column components.
[0016] U.S. Pat. No. 3,792,680 issued on Feb. 19, 1974 to Francis R. Allen, titled “Flag Pole,” describes a hinged pole assembly with an upper portion which is hingedly attached to a fixed lower portion. The lower end of the upper portion is counter weighted and nests within the hollow upper portion of the fixed lower end of the assembly when the upper portion of the pole is erected. The upper portion of the Allen pole cannot break away from the lower portion without damage. The Allen assembly thus more closely resembles the flagpole of the '040 U.S. patent to Crum, discussed further above, than it does the present assembly.
[0017] U.S. Pat. No. 3,820,906 issued on Jun. 28, 1974 to Herbert L. Katt, titled “Highway Sign Post,” describes a specially configured, frangible assembly for use in assembling lengths of channel end to end in a highway sign post. One component comprises a casting or the like having a generally U-shaped cross section, with a groove formed medially thereabout to provide a line of weakening. A second component bolts to the opposite side of the channel, to sandwich the two ends of the channel therebetween. Impact on the upper channel causes the U-shaped casting to break along its line of weakening and also breaking the second component. The lower bolt holding the assembly to the lower portion of the channel, bends as the upper portion of the sign is pushed over but continues to hold all of the components together. Katt thus teaches away from the present invention, which provides for separation of the sign post components without damage to any significant or costly components thereof.
[0018] U.S. Pat. No. 4,032,248 issued on Jun. 28, 1977 to Alfred P. Parduhn et al., titled “Articulated Highway Delineator Post,” describes a two piece post formed of channel sections, with a sleeve having one open side connecting the two sections together end to end. When the upper portion of the post is struck, the lower end pivots about its attachment in the sleeve to extend out of the open side of the sleeve. The Parduhn et al. assembly thus remains completely assembled and does not separate, as does the present sign post assembly.
[0019] U.S. Pat. No. 4,052,826 issued on Oct. 11, 1977 to Douglas B. Chisholm, titled “Breakaway Coupling Assembly With Fracture-Initiating Washer,” describes various embodiments of a cylindrical sleeve having a partially threaded core and a series of weakening grooves in the outer surface thereof. The sleeves are used to support a base plate, with bolts passing through the base plate and engaging the threaded cores of the sleeves. A washer having a toothed surface is installed between each sleeve and the plate. Bending force upon a pole or the like supported by the base plate, results in excessive compressive force being applied to the sleeves to the side away from the compressive force. This drives the toothed washers downwardly against the sleeves, fracturing the sleeves along their weakening lines and allowing the assembly to collapse. The Chisholm sleeves are specialized components which must be replaced after the sign is displaced, whereas all specialized components of the present system are reusable.
[0020] U.S. Pat. No. 4,926,592 issued on May 22, 1990 to Charles O. Nehls, titled “Breakaway Sign Post Coupling,” describes several different embodiments of an assembly essentially comprising a pair of opposed, triangular plates with notched apices. Bolts are installed in the notches to secure the plates together. Each plate has an additional component extending therefrom, which accepts a post therein. An impact upon the upper post causes the two plates to separate in horizontal shear, with the bolts dislodging from their positions in the notches of the triangular plates. In one embodiment (FIG. 8), a cylindrical pipe is installed in the upper connector component. This assembly is the earliest example of which the present inventors are aware, of pairs of opposed triangular slip bases being used to secure a separable upper post to a fixed lower post. The Nehls assembly is also similar to the structure of the Texas Universal Triangular Slipbase System (TUTSS), noted further above. However, Nehls does not provide a collar integrally formed with the triangular plates, which collar completely surrounds the associated end of the cylindrical pipe component, as provided by the present invention. Moreover, Nehls bolts the ends of the pipes (or other elongate posts) completely through the posts and upright post mounting components extending from the triangular plates. Separation of the posts from their respective fittings, would require removal or destruction of the bolts. In contrast, the set screws of the present arrangement hold the post securely in place, but still allow withdrawal of the post from the corresponding fitting without damage to the fasteners or requiring removal thereof, when excessive force is applied.
[0021] U.S. Pat. No. 5,749,189 issued on May 12, 1998 to Dan Oberg, titled “Post Device,” describes a socket for installing a pipe or the like therein. The socket includes a series of radially disposed lugs, through which corresponding bolts or studs are installed to secure the socket to an underlying concrete pad or the like. The lugs have open sides, which allow the bolts to pull free in the event the socket is dislodged from its base due to impact with the pole extending therefrom. Oberg does not disclose any means for securing the pole within the socket, however.
[0022] U.S. Pat. No. 5,855,443 issued on Jan. 5, 1999 to Ronald K. Faller et al., titled “Breakaway Connection System For Roadside Use,” describes an assembly comprising a pair of parallel plates welded to the adjacent ends of a base and an extension pole. A series of bolts are installed through holes in the plates, with one or more collars or shearing plates installed on each bolt between each of the parallel plates. When the upper pole is struck, the relatively larger diameters of the collars impart shearing forces upon the relatively smaller diameters of the connecting bolts, thereby breaking the bolts and allowing the upper portion of the sign to break away from the fixed base. As the bolts pass through holes in the plates, they cannot escape from the plates and must break in order to allow the upper portion of the structure to break away. Also, it is noted that the posts are welded to the plates, and cannot be replaced after impact damage. In contrast, the bolts securing the two subassemblies of the present sign structure together and the pipe(s) or post(s) of the structure, may be reused or replaced as separate components, as required.
[0023] U.S. Pat. No. 6,254,063 issued on Jul. 3, 2001 to John R. Rohde et al., titled “Energy Absorbing Breakaway Steel Guardrail Post,” describes a series of embodiments for guard rail posts, each including some means of predictable failure in a given direction. Each of the embodiments includes some component(s) (cables, shear plates, and/or bolts) which are damaged as a result of impact force on the guard rail supported by the post, with such damaged components requiring replacement, unlike the present invention.
[0024] U.S. Pat. No. 6,264,162 issued on Jul. 24, 2001 to Theodore D. Barnes et al., titled “Breakaway Sign Post,” describes an assembly having a frangible collar joining the base and upper sections of the post. The collar includes vertically disposed slots therein, which allow the portion of the collar wall defined by the slots to fold when the upper portion of the post assembly is struck. The components of the Barnes et al. post assembly do not separate from one another, and the Barnes et al. collar must be replaced after the upper post is bent over. The Barnes et al. post assembly thus more closely resembles the post assembly of the Katt '906 U.S. patent, discussed further above, than it does the present invention.
[0025] Canadian Patent Publication No. 973,677 issued on Sep. 2, 1975 to John Shewchuck, titled “Coupling For Break Away Pole Bases,” describes a system wherein a pole is supported above a base by a series of frangible spacers. An impact force on the pole causes the spacers to break, thereby allowing the pole to separate from the base and fall rather than resisting the impact. The same problem occurs here as has been noted further above in the discussion of other assemblies having frangible components, i.e., the specially formed frangible components must be replaced before the pole or post assembly can be reassembled. These frangible components are generally specially made and are therefore relatively costly, in comparison to “off the shelf” stock items such as conventional bolts, etc. The present invention enables most, if not all, components to be reused after an impact.
[0026] German Patent Publication No. 1,255,128 published on Nov. 30, 1967 illustrates a post having a base bracket with a pair of laterally spaced bolts passing therethrough and through the bottom of the post seated in the bracket. The bracket also includes opposed, inwardly turned flanges which penetrate the wood post along opposite sides thereof. If a post having this construction were to be impacted, either the bottom of the post, the bracket, or the bolts, or some combination of these components, would be damaged and would require replacement, unlike the present post or pole assembly.
[0027] Finally, the inventors are aware of an assembly manufactured by the P. & H. Tube Corporation of Houston, Tex., titled the “Poz-Loc Slip-Base System.” The Poz-Loc System comprises a series of embodiments, each having a pair of triangular slip base plates which are secured to the adjacent ends of an anchor post and a second post extending upwardly therefrom. Each of the triangular plates includes a notch at each apex, with a bolt being installed through each notch to hold the plates together. This system is similar to that described in the Nehls '592 U.S. patent, with the present invention also utilizing paired triangular slip base plates having notched apices for the connecting bolts. The triangular slip base plate of the Poz-Loc base post is permanently attached thereto (welded, etc.), while the slip base plate of the upper post section includes a cylindrical sleeve, into which the lower end of the upper post is installed. The sleeve of the upper slip base plate is installed over the lower end of the upper post, and a split ring collar is installed between the slip base plate and the lower end of the post to retain the upper slip base plate on the upper post. The collar is secured by means of a pinch bolt. The Poz-Loc System meets the standards of the Texas Universal Triangular Slipbase System (TUTSS), but a problem arises when posts having a cylindrical shape (i.e., pipe, round tubing, etc.) is used in an assembly comprising a single post, as in the case of a relatively small sign (stop sign, etc.). In conditions of high wind, and/or gusts created by passing vehicles (particularly large trucks), the wind may impart sufficient force on the flat plate of the sign to produce significant torsional loads on the post to which the sign is attached. The sign generally cannot turn on the post, as such signs are generally attached by means of through bolts or other fastening means which preclude rotation of the sign relative to the post. However, the torsional force produced by the sign is transferred to the post, where it attempts to turn the base of the post in the slip base. The upper slip base cannot turn, as it is bolted to the fixed lower slip base by means of the three apex bolts. However, the upper pipe can turn or rotate within the sleeve of the upper triangular slip base plate, even though it is held in place by the split ring collar. It is extremely difficult to torque the pinch bolt of the collar sufficiently to completely immobilize the base of the upper post within the collar, and/or to clamp the two slip bases sufficiently to immobilize the collar therebetween. In high wind conditions, a sign supported by the Poz-Loc system can rotate out of its desired alignment where it is visible to drivers, within a week or so of adjustment. The Poz-Loc system requires regular and frequent maintenance in order to maintain the alignment of signs supported thereby, with the maintenance requiring the entire slip base assembly to be disassembled in order to access the pinch bolt of the split collar for retorquing of that bolt. In contrast, the present system utilizes a series of set screws which pass through the walls of the cylindrical sleeve of the slip base, and engage the pipe installed therein. No separate collar is used with the present sign support system. It is impossible for the sign support pipe to rotate within the slip base plate using the set screws of the present invention which penetrate the walls of the slip base sleeve and engage the pipe therein, to immovably affix it in place.
[0028] None of the above inventions and patents, taken either singularly or in combination, is seen to describe the instant invention as claimed. Thus a breakaway post base solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0029] The present invention comprises a breakaway post base for use with highway and road signs and the like, where the support structure includes an intentionally weakened area allowing it to separate at that point in order to avoid further damage to the structure upon impact by a vehicle or the like. The present system meets the standards of the Texas Universal Triangular Slipbase System (TUTSS), and incorporates a pair of slip base components.
[0030] The two slip base components each comprise a triangular shape with a notch at each of the three apices of each triangle. One slip base is secured to each of the post components of the assembly, and are disposed adjacent one another when the components are assembled. A bolt is installed in each apex notch, to hold the two slip base components together. An impact on the upper pipe or support dislodges the bolts from the apex notches, allowing the upper portion of the assembly to depart from the base which is permanently and immovably affixed in the ground, without damage to either the base or upper components of the assembly.
[0031] The present invention differs from the prior art in that at least one of the slip bases includes a sleeve into which the end of the cylindrical pipe is installed, with the pipe being immovably affixed within the sleeve by means of a series of set screws which pass through the wall of the sleeve and engage the pipe therein to lock the pipe immovably relative to the sleeve. Thus, a sign supported on an upper pipe or tube which is in turn secured in a slip base constructed in accordance with the present invention, cannot rotate or become misaligned.
[0032] Accordingly, it is a principal object of the invention to provide a breakaway post base for highway and road signs and the like, which assembly includes a pair of adjacent, triangular slip base plates which are assembled together, with the assembly meeting the standards of the Texas Universal Triangular Slipbase System.
[0033] It is another object of the invention to provide such a breakaway post base system or assembly which includes at least one slip base component having a cylindrical sleeve extending therefrom for accepting one end of a cylindrical pipe or tube therein, with the pipe or tube being secured within the sleeve by a series of set screws which pass through the sleeve and engage the pipe or tube end within the sleeve to affix the pipe or tube immovably therein and prevent rotation of the pipe within the sleeve.
[0034] It is a further object of the invention to provide such a breakaway post system or assembly including componentry for mounting the assembly to a concrete pad and/or joining pipes and tubes of equal or different diameters together, as desired.
[0035] Still another object of the invention is to provide such a breakaway system including spacer means and means for retaining the plate attachment bolts together as a group in the event the plates are separated by impact or other force.
[0036] It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
[0037] These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] [0038]FIG. 1 is an exploded perspective view of a first embodiment of the breakaway post base of the present invention, illustrating a base plate for mounting the assembly to a concrete pad.
[0039] [0039]FIG. 2 is an exploded perspective view of a second embodiment of the present breakaway post base, illustrating a base comprising a base pipe and slip base plate welded thereto.
[0040] [0040]FIG. 3 is an exploded perspective view of a third embodiment of the present breakaway post base, illustrating two triangular slip base plates and integral sleeves for joining two pipes.
[0041] [0041]FIG. 4 is an exploded perspective view of a prior art breakaway post base assembly, illustrating the split ring collar and pinch bolt used to secure the pipe within the slip base.
[0042] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The present invention comprises various embodiments of a breakaway post base, for supporting traffic signs and the like which may be subject to impact from a motor vehicle. The present post base embodiments all include means for preventing rotation of the post or sign support column within the base, thereby eliminating the periodic maintenance and corresponding labor costs involved in readjusting the orientation of the post or support column and the sign supported thereon.
[0044] [0044]FIG. 1 of the drawings illustrates a first embodiment of the present invention, wherein a breakaway device 10 is secured to a mounting base 12 which is in turn secured to a concrete base pad P. The breakaway device 10 comprises a slip base plate 14 having a plurality of bolt clearance notches 16 formed in the periphery 18 thereof. The slip base plate 14 may be formed to have any practicable shape or planform as desired, but a triangular planform with three apices each containing a bolt clearance notch 16 therein, has been found to work well. A support column sleeve 20 having a cylindrical configuration extends from the slip base plate 14 , with the cylindrical axis of the sleeve 20 oriented substantially normal to the plane of the slip base plate 14 . The slip base plate 14 and support column sleeve 20 are preferably formed as a single, monolithic component, e.g. cast, forged, etc., although the sleeve 20 may be welded or otherwise securely affixed to the plate 14 , if so desired.
[0045] The area of the slip base plate 14 subtended by the support column sleeve 20 , along with the sleeve 20 , define a socket 22 for a support column 24 . A support column 24 for a sign or other structure is provided, with the column 24 having a diameter 26 which closely fits within the interior of the support column socket 22 . The support column 24 may be formed of any suitable elongate material providing sufficient structural strength to support the structure attached thereto. Preferably, a length of galvanized steel pipe having sufficient wall thickness (e.g., schedule 10, 20, 40, 80, 120, 160, etc.) is used, as required. The first or lower end 28 of the support column 24 is inserted into the socket 22 and is secured therein by a series of set screws 30 , which thread into cooperating passages 32 formed in the side wall of the support column sleeve 20 . Additional reinforcing bosses 34 surround each of the set screw passages 32 , and extend along the side of the sleeve 20 to join with the slip base plate 14 . The set screws 30 provide sufficient force when torqued to the desired value, to slightly penetrate the support column 24 wall, particularly when chisel point set screws are used. This serves to lock the support column 24 immovably within the socket 22 , precluding rotation of the support column 24 relative to the socket 22 and its integral slip base plate 14 , thereby assuring that any structure (sign, etc.) attached to the support column 24 cannot rotate to some other orientation than that originally installed.
[0046] The mounting base 12 provides for the secure and immovable attachment of the breakaway device 10 to a fixed structure, e.g., the concrete mounting pad P of FIG. 1. The mounting base 12 is immovably affixed to the underlying concrete pad P (or other suitable structure) by a series of bolts 36 , which in turn engage conventional anchors (not shown) imbedded in the concrete. Other attachment means may be provided as desired. The mounting base 12 includes an integral raised mounting pad 38 extending upwardly therefrom, atop which the slip base plate 14 is installed. The, periphery of the mounting pad 38 includes a plurality of bolt slots or passages 40 therein, corresponding in number to the number of bolt clearance notches 16 provided in the slip base plate 14 .
[0047] A series of base plate attachment bolts 42 are installed from beneath the slip plate mounting pad 38 of the base 12 , with their threaded shanks extending upwardly to engage the corresponding bolt clearance notches 16 of the overlying slip plate 14 . Corresponding nuts 44 are used atop the corners of the slip base plate 14 to clamp the plate 14 to the underlying mounting base structure 12 . Washers 46 may be installed between the heads of the bolts 42 and the overlying mounting pad 38 structure, and between the upper surface of the slip base plate 14 and overlying nuts 44 , with additional spacer washers 48 being installed as desired between the mounting pad 38 and the overlying slip base plate 14 . A bolt retainer plate 50 having a series of bolt passages 52 therein is disposed between the mounting pad 38 and the slip base plate 14 , with the bolts 42 installed through the retainer plate bolt holes 52 when the components are assembled. The retainer plate 50 serves to hold the bolts 42 , their corresponding nuts 44 , washers 46 , and spacers 48 together as a group in the event the breakaway device 10 and its support column 24 are dislodged from the mounting base 12 .
[0048] The notched slip base plate 14 , along with the notched mounting pad 38 of the mounting base 12 , allow the bolts 42 to slip from those notches in the event the support column 24 is struck by a vehicle or other impact, thereby releasing the breakaway device 10 from its mounting base 12 . This reduces impact forces by allowing free movement of the support column 24 and structure attached thereto, and greatly reduces or eliminates damage to any of the components to allow their reuse.
[0049] [0049]FIG. 2 illustrates a second embodiment of the present breakaway post base invention, wherein the breakaway device 10 attaches to a similar fitting which is in turn permanently and immovably affixed (e.g., welded, etc.) to a lower support column. The upper breakaway device 10 of FIG. 2 will be seen to be identical to the breakaway device 10 illustrated in FIG. 1 (although it is turned sixty degrees relative to the breakaway device 10 of FIG. 1), comprising a slip base plate 14 having a series of corners or apices, each with a bolt clearance notch 16 formed therein. As in the case of the breakaway device 10 of FIG. 1, the device 10 of FIG. 2 has a triangular periphery 18 with three apices and bolt clearance notches 16 , but other plate shapes and different numbers of bolt clearance notches may be used as desired.
[0050] A support column sleeve 20 extends from the plate 14 , with the sleeve 20 defining a support column socket 22 for securing a first end 28 of a support column 24 therein. The column 24 has a diameter 26 fitting closely within the socket 22 , and may be formed of any suitable pipe schedule material, depending upon the wall thickness required, as described further above in the discussion of the support column 24 of FIG. 1. The column 24 is retained in the socket 22 by a series of set screws 30 which thread into corresponding threaded passages 32 in the side wall of the support column sleeve 20 , to grip the first end 28 of the support column 24 immovably therein. Corresponding reinforcement bosses 34 extend along the sides of the sleeve 20 , surrounding the threaded set screw passages 32 and extending to merge with the base plate 14 .
[0051] The breakaway device 10 of FIG. 2 secures to a lower slip base anchor plate 54 which includes a series of bolt clearance notches 56 formed in the periphery 58 thereof, with the notches 56 corresponding in number and spacing to the bolt clearance notches 16 of the slip base plate 14 of the breakaway device 10 . Preferably, the lower slip base plate 54 is congruent with the slip base plate 14 of the breakaway device 10 . However, this is not critical, so long as the bolt clearance notches 16 and 56 respectively of the slip base plate 14 and lower plate 54 correspond and are in alignment with one another upon assembly. The lower anchor slip base plate 54 is permanently affixed (welded, etc.) to an anchor support column 60 , comprising a pipe of suitable wall thickness or schedule, as in the first support column 24 , or other suitable structural material which may in turn be anchored in a concrete pad or footing, etc. to secure the assembly.
[0052] The breakaway device 10 is secured to the lower anchor slip base plate 54 by a series of base plate attachment bolts 42 , nuts 44 , and washers 46 , with the fastener components 42 through 46 being conventional and essentially the same as those identically numbered components illustrated in FIG. 1 of the drawings. A series of spacer washers 48 and a bolt retainer plate 50 may be installed between the two slip base plates 14 and 54 . The bolt retainer plate 50 includes a series of bolt passages 52 therethrough, through which the bolts 42 pass. The retainer 50 functions in the manner described for the plate 50 of FIG. 1, capturing the bolts 42 , nuts 44 , and washers 46 , 48 as an assembly.
[0053] [0053]FIG. 3 illustrates a further embodiment of the present invention, wherein two breakaway devices 10 are assembled in mirror image. The two breakaway devices 10 of FIG. 3 will be seen to be identical to the breakaway devices 10 illustrated in FIGS. 1 and 2, each including a slip base plate 14 having a series of corners or apices, each with a bolt clearance notch 16 formed therein. As in the case of the breakaway devices 10 of FIGS. 1 and 2, the devices 10 of FIG. 3 have triangular peripheries 18 each with three apices and bolt clearance notches 16 , but other plate shapes and different numbers of bolt clearance notches may be used as desired.
[0054] A support column sleeve 20 extends from each plate 14 , with each sleeve 20 defining a support column socket 22 for securing a first end 28 of a support column 24 therein. The column 24 has a diameter 26 fitting closely within the socket 22 , and may be formed of any suitable pipe schedule material, depending upon the wall thickness required, as described further above in the discussion of the support column 24 of FIG. 1. The column 24 is retained in the corresponding socket 22 by a series of set screws 30 which thread into corresponding threaded passages 32 in the side wall of each support column sleeve 20 , to grip the first end 28 of the support column 24 immovably therein. Corresponding reinforcement bosses 34 extend along the sides of each sleeve 20 , surrounding the threaded set screw passages 32 and extending to merge with the corresponding base plate 14 . The support column sleeve 20 and support column 24 of the lower breakaway device 10 may have different diameters than the corresponding components of the upper breakaway device 10 .
[0055] The breakaway devices 10 of FIG. 3 are secured to one another by a series of base plate attachment bolts 42 , nuts 44 , and washers 46 , with the fastener components 42 through 46 being conventional and essentially the same as those identically numbered components illustrated in FIGS. 1 and 2 of the drawings. A series of spacer washers 48 and a bolt retainer plate 50 may be installed between the two slip base plates 14 and 54 . The bolt retainer plate 50 includes a series of bolt passages 52 therethrough, through which the bolts 42 pass. The retainer 50 of FIG. 3 functions in the manner described for the plate 50 of FIG. 1, capturing the bolts 42 , nuts 44 , and washers 46 , 48 as an assembly and precluding their separation from one another in the event the two breakaway devices 10 become dislodged from one another.
[0056] It will be noted upon review of the lower breakaway device 10 illustrated in FIG. 3 in an inverted position relative to the upper breakaway device of that Fig., that a passage 62 is formed through the slip base plate 14 , generally concentric with the support post socket 22 . It will be seen that the rim of the passage 62 is relatively smaller than the diameter 26 of the support post 24 . This smaller diameter rim defines a support column stop 64 within the base of the corresponding support column socket 22 . This serves to preclude passage of any portion of the support column 24 through the slip base plate 14 , unlike the P. & H. Tube Corporation slip base system, which requires the slip base assembly to be passed completely over a portion of the support column in order to install a split collar clamp on the support column.
[0057] [0057]FIG. 4 of the drawings provides an exploded perspective view in partial section of an exemplary P. & H. Tube Corporation slip base assembly of the prior art. The P. & H. Tube Corporation assembly comprises a first breakaway device 100 , including a slip base plate 102 with a plurality of bolt clearance notches 104 formed in the periphery 106 thereof. A support column sleeve 108 extends from the slip base plate 102 to define a support column socket 110 for a support column 112 . However, it will be noted that the interior of the lower end 114 of the sleeve 108 , where it joins the slip base plate 102 , is considerably wider than the remainder of the sleeve interior 108 . This is due to the need for the P. & H. assembly to provide room for a split shaft collar 116 , which is secured about the first end of the support column 112 by a pinch bolt 118 .
[0058] The P. & H. post support is assembled by first sliding the breakaway device 100 along the support column 112 , with the end of the support column 112 passing completely through the breakaway device 100 . This exposes the end of the column 112 beyond the slip base plate portion 102 thereof to allow the split shaft collar 116 to be secured about the end of the support column 112 , thereby capturing the end of the support column 112 within the sleeve 108 of the breakaway device 100 . The assembly comprising the breakaway device 100 , the support column 112 , and the split shaft collar 116 , is then bolted to a mating slip base plate 120 , using conventional bolts 122 , nuts 124 , and washers 126 . A bolt retainer plate 128 may be installed between the two slip base plates 102 and 120 .
[0059] The problem with the above described P. & H. breakaway assembly of FIG. 4, is that in areas of relatively high winds, a sign supported by such an assembly can produce a torque on the cylindrical support column 112 . Such signs are generally bolted to the support column by bolts passing through the column, so the sign and column are rotationally affixed to one another. However, the rotational force imparted to the sign, is transferred along the length of the support column 112 , whereupon the bottom end of the column 112 attempts to turn or rotate within the rotationally fixed breakaway device 100 .
[0060] The primary force developed for resisting such rotation of the base of the column 112 within the breakaway device 100 , is due to the clamping action of the two slip base plates 102 and 120 , clamping and sandwiching the split shaft collar 116 therebetween, with the collar 116 being clamped to the end of the support column 112 . It will be seen that the circular shapes of these components results in considerable clamping force being required to lock the components together, as the relatively long moment arm provided by the span of a sign secured to the support column 112 , results in an extremely high torque being developed within the breakaway device 100 . Even torquing the pinch bolt to sixty foot-pounds and torquing the attachment bolts to forty foot-pounds, is often insufficient to lock the components immovably relative to one another for an extended period of time, with maintenance crews having to travel to the location of the sign, to disassemble, retorque, and reassemble the components on a frequent basis.
[0061] In contrast, the set screws used to lock the support column within the breakaway device of the present invention, provide some penetration of the wall of the support column to lock the column immovably in place relative to the breakaway device. The support column is essentially pinned in place within the breakaway device by the series of set screws, and cannot move relative to the screws or the breakaway device. The result is a sign installation which remains fixed and immobile, regardless of torsional forces imposed upon the sign due to winds, gusts due to the passage of trucks and other vehicles, etc. The present breakaway post base will thus pay for itself in short order, by greatly reducing or eliminating the periodic maintenance required of earlier devices of the prior art.
[0062] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | A breakaway post base includes a pair of adjacent slip plates to allow separation of the upper portion of a traffic sign or the like from its permanently mounted base. The two plates are triangular with notches at their apices, with the plates and related structure secured together by bolts through the apex notches. An impact on the upper post dislodges the bolts, allowing the upper post to move freely and preventing significant damage to the sign structure. At least one of the slip base plates includes a sleeve extending therefrom, into which one end of the post is installed. The post is prevented from rotating relative to the slip base by a series of set screws installed through the slip base sleeve and locking the post immovably therein. Thus, a sign supported by the present assembly cannot rotate relative to the slip base plate. |
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This Application is a Section 371 National Stage Application of International Application No. PCT/KR2010/009236, filed Dec. 23, 2010 and published, not in English, as WO2011/078586 on Jun. 30, 2011.
BACKGROUND
The present disclosure is contrived to solve the problems in the related art and an object of the present disclosure is to provide a system for driving a boom of a hybrid excavator that minimize energy loss, ensures operability of a boom, and restores recoverable energy of the boom while excavating that is the main use of the excavator, even with a use of an electric motor, and a method of controlling the system.
The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter.
SUMMARY
A system for driving a boom in a hybrid excavator according to the present disclosure includes: an electric motor that operates as a motor or an electricity generator; a capacitor that stores electricity generated by the electric motor; a hydraulic pump motor that is driven by the electric motor and supplies working fluid to a boom; a boom control valve that constitutes a closed circuit selectively connecting/disconnecting a discharge line and an intake line of the hydraulic pump motor to/from a head or a rod of the boom; a main pump that is driven by a driving source disposed separately from the electric motor and supplies the working fluid to a bucket, a traveling motor, or an arm; a boom-assistant valve that allows the working fluid discharged from the main pump and the hydraulic pump motor to meet each other by connecting the discharge line of the main pump to the discharge line of the hydraulic pump motor; and a control unit that controls the electric motor, the hydraulic pump motor, and the boom control valve.
The first control valve is selectively switched when the boom is lifted, and is disconnected when the boom is descended, and the second control valve is disconnected when the boom is lifted, and is selectively switched when the boom is descended.
Further, the first control valve may be connected and allow the flow rate flowing into the hydraulic pump motor from the boom cylinder to flow into the tank, when the flow rate flowing into the hydraulic pump motor from the boom cylinder exceeds the available capacity of the hydraulic pump motor or the capacity of the electric motor when the boom is descended.
A method of controlling a system for driving a boom of a hybrid excavator according to the present disclosure includes: detecting the amount of operation of a boom joystick; determining lifting or descending of a boom due to operation of the boom joystick; opening a first control valve when the boom is lifted; comparing the driving power of the boom according to the amount of operation of the boom joystick with the maximum suppliable power of an electric motor when the boom is lifted and comparing the consumed flow rate of a boom cylinder with the maximum flow rate of a hydraulic pump motor when the driving power of the boom is smaller than the maximum suppliable power of the electric motor; disconnecting the boom-assistant valve, when the consumed flow rate of the boom cylinder is smaller than the maximum flow rate of the hydraulic pump motor; connecting the boom-assistant valve, when the driving power of the boom is larger than the maximum suppliable power of the electric motor; opening the second control valve when the boom is descended, comparing the recovery flow rate of the boom cylinder with the available flow rate of the hydraulic pump motor, when the recovery power of the boom is larger the maximum recoverable power of the electric motor by comparing the recovery power of the boom with the maximum recoverable power of the electric motor; disconnecting the first control valve, when the recovery flow rate of the boom cylinder is smaller than the available flow rate of the hydraulic pump motor; connecting the first control valve, when the recovery flow rate of the boom cylinder is larger than the available flow rate of the hydraulic pump motor; and connecting the first control valve, when the recovery power of the boom is larger than the maximum recoverable power of the electric motor.
According to the system for driving a boom in a hybrid excavator and a control method thereof of the present disclosure, it is possible to minimize energy loss, ensure operational performance of a boom and recover recoverable energy of the boom, while excavating that is the main use of the excavator, even with a use of an electric motor.
That is, it is possible to improve fuel efficiency by removing a loss generated in a hydraulic system in a low-flow rate fine operation by driving the boom, using the electric motor and the boom hydraulic pump motor when the boom is lifted.
Further, the flow rate required for the initial fine operation section when the boom operates alone is supplied from the electric motor and the boom hydraulic pump motor, and the part exceeding the part corresponding to the maximum suppliable flow rate of the boom and power can be supplied by using the existing hydraulic system with the main pump.
Further, it is possible to ensure operation performance of the boom equivalent to the existing excavator while using small-capacity electric motor and pump motor, and recover the energy of the boom, and when high power and a large flow rate are suddenly required, it is possible to ensure the performance equivalent to the existing excavator by assisting power and flow rate by using the existing hydraulic system.
Further, when there is suddenly large recovery energy, the part exceeding the capacity is bypassed, and it is possible to supply most energy required to drive the boom from only the capacities of the hydraulic pump and the electric motor of about the maximum suppliable flow rate of the boom and the maximum power of the engine, and it is possible to recover most of the recoverable energy of the boom.
Further, it is possible to remove a loss in the existing hydraulic system and simplify the structure of the main control valve, by separating the boom from the existing hydraulic system.
Further, it is possible to improve operational performance of the arm and the bucket by making two main pumps in charge of the arm and the bucket.
This summary and the abstract are provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. The summary and the abstract are not intended to identify key features or essential features of the claimed subject matter, nor are they intended to be used as an aid in determining the scope of the claimed subject matter.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a configuration diagram of a system for driving a boom of a hybrid excavator according to an exemplary embodiment of the present disclosure.
FIG. 2 is a configuration diagram showing a lifting state of the boom of FIG. 1 .
FIG. 3 is a configuration diagram showing a descending state of the boom of FIG. 1 .
FIG. 4 is a flowchart of a method of controlling a system for driving a boom of a hybrid excavator according to an exemplary embodiment of the present disclosure.
100: Boom
105: Boom cylinder
106: Head
107: Rod
110: Electric motor
115: Capacitor
116: Electricity storage
120: Hydraulic pump motor
121: Discharge line
122: Intake line
125: Boom control valve
126: Normal-directional connecting portion
127: Cross-connecting portion
128: Disconnecting portion
129: Check valve
140: Main pump
141: Engine
144: Boom-assistant valve
145: Boom-assistant line
151: First control valve
152: Second control valve
160: Control unit
170: Tilting angle control device
DETAILED DESCRIPTION
Hereinafter, preferable embodiments of a system for driving a boom of a hybrid excavator according to the present disclosure and a method of controlling the system will be described with reference to the accompanying drawings. The thicknesses of lines or sizes of components illustrated in the drawings may be exaggerated for the clarity and convenience of the following description. Further, the terminologies described below are terminologies determined in consideration of the functions in the present disclosure and may be construed in different ways by the intention of users and operators or a custom.
FIG. 1 is a configuration diagram of a system for driving a boom of a hybrid excavator according to an exemplary embodiment of the present disclosure, FIG. 2 is a configuration diagram showing a lifting state of the boom of FIG. 1 , FIG. 3 is a configuration diagram showing a descending state of the boom of FIG. 1 , and FIG. 4 is a flowchart of a method of controlling a system for driving a boom of a hybrid excavator according to an exemplary embodiment of the present disclosure.
Referring to FIG. 1 , a system for driving a boom of a hybrid excavator according to an exemplary embodiment of the present disclosure includes an electric motor 110 that is operated as a motor or an electricity generator, a capacitor 115 that stores electricity generated by the electric motor 110 , a hydraulic pump motor 120 that is driven by the electric motor 110 and supplies working fluid to a boom 110 , and a boom control valve 125 that selectively connects/disconnects a discharge line 121 and an intake line 122 of the hydraulic pump motor 120 to/from a head 106 or a rod 107 of the boom 100 . The capacitor of the present exemplary embodiment can be supplied with most power by the operation of a motor/electricity generator (not shown) connected to an engine.
The boom control valve 125 is connected to a main pump 140 by a boom-assistant line 145 through which working fluid is supplied. Two main pumps 140 are provided and supply the working fluid to a bucket, a traveling motor, or an arm by being driven by an engine 141 .
The hydraulic pump motor 120 is connected with the discharge line 121 through which the working fluid is discharged and the intake line 122 through which the working fluid flows inside. The discharge line 121 and the intake line 122 are connected to the head 106 or the rod 107 of a boom cylinder 105 by the boom control valve 125 . That is, the hydraulic circuit contact point of the discharge line 121 and the intake line 122 is connected or disconnected by the boom control valve 125 .
The boom control valve 125 has a normal-directional connecting portion 126 for lifting the boom 100 by connecting the discharge line 121 with the intake line 122 in a normal direction, a cross-connecting portion 127 that connects the discharge line 121 with the intake line 122 in the opposite direction, and a disconnecting portion 128 that cuts the connection between the discharge line 121 and the intake line 122 . The boom control valve 125 is operated by an electronic proportional control valve or a separate pilot hydraulic line and changes the connection state between the discharge line 121 and the intake line 122 .
A check valve 129 is disposed in the discharge line 121 of the hydraulic pump motor 120 to prevent a backward flow and the boom-assistant line 145 is connected close to the check valve 129 from the hydraulic pump motor 120 . A first control valve 151 for connection with a tank is connected between the hydraulic pump motor 120 and the discharge line 121 of the boom control line 125 . A second control valve 152 for connection with the tank is connected between the connection portion of the boom-assistant line 145 and the hydraulic pump motor 120 . The operations of the electric motor 110 , the hydraulic pump motor 120 , the boom control valve 125 , the first control valve 151 , and the second control valve 152 are controlled by a control unit 160 .
Referring to FIG. 2 , when a signal for lifting the boom 100 is input to the control unit 160 from a boom joystick 161 , the electric motor 110 is operated as a motor by the control unit 160 and drives the hydraulic pump motor 120 as a pump. Further, the outlet of the hydraulic pump motor 120 is connected to the head 106 of the boom 100 through the discharge line 121 and the rod 107 of the boom 100 is connected to the inlet of the hydraulic pump motor 120 through the intake line 122 of the hydraulic pump motor 120 , by switching the boom control valve 125 . In this process, the boom 100 starts to be lifted by the flow rate discharged from the hydraulic pump motor 120 and the speed of the boom 100 is controlled by control of the revolution speed of the electric motor 110 and tilting angle control performed by a tilting angle control device 170 .
A closed circuit is implemented between the hydraulic pump motor 120 and the boom cylinder 105 and the flow rate supplied to the hydraulic pump motor 120 from the boom cylinder 105 is smaller than the flow rate supplied to the boom cylinder 105 from the hydraulic pump motor 120 by a cylinder area difference. The deficit of the flow rate is supplied from the tank by connecting the first control valve 151 .
Further, the control unit 160 calculates the power of the electric motor 110 from the torque and rotation speed of the electric motor 110 and monitors the flow rate of the hydraulic pump motor 120 from the tilting angle and the rotation speed outputted from the tilting angle control device 170 .
Meanwhile, when the control signal of the boom joystick 161 increases over the flow rate supplied from the hydraulic pump motor 120 or the capacity of the electric motor 110 , the control unit 160 supplies the flow rate of the main pump 140 to the boom cylinder 105 by controlling the boom-assistant valve 144 . The control unit 160 controls opening/closing of the boom-assistant valve 144 such that the boom cylinder 105 can follow the signal of the boom joystick 161 . The boom-assistant valve 144 is switched to the right by the control unit 160 when being disconnected, and the boom-assistant line 145 is connected to the main pump 140 driven by the engine 141 .
Referring to FIG. 3 , when a signal for descending the boom 100 is inputted to the control unit 160 from the boom joystick 161 , the hydraulic pump motor 120 is operated by the flow rate returning from the boom cylinder 105 by the control unit 160 , the electric motor 110 is operated as an electricity generator by the driving force of the hydraulic pump motor 120 , and the generated power is stored in an electricity storage 116 equipped with the capacitor 115 .
As the boom 100 is descended, the boom control valve 125 is switched and the head 106 of the boom 100 is connected to the inlet of the hydraulic pump motor 120 by the intake line 122 , and the rod 107 of the boom 100 is connected to the outlet of the hydraulic pump motor 120 by the discharge line 121 . The descending speed of the boom 100 is controlled by controlling the rotation speed of the hydraulic pump motor 120 by controlling the tilting angle through the tilting angle control device 170 , and the amount of electricity generated by the electric motor 110 is also controlled.
Further, a closed circuit is implemented between the hydraulic pump motor 120 and the cylinder and the flow rate supplied to the hydraulic pump motor 120 from the boom cylinder 105 is larger than the flow rate supplied to the boom cylinder 105 from the hydraulic pump motor 120 by an area difference of the boom cylinder 105 due to whether there is the rod 107 . The excessive flow rate supplied from the hydraulic pump motor 120 to the boom cylinder 105 is discharged to the tank, as the second control valve 152 connected to the discharge line 121 is connected by a signal of the control unit 160 .
Further, when a flow rate over the available flow rate of the hydraulic pump motor 120 or the capacity of the electric motor 110 is discharged from the boom cylinder 105 and supplied to the hydraulic pump motor 120 , the control unit 160 can discharge an excessive flow rate over the capacities of the hydraulic pump motor 120 and the electric motor 110 to the tank by connecting the first control valve 151 . The first control valve 151 discharges the excessive flow rate of the working fluid flowing to the hydraulic pump motor 120 through the intake line 122 from the boom cylinder 105 to the tank.
Referring to FIGS. 2 and 3 , the first control valve 151 can supply insufficient working fluid to the boom cylinder 105 by connecting the tank when the boom 100 is lifted, and on the contrary, it is disconnected except for when an excessive flow rate is generated to the hydraulic pump motor 120 from the boom cylinder 105 , when the boom 100 is descended.
Further, the second control valve 152 that has been disconnected when the boom 100 is lifted discharges the flow rate excessively supplied to the boom cylinder 105 from the hydraulic pump motor 120 to the tank by being connected when the boom 100 is descended, The second control valve 152 can be controlled when being open as the boom is descended, as described above, but it may be additionally controlled, as described below.
That is, the second control valve 152 may be controlled to be opened only when the flow rate supplied through the hydraulic pump motor 120 is larger than the flow rate necessary for the boom head 106 , while keeping closed when the boom 100 is descended.
Further, when the hydraulic pump motor 120 supplies an unnecessarily excessive flow rate due to various problems, the flow rate circulating is drained to prevent a safety accident and damage to the system, in which it is more preferable that the first control valve 151 operates with the second control valve 152 to be opened such that the working fluid is drained.
Further, the boom-assistant valve 144 is connected by the control unit 160 such that the flow rate of the main pump 140 is supplied to the boom cylinder 105 , when the control signal of the boom joystick 161 increases over the flow rate supplied from the hydraulic pump motor 120 or the capacity of the electric motor 110 .
Referring to FIGS. 2 to 4 , a method of controlling a system for driving a boom of a hybrid excavator according to an exemplary embodiment of the present disclosure includes (a) detecting the amount of operation of the boom joystick 161 , (b) determining lifting or descending of the boom 100 due to the operation of the boom joystick 161 , (c) opening the first control valve 151 when the boom 100 is lifted, (d) comparing the driving power of the boom 100 according to the amount of operation of the boom joystick 161 with the maximum suppliable power of the electric motor 110 when the boom 100 is lifted, and (e) comparing the consumed flow rate of the boom cylinder 105 with the maximum flow rate of the hydraulic pump motor 120 when the driving power of the boom 100 is smaller than the maximum suppliable power of the electric motor 110 .
When the consumed flow rate of the boom cylinder 105 is smaller than the maximum flow rate of the hydraulic pump motor 120 , (f) disconnecting the boom-assistant valve 144 is performed. Further, when the driving power of the boom 100 is larger than the maximum suppliable power of the electric motor 110 , (g) supplying insufficient working fluid by connecting the main pump 140 by opening to the boom-assistant valve 144 is included.
Meanwhile, when the boom 100 is descended, (h) opening the second control valve 152 and (i) comparing the recovery power of the boom 100 with the maximum recoverable power of the electric motor 110 is included. Further, when the recovery power of the boom 100 is smaller the maximum recoverable power of the electric motor 110 , (j) comparing the recovery flow rate of the boom cylinder 105 with the available flow rate of the hydraulic pump motor 120 is included. When the recovery flow rate of the boom cylinder 105 is smaller than the available flow rate of the hydraulic pump motor 120 , (k) disconnecting the first control valve 151 is included. On the contrary, when the recovery flow rate of the boom cylinder 105 is larger than the available flow rate of the hydraulic pump motor 120 , (l) discharging the excessive flow rate to the tank by connecting the first control valve 151 is included. Further, when the recovery power of the boom 100 is larger than the maximum recoverable power of the electric motor 110 , (m) discharging the excessive flow rate to the tank by connecting the first control valve 151 is included.
As described above, the system for driving a boom of a hybrid excavator according to an exemplary embodiment of the present disclosure and a method of controlling the system can improve fuel efficiency by removing a loss generated in a hydraulic system in a low-flow rate fine operation by driving the boom 100 by using the electric motor 110 and the hydraulic pump motor 120 when the boom 100 is lifted.
Further, the flow rate required for the initial fine operation section when the boom 100 operates alone is supplied from the electric motor 110 and the hydraulic pump motor 120 , and the part exceeding the part corresponding to the maximum suppliable flow rate of the boom 100 can be supplied by using the existing hydraulic system with the main pump 140 .
Further, it is possible to ensure operation performance of the boom 100 equivalent to the existing excavator even while using the small-capacity electric motor 110 and pump motor, and recover the energy of the boom 100 . Further, the hybrid driving system using the electric motor 110 and the hydraulic pump motor 120 can perform most energy supply and energy recovery in excavating.
Further, when high power and large flow rate are suddenly required, it is possible to ensure the performance equivalent to the existing excavator by assisting power and flow rate by using the existing hydraulic system. Further, when there is a suddenly large recovery energy, the part exceeding the capacity is bypassed, and it is possible to supply most energy required to drive the boom 100 from only the capacities of the hydraulic pump and the electric motor 110 of about the maximum suppliable flow rate of the boom 100 and the maximum power of the engine 141 , and it is possible to recover most of the recoverable energy of the boom 100 .
The present disclosure may be applied to a system for driving a hybrid excavator in construction equipment.
Although the present disclosure has been described with reference to exemplary and preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure. | Disclosed is a system for driving a boom of a hybrid excavator, and a method for controlling the same. The system comprises: an electric motor; a capacitor for storing electricity generated by the electric motor; a hydraulic pump motor driven by the electric motor to supply working oil to a boom; a boom control valve having a closed circuit selectively connecting/disconnecting a discharge line and an inlet line of the hydraulic pump motor to/from a head or a load of the boom; a main pump arranged separately from the motor to supply working oil; a boom-assisting valve connecting discharge lines of the main pump and the hydraulic pump motor to combine discharged working oil; and a control unit controlling the electric motor, the hydraulic pump motor, and the boom control valve. The system minimizes energy loss during excavation, ensures performance of the boom, and recovers regenerative energy from the boom. |
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BACKGROUND OF THE INVENTION
This invention relates to a single-hung door hinge assembly and more particularly to a door hinge assembly having a pair of mating spherical surfaces for allowing variance in alignment of the hinge straps.
It is known to have a hinge assembly to support a door on a body structure of a vehicle which allows the door to pivot in relation to the body structure. The hinge assembly consists of a pair of hinge straps with an interconnecting hinge pin. It is known to use a single hung door hinge, where one of the hinge straps is positioned above the other hinge and connected by the interconnect hinge pin whereby the hinge straps do not intermesh.
It is also known to use two separate single hung hinge assemblies to attach the vehicle door to the body structure and mount the hinge assemblies in the same direction with the movable hinge strap, which is mounted to the vehicle door, located above the stationary hinge strap. This allows the door to be removed from the vehicle for manufacturing and maintenance by removing a retaining bolt, which disassembles the hinge pin from one of the straps, and lifting the door. U.S. Pat. No. 4,542,558 discloses a single-hung hinge which has a hinge pin shaped so that it is non rotatable relative to one of the hinge straps and allows the hinge strap and door to be reinstalled on the hinge pin and returned to their originally adjusted position. The hinge assembly must be properly aligned initially in the vehicle.
It is also known that hinge assemblies work with the greatest ease and least wear when the axis of rotation of the hinge assemblies are aligned in a single axis.
It is also recognized that slight variations in the body structure from the desired or proper plane as the result of build variations might make it more difficult to align the axis of the hinge assemblies in a single axis. It would be desirable to have a single-hung hinge assembly which provides for variance in the orientation of the hinge pin relative to one of the hinge straps thereby allowing the hinge pin to be aligned with the other hinge strap and the axis of rotation of the hinge assembly.
SUMMARY OF THE INVENTION
This invention provides a door hinge assembly to pivotably mount a vehicle door member to a body structure member. The assembly includes a first hinge strap mounted to one of the members and having a vertical opening. A second hinge strap is mounted to the other member and has a spherical concave surface. A hinge pin is interposed between the hinge straps. The hinge pin has a portion received by the vertical opening of the first hinge strap. The hinge pin has a spherical convex surface for engaging the concave surface of the second hinge strap allowing variance in relative orientation of the hinge pin to the second hinge strap. The hinge pin is rotatably retained to one of the hinge straps allowing pivotable movement between the members. A removable retention bolt is carried between the hinge pin and the other hinge strap for retaining the hinge pin to the other hinge strap. The retention bolt allows removable retention of the door member to the body structure member. The concave and convex surfaces allow for variance in relative orientation of the hinge pin to the second hinge strap.
One object, feature and advantage resides in the provision of a hinge assembly having a pair of hinge straps and a hinge pin, whereby the hinge pin varies in alignment or orientation with one of the hinge straps allowing alignment with the other hinge strap.
Another object, feature and advantage resides in the provision of a hinge assembly, which allows the vehicle door to be removed by removing a bolt and lifting the door, and also allows the hinge pin to vary in alignment or orientation with one of the hinge straps thereby maintaining alignment with the other hinge strap.
Further objects, features and advantages of the present invention will become more apparent to those skilled in the art as the nature of the invention is better understood from the accompanying drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the hinge assembly of the invention mounted on a vehicle body and door structure;
FIG. 2 is a sectional view of a hinge assembly; and
FIG. 3 is a sectional view of a hinge assembly of a second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the hinge assembly of the invention, designated generally at 10, is shown in place on a vehicle body structure member 12 and a vehicle door member 14. The hinge assembly 10 can be used with any vehicle door, but is disclosed as the hinge assembly 10 for a front driver side door. The hinge assembly 10 includes a pair of hinge straps, a stationary hinge strap, designated generally at 16, and a movable hinge strap, designated generally at 18.
The movable hinge strap 18 has a base 24 secured to door 14 by a pair of bolts 26. Referring to FIG. 2, a hinge pin receptacle 28 of the movable hinge strap 18 has a cylindrical vertical opening or hinge eye 30 to receive a hinge pin 32.
Referring to FIG. 2, the hinge pin 32 is generally cylindrical and has an upper portion 34 and a lower portion 36 where the upper portion 34 has a smaller diameter than the lower portion 36. The upper portion 36 is received by the vertical opening 30 of the movable hinge strap 18 with a pair of interposed bushings 42 and 46 allowing for rotatable movement between the hinge pin 32 and the movable hinge strap 18. A top surface 52 of the hinge pin 32 is peened to a washer 50, securing the two bushings 42 and 46 and the movable hinge strap 18 on the hinge pin 32.
The lower portion 36 of the hinge pin 32 has a lower surface, a hemispherical convex surface 54, as seen in FIG. 2. The hemispherical convex surface 54 projects upward to an outside diameter greater than the shoulder 38 of the hinge pin 32. A tapped or internally threaded hole 56 opens onto the undermost portion of the hemispherical convex surface 54.
Referring back to FIG. 1, the stationary hinge strap 16 has a base 58 secured to the vehicle body structure 12 by a pair of bolts 60. Referring to FIG. 2, a hinge pin receptacle portion 62 of the stationary hinge strap 16 has a lower edge 64 with a partial spherical convex surface 66. A bore 68 formed downward from an upper edge 70 of the hinge pin receptacle portion 62 has a hemispherical concave lower surface 72 for receiving the hemispherical convex surface 54 of the hinge pin 32. A hole 74 extends between the hemispherical concave surface 72 and the partial spherical convex surface 66 of the hinge pin receptacle portion 62 of the stationary hinge strap 16.
A retainer bolt 78 is threaded through a partial spherical concave washer 80 and the hole 74 in the hinge pin receptacle portion 62 of the stationary hinge strap 16 and received by the threaded hole 56 in the hinge pin 32. The partial spherical concave washer 80 engages a head 81 of the retainer bolt 78 and the partial spherical convex surface 66 of the stationary hinge strap 16 allowing the bolt 78 to snugly hold the hemispherical convex surface 54 of the hinge pin 32 against the hemispherical concave lower surface 72 of the stationary hinge strap 16. However, the hemispherical convex surface 54 of the hinge pin 32 can move relative to the hemispherical concave lower surface 72 of the stationary hinge strap 16 prior to the retainer bolt 78 being tightened.
Referring to FIGS. 1 and 2, the hole 74 in the stationary hinge strap 16 has a large enough diameter to allow relative change in orientation, as shown by an angle α, between a vertical axis 82 of the hinge pin 32, which extends along the hole 56 which opens onto the hemispherical convex surface 54, and a vertical axis 84 of the stationary hinge strap 16, which extends along the hole 74. FIG. 2 shows a vertical axis 84' which is shifted by the angle α from the vertical axis 82. This change in relative orientation or position of the vertical axes is done without the binding of the hinge pin 32 or the retaining bolt 78 with the hinge strap 16.
Referring to FIG. 1, a second hinge assembly 22, identical to the first hinge assembly 10, works in conjunction with the first hinge assembly 10 to rotatably mount the door 14 to the vehicle body structure 12. A door swing axis 88, which is the axis of rotation of the door, runs through the vertical axes of the hinge pins 32 of both hinge assemblies 10 and 22.
Referring to FIGS. 1 and 2, the door 14 is initially installed on the vehicle body structure 12 by assembling the hinge assemblies 10 and 22. The movable hinge strap 18, which is rotatably connected to the hinge pin 32, is attached to the stationary hinge strap 16 by the hinge pin 32 being seated in the bore 68 of the stationary hinge strap 16. The retainer bolt 78 is inserted through the partial spherical concave washer 80 and the hole 74 in the stationary hinge strap 16 and threaded into the tapped hole 56 in the hinge pin 32, but not tightened. The hinge assemblies 10 and 22 are mounted to the door 14 by the base 24 of the movable hinge strap 18 being bolted to the door 14. The movable hinge straps 18 of the hinge assemblies are located on the door 14 to ensure alignment with the door swing axis 88 running through the vertical axes of hinge pins 32 of both hinge assemblies 10 and 22.
The base of the stationary hinge strap 16 is then bolted to the body structure whereby the door 14 with the hinge assemblies 10 and 22 is mounted on the body structure 12. The vertical axes 84 of the the stationary hinge straps 16 need not be aligned. Referring to FIG. 2, such mis-alignment might result from variations in a pillar 86 of the body structure 12 where the base 58 of the stationary hinge strap 16 is mounted, such as not being in the proper plane, or the hinge strap 16 not properly aligned on the pillar 86. A variation by angle α where the base 58 of the stationary hinge strap 16 is mounted to the pillar 86 will result in relative change of orientation, as represented by angle α, between the vertical axis 82 of the hinge pin 32 and the vertical axis 84 of the the stationary hinge strap 16, with the hemispherical convex surface 54 moving relative to the hemispherical concave lower surface 72.
After the door 14, including the hinge assemblies 10 and 22, is mounted to the body structure 12, the retainer bolt 78 is tightened, so that the hinge pin 32 is clamped into place relative to the stationary hinge strap 16 with the adjustment for the variation of the vertical axes. The hinge pin 32, as retained, is automatically aligned with the door swing axis 88, which is the rotation axis of the door.
The vehicle door 14 can be easily removed by removing the retainer bolts 78 and lifting the door 14 with the movable hinge strap 14 and hinge pin 32 and then replaced without altering the fit of the vehicle door 12.
A second embodiment of the invention, shown in FIG. 3, has a hinge assembly 90 for placement on the vehicle body structure 12 and the vehicle door 14. The hinge assembly 90 includes a pair of hinge members, a stationary hinge strap 92 and a movable hinge strap 94.
The movable hinge strap 94 has a base secured to the vehicle door 14 by a pair of bolts in an identical manner as the first embodiment. A hinge pin receptacle portion 96 of the movable hinge strap 94 has a vertical hole 98 extending between an upper edge 100 and a lower edge 102 for receiving a hinge pin 104 and a retaining bolt 106. The hole 98 varies in diameter as it extends from the lower edge 102 to the upper edge 100 of the hinge pin receptacle portion 96 and has a conical portion 108.
The hinge pin 104 has an upper portion 118 with a generally cylindrically shaped side wall 120. A tapped hole 128 opens onto an upper surface 124 of the hinge pin 104 for receiving the retaining bolt 106. A conical section 126 of the upper portion 118 projects downward and outward from the cylindrically shaped side wall 120 for engaging the conical portion 108 of the hole 98 of the movable hinge strap 94. A lower portion 130 of the hinge pin 104 depends downward from the conical section 126 of the upper portion 118 and has a cylindrical shaft 132 ending in a sphere 133 having a partial spherical convex surface 134.
Referring to FIG. 3, the stationary hinge strap 92 has a base 135 secured to the vehicle body structure 12 by a pair of bolts in an identical manner as the first embodiment. A hinge pin receptacle portion 136 of the stationary hinge strap 92 has a cylindrical bore 138 opening downward. A tapered hole 140 extends from an upper surface 142 of the hinge pin receptacle portion 136 and narrows as it opens into the cylindrical bore 138.
A plastic bearing 144 is located at an upper end 148 of the cylindrical bore 138 and has a hemispherical concave surface 146 which opens downward. A tapered hole 150 in the plastic bearing 144 aligns with the tapered hole 140 in the hinge pin receptacle portion 136 to form one continuous tapered hole. The hemispherical concave surface 146 of the plastic bearing 144 engages the partial spherical convex surface 134 of the hinge pin 104 with the upper portion 118 of the hinge pin 104 protruding through the tapered holes 150 and 140.
A frustoconical "bellville" washer 152 is located in the cylindrical bore 138 of the hinge pin receptacle portion 136 and preloads the hinge pin 104 for ensuring engagement of the partial spherical convex surface 134 of the hinge pin 104 with the plastic bearing 144, thereby maintaining the hinge pin 104 in the desired position.
A metal plate 154 located in the cylindrical bore 138 and a lower edge 156 of the hinge pin receptacle portion 136, which is peened over, secure the plastic bearing 144, the hinge pin 104 and the bellville washer 152 in the cylindrical bore 138.
The partial spherical convex surface 134 of the hinge pin 104 can move relative to the hemispherical concave surface 146 of the plastic bearing 144 of the stationary hinge strap 92. The tapered holes 140 and 150 in the stationary hinge strap 92 and the plastic bearing 144 are of a large enough diameter to allow relative change in orientation, as shown by an angle α, between a vertical axis 162 of the hinge pin 104, which extend along the upper and lower portions 118 and 130, and a vertical axis 164 of the stationary hinge strap 92, which extends along the cylindrical bore 138. FIG. 3 shows a vertical axis 164' which is shifted by the angle α from the vertical axis 162. This change in relative orientation or position of the vertical axes is done without binding the hinge pin 104 including the cylindrical shaft 132 with the hinge pin receptacle portion 136.
Similar to the first embodiment, a second hinge assembly, identical to the first hinge assembly 90, works in conjunction with the first hinge assembly to rotatably mount the door 14 to the vehicle body structure 12. The door swing axis, which is the axis of rotation of the door, runs through a pivot center 170 of the sphere 133 of the hinge pins 104 of both hinge assemblies 90.
The door 14 is initially installed on the vehicle body structure by assembling the hinge assemblies 90. The hinge pin 104 is rotatably mounted to the stationary hinge strap 92 with the bellville washer 152 ensuring contact between the hinge pin 104 and the plastic bearing 144. The hinge pin receptacle portion 96 of the movable hinge strap 94 is slid over the hinge pin 104. The retaining bolt 106 is inserted in the hinge pin receptacle portion 96 from the upper edge 100 and is received by the tapped hole 128 of the hinge pin 104. The retaining bolt 106 is tightened until the conical section 126 of the hinge pin 104 is firmly engaged with the conical portion 108 of the hole 98. The hinge pin 104, as retained, does not rotate relative to the movable hinge strap 94.
The hinge assemblies 90 are mounted on the door 14 by the base of the movable hinge strap 94 being bolted to the door similar to the first embodiment. However, the vertical axes 162 of the hinge pins 104 need not be aligned for smooth "bind free" door swing operation as explained below.
The base 135 of the stationary hinge strap 92 is then bolted to the body structure 14 whereby the door 14 with the hinge assemblies 90 is mounted on the body structure 12. The vertical axes 164 of the the stationary hinge straps 92 need not be aligned. This mis-alignment could be for the same reasons as discussed in relation to the first embodiment. A variation by angle α where the base 135 of the stationary hinge strap 92 is mounted to the pillar 86 will result in relative change of orientation, as shown by angle α, between the vertical axis 162 of the hinge pin 104 and the vertical axis 164 of the the stationary hinge strap 92, with the spherical convex surface 134 moving relative to the partial spherical concave surface 146.
Furthermore, since the vertical axes 162 and 164 of the hinge pin 104 and the stationary hinge strap 92 are not held relative to each other by a retaining bolt, as is done in the first embodiment, the hinge assembly 90 can adjust as the door is rotating. For example, if the movable hinge straps 94 of the hinge assemblies are slightly out of alignment with each other, the hinge pin 104 will adjust relative to the stationary hinge strap 92 as the door rotates to prevent binding of the hinge pin 104 with the stationary hinge straps 92. Therefore, the movable hinge strap 94 need not be aligned with a door swing axis.
The bellville washer 152 holds the hinge pin 104 snug against the plastic bearing 144 preventing the partial spherical convex surface 134 of hinge pin 104 from unseating when the door is open. The preload of the bellville washer 152 is sufficient to assure that the weigh of the door does not unseat the partial spherical convex surface 134 from the plastic bearing 144.
The vehicle door 14 can be easily removed by removing the retaining bolt 106 and lifting the door with the movable hinge strap 94 and then replaced without altering the vehicle door 14 fit. The conical section 126 of the hinge pin 104 and the conical portion 108 of the hinge pin receptacle portion 96 ease the alignment and insertion of the hinge pin 104 in the hinge pin receptacle portion 96.
While two embodiments of the present invention have been explained, various modifications within the spirit and scope of the following claims will be readily apparent to those skilled in the art. | A door hinge assembly pivotably mounts a vehicle door member to a body structure member. The assembly includes a first hinge strap mounted to one of the members and having a vertical opening. A second hinge strap is mounted to the other member and has a spherical concave surface. A hinge pin is interposed between the hinge straps. The hinge pin has a portion received by the vertical opening of the first hinge strap. The hinge pin has a spherical convex surface for engaging the concave surface of the second hinge strap allowing variance in relative orientation of the hinge pin to the second hinge strap. The hinge pin is rotatably retained to one of the hinge straps allowing pivotable movement between the members. A removable retention bolt is carried between the hinge pin and the other hinge strap for retaining the hinge pin to the other hinge strap. The retention bolt allows removable retention of the door member to the body structure member. The concave and convex surfaces allow for variance in relative orientation of the hinge pin to the second hinge strap. |
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SUMMARY OF THE INVENTION
This invention relates to prefabricated building sections or room units and to methods for their use in erecting buildings. Such prefabricated building sections are of the kind comprising a framework of metal beams and building components such as, at lease one wall or other partition and/or a floor and a ceiling.
In accordance with one aspect of the invention, there is provided a section of the kind set forth, wherein at least one vertical beam of the framework is embraced by fireproof material substantially throughout its length and around at least part of its periphery as seen in cross-section.
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic elevation of part of a prefabricated building constructed in accordance with one aspect of the invention,
FIG. 2 is a somewhat diagrammatic horizontal section through part of the upper story of the building of FIG. 1,
FIG. 3 is a perspective view, to an enlarged scale and as seen in the direction indicated by an arrow III in FIG. 2, illustrating two superposed prefabricated building sections of the building of FIGS. 1 and 2,
FIG. 4 is a section, to an enlarged scale, taken on the line IV--IV of FIG. 3,
FIG. 5 is a section, to an enlarged scale, taken on the line V--V V of FIG. 3,
FIG. 6 is a section, to an enlarged scale, taken on the line VI--VI of FIG. 3, and
FIG. 7 is a section, to an enlarged scale, taken on the line VII--VII of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the building 1 shown in FIG. 1 is a block of apartments formed substantially completely from prefabricated three-dimensional building sections or room units. Each story of building 1 includes a plurality of adjoining apartments each of which is afforded by a plurality of appropriate building sections disposed in juxtaposed relationship. Apartments of different sizes can be provided by forming them from lesser or greater numbers of building sections.
FIG. 2 of the drawings illustrates part of the top story of the building 1 and it will be seen from that Figure that, at one end 2 of the elongated building 1, there are two adjoining sections 3 and 4 that afford a landing giving access to a staircase 5 and to two elevator shafts 6 and 7. At the side of the section or unit 4 that is remote from the section or unit 3, four sections or units 8, 9, 10 and 11 are arranged in successively adjoining juxtaposed relationship to form one apartment. As can be seen somewhat diagrammatically in FIG. 2 of the drawings, the building sections 8 to 11 thereof are provided with internal and external walls or other partitions to form a living room 12, three bedrooms 13, 14 and 15, a kitchen 16, a hall or vestibule 17, a corridor or passage 18, a toilet 19, a bathroom 20 and a storage room 21 at one side of the corridor or passage 18. Moving along the story illustrated in FIG. 2 from the end of the building 1, a further apartment is provided immediately beyond the one that has just been described, this further apartment being substantially symmetrically identical relative to a substantially vertical plane containing the junction between the two apartments. The further apartment that has just been mentioned has an over-all dimension 22, extending lengthwise of the building 1, that may conveniently have a magnitude of substantially 12 meters, this dimension being equal to the equivalent dimension of the apartment afforded by the four building sections 8 to 11 inclusive.
Passing along the story shown in FIG. 2 of the drawings beyond the second of further apartment or flat mentioned in the preceding paragraph, a third, smaller apartment is reached that is afforded by only three building sections 26, 27 and 28 arranged in successively adjoining juxtaposed relationship. The internal and external walls or other partitions that are provided in the building sections 26 to 28 inclusive define a living room 29, two bedrooms 30 and 31, a kitchen 32, a corridor or passage 33, a bathroom 34, a toilet 35 and a storage room 36 disposed between the bathroom 34 and the toilet 35. As mentioned above it is possible to form apartments, flats or other dwellings of larger or smaller sizes by employing an appropriate number of prefabricated building sections with suitable internal subdivisions.
FIG. 3 of the drawings shows that each of the prefabricated building sections is afforded principally by a lower portion or floor panel 40 from the upper surface of which project a plurality of vertical supporting columns, the numbers of which depends upon the particular shape and function of the section concerned. Each of the two sections illustrated in FIG. 3 comprises six supporting columns 41, 42, 43, 44, 45 and 46 and it will be seen from FIG. 4 of the drawings that the lowermost end of one column bears directly upon the top of the corresponding column of the underlying section. The columns thus afford unbroken support for the building 1 from the foundation thereof to the top of the uppermost story. It is to be noted from FIG. 3 that the upper ends of columns 41 and 46 and also 43 and 44 are interconnected at their tops by guide beams which are substantially L-shaped in cross-section and are designated 62A and 63A respectively. Each building section has a length 47 that, in this embodiment, is substantially 12 meters with a width 48 that, in this embodiment, is substantially 3 meters. The height 49 of each section is substantially 3 meters in this embodiment but it is emphasised that any or all of the dimensions 47, 48 and 49 may be varied as required. It is clearly desirable that the dimensions should be as large as possible if the building 1 is to be formed from a minimum number of sections but it will, of course, be realized that limitations are effectively placed upon the maximum values of three dimensions by the technical difficulties involved in constructing and handling very large units without damage or distortion and the technical difficulties and legal regulations that prevent the transport of very large sections along public roads, railways and the like.
FIGS. 4, 5 and 6 of the drawings show one of the columns 45 and an overlying column 45A, both these columns having a corresponding core in the form of a metal tube 51 of substantially square cross-section. In this embodiment, the tube 51 is 150 millimeters square and the metal from which the tube is formed has a thickness 52 (FIG. 4) of 10 millimeters. It will be evident that these dimensions are not mandatory and that alternative cross-sectional shapes and dimensions may be employed. The core afforded by the metal tube 51 extends throughout the height of the corresponding column 45 and, similarly, a tube 51A affording the core of the overlying column 45A extends throughout the height of that column. The same is true of the other supporting columns of all of the sections of the building 1 so that the strong metal tubes, which constitute the principal factors in giving the columns their load-bearing rigidity, extend in uniterrupted relationship from the foundation of the building to the top of its upper story. The tubes 51 and 51A are surrounded throughout substantially the whole of their lengths by sheath-like layers 53 of fireproof material. In the embodiment that is being described, the fireproof material is concrete having a thickness 54 (FIG. 4) of substantially 50 millimeters. Bonding of the concrete of the layers 53 to the outer surfaces of the metal tubes 51 and 51A is improved by winding a metal helix 55 around each tube between its upper and lowermost ends and preferably, but not essentially, welding the helix to at least some of the corners of the tubes 51 and 51A where the circumscribing (in plan view) helix touches those corners (see FIGS. 5 and 6). The concrete of the layers 53 surround the helices 55 as well as the tubes 51 and 51A. It is not essential that the fireproof material of the layers 53 should be concrete and it is emphasized that other fireproof materials may be arranged around the tubes 51 and 51A either by casting or in some other convenient manner.
The lower portions or floor panels 40 of the various building sections each comprise an oblong frame afforded by two longer parallel beams 60 and 71 and two shorter parallel beams 62 and 63 that are horizontally perpendicular to the beams 60 and 61. Each of the beams 60 and 63 is of channel-shaped cross-section and is so arranged that, in cross-sectional view, the base of the channel is substantially vertically disposed with the limbs projecting substantially horizontally towards the interior of the frame from the upper and lower edges of the base. The limbs of the beams 60 to 63 are welded or otherwise rigidly secured to the metal tubes 51 and 51A that afford the cores of the various supporting columns such as the columns 41 to 46 inclusive illustrated in FIG. 3. The sheath-like layers 53 of fireproof material around the tubes 51 and 51A are only interrupted over very short lengths of the supporting columns where those tubes are welded or otherwise rigidly secured to the flanges of the beams 60 and 63 inclusive. The flanges of the beams 60 and 63 are notched or otherwise recessed at the locations at which they are to cooperate with the columns 41 to 46, the widths of the notches or recesses being equal to the widths of the tubes 51 and 51A and the depths 64 (FIG. 4) of the notches or recesses having magnitudes that are substantially equal to one-third of the width of one of the tubes 51 or 51A so that the outer surfaces of the completed sheath-like layers 53 will be substantially coplanar with the outer surfaces of the bases of the beams 60 to 63 inclusive in the finished building sections as illustrated in the drawings. The notches or recesses that are formed in the limbs of the beams 60 to 63 inclusive at the four corners of the oblong frame, where those beams are rigidly interconnected, are appropriately shaped to receive the tubular cores of the columns 41, 43, 44 and 46, it being evident that the notches or recesses will be somewhat different in shape to those that co-operate with the cores of the columns 42 and 45. However, once again, the tubes 51 or 51A of the supporting columns at the corners of the sections or units are welded or otherwise rigidly secured to the flanges of the beams 60 to 63 inclusive at the corners of the frame which those beams define so that the whole of each unit will be of a strong and rigid construction.
Inner walls and other partitions may be arranged at the required locations in the various building sections so as to define the required rooms and other spaces in the building 1 or other building that is to be formed by assembling the sections. FIG. 3 of the drawings illustrates two similar building sections 8 in superposed relationship, FIG. 3 being a view as seen in the direction indicated by an arrow III in FIG. 2 of the drawings. Each of these sections 8 has a wall 65 extending between the columns 42 and 43, a partition 67 extending between the columns 42 and 45 and a wall 66 that extends from the column 42 towards the column 41 as far as a further relatively perpendicular wall 68 that is not directly connected to any of the columns. The wall 68 forms part of the front of the apartment that is afforded by the four juxtaposed building sections or room units 8, 9, 10 and 11 and it will be seen from FIGS. 2 and 3 of the drawings that the space between the wall 68 and an outer wall of the building 1 that substantially coincides with the columns 41 and 46 forms part of a gallery or hallway common to all of the apartments in the same story which gives access to all apartments from the landing defined by the sections or units 3 and 4 at the end 2 of the building. The outer wall of the building 1 that substantially coincides with the columns 41 and 46 preferably comprises a lower parapet and a large upper window in respect of each building section of each story as is shown somewhat diagrammatically in FIG. 1 of the drawings. The portions of the outer walls of the building 1 at each end of each building section will normally be provided during the prefabrication of that section even though the portions of the outer walls in question are not shown in FIG. 3 of the drawings. Since all of the inner and outer walls and other partitions are installed in the building sections prior to their delivery to the building site, only a minimum of finishing work is necessary in addition to the actual erection of the building. This finishing work may be limited substantially only to the structural interconnection of the various building sections and the interconnection of various service pipes and other conduits for water, gas, electricity, heating, telephone and like services. If, as is preferred, decorative wall coverings, cooking appliances, sanitary ware and the like are already installed in the sections prior to their delivery to the building site, only minor matters normally require attention after the building has been erected and the various structural and other connections have been made as mentioned above.
The lower portion or floor panel 40 of each building section comprises an upper load-bearing floor slab or plate 70 and a lower ceiling slab or plate 71. The ceiling slab or plate 71 affords the bottom of one story and the ceiling for the rooms and other spaces of the next underlying story. This allows each section to have an open top so that it is only necessary to provide additional parts at the ceiling level of the uppermost story of the building 1 or other building. It is, however, possible to interconnect the upper ends of the columns 40 to 46 by substantially horizontal beams but this is not shown in any detail in the accompanying drawings. Each section is strengthened to some extent by the internal walls and other partitions that are arranged between its supporting columns during prefabrication. Each completed section is, accordingly, of sufficient strength and rigidity to enable it to be mechanically handled and transported between the factory or the like at which it is made and its eventual position in a building such as the building 1. The strength and rigidity of the building sections are such that there is very little danger of distortion or breakage during such handling and transport.
Strong and reliable connections between superposed building sections can be established advantageously by casting material such as concrete internally of the tubes 51 and 51A that afford the cores of the supporting columns and, effectively, tubular frame beams of the sections. Such casting is effected after the sections have been placed in their appointed positions in a building such as the building 1. When the sections of the lowermost or ground floor story have been disposed on the foundation of the building, the interiors of the tubes 51 may be filled with liquid concrete up to, for example, approximately half their heights so that a satisfactory junction with the foundation and fastening to that foundation is achieved. To this end, the foundation itself is preferably provided with downwardly extending openings that register with the open lower ends of the tubes 51 of the columns forming parts of the lowermost story. When the sections of the lowermost story are in position with the tubes 51 registering with said openings, concrete is poured into the open upper ends of the tubes to fill the foundation openings and the tubes 51 themselves up to approximately half the heights of those tubes. Reinforcing mesh may, if considered necessary, be arranged in the foundation openings and in the interiors of the tubes 51 before the concrete is poured. A firm and reliable anchorage of the lowermost story to the foundation is thus effected. When the next story comprising a plurality of building sections is erected on top of the ground level or lowermost story, further concrete can be poured into the open upper ends of the tubes 51 or 51A of the supporting columns in that story so that the further concrete extends up to approximately half the height of the supporting columns of such story. It can be seen from FIG. 4 of the drawings that a mass 72 of concrete is thus formed that extends in an unbroken condition right through the junction between, for example, an underlying tube 51 and an aligned overlying tube 51A. Mesh or other reinforcing elements may, if considered necessary, be arranged at the junctions between the upper and lower tubes before the concrete of the mass 72 is poured so that said mass will be strengthened thereby when it has set. Each of the masses 72 constitutes an effective connection between each pair of vertically superposed tubes such as the tubes 51 and 51A. The superposed columns of the building sections thus constitute a satisfactory skeletal supporting structure for the whole building 1.
The supporting columns of sections in lower stories of the building 1 are, of course, subject to heavier loads than are the columns of upper stories thereof. It is accordingly possible to form the tubular cores or frame beams of the columns in upper stories of the building from thinner metal than those of lower stories, that is to say, the thickness 52 (FIG. 4) may be varied in dependence upon the load which the corresponding column will have to bear which load will normally be dependent upon the horizontal level of that column in the building 1 or other building of which it is to form a part. Adjoining sections in a single story can be structurally interconnected by, for example, fastening abutting horizontal beams of such sections or units to one another. Such fastening can take the form of a row of spot welds and this is illustrated in FIG. 7 of the drawings where the abutting horizontal beams 82 and 83 of two floor panels (such as the floor panel 40 shown in FIG. 3) are interconnected by a line of spot welds 81. Since the supporting columns of the building that are formed by series of superposed columns of the individual building sections are of fireproof construction throughout their vertical lengths, the building sections have a very high resistance to combustion and the basic supporting parts of the building, in particular, are of a construction which will not burn for all practical purposes. Such a construction is particularly important in multiple story buildings. In the building 1 which has been described, the columns, such as the columns 41 to 46, of all of the sections or units of each story are located in strict vertical alignment. It is, however, possible to arrange at least some of the columns in at least some of the stories in relatively offset positions where this is more convenient for the particular internal divisions of the building that are desired. Under such conditions, horizontal supporting structures are provided in the building sections that have supporting columns which are laterally offset with respect to those of the sections or units of an underlying story.
It will be evident that supporting columns which extend throughout the heights of the various building sections and that are surrounded throughout substantially the whole of their vertical lengths by layers of fireproof material constitute a simple and satisfactory structure for the prefabrication of the three-dimensional building sections. Building sections of the kind that have been described are particularly, but not exclusively, advantageous for use in erecting multi-story buildings and it has been found that buildings which extend to five or more stories in height are particularly suitable for erection in a simple and economic manner using the described and illustrated building sections. The specified height 49 of substantially 3 meters is particularly suitable when the sections are principally intended for blocks of apartments but sections of other heights can readily be produced when, for example, they are to serve for the erection of office buildings or the like. Alternative internal and external walls and other partitions for office or other commercial use can readily be provided. The indicated length 47 of substantially 12 meters and width 48 of substantially 3 meters can also be changed if required and it is also possible to give the sections shapes other than the strict rectangular parallelepiped shape that has been described and illustrated. It is noted that, in the construction shown in FIG. 3 of the drawings, the columns 42 and 45 are located at a distance 90 of substantially 41/2meters from the short end of the section or unit concerned which incorporates the columns 41 and 46 whereas the far end thereof which comprises the columns 43 and 44 is at a further distance 91 of substantially 71/2meters from the columns 42 and 45. These distances 90 and 91, also, may be varied to meet the individual requirements of any particular building construction.
Although various features of the building sections and their methods of use in erecting buildings described and illustrated in the accompanying drawings will be set forth in the following claims as inventive features, it is emphasized that the invention is not limited to those features and includes within its scope all of the parts of the building sections described or illustrated or both and all of the steps in their methods of use described or illustrated or both, individually and in various combinations. | A multistory building constructed of prefabricated parallelepiped sections, each of which has a similar framework of metal beams disposed at the section's edges, the upright beams at the vertical edges being hollow and disposed so that in superimposed sections they are abutting, said upright beams being covered with concrete for fireproofing and filled with concrete to extend between abutting beams rigidly to connect same. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The invention pertains to the field of jack devices useful for floor installation or repair. More particularly, the invention pertains to a jack designed to aid in the repair and installation of wooden flooring by forcing abutting edges of individual pieces of flooring into proper position until they can be fastened into place.
BACKGROUND OF THE INVENTION
Wooden flooring is usually supplied as boards having tongue-and-groove edges, such that the floor is laid over a subfloor by placing the boards next to each other, forcing the tongue on the edge of one board into the mating groove of the next, and nailing the boards in place through the edge, so that the nails are invisible when the next board is installed. Forcing the tongues into the grooves requires a fair amount of force, and the boards must be held tightly together as the nails are driven.
Traditionally the installation and repair of wooden flooring has required two carpenters. To assure a tight fit between the individual pieces of flooring the first carpenter forces the flooring being installed or repaired into proper position, while the second carpenter securely fastens the flooring being held to the subfloor. To insure that the floor is held tightly together it has generally been the situation that nails are driven into the flooring used at an angle so that as the nail engages with the subfloor, the individual pieces of flooring are driven laterally into a tighter abutment with the piece of flooring previously put in place. In this manner the flooring is constructed, one piece at a time, gradually being laid from the base of a starting wall towards the base of an ending wall where the last piece will be put in place.
A number of devices have been developed in the past to aid in the installation of flooring, but they have had a number of deficiencies which make them difficult to use in the modern method of installation on a subfloor.
Examples of these prior art flooring clamps or jacks are Parrish, "FLOOR CLAMP" U.S. Pat. No. 10,061, issued in 1853; Foster, "FLOOR-CLAMPS", U.S. Pat. No. 136,428, issued in 1873; or Lassahn, "CLAMPING DEVICE FOR CONSTRUCTING FLOORING, DECKING AND THE LIKE", issued in 1964. All of these devices force the flooring into alignment using screw (Parrish), rack-and-pinion (Foster) or hydraulic (Lassahn) force exerted against the floor joists. Obviously, this would not work if the floor is being installed in the present manner over a plywood subfloor.
Masters, "PUSH STICK FOR PLUMB AND LINE ADJUSTMENT OF STUD WALLS", U.S. Pat. No. 4,660,806, issued in 1987, is a more general pushing device using a hydraulic ram, but is not used for flooring.
Powernail Co. Inc, P.O Box 300, Lincolnshire, Ill. 60069, currently markets two models of a flooring jack called a Powerjack™. Both use a ratchet mechanism to exert force on flooring. The Powerjack 100 has a bent leg which hooks over the edge of the tongue-in-groove flooring and a flat pressor foot moved by a ratchet. The unit rides on the flooring to be moved, while the pressor foot pushes against a stationary object such as a wall or a stud nailed to the subfloor, thus pulling the flooring into place. The Powerjack 200 is designed for glue down and gym floor installation by pushing from a subfloor anchor point. It has a flat foot which must be attached by nails or screws to the subfloor, and a second foot which can be moved by a ratchet to press against the tongue-in-groove flooring. Both have relatively restricted maximum distances from their anchor points, and, unless used right next to a wall in the case of the model 100, both require some sort of anchor attached to the subfloor.
SUMMARY OF THE INVENTION
The invention comprises a flooring tool for use in installing tongue-in-groove wooden floor in which a jack is used to push a foot against the strips of flooring to be installed, forcing the strips into alignment for nailing.
A pivoting gripper attaches the jack to a board, allowing use of the invention at widely varying distances from a wall, well in excess of the maximum extension of the jack. For use on boards in the middle of the room, the foot is on the opposite end of the jack from the pivoting gripper, allowing maximum extension and distance. For installing the last few boards, the pivoting gripper may be removed or swiveled out of the way, and the foot moved to the other end of the jack, allowing the tool to exert force against boards only inches from the wall.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the invention being used to install a wooden tongue and groove floor covering.
FIG. 2 shows a side view of the invention, corresponding to FIG. 1.
FIG. 3 shows the invention, configured for use with boards close to a wall.
FIG. 4 shows an end view of the jack of the invention, at the location of the fixed guide, along lines 4--4 in FIG. 1.
FIG. 5 shows an end view of the jack of the invention, at the location of the pivoting gripper, along lines 5--5 in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show the invention in use. The floor jack of the invention uses a jack to exert force, which comprises a movable portion (2) and a fixed portion (1). It will be understood that "fixed portion" and "movable portion" are terms which are adopted herein for convenience, and that, in fact, both sections are movable relative to each other. The fixed portion houses an actuating mechanism such as a worm gear or rack-and-pinion actuated by a crank (9) and handle (10). If desired, the crank (9) and handle (10) can be replaced by a standard 1/4, 3/8, or 1/2 inch drive socket, so that a conventional socket wrench drive could be used as the handle, or by a hex head suitable for actuation by a socket wrench with socket. Alternatively, the fixed portion could contain a hydraulic or pneumatic cylinder driven by a lever or pump, or an electric motor, depending on the form of the jack. Turning the crank (9), or whatever actuation is appropriate for hydraulic or pneumatic jacks, causes the movable portion (2) of the jack to be extended, exerting an outward force.
A conventional trailer jack (that is, a jack which is used to support trailer tongues when the trailer is detached from the towing vehicle) is an appropriate jack for use with the invention. By removal of the swivel wheel or jack plate and addition of the fittings described below, the trailer jack mechanism can form the basis of a flooring jack according to the teachings of the invention. Such jacks are available from a number of manufacturers, in mechanical, electric, pneumatic or hydraulic forms.
The JP214S0317 trailer jack manufactured by Fulton Performance Products of Mosinee, Wis., for example, can provide up to 2000 pounds of force and up to 14 inches of extension. Other models in the Magnum series by the same manufacturer can apply up to 7,000 pounds of force, and still other models have maximum extensions of 27 inches or more.
Some mechanical jacks have the additional benefit that they can exert a force both in extension and retraction, which a hydraulic, pneumatic, or ratchet-type jack could not do. Under some circumstances, this would add to the flexibility of use of the invention.
Two tabs (20) and (22) are attached to opposite ends of the fixed portion (1) of the jack, allowing the pressure foot (15) on push/pull rod (14) to be attached to either end of the jack, for reasons to be explained below. This multiple mounting allows great flexibility in the configuration of the flooring jack of the invention. If desired, a third tab could be added to the movable portion (2) of the jack, and a second foot and rod attached there.
Also attached to the fixed portion (1) of the jack is a fixed guide (3). FIG. 4 is an end view of the jack, showing how the guide (3) is attached to the fixed portion (1) by bolts (4) clamping the guide (3) around the jack. There is sufficient space within the generally U-shaped guide (3), above the upper bolt (4) to allow a board (8), preferably a "2×4" (conventionally 11/2 by 31/2), to be inserted.
A pivoting gripper (5) is attached to the movable end (2) of the jack. FIG. 5 shows a detail of the gripper (5). The gripper (5) is pivotally mounted to the movable end (2), and has a pair of gripping elements (6) for holding the board or brace (8). As can be seen in that figure, the gripper (5) can be made of two plates (24) joined by welded-in pins (6), as shown, or by bars or bolts. Alternatively, the gripper could be made in a U-shape as shown for the guide, and only a single pin (6) used as the second gripping element. The pins (6) are spaced apart sufficiently to allow a board (8), preferably a 2×4, to fit between the pins (6). The gripper (5) is free to pivot around pivot bolt (7), passing through the movable end (2) of the jack. By pivoting the gripper (5), the board (8) will be gripped between the pins (6). The pins may be cylindrical in cross-section, or square, rectangular, hexagonal, oval or any other shape desired.
Referring to FIGS. 1 and 2, the invention can be seen in use. One row of tongue-in-groove flooring (11) has been installed next to a wall (13). A second row of flooring (12) is placed next to the first row (11), and must be forced tightly against the first row, to cause the tongue to fit tightly and fully into the groove, so that the row (12) can be nailed in place.
The foot (15) on its push/pull rod (14), attached to tab (22) on the end of the fixed portion (1) furthest from the movable portion (2) to gain maximum extension, is placed in contact with the row of boards (12) to be forced into place. If the distance between the foot (15) and the end of the movable portion (2) is not enough to allow the movable portion (2) to reach the far wall (17), a long board (8), preferably a 2×4 or the like, is placed through the fixed guide (3) and the pivoting gripper (5), with its far end pressing against the far wall (17). If desired, a facing board (16) between the board (8) and the wall (17) can provide protection from marring the wall (17).
The gripper (5) is pivoted to grip the board (8), and the actuator (here crank (9) and handle (10)) is actuated to cause the movable portion (2) to extend, exerting force between the wall (17) and the foot (15), forcing the flooring (12) into place. With the flooring (12) held in place, nails can then be driven in conventional fashion.
With an 8 foot long 2×4, and a jack with 24" extension, the jack of the invention can thus be used across a room of nearly 10 feet in width. A ten- or twelve-foot board would allow use in even wider rooms, or a temporary brace could be installed on the floor to allow use of the tool over arbitrary distances.
As shown in FIG. 3, as the floor nears completion, the board (8) could be omitted and the movable portion (2) could press directly against the wall (17), perhaps with a facing board (16) between the wall (17) and the movable portion (2). By moving the foot (15) to the tab (20) on the end of the fixed portion (1) closest to the movable portion (2), the jack of the invention can be used up to the last few rows of flooring (30) and (31), right up against the wall (17).
The ability to move the foot (15) from tab (22) at one end of the fixed portion (1) to tab (20) at the other, and to reverse the foot (15) on its push/pull rod (14), plus the ability to use a 2×4 to extend the reach of the jack, gives the invention a flexibility of use unmatched in the prior art.
A single jack can thus be used to press every row of tongue-in-groove flooring into place right across a room. For the first rows of flooring (12) near wall (13), the jack is used at maximum extension, with the end of the board (8) near guide (3), and with the foot on tab (22). As the flooring progresses across the floor, the board (8) can be slid through guide (3), with gripper (5) progressively loosened and tightened. Within two or three feet of the far wall (17), the board can be dispensed with and the movable portion (2) placed against the wall. Alternatively, if a tab is provided on the movable portion, a foot and push/pull rod can be attached to the tab and the foot pressed against the wall (17). Finally, for the last few boards (30), (31), the foot (15) and push/pull rod (14) are reversed and moved to tab (20).
Although the invention has been described herein primarily as a flooring installation tool, it will be understood that the flexible arrangement of the invention allows its use in other applications, as well. With the board (8) vertically arranged, the foot (15) could be mounted to either tab (20) or (22), as needed, and used to support horizontal sheets of wallboard or paneling while they are screwed to studs.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. References herein to details of the illustrated embodiments are not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention. | A flooring tool for the installation or repair of wooden tongue and groove flooring. The tool has a jack for exerting linear force, with a fixed and a movable portion. A pivoting gripper is mounted upon the movable portion, and a guide is mounted upon the fixed portion, which allows a brace such as a 2×4 board to be inserted into the guide and gripper and held in place, extending the reach and usefulness of the tool. A foot upon a push-pull rod extends downwards from the fixed portion of the jack, and pushes upon the flooring planks. In a preferred embodiment, two attachment points are provided for the foot on its rod, at each end of the fixed portion, providing maximum flexibility. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates to the compaction of paved surfaces which have an inclined and/or curved profile in vertical cross section. A typical surface in this category is an asphalt automotive test track.
As is well known, a slope face is paved by laying a paving material on a graded slope with a machine known in the art as an asphalt finisher or "paver." Then, the laid asphalt is compacted by a vehicle known as a "roller" which has steel wheels or rubber tires. As shown in FIG. 4, a roller vehicle B runs on a slope face D, performing the compacting work while it is connected to and supported by a wire W which extends from an anchor vehicle A which runs along the top of the slope.
In a test course for automobiles, the roadbed is generally paved by machines which move in the travel direction of the test course. The compacting rollers and the like are run in the same travel direction to perform the roller-pressurizing work.
Since the test course has a special three-dimensional curved surface, the radii of curvature of the curved surfaces of the slope bottom portion and of the slope shoulder portion largely differ across the width of each profile of the course, i.e. in each vertical plane which is transverse to the longitudinal travel direction. These radii also sequentially vary from one profile to another taken along the course. Therefore, it is fairly difficult to roller-pressurize a curved surface to conform accurately to the designed profile. In particular, if the pressure-applying surfaces of steel roller wheels do not completely coincide with the surface of the asphalt mixture, the shape of the curved surface may change after it is rolled and an accurate paved surface cannot be obtained. Conventional compacting systems do not have wheels capable of conforming to the surfaces with curved profiles.
In an apparatus for rolling curved surfaces disclosed in the Official Gazette of Japanese Patent Publication No. 3024/1969 (JP-B 44-3024), the wheels are forcedly inclined by an hydraulic cylinder. Therefore, no problem will occur if the designed radius of curvature of the roadway profile is constant. If the radius of curvature sequentially varies from one position to another along the length of the roadway as in an easement curve portion of a test course, it is necessary to continuously change the angles of inclination of the wheels in accordance with the movement of the roller vehicle in its longitudinal direction of travel. However, it is extremely difficult to control the pressure of the hydraulic cylinder in such a manner.
When a roller is supported from an anchor vehicle by a wire on an ordinary hydraulic winch, the distribution of weight on the right and left wheels will differ due to the inclination of the roller main body, thus preventing uniform roller pressurization. Therefore, it is necessary to offset the deflected load of the roller by the tension of the wire rope of the winch. However, since the tension of a conventional winch is adjusted by manually operated controls, equal distribution of weight on the left and right wheels cannot be accurately maintained.
SUMMARY OF THE INVENTION
Acccording to the invention, an apparatus for compacting a paved curved surface comprises a vehicle body with right and left shafts mounted thereon so as to be variably inclinable relative to each other and to the vehicle body. Right and left wheels are rotatable and are mounted on the respective shafts, and the apparatus has means for changing the inclinations of the right and left shafts in opposite directions relative to the vehicle body.
Preferably the shafts are connected to the body by left and right members which each have a lower portion connected to the vehicle body. A link-moving means is connected to left and right links which, in turn, are connected to upper portions of the left and right shaft-supporting members. The link-moving means moves the links relative to the vehicle body and to change the inclinations of the shafts. The link moving means may be a pivoted member with opposite arms which are connected to the links.
The vehicle body is connectible to a tension member which deters lateral slipping of the vehicle body on the paved surface. Sensor means are provided on the vehicle body for providing signals which indicate the inclination angle of the vehicle body, and a control means is provided to change the tension of the tension member in response to signals from the sensor means. In use, an anchor vehicle is connected to the vehicle body by the tension member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view with a part cut away showing the main components of a compacting vehicle which embodies the present invention.
FIG. 2 is a diagrammatic view which includes a vector diagram illustrating the pressure equalizing feature of the invention.
FIG. 3 is a block diagram of a control unit which is used in the invention.
FIG. 4 is an explanatory diagram of a worksite where a slope face is being compacted.
DETAILED DESCRIPTION
In FIG. 1, wheels 2 and 2' are attached to the right and left sides of the main body 1 of the roller vehicle. In this case, the wheels 2 and 2' are rotatably mounted on the shafts 10 and 10', respectively. Bar members 15 and 15' are integrally attached with the shafts 10 and 10', and they are mounted on the vehicle body 1 in a manner which enables them to be freely inclined with respect to the main body 1. Pivot pins 3 and 3' attach the lower portions of the bars 15 and 15' to the body 1. Balance links 5 and 5' have their outboard ends coupled by pins 4 and 4' to the upper end portions of the bars 15 and 15'. The inboard ends of the balance links 5 and 5' are coupled by pins 6 and 6' to arms on opposite sides of a link 7. The link 7 has its center pivotally connected to the main body 1 by a pin 8.
The wheels 2 and 2' can automatically follow along the curved pavement surface a without intervention by the machine operator.
The balance links 5 and 5' and the link 7 constitute a link mechanism which offsets the overturning components of forces Fl and F2 which are exerted on the wheels 2 and 2' by the inclined ground. Without the link mechanism, the wheels 2 and 2' will slip laterally due to the overturning components of force in the steep inclined ground, or a large difference will occur between the pressures at the opposite edges of the wheels, so that the roller-pressurizing work cannot be performed.
Stops 9 and 9' are affixed to the body 1 to limit the movement of the link 7, thus preventing the wheels 2 and 2' from inclining so far that they come into contact with the main body. Numerals 11 and 11' denote hydraulic motors for driving the vehicle, and 12 represents a supporting point on the roller main body 1 which is connected to the anchor wire 13.
The right and left wheel shafts can follow the curved surface, and the link mechanism always locates the vehicle body at the center between the right and left wheels, so that the roller-pressurizing forces exerted by the right and left wheels are equal. Even if the surface curvature changes, the link mechanism moves the shafts and wheels in opposite directions to prevent any unbalanced roller pressures due to the curved surface.
As shown in FIG. 2, the main body 1 of the roller carries a hydraulic winch 14, an inclination angle sensor 17, and a hydraulic control unit 18. The roller 1 is coupled to and supported by the anchor wire 13 which is connected to a supporting point 15 on an anchor vehicle 16.
In operation, when the roller main body 1 runs on the inclined surface, a component F of the weight W of the vehicle body is generated in proportion to the inclination angle θ of the roller body 1. Therefore, two machines can be supported by the wires 13 from the anchor vehicle 16 and they are run in parallel with the anchor vehicle 16 to prevent the main body 1 of the roller from falling down, overturning or slipping transversely. Differential roller pressures are prevented by applying the deflected loads to the right and left wheels 2 and 2'.
In this case, by adjusting the tension F' of the wire 13 so it is equal and opposite to the component F, only the force P which is perpendicular to the inclined surface acts on the roller body 1. Thus, the roller body 1 runs under conditions which are the same as if it were running on a flat horizontal surface. In this state, the roller body 1 is steerable by operating its steering wheel or handle. It can be steered toward the slope shoulder c or slope bottom d, thus changing its position on the slope. This mobility is irrespective of changes in the inclination of the roller body 1. Moreover, the forces applied to and by the right and left wheels 2 and 2' are uniform and equal.
In conventional systems for supporting a roller main body, a hydraulic winch on an anchor vehicle is wound up or down in response to instructions from the operator of the roller vehicle 1, thereby changing the transverse position of the roller main body 1. Therefore, the wire is frequently too taut or too slack. Uniform roller pressurization is not possible due to the deflected loads to the right and left wheels 2 and 2'. Further, there is a danger that the roller main body may slip or overturn due to incorrect or misunderstood instructions between the roller operator and the anchor vehicle operator.
FIG. 3 shows an example of a unit for controlling the apparatus so the tension F' of the wire 13 will equal the force component F. In this drawing, solid lines represent hydraulic connections, and broken lines represent electrical connections. A voltage signal proportional to the inclination angle 0 is generated by the inclination angle sensor 17 on the roller vehicle. This signal is amplified by a command signal converter 20 and output as a command signal to a proportional electromagnetic relief valve 22. This gives a constant proportional relation between the command signal and the hydraulic pressure which is supplied to a hydraulic motor 21.
A variable hydraulic pump 23 is driven by a prime mover E to supply the hydraulic pressure to the hydraulic motor 21 through a change-over valve 24, thereby forwardly or reversely rotating the hydraulic winch 14. The hydraulic pressure of the motor 21 is detected by a pressure sensor 25 of the electromagnetic relief valve. At the same time, this hydraulic pressure is reduced to a predetermined pressure by a proportional electromagnetic valve 26 in response to a signal from a servo amplifier 27. Hydraulic fluid released by the valve 26 is returned to a hydraulic tank T.
The hydraulic pressure which is supplied to the hydraulic motor 21 can be automatically adjusted to be proportional to the inclination angle 8 of the roller body as described above. The control pressure is also detected by the pressure sensor 25 and the detection signal is returned to the control unit. The relation between the inclination angle 8 of the roller main body 1 and the pressure to be supplied to the hydraulic motor 21 is previously calculated and set and, thereafter, it can be confirmed and adjusted experimentally.
When the tension of the wire is controlled in response to the angle of inclination of the vehicle body, to balance against the gravitational component of force in the direction perpendicular to the slope face due to the inclination, the roller-pressurization can be performed so that constant and equal forces are exerted by the left and right compactor wheels. | A compactor having the roller shafts mounted for changing the inclination of the roller through a linkage system. The compactor is connected to an anchor vehicle by a tension member which deters lateral shifting and has a sensor indicating the inclination angle. The sensor is connected to a control which varies the tension. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation-In-Part Application based on U.S. application Ser. No. 10/512,409, which now is abandoned.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a system, a method and a device for producing a truss from bar-elements, which are joined or joinable, and from connection-elements located or placeable between those at their joint places, whereby the bar-elements consist of at least one segment of a material of high-growing plants each, and the connection-elements consist of a rigid, regenerative material. Preferably, connection-elements are provided wherever two or more bar-elements meet whose longitudinal axes are not coaxial to each other.
The inventor has found that natural occurring materials, especially wood, bamboo culms or the like, have very advantageous properties for producing a framework, for example as supporting structure of a house. Such material is much more lighter than for example steel or concrete, and it is much more elastic and little brittle. Additionally, plant material can be cultivated in every desired amount, whereas steel and other materials are limited and are much more difficult to achieve and therefore should be avoided, if possible. On the other hand, at present, there exists no satisfactory connecting structure for connecting two or more bar-elements made from wood, bamboo culms or the like.
BRIEF SUMMARY OF THE INVENTION
From the disadvantages of the described prior art, there arises the problem initiating the invention, to improve a generic system for producing a truss or framework from plant material in such a way, that there results an optimum ratio between efforts and achievement, i.e. that the costs and/or the expenditure of work for producing a building can be decreased, without its stability suffering therefrom.
At a generic system, the solution of this problem is achieved by a system for to supporting a framework, the system comprising bar-elements joinable to form a truss, and connecting elements insertable between said bar-elements at all junctures where two or more bar-elements, whose longitudinal axes are not coaxial to each other, are joined, wherein
a) each of said bar-elements comprises at least one portion of a material is selected from high-growing plants, comprising giant grasses deciduous trees, coniferous trees, palm trees, and bamboo plants, and b) each of said connecting elements comprises a selected rigid, regenerative material comprising raw material built up by plants using photosynthesis, like wood; and wherein c) at least one end of a bar-element, a connecting element which is to be mounted to said bar-element, and at least one end of a further bar-element which is to be connected to said connecting element, are provided with surfaces configured as geometrical bodies at least in selected areas, d) such that at a joint between at least one end of one of said bar-elements and said connecting element which is to be mounted to said bar-element, or the further bar-element, each of the elements exhibits at least in a selected area a surface which runs along a surface generated by a selected one of a cylinder, a cone, a prism and a pyramid, as well as at least in another selected area a surface which is configured as a selected one of a hollow cylinder, a hollow cone, a hollow prism and a hollow pyramid, respectively, e) whereby multiple of said bar-elements are connected to one connecting element with two or more of said bar-elements having their longitudinal axes not coaxial to each other, and whereby said connecting element comprises at its surface multiple connecting structures in the shape of annular recesses machined into a continuous surface, so that each recess surrounds a core which ends in a front side flush with an area surrounding the recess, the annular recess having two concentric bounding surfaces for the connection of each bar-element, which bounding surfaces permit an assembly by plugging one bar-element into the annular recess of each connecting structure with two pairs of closely adjoining surfaces complementary to each other and glued together in pairs.
High growing plants are reinforced with fibres running in longitudinal direction and therefore show an optimum stability for (tensile) stress along their longitudinal direction. On the other hand, since buildings produced by the system according to the invention are broken up into trusses with nodes and straight connections between those, it is not required that the bar-elements have a high bending strength. Therefore, fibres running slantwise or transversal with regard to the longitudinal axis of the bar element, and in particular those running in radial directions or crosswise with regard to each other, can be renounced. By using regenerative raw materials for the bar-elements, the use of expensive chemicals can be saved, which furthermore come from fossil and therefore only limited available materials. Furthermore, regenerative raw materials are built up by photosynthesis, whereby the carbon, which is required for a multitude of organic compounds, is abstracted from the carbon dioxide of the air; therefore, its climate-changing effect as a greenhouse gas is reduced. Biological materials can also be disposed of more easily without pollution of the environment.
For the system according to the invention, it is of central importance that at the joint between a bar-element and a connecting element or a further bar-element, each of both bodies exhibits at least in a selected area a surface which runs along the surface generated by a cylinder, cone, prism or a pyramid, as well as at least in another selected area a surface which runs along a hollow cylinder, hollow cone, hollow prism and/or a hollow pyramid respectively. On the one hand, these are bodies which can be produced with relatively simple processes like milling or lathing. On the other hand, this enables a connection by plugging with closely adjoining surfaces, which are suitable for a locking by clamping and/or glueing. By utilization of a press fit an even higher strength of the bonding is achievable. For instance, at a bar-element a convex hollow element (inside) is always present within a concave solid element (outside), so that two standardized surfaces lying in each other can be created easily by processing the inner and the outer side. If two surfaces, which are approximately complementary, are created at the connection-element, whereby the convex hollow element is located outside of the concave solid element (core), then the potential bonding area and therefore the strength of the joint can be approximately doubled. Furthermore, a bar-element inserted into the recess is completely covered at its face side, and therefore is always firmly pressed to both bonding areas even during different expansions, e.g. caused by moisture (swelling).
The invention recommends that the two different geometrical shapes, along which the surface of a body runs, are aligned concentrically to each other. Such an arrangement of special homogeneity can be produced in a very simple way, and, for instance, it comes closest to the natural geometry of a bamboo culm.
If the two different, but somehow symmetric shapes, along which the surface of the body runs, exhibit constant distances from each other, then the result is an isotropic structure, which permits an arbitrary rotation of the bamboo culm around its axis, and therefore offers an additional degree of freedom to enable a fine adjustment at difficult nodes of the truss.
At the connection-elements, a plurality of recesses exist, one for each connected bar-element. Each recess has an annular shape and is machined into a continuous surface, so that each recess surrounds a core. This core ends in a front side which is flush with the area surrounding the recess. In this context, flush means lying in a common surface, especially in a common even or flat plane or in a common surface of the same (constant) curvature.
An important aspect of the invention is that the depth of the recess, as measured at its outside periphery against the surrounding area of the connection element, is equal to the maximum height of the core within the recess, as measured from the bottom of the recess to the most protruding area of the core inside the recess.
Another feature of the invention is that the cross-section of the recess is symmetrical to a line between both boundaries of the recess. According to the present invention, there is a full symmetry of the cross-section from the area surrounding the recess at its outside to the core inside the recess, resulting in two pairs of closely adjoining surfaces, which are glued together in pairs.
The outer lateral surfaces adjoining each other have identical surface areas
F o =p o *h= 2π R*h,
where p o is the perimeter of the radial outer boundary of the recess, h is the depth of the recess; in case of a cylindrical surface, R is the radius of the outer cylindrical boundary surface.
The inner lateral surfaces adjoining each other have identical surface areas:
F i =p i *h= 2 πr*h,
where p i is the perimeter of the radial inner boundary of the recess, h is the height of the core or the depth of the recess; in case of a cylindrical surface, r is the radius of the inner cylindrical boundary surface.
The whole surface F glued together is:
F=F o +F i =2π( R+r )* h
As the difference between F o and F i is equal to the cross-section of the recess, multiplied by 2π:
F o −F i =2π( R−r )* h= 2 π[R −( R−d )]* h= 2 πd*h,
where d is the width of the recess, this difference can be ignored, and then the whole surface F glued together is nearly
F= 2 *F o =4 πR*h.
For a maximum efficiency and strength of the adhesive connection, the complete lateral surface of the core inside the recess should be in close contact to the plugged-in bar-element, without any clearance or distance therebetween in any area of the lateral core surface, from the core's bottom up to its tip or front end.
Furthermore, for the purpose of producing a strong truss, the connecting elements should be made massive, that is without inner cavities.
The joint of a bar-element with a connection-element is constructed as a plug-connection, whereby both elements are glued together. Clamping joints can support adhesive joints, for instance with the help of wood glue, as locking means. Additionally to the positive locking of the plugging connection, threaded sleeves and/or screwing bolts can be arranged to transmit forces acting along the longitudinal direction of the plugging connection (partially) via a screwed joint.
For clamping a bar-element at a connection-element or at an additional bar-element, a core, which is integrated there and designed for engagement with the bar-element, can be spreaded and thereby pressed from the inside against the inner side of the bar-element. To spread the core a continually widening element, e.g. of the shape of a cone or of a frustum of a pyramid, can be pushed or pulled into an inner, preferably centric recess of the spreadable core. Thereby, this element transforms an actuating force of axial direction into a radial deformation of a spreadable core. For this purpose, connection-element can have a cut-out running through its core, into which the shaft of a screw, a threaded bolt or the like is insertable. The latter derives its axial force from a self-locking twist with regard to another threaded element, which thereby receives the counter-force appearing during the pulling of an element with a widening cross-section into the core.
If a connecting element is in the shape of a ring, then not only bar-elements directed to said connecting element from arbitrary directions within the base plane of the ring can be accommodated and securely anchored. Moreover, it is possible to prolong the recesses for accommodation of a screw-like spreading element each as far as to the inner side of the ring, in order to be able to apply a threaded element or another clamping element there, which in turn can be comfortably actuated after the concerned connections have been made. However, preferably the longitudinal axes of all connected bar-elements are directed towards a central point of the connection-element, so that no torque appears in the truss which could lead to flexural stress of the bar-elements.
Preferably, a connection-element has a discoid shape, for instance with a circular or triangular, quadrilateral or hexagonal base. Such a connection-element is especially suitable for planar trusses, as all connections lie within one plane there. If, for instance, a crossbar to a parallel planar truss is to be made, then it is advisable to design these connections not to be perpendicular to a planar truss. The slanted anchoring structures required for this can be accommodated at a variety of locations at a discoid connection-element, but also at a further connection-element affixed to it. The thickness of such a discoid connection-element should be greater than the maximum diameter of a bar-element, so that its ending region is completely embedded into the connection-element. Thereby, if for instance bamboo is used for the bar-elements, the more sensitive inner side of the bamboo culm is not accessible from outside.
Next to the described embodiment of a connection-element made as one piece, it could also be made from two pieces, so that the two halves initially separated from one another can be put around a continuous bar-element in order to completely surround it after joining, and, for instance, to anchor a further bar-element at a place of a truss where previously no node was present. In this way such a “half” connection-element can also be fixed to the shaft of a bar-element, e.g. with adhesives. For this purpose, such connection-element comprises a concave connecting surface which encloses the concerned bar-element partially. In order to produce such a bonding joint, the concerned area of the shaft of a bar-element should be machined at its outer side, too, especially milled to a round shape.
It is in the scope of the invention that a bar-element can be inserted between two connection-elements, or between two other bar-elements in order to prolong these in coaxial direction. While in the first case both ends of the bar-element should exhibit the same plug-connection-structure (e.g. annular tongue-annular tongue), it is advisable in the latter case that principally complementary plug-connection-structures are designated at both ends (e.g. annular tongue-annular groove), so that the result are normed bar-elements matching to each other.
Moreover, the invention suggests the utilization of stems, stalks or shanks of high-growing plants, which can be easily processed to elongated elements for trusses. Besides the Dicotyledones prevalent in Europe, especially the deciduous and coniferous trees, where thin trunks with a diameter up to approximately 10 or 15 cm (so-called weak-wood) are especially suitable, also plants of the species of the Monocotyledones (palm trees, grasses, etc.) can be used, as the vascular bundles of said Monocotyledones are spread so irregularly that no xylem rays appear. As a result the fibres are not arranged in a regular pattern side by side. As all fibres run parallel to each other, a configuration for instance in isogonal rows or even in one single ring would lead to layers of bonding agent which are not reinforced, along which a peeling-off, i.e. the formation of cracks would be considerably facilitated. Therefore, such fibreless central or xylem rays should be avoided where possible. Further, an increase of the density of the fibres is desirable from the center to the outer circumference of the bar-element, where naturally the highest forces appear in the case of still appearing flexural stress. Following this idea of the invention, among the family of the Gramineae one will find the so-called giant grasses or bamboo plants, which have the further advantage of an increase of vascular bundles or vascular fibres at the outer circumference and therefore feature a high flexural strength despite of fibres running in longitudinal direction. Certainly, the stems or stalks of bamboo plants are divided in their longitudinal direction into nodes (node levels) and into internodes (tube-like areas). The cross-linking of the fibres at the nodes shall increase the elasticity of the living bamboo; however, in harvested and dried bamboo those can cause tensions, and therefore they should be pierced. An excessive impairment of the stability of such bamboo culm is not to be expected therefrom. As the internode-segments have a structure of extreme homogeneity and as the nodes as centres of growth constitute only thin layers, the properties of the tubes are dominated by the segments, i.e. the internodes. Merely the tensile strength is decreased in the nodes, but not compressive, shear and flexural strength, so that the stability of a truss which is predominately subjected to compressive forces does not suffer from this.
Some bamboo plants grow within one year to a height of up to 30 meters, while in the following years only a lignification without additional growth occurs. With the high-growing bamboo-plants the diameter of the trunk is between 5 and 20 centimeters, and the wall-thickness of the tube is approximately between 0.5 and 8.0 centimeters. With the exception of the regularly appearing nodes, Bamboo has no defects like they are found at Dicotyledones, for instance in the form of starting points of branches (so-called knotholes), and which additionally impair the stability. Due to its high mechanical strength, a bamboo culm can absorb high tensile and/or compressive forces in longitudinal direction, which are comparable to those of steel in the area of the internodes. The flexural stress is only limited by a tendency towards the creation of bucklings when high flexural forces are applied. Although bamboo plants are growing slightly more straight than most types of trees, almost always inestimable curvatures are present as well as considerable irregularities regarding the diameter of the tube. For this reason, until now bamboo culms were always bound together with strings, fibres or the like, which again is absolutely insufficient for the production of a framework or truss, as with this no forces in longitudinal direction of the involved bamboo culms can be transmitted.
As the outside of the stem is covered by a hard, water-repellent and extremely lasting layer, which contains silicates, while the inside bears a wax-like coating, these areas cannot be wetted by many adhesives and therefore would impair the durability of a bonded joint. Furthermore, as these layers are relatively smooth, the achievable frictional connection is relatively low, and so the invention suggests to ablate these layers, but only at an area which is not subjected to the atmosphere so that no water can enter at the areas which are not protected against moisture anymore.
The shape of the bar-elements themselves may be manifold. According to the chosen material a bar-like structure, i.e. with a massive core like it results for instance from deciduous or coniferous wood, can be preferred, or a tube-like structure, which presents itself when using bamboo culms. Furthermore, core drilling of solid log wood bars has the advantage of a steady drying across the diameter with consequently steady and therefore crack-free shrinking.
A further aspect is that bamboo is a biological material, which shrinks or swells under the influence of its environmental conditions and therefore tends to develop cracks in the course of time, for example when a rigid end-piece, for instance made from metal or plastic, is inserted. This in turn would have disastrous consequences, as afterwards the water-repellent surface would be interrupted and after that water could enter and cause rottenness or the like. For this reason, the invention prefers the use of connection-elements of a comparable biological material like for instance Dicotyledones, especially deciduous or coniferous wood. Those exhibit similar reactions to changed environmental conditions as Monocotyledones and therefore can shrink or swell in the same fashion, so that the inner tensions in the material remain comparably low. However, to insure this any intermediate pieces between the Monocotyledone tubes and the connection-elements have to be avoided as possible. Therefore, the invention provides a direct joint, either as a plugging, clamping and/or a bonding joint. On the other hand, such joining technique which is industrially applicable with justifiable effort requires standardized contact surfaces, which are not offered by a naturally grown giant grass. This is remedied by the invention in that initially the irregular ends of a bamboo culm which is to be used are treated in such a way that surfaces running along well-defined geometric bodies are created. This work step can be integrated with the aforementioned ablating of the outward surface layers in the proximity of the joining area.
As mentioned before, for the sake of optimal compatibility of a connection-element with a bar-element the former can consist of wood. Although wood and bamboo both are organic materials, they have fundamental differences. Therefore also panelling material made of multi-layer glued bamboo can be used if necessary, so that the material properties are identical to that of the bamboo culms.
As the joint element is connected for instance by a sealing adhesive with a tube-like bar-element, for instance a bamboo tube, and features internally connected channels which lead to the cavities of the connected, tube-like bar-elements, whereby in the case of bamboo tubes their nodes are drilled, so a closed cavity with an intentionally influenced sub-climate is created within a framework or truss produced in such way. This sub-climate can be influenced in a multitude of ways in order to control and/or monitor the behaviour of the truss, or to keep potentially destroying influences like infestation of pests from the inside, fire or the like away from the truss. For this it has proven pertinent if at least one joint element and/or tube-like bar-element comprises a port at which gases, foams and/or liquids can be fed into the cavity of the system, for example moist or dry air to keep the bamboo flexible through a controlled climate, further toxins as well as hot, cold or compressed air for pest control, fire extinguishing agents like for instance nitrogen, foams or water or the like.
To solve the set problem, a generic manufacturing process is embodied according to the characterizing part of the co-ordinated process claim. In the claims subordinated to that further, preferred features of the process according to the present invention are described.
The requirement of standardized surface areas which is at first not fulfilled with naturally grown materials, for instance wood or bamboo culms, is indispensable for their employment in the scope of the production of a truss, so that the individual parts fit exactly to each other and are pluggable in the desired way. Furthermore it is of great benefit if also the alignment of the standardized end areas relative to each other is exactly specified. Especially favourable conditions are created if the end areas are machined in such a way that the geometric bodies defining their surfaces at least in selected areas exhibit at least one axis of symmetry each which can be arranged in mutual relation, for instance to share a common alignment. Only through this it becomes possible to comply with precisely specified angles of inclination of bar-elements in order to bring them together at predetermined nodes of the truss. These requirements enable the production of trusses according to plan which are calculated in advance with regard to their statics, what is the more important the bigger a building is. Again, the possibility of the use of (wooden) bars and/or (bamboo) tubes of variable length is not impaired, as the machining of the ends can take place at the construction site after a (tube-like as applicable) bar-element was cut to the desired length. Further, at least one lateral surface area has to be created at a connection-element, which permits the plugging with a lateral surface of the end of a bar-element. The diameter of this lateral surface and therefore the selection of the tool required for its creation is determined by the classification, if applicable, of the end of the concerned wooden bar or bamboo tube. As this is determined usually only directly preceding to the mounting of the concerned bar-element, the suitable plug-structure is formed at the concerned connection-element only on the site.
Preferably the bodies and/or surfaces of the parts which have to be joined are machined by ablating, especially by cutting. This technology is equally suitable for bamboo and wood. The tools required for this are handy and therefore they can comfortably be carried along at a construction side. For this reason, the machining or rework of already assembled connection-elements is possible, for instance by means of hand drilling- or hand milling-machines. Bar-elements like wooden bars or bamboo tubes are machined before assembly, but after appropriately cutting them to length. Therefor, a clamping apparatus is required.
In order to allow (selected areas of) a lateral surface of a connection structure, especially a core, of connecting elements (but also of bar-elements which are to be directly joined), which are designated for (detachable) clamping joints, a spring like movement, slots which are preferably parallel to the longitudinal axis of the concerned plugging connection can be formed in areas close to said lateral surface. These slots can also be designated already in a factory. As a part of the connection-element has to be removed anyway during the (later) preparing of a ring-shaped recess as a connection structure, an exact radial extension of the slots is not required; those just have to be sized in such a way that they always reach the concerned lateral surface.
Previous to the mounting of a bar-element, at such clamping joint first a spreading element has to be inserted into a bore directed in parallel or in coaxial alignment to the longitudinal axis of the connection-element, which can be used after the assembly to exert (radial) pressure to (selected areas of) the concerned lateral surface in direction of the lateral surface at the end of a bar-element which is to be connected.
After that the bar-elements are plugged together with the concerned connection- or bar-elements and glued or clamped to each other. Naturally, these work steps are executed partly in parallel, as almost every nodal connection-element is on the one hand supported by bar-elements, on the other hand it is bearing further bar-elements, so that some connections are formed sooner, others later.
Along the longitudinal edges of a truss or framework, connection-elements are used as end pieces, which are attachable to a foundation, a ceiling, a roof or the like. These are equipped with a preferably planar base surface having an anchoring facility, for instance one or more bore(s) for passing through mounting screws.
A panelling or the like can be attached to the joints of a truss to obtain a wall-like structure, like it is required for example for the construction of houses. While a corresponding anchoring takes place exclusively at the connection-elements, but not at the bar-elements, the latter remain uninjured and therefore conserve their water-repellent properties of their outer surface where applicable, and a cavity contained inside the truss remains sealed. If relatively delicate panellings, for instance plasterboards, have to be fixed to the truss, then either the distances of the nodes can be reduced, or first a sub-batten is fixed to those, onto which the concerned panelling can be mounted at short intervals.
The inner and/or outer lateral surface at the end parts of a tubular bar-element, especially of a bamboo tube, can be machined. The machining of one lateral surface each, for instance of the outer, may suffice for smaller trusses, while for highly stressable trusses both lateral surfaces at each end of a bamboo tube each should be machined, in order to optimize the stability of each individual connection by an increase of the potential bonding surface and by an additional positive lock in both radial directions (inside and outside).
By doing so, it has to be taken into account that the radius varies with lumbers or bamboo tubes, additionally, with bamboo tubes or core-drilled lumbers even the wall thickness varies. For instance, considering a 30 m high bamboo tube, the outer diameter decreases from bottom to top, but especially the wall thickness, too. Due to this reduction of the wall-thickness, usually only the lower 10 m of a bamboo tube can be used for the purpose of the present invention. If, for example, this section is sawn into single parts with a length of 1.5 m each, then each short bamboo-tube still has different wall-thicknesses and eventually different outer diameters. As the case may be, these deviations can be so significant, that the outer diameter of a cut bamboo tube is smaller than the inner diameter of another bamboo tube. Therefore, a common machining with identical tools is out of question. For this purpose, the invention suggests to create different classes for (the ends of) pieces of bamboo tubes with regard to their wall thickness and/or regarding their inner and outer diameter or circumference. In doing so, the (minimum) inner diameter as well as the (maximum) outer diameter can easily be determined with one gauge each. Such gauges can have the shape of a cylinder or of a flat rectangle (for the inside) or the shape of a hollow cylinder or of a fork (for the outside). Of course, these dimensions can be measured in different ways also. Each (end of a) bamboo tube is sorted into a more or less finely graded system of classification, according to which the selection of the further treatment tool(s) is decided. Thereby, the invention recommends that the lateral surface(s) of the end of a bamboo tube are machined in such a way, that the wall-thickness of the bamboo-tube is equal to or smaller than a wall-thickness previously selected (according to the system of classification).
Before mounting a bamboo tube, eventually present diaphragms should be bored or made passable otherwise in order to create a cavity within the finished truss which is usable for a variety of purposes. To obtain a connection of the cavities of the bamboo tubes which are connected to one connection-element, drillings have to be made, which join inside of the connection-element and which lead to the surface areas of the connection-element covered by a face side of a connected bamboo tube. On the other hand, if required, the complete cavity of a truss can be divided into multiple sections, which can be influenced independently from each other, by using special connection-elements without such continuous channels. Moreover, the boring is intended to provide a homogeneous shrinking of the bamboo tube during the seasoning after the harvesting, and therefore to prevent tensions and therewith cracks in the bamboo.
On the other hand, the diameter of internal channels connecting cavities is entirely independent from the diameter of a wood or bamboo tube which is to be connected. Provided that it is known from the completed design data under which inclination angles tubular bar-elements meet with a connection-element, the necessary connecting channels can be created during the manufacturing of the connecting elements and thus before their mounting. For this purpose, the raw connection-element can be exactly clamped, so that the drillings placed from different sides in fact do meet in the centre. For this, preferably a mobile machining centre with guides of aluminium profiles and multi-axled servo drives is used, which works according to the specifications of a design software. The like drillings for the connection of cavities can serve as tool-guidings at the construction site during the creation of the concerned lateral surface(s) for the connection of one bar-element each. At connecting elements without cavity-connecting channels, drillings may be provided during their production, which are specially intended for the purpose of acting as a tool-guiding.
If at least one tubular bar-element, especially bamboo tube, and/or preferably at least one connection-element is provided with a port to the cavity within the tubular bar-elements and connection-elements, different media can be conducted into this cavity as necessary. In order to permit an exhaustion of a medium which is already contained within the cavity, for instance air, it is advisable to always designate at least two such ports at a cavity closed apart from that. Those should be arranged at distant places to create defined flow conditions. Thereby, it has proven beneficial to arrange one such port at the lowest position and as necessary another port at the highest position of a section of a truss, so that on the one hand liquids, and on the other hand gases each can be completely removed from the cavity.
An apparatus for carrying out the process according to the present invention is described by the characterising features of the independent apparatus claim.
The utilization of such an apparatus simplifies the production of a truss insofar, as thereby a time-consuming, manual individual treatment respectively rework of the different nodes of the truss can be omitted because surface areas which are compatible to each other are created. As a machining apparatus according to the present invention is configured as an ablating tool, especially as a cutting tool, it can be configured to be mobile due to its small required space, and therefore it can be transported to the construction site without problems.
An apparatus for machining of the ends of a bar-element is characterised by a device for clamping a bar-element in such a way, that both of its ends are as concentrically as possible aligned to a longitudinal axis of the machining apparatus. Thus, the actual machining-tools always come across a bar-element which is to be processed at one and the same predetermined position, so that they can be adjusted with regard to the body of the machine in a defined way. Thereby, in general a holding and/or fixing device for each treatment tool is placed at each end of the clamping device. Such a fixing device can, for example, be configured as a slide, which is moveable in a defined way through a guide in the feeding direction along the longitudinal axis of the machining apparatus, and which on the other hand is carrying the actual holding and/or mounting for the machining tool and/or its drive motor.
A cutting tool, for example in the form of a milling head, which is configured for the simultaneously processing of the inner and outer lateral surfaces of the ends of a bar-element, in particular of a bamboo tube, serves for the processing of the lateral surfaces at the ends and, for this purpose, is equipped with two separate machining areas, in particular cutting areas. The actual cutting areas can be detachably and thus exchangeably fixed to a base body of the tool, or they can be adjustable with regard to it so that the tool can be adapted to differently classified ends of bamboo tubes.
A preferred apparatus for the machining of a connection-element is characterised by a tool rotating around at least one axis with at least one cutting area for the creation of a rotational symmetric recess of defined cross section. Preferably, the tool can be configured to be clampable into a hand drilling machine or the like, in order to be utilizable also for nodal connection-elements which are already mounted in the truss. With a different configuration, the bar-element, in particular a bamboo tube, can rotate, and the tool can be fixed in such a way that it only performs feed motion similar to the function of a classical lathe machine.
According to a further aspect of the invention, the cutting area is arranged at a peripheral lateral surface area of the base body of the tool, which encircles a central guiding device, for example a forward protruding pin. By means of such a guiding device, the tool can be centred at a predrilled hole, for instance at a cylindrical guiding recess, in order to assure that the bar-element which is to be inserted exactly takes up a specified inclination angle, and thus its opposed end is precisely insertable into the nodal connection-element there.
Finally, according to the teaching of the invention, the central guiding device is configured as a drill, so that the guiding drill hole and the guiding recess can be produced in one work step. This embodiment is in particular intended for nodes of the truss which have not been calculated in advance and where no guiding drill holes can be produced at the connection-elements in the factory. In those cases the direction of the plugging connection which receives a bar-element can be adjusted by an assembly mechanic on his own; however, he has to work very carefully in order to find a central cavity-channel and to exactly determine the right orientation of the bar-element.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
Further features, details, advantages and effects on the basis of the invention result from the following description of preferred embodiments of the invention as well as from the drawing. There,
FIG. 1 shows a perspective view of the first connection-element of a truss-system according to the present invention;
FIG. 2 shows a modified embodiment of a connection-element in an illustration corresponding to FIG. 1 ;
FIG. 3 is a section through two connection-elements according to FIG. 2 fixed to each other;
FIG. 4 shows a modification of the connection-element from FIG. 2 in a perspective view;
FIG. 5 is an exploded view of a pluggable connection with the connection-element from FIG. 4 as well as a partly cut and broken bamboo tube;
FIG. 6 shows the composition from FIG. 5 after assembly of the connection;
FIG. 7 shows a different configuration of the invention;
FIG. 8 shows a connection-element, which is for instance usable as a base element, in a perspective view;
FIG. 9 is a side-view to a planar truss, built with the system according to the present invention;
FIG. 10 shows a connection-element from the truss in FIG. 9 in broken and partly cut view, together with a tool applied at a lateral surface to create the cavity for receiving a bamboo tube;
FIG. 11 is a longitudinal section through the tool from FIG. 10 ;
FIG. 12 is a broken side-view to an apparatus for clamping and processing the ends of a bamboo tube;
FIG. 13 is a perspective view of a clamping device of the apparatus from FIG. 12 ;
FIG. 14 is a front view in the direction of the arrow XIV to the tool from FIG. 12 ; as well as
FIG. 15 is a section through two coaxially joined bar-elements.
DETAILED DESCRIPTION OF THE INVENTION
The perspective view of a connecting element 1 in FIG. 1 is intended to illustrate the basic principle of the present invention. An arbitrarily or randomly shaped connection-element 1 exhibits at its surface 2 one or more three-dimensional structures 3 for the connection of one bamboo tube 4 each. By assembly of multiple bamboo tubes 4 at such a connection-element 1 , the latter becomes a node in a truss or framework 5 .
The connection-element 1 from FIG. 1 has the basic shape of a rectangular parallelepiped with four equally sized lateral faces 6 and one square top and bottom side 7 each. The epipedal-shaped connection-element 1 consists of many layers of plywood 8 glued on top of each other with crossed direction of fibres each. As these glued layers of plywood 8 run parallel to the square top or bottom side 7 , the connection-element 1 has a high tensile strength in directions running parallel to those planes.
A structure 3 for the connection of one bamboo tube 4 each is arranged at all six faces 6 , 7 of the connection-element 1 , so that six bamboo tubes 4 can be brought together at such node of the truss, of which two each are aligned with each other and are standing perpendicularly to the plane spanned by the remaining four bamboo tubes 4 . Thus a three-dimensional truss is feasible.
As is further shown in FIG. 1 , each structure 3 for the mounting of a bamboo tube 4 has approximately the shape of an annular recess 9 with two bounding surfaces 10 , 11 in the shape of lateral surfaces of cylinders which are concentrical to each other. The outer diameter of this recess 9 corresponds approximately to the outer diameter of the concerned bamboo tube 4 , and the constant distance of the bounding surfaces 10 , 11 with the shape of lateral surfaces of cylinders corresponds approximately to the standardized maximal thickness of an end area of a bamboo tube 4 which is insertable into this recess.
With the embodiment according to FIG. 1 , the ends of the bamboo tubes 4 are glued into the annular recesses of the connection-element 1 , so that a rigid and non-detachable connection is obtained. As FIG. 1 further shows, a cylindrical core 12 remains within each annular recess 9 , which is adhesively connected to the inside of a bamboo tube 4 and thus additionally fixes and stabilizes this bamboo tube 4 . As wood exhibits comparable temperature coefficients and swelling phenomena due to moisture as bamboo, a formation of cracks is thus effectively prevented.
Further, each of the cylindrical cores 12 is penetrated by a drilling 13 in its longitudinal direction. All of these drillings 13 join within the connection-element 1 and thus create a system of connecting channels between the cavities of all connected bamboo tubes 4 .
If—as the invention further provides—all diaphragms of the bamboo tubes 4 are pierced, these cavities are connected with the connection-elements 1 present across the bamboo tubes 4 and in this way also with all other cavities of suchlike produced truss or framework 5 . As otherwise the cavities within the bamboo tubes 4 are hermetically sealed by their air-tight outer surface, a purposefully influenceable sub-climate is obtained in the connected cavities of a truss or framework 5 according to the present invention.
For instance, toxins, hot or cold air or other agents for pest control can be conducted into this cavity to prevent an infestation of pests of such a truss or framework 5 , without the utilized agent for pest control ever coming in contact with the outer environment. Therefore, the system according to the present invention has the advantage that the agents are always highly efficient in the smallest doses, regardless of their composition, without ever affecting the environment. For a similar purpose heavy temporal fluctuations of pressure can be created.
Furthermore, this cavity can be filled with a non-flammable gas, for example nitrogen, under positive pressure, so that in the case of a fire a significant amount of nitrogen is released at the source of the fire in order to extinguish the burning. At the same time the sudden decrease of pressure caused by this can be measured in order to thus infer a fire and to be able to make provisions against a further spreading of the fire by conducting water into the cavity. As soon as the fire is extinguished the water can be drained again, and the inner cavity of the truss or framework 5 can be dried again by conducting hot air.
The connection-element 14 from FIG. 2 has a cubical shape and is modified insofar, as there a structure 3 for connecting a bamboo tube 4 each is provided only at the top and bottom side 15 , while at the lateral faces 16 only central drillings 17 are provided which penetrate the connection-element 14 . This connection-element 14 also consists of layers of plywood 18 glued to each other, which are running perpendicular to the top or bottom side 15 .
The connection-element 14 serves mainly for the extension of bamboo tubes 4 . In order to also realise nodes of a truss with this, two or more such connection-elements 14 are fixed to each other as shown in FIG. 3 . For this purpose, the connection-elements are put together in the desired orientation in such a way that one drilling 17 each is aligned with the other. A screw or threaded bolt 19 is inserted in the two aligned drillings and is locked at both sides with a threaded element 20 , so that the connection-elements 14 are fixed to each other.
Now bamboo tubes 4 can be inserted into the accessible connection structures 3 and glued there in the desired manner. This arrangement has the further speciality, that at such node of a truss a rotation is possible for adaptation to framework structures running in slanted directions with regard to each other.
At the connection-element 1 , the bamboo tubes 4 agglutinated to the structures 3 at the top and bottom sides are only glued to a part of the layers of plywood 8 each, so that for instance the concerned core 12 and thus the whole bamboo tube 4 could be torn out when exposed to high tensile forces. This can be prevented by fixing a connection-element 14 each at the top and/or bottom side 7 of a connection-element 1 as required, for instance by means of an inserted and locked threaded bolt 19 . Thereby, the connection-elements 14 can be aligned in such a way, that their agglutinated layers of plywood 8 are running perpendicular to the top and bottom side 7 of the connection-element 1 and therefore almost all layers are glued to the concerned bamboo tube 4 .
The connection-element 21 from FIG. 4 has the same cubical shape as the connection-element 14 . As with this, the three-dimensional structure 22 for the connection of a bamboo tube 4 also comprises an annular recess 9 with two bounding surfaces 10 , 11 which are concentrical to each other. The core 23 remaining within this recess is penetrated by a central drilling 13 . However, contrary to the connection-element 14 , the core 23 is provided with two slittings 24 along the longitudinal axis of the drilling 13 , which extend approximately to the base of the core 23 respectively of the annular recess 9 , so that the remaining quarters 25 of the core can spring to the outside in a limited way.
The central drilling 13 in the core 23 exhibits a conical countersinking 26 , in which the head of a countersunk screw 27 with a machine thread 28 inserted into the drilling can be positioned. A threaded element 29 is screwed on this thread 28 at the outer surface 7 of the connection-element 21 opposite to the connection unit 22 . After the insertion 30 of a bamboo tube 4 into the annular recess 9 this threaded element 29 is firmly secured. Thereby the head of the screw 31 is pushed deeper and deeper into the conical countersinking 26 and thereby spreads the quarters 25 of the core to the outside. Those in turn are pressed with their outsides 11 against the inner side 32 of the lateral surface 33 of a bamboo tube 4 , clamping it tightly. Therefore, the gluing of a bamboo tube 4 is not required with this type of connection 21 , and the connection can always be detached in a non-destructive way. Instead of a countersunk screw 27 , a conical bolt or the like can be used, too.
A further connection-element 34 is shown in FIG. 7 . This has the shape of an annulus with rectangular or square cross-section. At the outer surface 36 of this ring 35 six three-dimensional structures 22 are located equidistantly distributed over the circumference for the connection of one bamboo tube 4 each. The three-dimensional connection structures 22 are identical to the concerned structures 22 of the connection-element 21 regarding their topology and function, so that a cross section through the ring 35 at a connection point 21 rather corresponds to FIG. 6 , with the exception of the fact that here the crossways running drilling 17 as well as a connection structure at the inner side 37 of the ring is missing.
The ring 35 offers the advantage, that an almost arbitrary number of connection points—only one up to six or possibly even more—can be provided as required, whereby all connections 21 can be implemented to be detachable.
With such a ring for instance planar trusses or frameworks 5 can be produced, like shown in FIG. 9 . Thereby, connection-elements 38 of the kind illustrated in FIG. 8 serve as base elements. Those consist of one cuboid 39 each, whose length is approximately double than its height and width. They feature a central, continuous vertical drilling 40 for the fixing by screws to a foundation 41 or the like. At the area of their upper narrow edges 42 a three-dimensional structure 43 is provided each for the connection of a bamboo tube.
The structure 43 corresponds to the structure 3 of the embodiments 1 and 14 regarding its function, where a bamboo tube is not fixed by clamping, but by glueing. However, here the annular recess 44 and the drilling 45 concentrical to it are not located perpendicular to a surface of the connection-element 38 , but inclined under an angle of 30° to the outside diverging from the vertical drilling 40 to the top. Moreover, the structure 43 overlaps the upper narrow edge 42 , so that in particular the face side of the core 46 of the connection structure 43 is composed of two partial surfaces 47 , 48 perpendicular to each other, which form a remaining part of the original surface 49 , 50 of the connection-element 38 . However, this fact does not impair the function of the three-dimensional structure 43 as a connecting and fixation point for a bamboo tube 4 .
As shown in FIG. 9 , initially a series of joint elements 38 is screwed or otherwise fixed to a foundation 41 in order to build a truss or framework 5 . After the connecting structures 43 are brushed with glue, the ends of bamboo tubes 4 diverging from each other to the top at together 60° are inserted. Two bamboo tubes 4 are joined at their adjacent upper ends 51 by one nodal connection-element 52 each.
The connection-element 52 forming a node of the truss 5 has a similar base shape as the connection-element 1 , however, unlike that it has a hexagonal base area with a constant thickness, which is greater than the maximum diameter of a bamboo tube 4 . Like all other connection-elements 1 , 14 , 21 , 34 , 38 , this also consists of layers of plywood crosswise laminated together, whose planes are parallel to the hexagonal base faces 53 . Accordingly, the circumference 54 of such connection-element 52 consists of six equally sized rectangles.
Before the curing of the glue, adjoining nodal connection-elements 52 are connected by one bamboo tube 4 running in horizontal direction each, which is glued at the same time. Thus the first layer of the truss 5 is created. As soon as this is stiffened due to the curing of the glue, which can take approximately 15 minutes if wood glue is used, another layer of the truss can be put on it according to the same principle, as it is indicated at in FIG. 9 . The completed truss 5 consists of many identical cells which have the shape of an equilateral triangle, and obtains thus optimal stability. Of course, another, also three-dimensional structure of a truss 5 can be chosen if required, for instance in the form of two planar and parallel trusses connected to each other or the like. Favourably the bamboo tubes 4 always have a length of only approximately 1 to 2 m, so that no buckling effects can appear due to a excessive flexural stress at a too long bamboo tube 4 .
The node elements 52 can be individually finished on the spot at the construction site like all other connection-elements 1 , 14 , 21 , 34 , 38 . For this purpose, initially base bodies 55 of the desired circumferential shape are cut out of a plate of preferably wood, in particular of moulded plywood, which can take place at a factory or sawmill as applicable. The required connecting structures 3 , 22 , 43 are then worked into these base bodies 55 on the spot, even in already mounted condition as required. A cutting tool 56 , shown in FIGS. 10 and 11 , serves for this purpose.
The cutting tool 56 comprises a rotating tool-head, which features a connection for a driving engine at the back. The connection can be embodied for instance as a cylindrical appendix 58 coaxial to the longitudinal axis of the tool 57 , which is insertable into the chuck 59 of a hand drilling machine. With the illustrated embodiment this cylindrical mounting appendix 58 is a part of the shaft of a (wood) drill 60 , with which the central cavities 13 , 45 of a connecting structure 3 , 22 , 43 are drilled. An approximately bell-shaped tool-component 62 is detachably fixed at the shaft of this drill 60 by means of a clamping screw 61 .
This bell-shaped tool-component 62 consists of a part 63 which is shaped like an annular disc, and a part 64 , which is shaped like the lateral surface of a cylinder and extends from the periphery of the first part to the front, carrying at its front side the actual cutting tools 65 for the creation of the annular recess 9 of the connection structure 3 , 22 , 43 . The part shaped like an annular disc has a inner diameter which corresponds to the diameter of the drill 60 , and an outer diameter, which approximately corresponds to the outer diameter of a bar-element 4 . At its backside 66 this part 63 is provided with an appendage 67 of reduced cross-section, but likewise cylindrical-shaped, through which a threaded hole with radial direction extends to accommodate the clamping screw 61 . Thus the part 63 shaped like an annular disc can be plugged over the shaft of a drill 60 , whereby it is aligned perpendicular to the longitudinal axis of the drill 57 by means of a fit almost free of play, in order to be locked in this position afterwards by tightening the clamping screw 61 .
The part 64 shaped like the lateral surface of a cylinder can be integrally manufactured with the part shaped like an annular disc, for instance casted together with the latter, or, for example, it can be produced from a tubular part, which is screwed to the part 63 shaped like an annular disc from the backside 66 of this part with screws 68 parallel to the axis of the drill 57 , as shown in FIG. 11 . In the area of its front side the part 64 shaped like the lateral surface of a cylinder is furnished with a number of equidistantly distributed rectangular recesses, so that approximately the shape of a crown is obtained.
At multiple cutting areas 69 of the part 64 shaped like the lateral surface of a cylinder, which are parallel to the longitudinal axis of the tool 57 , one cutting tip 70 each is fixed, preferable with a screw 71 passing through a central bore of the concerned cutting tip 70 . As shown in FIG. 11 , it is the object of this cutting tip 70 to cut the annular recess 9 into the body of a connection-element 1 , 14 , 21 , 34 , 38 during the rotation of the processing tool 56 as well as under the influence of a superimposed feeding motion 72 . Thereby, the drill 60 , whose front area is located before the cutting tip 70 , can take over a guiding function.
With other embodiments of the invention, the recess of the connection structure can be bounded by bounding surfaces which are overall conical or bevelled at their base; for the production of such recesses the cutting tools have to feature an according geometry; if required, the cross-section of the part 64 shaped like the lateral surface of a cylinder has to be adapted.
As previously explained, the growth of a bar-element 4 —especially a bamboo tube or a wooden rod—is always more or less irregular. As the annular recess 9 of a connection structure 3 , 22 , 43 according to the present invention is optimum round due to the use of a processing tool 56 revolving around an axis, normally a bar-element 4 cannot be inserted flush with it: Either the bamboo tube does not fit at all in the designated recess 9 , or it is seated much too tight or—if the recess is dimensioned larger—too loose, so that no clamping effect is created respectively vast quantities of glue are required, which not only increases the costs, but also the labour time due to the increased curing times.
For this reason, the invention provides that the ends 73 of bar-elements 4 , which have been cut to the desired length, are treated before they are mounted in a truss or framework 5 . Therefore, a standardized geometry has to be applied to those, so is that they fit into the designated recesses 9 of the concerned connection-elements 1 , 14 , 21 , 34 , 38 . However, in general this is not sufficient for the production of an exactly pre-planned truss 5 , as often both ends 73 of a cut bar-element 4 are not coaxial to each other. This in turn would lead to displacements and/or tensions within a truss 5 , which would gradually sum up themselves during the course of the construction, so that a bigger building would become more and more skewed with the progress of the construction. Therefore it is the additional object of an apparatus 74 for the machining of the ends 73 of a bar-element 4 to assure that not only the two end areas 73 of a bamboo tube 4 exhibit surfaces 75 , 76 running along lateral surfaces of cylinders (with other types of connections for instance lateral surfaces of cones) in selected areas, but also that the longitudinal axes of those cylindrical (conical, etc.) areas of both ends 73 are aligned to each other in coaxial relation. An apparatus 74 , which is capable of this, is shown in FIG. 12 .
In the strict sense, only approximately half of this machine 74 is visible; the left part of the machine, which is laterally reversed with regard to the symmetry plane 77 , was omitted for reasons of space. The machine 74 basically consists of four components: An elongated, rigid profile 78 , which is used as a reference for the longitudinal axis of the machine 74 as well as for mounting of the further components of the machine. Approximately in the middle of the profile 78 a device 79 for clamping a bamboo tube 4 , which is to be processed, is mounted to it. At last there are two processing devices 80 , which are located at both sides of the clamping device 79 , and which are likewise supported by the profile 78 . In the scope of a simpler version one processing device 80 can be saved if the remaining one can be relocated to the other end of the profile 81 in a simple way, or, for instance, if the clamping device is designed to be rotatable by 180° together with a clamped bamboo tube 4 .
A commercially available constructional element can be used as the profile 78 . Preferably this consists of a four-cornered profile with a square cross-section, whose to long sides 82 comprise a T-shaped undercut mounting groove 83 each, which is running along the longitudinal direction of the profile, compare FIG. 13 . Blocks, which are not shown, can be mounted at those grooves 83 for example at both end areas of the profile to support the machine 74 .
The clamping device 79 comprises two sets of grippers 84 as well as a common actuating mechanism 85 . Each set of grippers 84 is designed to grip a bar-element 4 distant to its end faces so that the end faces are free to be machined at the same time. The distance between a set of grippers 84 and to the respective end face should be 2 cm or more, for example 3 cm or more, especially 4 cm or more.
A set of grippers 84 is shown in FIG. 13 . At both ends of the supporting profile 78 , a bolt 87 , which is parallel to the supporting profile 78 , each is fixed in a not rotatable manner by means of lateral fastening angles 86 . Onto those thus fixed bolts 87 , there is plugged an upright standing plate 88 each, which comprises a through-hole for this purpose of a diameter corresponding to the diameter of the bolt. The plates 88 are limited by the concerned fastening angle 86 and are fixed at the other end of the concerned bolt 87 by a pinion 89 each which is non-turnably fixed to the bolt, for instance crimped, so that they are able to pivot around the concerned bolt 87 , but not to loosen from it. The plates 88 are embodied as two-armed levers with a shorter arm 90 which protrudes downwards from the concerned mounting hole, and a longer arm 91 , which protrudes upward. Both lower lever arms 90 are connected with each other through a tension spring 92 , which is routed under the supporting profile 78 , and are thus pulled to each other, until they are stopped by the long side 82 of the carrying profile 78 . In a such case, the upper arms 91 of the plates 88 take a maximum spreaded position.
Approximately at the upper end of each plate 88 , another through-hole is located for a rotating axis 93 , which is pivoted there. Each of these rotating axes 93 carries a pinion 94 at one end, and, at the other end, a plate 95 whose circumference comprises a concave side 96 , for instance with a course like a hyperbola.
The gear 94 as well as the plate 95 each are unturnably fixed at the rotating axis 93 , to respectively crimped, clamped (clamping screw), soldered and/or welded. Otherwise the pinion 94 is coupled with regard to the rotational movement with the pinion 89 at the stationary bolt 87 through a toothed belt 97 , which is kept tense by a device 98 . Thus it is achieved that the spatial orientation of the upper plates 95 is kept independently from the pivoted position of the lower plates 88 . This function has the same effect as a parallel guide by means of a leverage with two pivotable bars parallel to each other.
The upper plates 95 are aligned in such a way, that their concave sides 96 face each other. Therefore, when the upper lever arms 91 of the lower plates 88 are brought together, these sides 96 can approach each other in order to clamp a bamboo tube 4 in between them.
An appendix, for instance a screwed bolt 99 , protruding downwards each is provided at the lower face sides of the lever arms 90 of the plates 88 for the actuation of such set of grippers 84 . Here, the actuating device 85 engages.
The actuating device 85 comprises a pneumatic cylinder 100 which is located under the supporting profile 78 and which is aligned parallel to it. A conical apex 104 , 105 each facing axially to the outside is fixed at the casing of the cylinder 101 as well as at the piston through a rod 102 , 103 each which is coaxial to the axis of the cylinder. The two rods 102 , 103 pass through one bearing block 106 , 107 each, through which the complete actuating device 85 is supported at the underside of the supporting profile 78 so that it is movable in its longitudinal direction in a guided manner.
As the casing of the cylinder 101 itself is not fixed, it can move in the longitudinal direction of the supporting profile 78 in a limited way. If the pneumatic cylinder 100 is extended pneumatically, the conical apexes 104 , 105 move in between the pair of appendices protruding downside, in particular in between the bolts 99 , of one set of grippers 84 each, and press those apart. Thus the upper levers 91 are pivoted to the inside, and the bar-element 4 is clamped in the area of both of its ends 73 in between two concave brackets 95 , 96 , each. Thereby, a centrification of the two ends 73 symmetrical to the vertical longitudinal plane of the supporting profile 78 takes place, because the conical apexes 104 , 105 act evenly on the two arms 90 of a set of grippers 84 . The centrification with regard to the height is obtained through the concave shape of the clamping brackets 96 . Thereby, the exact dimensions, for instance the diameter of a bar-element 4 , are not important, as the pneumatic cylinder 100 moves in the longitudinal direction by itself until equal forces act on all arms 90 .
A bar-element 4 centred in such manner is afterwards machined in the area of its both ends, i.e. surface areas 75 , 76 which are projecting above a predetermined measure are ablated. This is achieved by one machining device 80 each.
Each machining device 80 comprises a slide 108 , which is movable along the supporting profile 78 , having a device 109 for mounting a drilling machine 110 under simultaneous alignment of the drill chuck coaxial to a processing axis, which is running in the centre above the supporting profile 78 as well as at a height determined by that area of the concave clamping brackets 96 , which is receded the most.
If the slide 108 , which for instance is movable in parallel orientation through lateral rolls 111 engaging into the longitudinal groove 83 , is moved to the concerned end 73 of a clamped bamboo tube 4 , thus the rotational axis of a machining tool 113 which is clamped into the chuck 112 of the drilling machine 110 remains always coaxial to the longitudinal axis of the bar-element 4 , which is predetermined by the previously explained clamping.
The machining tool 113 , which acts on the inner and outer side 75 , 76 of the bamboo tube 4 at the same time, is shown in FIG. 14 in a front view. It comprises an inner and an outer cutting tool 114 , 115 , to which the machining of the inner side 75 respectively of the outer side 76 of the bar-element 4 is allotted.
The inner cutting tool 114 has the shape of a milling cutter, in particular of a shell end mill, with a backward mounting appendix for clamping it into the chuck 112 . This cutting tool 114 enters into the cavity of a bamboo tube 4 in order to process its inside wall 75 at least in selected areas to a cylindrical shape.
Another part is fixed at the shaft of cutting tool 114 , which has a bell-shaped form similar to the outer part of the tool 56 . Although it could be casted integrally for example, the illustrated embodiment consists of a part shaped like an annular ring 116 at the one hand and at the other hand of a cylindrical part 118 which is fixed to the first.
At the part shaped like an annular ring 116 , a backward, cylindrical appendix 117 is located which is penetrated by a threaded hole running in a radial direction in order to accommodate a clamping screw. With this clamping screw the part shaped like an annular ring 116 is fixed at the shaft of the cutting tool 114 .
By means of screws which are penetrating the part shaped like an annular ring 116 , this is fixed to the cylindrical part. At the front side 119 of the latter, several teeth 120 are cut out, whose edges respectively tips are slightly bent inwards. When feeding the processing tool 113 , the outer surface 76 of the bamboo tube 4 is machined by these teeth 120 in order to create surfaces which run along lateral surfaces of cylinders at least in selected areas, and which permit the insertion of the end 73 of a bamboo tube into a corresponding recess 9 of a connection-element 1 , 14 , 21 , 34 , 38 .
In order to prevent that the cutting tools 114 , 115 , which as necessary due to an irregular growth act asymmetrically upon the end 73 of the bar-element 4 during this machining, may generate vibrations of the machining tool 113 , this is additionally supported at the outer lateral surface 121 of the cylindrical part 118 . This is accomplished by another trestle 122 fixed to the supporting profile 78 , which is encasing the cylindrical part 118 and comprises several, preferably three or four rolls 123 , which can revolve around rotating axes 124 parallel to the rotational axis of the processing tool 113 respectively parallel to the longitudinal axis of the supporting profile 78 . These rolls 123 push against the outer lateral surface 121 of the machining tool 113 from different sides, for instance from directions displaced by 90° or 120° against each other, so that vibrations are reliably prevented.
Both machining tools 13 placed at different end faces of a bar-element 4 are aligned with each other and rotate around the same, common axis. On the other hand, both machining tools 13 should be driven in opposite directions of rotation around the common axis, so that the resulting torque applied to the machined bar-element 4 is rather small, about zero.
When producing bar-elements 4 and connection-elements 1 , 14 , 21 , 34 , 38 , 52 fitting into each other, it should be kept in mind that the axial length of an end area 73 of a bar-element 4 machined by ablation is equal or preferably slightly shorter than the depth of the annular recess 9 in the concerned connection-element 1 , 14 , 21 , 34 , 38 , 52 which should accommodate it, so that the area 73 of a bamboo tube 4 exposed in this manner, i.e. liberated of its water-repellent coating, is covered by the connection-element 1 , 14 , 21 , 34 , 38 , 52 and a layer of glue or the like as applicable.
Besides bamboo tubes also wooden bars 125 , 126 , for instance of weak wood, can be used as bar-elements 4 with the system according to the present invention, which may either be directly employed as solid wooden bars or can be furnished with a coaxial drilling 127 completely or partly passing through it, for instance in order to favour a crack-free shrinking during the seasoning.
As necessary, such wooden bars 125 , 126 can be put together in coaxial alignment for the purpose of elongating them, as shown in FIG. 15 . For this purpose, the ends of adjoining bars 125 , 126 , which are to be put together, have embodiments fitting into each other: For example, an annular groove 128 is located at the face side of one bar 125 , a complementary annular tongue 129 is located at the face side 126 of the other bar. Together, those form a form-fitting plugging connection, which can be fixed for instance by applying glue at the surfaces of a plugging element 128 , 129 . Besides, it is also possible to press or glue one threaded element each into a central drill hole 127 —a threaded nut in the first and a threaded bolt in the other—, so that such bar-elements 125 , 126 can also be screwed together—additionally to the form-fitting plugging connection. | A system for making a truss from joinable bar elements. The bar elements are at least in part of plant material from high-growing plants. The system further includes connecting elements to interconnect at least two of the bar elements, the bar elements and connecting elements being adapted to be connected to each other to form the truss. |
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FIELD OF THE INVENTION
[0001] This invention relates to a loader with a hydraulically actuated extension arm, a sensor for monitoring the load condition on the loader and a hydraulic arrangement for actuation of the extension arm and/or an implement attached to the extension arm, the hydraulic arrangement exhibiting at least one hydraulic cylinder with a first supply line on the piston rod side and a second supply line on the piston side, at least one mechanically switchable control device for controlling the at least one hydraulic cylinder, a hydraulic source, a hydraulic tank and an electronic control unit.
BACKGROUND OF THE INVENTION
[0002] In the area of loaders/such as loading vehicles or telescopic loaders and the like, systems are previously disclosed which protect the vehicle from getting into an unsafe load condition. Unsafe load conditions arise, for example, when the vehicle overturns over the front axle as the result of a forward shift in the center of mass, in these systems, the hydraulic functions are braked and are brought to a halt as soon as a sensor detects that the vehicle is threatening to tip. Once the hydraulic actuators have been stopped, the only functions that can still be operated are those which bring the vehicle back into a safe condition, for example raising the extension arm, tilting back the implement or the load and retracting the extension arm.
[0003] In systems of this kind, it is sensible not to arrest the movements of an extension arm too abruptly, as this can lead to overturning of the vehicle due to the Inertia of the load and the extension arm. It is sensible to slow down the functions progressively the closer the vehicle approaches to a critical operating condition or load condition.
[0004] WO 2004/007339 A1 discloses a system of this kind. Here a tipping moment acting on the vehicle is detected by a sensor and Is transmitted to an electronic control unit. Also provided are a number of hydraulic cylinders for the lifting, lowering and telescoping of a telescopic extension arm as well as the electro-hydraulic actuation of the hydraulic cylinders. The system provides for the hydraulic functions for operating the hydraulic cylinders to be slowed down as a set threshold value for the tipping moment is approached, before the hydraulic cylinders come to a complete standstill. In this case, for example, the load signal is processed electronically and the possibilities for operation by the user are reduced and/or operation is prevented. The more advanced the technology, for example by the use of electronic control units, the easier is the intervention by means of the electronics.
[0005] For systems with mechanically controlled control devices, in which the valve gates of the control device are actuated via Bowden cables ore levers, the characterizing features disclosed in WO 2004/007339 A1 do not find an application, because it is not possible to intervene in a controlled manner by such simple means in the functions that are executed mechanically by the operator, due to the absence of suitable electronics.
SUMMARY OF THE INVENTION
[0006] The underlying object of the invention is to propose a loader of the kind Indicated by way of introduction, by which the aforementioned disadvantages are overcome.
[0007] According to the invention, a loader of the kind mentioned byway of introduction is configured in such a way that means for restricting the volumetric flow rate are provided between the control device and the hydraulic cylinder, by which means, depending on a sensor signal supplied by the sensor, a volumetric flow can be restricted in at least one of the first supply line on the piston rod side or the second supply line of the piston side of the hydraulic cylinder. The operability of the hydraulic cylinder actuated via a mechanically controlled control device is influenced via the means for varying the volumetric flow in such a way that a volumetric flow rate for the hydraulic fluid flowing into one of the two chambers of the hydraulic cylinder is restricted and/or reduced, and the movement of the hydraulic cylinder and/or piston is ultimately slowed down in this way. The volumetric flow of the hydraulic fluid flowing into the chamber of the hydraulic cylinder is reduced to an increasing extent in this way, the closer a critical value for the load condition is approached, which value is set by the electronic control unit. In order to prevent an operator from being able to bring the vehicle into an unsafe condition, which might ultimately result in over turning of the vehicle, the functions of the hydraulic cylinder are initially slowed down in this way and are then finally brought completely to a halt.
[0008] The means for restricting the volumetric flow rate preferably consists of at least one electro-hydraulic overpressure valve capable of actuation by the electronic control unit and are arranged in a connecting line extending between the supply line on the piston rod side and the supply line on the piston side. The electro-hydraulic overpressure valve can be opened progressively depending on the load signal supplied by the sensor and/or the overload signal. The closer one approaches to the pre-set threshold valve, the greater is the threat of the vehicle overturning, and the less the overpressure valves are adjusted and/or the more the overpressure valves are opened. Thus, for an increasing sensor signal, an increasing volume of hydraulic fluid can flow from one connecting line into the other connecting line. On the basis of the resulting decreasing volumetric flow rates for the chamber concerned, connected to the supply line on the piston rod side or the supply line on the piston side, the piston of the hydraulic cylinder is caused to move less rapidly and/or is brought to a halt increasingly slowly.
[0009] A check valve is preferably provided in the connecting line, so that the hydraulic fluid is able to flow through the overpressure valve in only one direction from the supply line on the piston rod side Into the supply line on the piston side, or vice versa. It Is also conceivable, however, for a check valve of this kind to be integrated already in the overpressure valve, in any case, the hydraulic cylinder can be actuated in this way in the opposite direction of movement form that which is customary. It is naturally also conceivable for a number of hydraulic cylinders to be arranged in the hydraulic arrangement, and thus for a number of control devices to be capable of being used for the control of the hydraulic cylinders. In the event that a number of control devices and a number of hydraulic cylinders are used, a number of electro-hydraulic over pressure valves can accordingly be used, which are adjusted by the electronic control unit depending on the sensor signal.
[0010] It is thus possible to restrict the movements of the extension arm in such a way that the vehicle is not able to get Into a dangerous operating condition, in conjunction with which the operator, in addition to the warning signals which are generated anyway in the cab of the loader, will be made aware of the fact that, in spite of the adjustment default, the extension arm is moving increasingly slowly until it comes to a halt.
[0011] In another embodiment, the means for restricting the volumetric flow also comprise at least one electro-hydraulic overpressure valve capable of being actuated by the electronic control unit, although the means are arranged in a discharge line branching from the supply line on the piston rod side or the supply line on the piston side of to the hydraulic tank. In this way, the hydraulic fluid branched through the overpressure valve from the supply line on the piston rod side or the supply line on the piston side is conveyed directly into the hydraulic tank, and not into the supply line on the piston side or the supply line on the piston rod side. This also permits smaller threshold pressure values to be set, since the pressure in the previous illustrative embodiment (connecting line) acting in the corresponding other supply line acts against the actual opening pressure, which has a negative effect on the sensitivity and/or on the response characteristic of the overpressure valve. This is not the case with an overpressure valve, which is arranged in a discharge line leading directly into the hydraulic tank.
[0012] The loader is preferably configured as a telescopic loader, in conjunction with which the extension arm is capable of being varied via a first hydraulic cylinder in respect of Its angle of attack and via a second hydraulic cylinder in respect of its length, in conjunction with which a third hydraulic cylinder may be provided, with which an Implement arranged on the extension arm is capable of being caused to pivot. Thus, for example, the tilting back of a loading shovel filled with material can also lessen a critical load condition, but without the extension arm being moved. In any case, the overpressure valves arranged in the control pressure lines of the control devices provide for a slow execution of the movements determined by the operating person, so that no disruptive inertia mass effects of the load material or of the extension arm occur, which can then provoke overturning of the loader in the vicinity of the threshold value range.
[0013] In another embodiment the loader comprises a front loader, in which the extension arm is configured as the load arm of the front loader, which is capable of being varied via a first or a first and a second hydraulic cylinder in respect of its angle of attack. A third hydraulic cylinder can be provided by means of which an implement provided on the extension arm, for example a loading shovel or a loading for, is capable of being caused to pivot.
[0014] Of course, ail other customary loading implements, for example buckets, bale grabbers, etc., are capable of being used both with the telescopic loader and with the loader equipped with the front loader.
[0015] The sensor is preferably configured and arranged in such a way that a critical load condition on the loader is detectable. The sensor can be arranged on an axle of the vehicle, for example, and can indicate a critical load condition in the event of a correspondingly high, unbalanced load. Strain gauges or force transducers, for example, can find an application in this case. It is also conceivable to position the sensor at some other suitable pint and, fore example, to define the inclination of a vehicle frame in relation to the vehicle axis as the critical load condition quantity.
[0016] The invention and further advantages and advantageous further developments and embodiments of the invention are described in more detail and explained below with reference to the drawing which depicts illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic right side view of a loader configured as a telescopic loader having a hydraulic arrangement according to FIGS. 2 or 3 ;
[0018] FIG. 2 is a schematic circuit diagram of a hydraulic arrangement;
[0019] FIG. 3 is a schematic circuit diagram of an alternate hydraulic arrangement, and
[0020] FIG. 4 is a schematic left side view of a loader exhibiting a front loader having a hydraulic arrangement according to FIGS. 2 or 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Illustrated in FIG. 1 is a loader 10 in the form of a telescopic loader. The telescopic loader 10 exhibits a frame 12 , to which an extension arm 14 is linked The frame 12 is supported by a front axle 16 and by a rear axle 18 with corresponding front and rear wheels 20 and 22 , respectively.
[0022] The extension arm 14 is configured as a telescopic extension arm and is adjustably linked via a hydraulic cylinder 24 in respect of its angle of attack in relation to the frame 12 . A second hydraulic cylinder (not illustrated) is arranged in the interior of the extension arm 14 and permits the retraction and/or extension (telescoping) of the extension arm. A third hydraulic cylinder (not illustrated) is arranged on the free end of the extension arm 14 in the interior and permits the oscillation and/or tilting of a loading implement 26 .
[0023] Referring now also to FIGS. 2 and 3 , it can be seen that the loader 10 possesses a hydraulic source 28 and a hydraulic tank 30 , which are arranged underneath the vehicle bodywork and serve the purpose of supplying the hydraulic components.
[0024] A mechanical operating device 34 arranged in the cab 32 serves the purpose of actuating the hydraulic components. The hydraulic components are illustrated substantially in FIG. 2 .
[0025] A hydraulic arrangement 38 envisaged for the loader 10 is illustrated in FIG. 2 . The hydraulic arrangement 38 comprises the hydraulic cylinder 24 and, should the need arise, the hydraulic cylinders (not illustrated) arranged for the telescoping of the extension arm and tilting of the loading implement. The hydraulic cylinder 24 is connected via a first supply line 38 and a second supply line 40 to a mechanically actuated control device 42 , via which the connection of the supply lines 38 , 40 to the hydraulic pump 28 and the hydraulic tank 30 can be produced, the control device 42 is mechanically connected to the operating device 34 , for example via Bowden cables, so that displacement of the control device 42 and/or the valve gate of the control device 42 can be effected by moving the operating device 34 .
[0026] A toad holding valve 44 is arranged in the supply line 40 associated with the chamber of the lifting side of the hydraulic cylinder 24 . The load holding valve 44 comprises a pressure-limiting valve 46 capable of being opened in the direction of the control device 42 , which pressure-limiting valve is arranged in the supply line 40 and Is capable of being opened in the direction of the control device 42 , which pressure-limiting valve is arranged in the supply line 40 which is capable of being opened via control pressure contained in control pressure lines 48 , 50 , which are connected to both supply lines 38 , 40 , as well as a check valve 52 arranged in a bypass line and opening in the direction of the hydraulic cylinder 24 . The load holding valve 44 serves to ensure that, in the event of a pipe fracture on the lifting side of the hydraulic cylinder 24 , no hydraulic fluid is able to escape and the hydraulic cylinder 24 maintains its position.
[0027] The control device 42 comprises three gate positions, one for lifting, one for lowering and one more for holding the hydraulic cylinders. The control device 42 is configured as a mechanically switchable or mechanically actuated proportional valve and can be mechanically actuated or adjusted via an actuating device 54 , the actuating device 54 being mechanically connected to the operating device 34 .
[0028] The mechanically actuated control device 42 provides for the engagement or disengagement of the hydraulic pump 28 with or from the supply lines 38 , 40 . For example, an actuating lever present on the operating device 34 is pushed forward, which results in the actuation of the control device 42 , and this is displaced into its lifting position and the hydraulic cylinder 24 is filled with hydraulic fluid on the lifting side, that is to say, it is extended. A corresponding actuation of the actuating lever in the opposite direction would cause the displacement of the control device 42 into the lowering position, whereupon the hydraulic cylinder 24 would be retracted and the extension arm 14 lowered.
[0029] Provided in the illustrative embodiment depicted in FIG. 2 , is a connecting line 56 , which extends between the two supply lines 38 , 40 . Arranged in the connecting line 58 is a check valve 58 closing in the direction of the supply line 38 on the piston rod side, which check valve prevents hydraulic fluid from the supply line 40 on the piston side from flowing into the supply line 38 on the piston rod side. Arranged in the connecting line 56 between the check valve 58 and the supply line 38 on the piston rod side Is an electro-hydraulic over pressure valve 82 . The overpressure valve 62 is arranged in such a way that hydraulic fluid can flow from the supply line 38 on the piston rod side in the direction of the supply line 40 on the piston side. For this purpose, the electro-hydraulic overpressure valve 62 is connected to an electronic control unit 64 . As soon as a pressure limit pressure is reached by the pressure building up in the supply line 38 on the piston rod side, the overpressure valve 82 opens, so that hydraulic fluid flows into the supply line on the piston side and from there into the hydraulic tank 30 , with the result that the speed of displacement of the hydraulic cylinder 24 is reduced, because the volumetric flow rate of the hydraulic fluid present in the supply line 38 on the piston rod side is reduced. This means that the quantity of hydraulic fluid, which flows info the chamber of the hydraulic cylinder on the piston rod side, is reduced and, as a result, the actuation of the hydraulic cylinder 24 , in this case retracting the hydraulic cylinder 24 , is slowed down. Of course, the arrangement of the check valve 58 and the electro hydraulic overpressure valve 62 can be in the opposite sense, so that hydraulic fluid can flow from the supply line 40 on the piston side into the supply line 38 on the piston rod side. In this case, extension of the hydraulic cylinder 24 would then be slowed down.
[0030] Control of the overpressure valve 62 takes place through the electronic control unit 64 , which for its part receives control signals from a bad case sensor 66 . Depending on the load condition, the sensor 86 indicates a more or less critical load condition. As the critical load condition is approached, the control input transmitted by the electronic control unit 84 for adjusting the overpressure valve 82 is strengthened, which then causes the valve to be opened further, so that the discharge volumetric flow rate increases. The adjustment or the increase of the control input in this case preferably takes place proportionally to the signal provided by the sensor.
[0031] The sensor 66 is preferably arranged on the rear axle 18 of the loader 10 . For example, the sensor 66 is configured as a strain gauge and registers or records the deflection of the rear axle 18 . It is then possible to arrive at a conclusion in respect of the application and removal of the load on the rear axle 18 from the signal values for the deflection. If the load on the rear axle 18 were to reduce increasingly, this can point to the existence of a critical load condition, namely at the latest if a bad was no longer to be detected or indicated on the rear axle 18 . In this case, the loader 10 begins to overturn. A similar approach Is conceivable for the front axle 16 .
[0032] Illustrated in FIG. 3 is an alternate illustrative embodiment for a hydraulic arrangement 36 ′, in which there is arranged, in place of the connecting line 56 from FIG. 2 , a discharge line 56 ′ in which the electro-hydraulic overpressure valve 62 is arranged. The discharge line 56 ′ branches from the supply line 38 on the piston rod side and passes into the hydraulic tank 30 . In this way, hydraulic fluid can flow directly from the supply line 38 on the piston rod side via the overpressure valve 62 into the hydraulic tank 30 . Control of the overpressure valve in this case takes place in an analogous manner to the illustrative embodiment depicted in FIG. 2 . No check valve 58 is provided in the hydraulic arrangement 36 ′ depicted in FIG. 3 , because no connection of the supply line 40 on the piston side to the discharge line 56 ′ is present. In an analogous manner to the illustrative embodiment depicted in FIG. 2 , only the contraction of the hydraulic cylinder 24 is slowed down in FIG. 3 . As in the illustrative embodiment described in relation to FIG. 2 , it is also possible in the illustrative embodiment depicted in FIG. 3 for the flow of hydraulic fluid to be provided from the supply line 40 on the piston side, and for the extension of the hydraulic cylinder 24 to be slowed down by this means. In this case, the discharge line 56 ′ is connected to the supply line 40 on the piston side, in conjunction with which the control of the overpressure valve takes place in an analogous manner to the example depicted in FIG. 3 .
[0033] The illustrative embodiments of the hydraulic arrangements 36 , 36 ′ depicted in FIGS. 2 and 3 provide a representative indication of the arrangement of only a single hydraulic cylinder 24 . As mentioned above, further hydraulic cylinders (not illustrated) can be used in parallel, which cylinders are capable of actuation in the same way as an actuating device 34 and are also incorporated in the hydraulic arrangements 36 , 36 ′ of the kind depicted in FIGS. 2 and 3 . Furthermore, as already mentioned, it is possible not only to restrict and/or to slow down the retraction and/or lowering of the hydraulic cylinder 24 . It is naturally also conceivable to restrict and/or slow down the extension, as would be required, for example, in order to avoid the extension of the extension arm 14 in order to prevent overturning of the telescopic loader. In this case, for the illustrative embodiment in FIG. 2 , the control pressure line 56 , with which the lilting position of the control device 42 and with it the extension of the hydraulic cylinder 24 is actuated, would be provided with, or connected to, an electro-hydraulic overpressure valve 62 . For the illustrative embodiment in FIG. 3 , the supply line 40 of the piston side would be connected to a corresponding discharge line 56 ′ with an electro-hydraulic overpressure valve 62 .
[0034] FIG. 4 depicts a loader 10 in the form of a tractor 68 with a front loader 70 as a further illustrative embodiment, in conjunction with which the same reference designations are used for the same components of the loader 10 , such as the frame 12 , front axle 16 , rear axle 18 , wheels 20 , 22 , loading implement 26 and cab 32 . In this case, the load arms 70 , which are arranged to either side of the tractor 68 , represent an extension arm, the actuation of which in specific situations and in the event of overloading can give rise to critical load conditions of the loader 10 . The hydraulic cylinders 74 provided for the actuation of the load arms 70 and the hydraulic cylinders 78 provided for the actuation of the loader implement 26 are operated in this case in an analogous manner to the hydraulic arrangements 36 , 36 ′ depicted in FIGS. 2 and 3 .
[0035] Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | A loader includes a hydraulically operated extension arm, a load sensor for monitoring the load condition on the loader and a hydraulic arrangement for actuation of the extension arm and/or an implement attached to the extension arm. The hydraulic arrangement exhibits at least one hydraulic cylinder with one supply line on the piston rod side and one supply line on the piston side. At least one mechanically switchable control device is coupled between a source of fluid pressure and a hydraulic tank, on the one hand, and the supply lines on the other hand. An electronic control unit is connected for effecting operation of a restricting device coupled between the supply lines in response to a load signal received from the load sensor so as to achieve a slowed-down actuation of the hydraulic cylinder in conjunction with the on set of a critical load condition. Thus, a restriction of a volumetric flow is achieved in at least one of the supply line on the piston rod side or the supply line on the piston side of the hydraulic cylinder. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to co-pending nonprovisional application Ser. No. 09/050,507, filed Mar. 30, 1998 (the '507 application), and claiming priority to provisional application Ser. No. 60/041,791, filed Apr. 2, 1997. The '507 application is hereby incorporated by reference as though fully set forth herein. This application also claims priority to provisional application Ser. No. 60/090,278, filed Jun. 22, 1998 (the '278 application). The '278 application is hereby incorporated by reference as though fully set forth herein.
BACKGROUND OF THE INVENTION
a. Field of the Invention
The instant invention is directed toward a control and suspension system for a covering for architectural openings. More specifically, it relates to hardware for suspending and controlling the operation of a panel used to cover an architectural opening.
b. Background Art
It is well known to place coverings over architectural openings. It is also well known to make these coverings retractable so that the architectural opening may be exposed or hidden as desired. A common problem with the use of such retractable coverings is ensuring that the retractable covering is not over-extended or over-retracted. For example, if an architectural covering that is mounted on a roll bar is over-extended, it may detach from the roll bar. This type of detachment is highly undesirable and may damage the architectural covering permanently. If a window covering that is mounted on a roll bar is over-retracted, that is also highly undesirable. For example, if the covering is over-retracted, it may jam in the head rail, making the architectural covering unusable. Another common problem that occurs with retractable coverings is skewing of the covering as it is retracted. For example, if the architectural covering is mounted on a roll bar, it may wind onto the roll bar unevenly or unwind from the roll bar unevenly for a variety of reasons. Such uneven winding or unwinding is known as skewing. Skewing may result from a manufacturing defect, an error in hanging the retractable covering in proximity to the architectural opening, wear on the hardware and support system, or a variety of other reasons.
Various suspension and control systems have been proposed heretofore to address these common problems with retractable coverings for architectural openings. There remains, however, a need for more efficient means of compensating for the above types of problems encountered during the use of retractable coverings for architectural openings.
SUMMARY OF THE INVENTION
It is desirable to have a control and suspension system for retractable coverings or barriers that avoids over-extensions and over-retractions of the retractable covering. It is also desirable that the control system be able to compensate for any undesirable skewing that might occur. Accordingly, it is an object of the disclosed invention to provide an improved control and suspension system for retractable coverings.
A more detailed explanation of the invention is provided in the following description and claims, and is illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view in partial section of a retractable covering for an architectural opening in an extended configuration;
FIG. 2 is a left-end view of the retractable covering depicted in FIG. 1 with the covering in a fully retracted configuration;
FIG. 3A is a fragmentary sectional view taken about line 3 A— 3 A of FIG. 2, depicting control system hardware;
FIG. 3B is a fragmentary view of the covering depicted in FIG. 3A, depicting skew compensation;
FIG. 4 is a downward fragmentary cross-sectional view taken about line 4 — 4 of FIG. 2, depicting control system hardware;
FIGS. 5A, 5 B, and 5 C together depict an exploded isometric view of control system hardware located at each end of the head rail;
FIG. 6A is an isometric view of hardware also depicted in FIG. 5A, but from the opposite direction;
FIG. 6B is an isometric view of the releasable mounting plate, the other side of which is depicted in FIG. 5C;
FIG. 7 is a cross-sectional view of the clutch mechanism of the control system taken about line 7 — 7 of FIG. 4;
FIG. 8 is a cross-sectional view of the clutch mechanism of the control system taken about line 8 — 8 of FIG. 4;
FIG. 9 is a partial sectional view of the left end of the bottom rail taken about line 9 — 9 of FIG. 1;
FIG. 10 is a view of the inside surface of a bottom rail end cap, depicting the projections extending from the inside surface of the bottom rail end cap;
FIG. 11 is a top planform view of the bottom rail end cap depicted in FIG. 10;
FIG. 12 is an end view of the compression plate, which forms a portion of the bottom rail;
FIG. 13 is an end view of the bottom plate, which forms a portion of the bottom rail;
FIG. 14 is a fragmentary cross-sectional view of the bottom rail and a portion of the covering taken about line 14 — 14 of FIG. 9;
FIG. 15 is a fragmentary cross-sectional view of the bottom rail and the covering taken about line 15 — 15 of FIG. 9;
FIG. 16 is an exploded, fragmentary cross-sectional view of the bottom rail depicting how the first and second flexible sheets are attached to the bottom rail;
FIG. 17 depicts the control system hardware at the left end of the head rail, showing that the internal, roll bar support wheel moves left and right (as depicted) along the threaded shaft as the covering is extended or retracted;
FIG. 18 is an enlarged sectional view of a portion of the control system taken about line 18 — 18 of FIG. 17;
FIG. 19 is a second view of the control system depicted in FIG. 18, depicting abutment of the stopping ledge and the intercepting ledge;
FIG. 20 depicts adjustment of the control system hardware that controls the fully retracted configuration of the covering;
FIG. 21 is an enlarged cross-sectional view of control system hardware taken along line 21 — 21 of FIG. 20, depicting adjustment of the hardware that controls when during the covering-retraction process the covering is fully retracted;
FIG. 22 depicts the internal, roll-bar-support wheel installed in the roll bar, and shows the covering wrapped around the outer surface of the roll bar;
FIG. 23A shows the left end of the head rail in partial cross-section taken along line 23 A— 23 A of FIG. 4, depicting the covering approaching full extension;
FIG. 23B depicts the head rail components depicted in FIG. 23A, but shows the covering at full extension;
FIG. 24A depicts control system components shown in FIG. 23A in partial cross-section taken along line 24 A— 24 A of FIG. 4 as the covering approaches full extension;
FIG. 24B shows the control system hardware depicted in FIG. 24A after the covering has reached full extension;
FIG. 24C is a fragmentary cross-sectional view taken about line 24 C— 24 C of FIG. 24B; and
FIG. 25 depicts, in partial cross-section and partially broken out, control system components that facilitate skew adjustment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates most directly to devices 10 for covering architectural openings and control systems for retractable coverings or barriers for architectural openings. A sample of the type of covering contemplated for use with the disclosed control system is depicted in FIG. 1 . In this figure, the covering 12 comprises a first flexible sheet 14 , a second flexible sheet 16 , and substantially horizontal vanes 18 attached between the first and second sheets. A bottom rail 20 is attached to the first and second flexible sheets in a manner more fully discussed below. The upper end (as depicted) of the covering is attached to a roll bar, which is not visible in FIG. 1 . The control system hardware responsible for limiting the travel of the covering (i.e., the hardware that sets the fully extended position and the fully retracted position of the covering) is incorporated into the head rail 22 . The head rail 22 comprises a left end cap 24 and a right end cap 26 , and includes an arcuate cover plate 28 . The head rail 22 is attached to a support structure (e.g., a wall) by a pair of mounting brackets 30 .
FIG. 2 is an enlarged view of a portion of the left end of the apparatus 10 for covering an architectural opening. In this view an access door 32 through which the system components that control the fully retracted position is clearly visible. A slot 34 is formed into the left end cap 24 . In order to gain access to the control system hardware inside the head rail 22 , the access door 32 depicted in FIG. 2 is first removed by using a flat blade screwdriver, for example, into the door removal slot 34 molded into the left end cap 24 and prying the access door 32 from the door support ledge 44 (see FIG. 5 A). Once the desired adjustments have been made, the access door 32 may be popped or snapped back into position in the left end cap 24 to restore a more aesthetically pleasing appearance to the head rail 22 . Also, as depicted in FIG. 2, the covering 12 is fully retracted such that the bottom rail 20 is adjacent to the bottom side of the end caps 24 , 26 .
FIGS. 3A, 3 B, and 4 depict fragmentary cross-sectional views of the head rail 22 taken along two perpendicular planes passing through the longitudinal axis of rotation of the roll bar 36 . In particular, FIGS. 3A and 3B show a partial cross-sectional view of the head rail 22 taken along line 3 A— 3 A of FIG. 2 . These views are taken along a vertical plane that passes through the longitudinal axis of rotation of the roll bar 36 incorporated in the head rail 22 . FIG. 4, on the other hand, is a fragmentary cross-sectional view taken along the plane containing line 4 — 4 of FIG. 2, which passes horizontally through the longitudinal axis of rotation of the roll bar 36 mounted in the head rail 22 depicted in FIG. 1 . The left end, as depicted, of these three figures show details concerning the skew adjustment features of the invention, and details concerning the system components that permit adjustment of an upper stop limit (i.e., the components that control how far the covering may be retracted). The right-hand end, as depicted in FIGS. 3A, 3 B, and 4 , show components of the control system that control retraction and extension of the covering via a clutch mechanism. The clutch mechanism used in the present invention is closely related to the clutch mechanism described in co-pending application Ser. No. 09/050,507, which has been incorporated herein by reference as though fully set forth in the present application. The reader should refer to this related application for details concerning the break away cord system used in the right-hand end of the head rail 22 of the present invention.
FIGS. 5A, 5 B, and 5 C together depict the major components of the control system 10 comprising part of the head rail 22 of the present invention. These three figures together comprise an exploded perspective view of components comprising the control system. Referring first to FIG. 5 A and the top half of FIG. 5B, the components associated with the left end, as depicted, of the head rail 22 are described first. Depicted at the left-hand edge of FIG. 5A is the access door 32 . The access door 32 covers the access port 42 in the left end cap 24 . When in position, the circumferential edge of the access door rides in a door support ledge 44 formed in the left end cap 24 . Also formed in the left end cap 24 is a slot 34 that permits someone desiring to make adjustments in the head rail components to remove the access door 32 . The access door 32 fits into position by pressing it into the access port 42 until it snaps or pops into position.
Moving from left to right in FIG. 5A following the dashed line, the next component encountered is the plunger 46 . The plunger 46 comprises a plunger head 48 followed by a large cylindrical portion 50 , an intermediate cylindrical portion 52 , a small cylindrical portion 54 , and two flexible arms 56 . A screwdriver slot 58 is formed into the plunger head 48 . The large cylindrical portion 50 has a cross-sectional diameter that accommodates a setting retention spring 60 , also depicted in FIG. 5A (see, e.g., FIGS. 3A, 3 B, and 4 ). The inside diameter of the generally cylindrical cavity within the setting retention spring 60 is slightly larger than the outside diameter of the large cylindrical portion 50 of the plunger 46 . As shown in FIG. 3A, for example, the setting retention spring 60 slides over the large cylindrical portion 50 of the plunger 46 when the head rail 22 is assembled. The diameter of the intermediate cylindrical portion 52 is slightly smaller than the diameter of a spring retention ring 62 (see, e.g., FIG. 3A) located inside a cylindrical housing 64 extending longitudinally from the inward side of a skew adjustment plate 66 . The spring retention ring 62 is an integral part of the skew adjustment plate 66 . In particular, the spring retention ring 62 is formed on the inner surface of the cylindrical housing 64 projecting from the skew adjustment plate 66 . In the assembled head rail 22 , the setting retention spring 60 is mounted around the large cylindrical portion 50 of the plunger 46 and is trapped between the underside of the plunger head 48 and the spring retention ring 62 of the cylindrical housing 64 that is part of the skew adjustment plate 66 .
As shown in FIG. 5A, the intermediate cylindrical portion 52 of the plunger 46 includes two interlocking channels 68 , which are offset from each other by approximately 180° in the preferred embodiment. As will be described further below, these interlocking channels receive interlocking tabs 70 of a threaded shaft 72 (see FIG. 5 B). Locking tabs 74 are located at the distal ends of the two flexible arms 56 of the plunger 46 . As explained in more detail below, these locking tabs 74 help ensure that the plunger 46 and the threaded shaft 72 in the assembled head rail 22 move as a single unit.
Continuing from left to right in FIG. 5A, the next components of interest are the skew adjustment plate 66 and a threaded skew adjustment plug 76 . The cooperation or relationship between the left end cap 24 , the threaded skew adjustment plug 76 , and the skew adjustment plate 66 is best seen by considering FIG. 5A in conjunction with FIG. 6 A and FIG. 3 B. As best seen in FIG. 6A, the left end cap has molded on its inner surface a plug bed 78 . The threaded skew adjustment plug 76 rides in the plug bed such that the screwdriver slot 58 in the bottom end of the skew adjustment plug 76 is accessible through an access hole 80 , which is also molded on the inner surface of the left end cap 24 . When the skew adjustment plate 66 , which also mounts the roll bar 36 , is positioned in a pair of the channels 82 located on the back side of the left end cap 24 , the threaded skew adjustment plug 76 is pinched between the bottom of the plug bed 78 (FIG. 6A) and an arcuate threaded surface 84 (FIG. 5A) on the left-hand side, as depicted, of the skew adjustment plate 66 . The skew adjustment plug 76 is thereby trapped in the plug bed 78 between the left end cap 24 and the skew adjustment plate 66 . The pressure exerted on the threaded skew adjustment plug 76 by the left end cap 24 and the skew adjustment plate 66 prevents the skew adjustment plug 76 from easily rotating, but it remains possible to rotate the skew adjustment plug 76 using a flat-blade screwdriver inserted through the access hole 80 molded in the left end plate 24 as depicted in FIG. 3 B.
Referring again to FIG. 5A, a roll-bar-end support wheel 86 and its associated down limit stop 88 are described next. As depicted, the down limit stop comprises three primary components: a mounting tang 90 , a wedge 92 , and an arcuate arm 94 . As depicted, the distal end of the mounting tang 90 is split, and a locking tab 96 is integrally formed on opposing sides of the mounting tang 90 adjacent to the split. The opposite end of the mounting tang 90 is integrally formed with one end of the arcuate arm 94 . The arcuate arm 94 includes an arcuate outer edge 98 and a substantially flat leading edge 100 . The wedge 92 is attached to the same side of the arcuate arm 94 as the mounting tang 90 , but the wedge 92 is attached adjacent, but not flush with, the leading edge 100 of the arcuate arm 94 , whereas the mounting tang 90 is integrally formed with the opposite end of the arcuate arm 94 . The wedge 92 includes an outer surface 102 , a leading edge 104 , and a trailing edge 106 .
The roll-bar-end support wheel 86 includes a mounting hole 108 that accommodates the mounting tang 90 of the down limit stop 88 . When the mounting tang 90 is properly inserted into the mounting hole 108 , the locking tabs 96 on the distal end of the mounting tang 90 rotatably lock the down limit stop 88 to the roll-bar-end support wheel 86 . Since the diameter of the mounting hole 108 substantially corresponds to the diameter of the mounting tang 90 , the locking tabs 96 snap outward once they pass an annular ledge 526 inside the mounting hole 108 (see FIG. 24 C). The portion of the mounting tang 90 between the back side of the arcuate arm 94 and the bottom of the slot existing in the distal end of the mounting tang 90 substantially corresponds to the length of the mounting hole 108 in the roll-bar-end support wheel 86 . When the down limit stop 88 is thus snapped into position onto the roll-bar-end support wheel 86 , and after the roll-bar-end support wheel 86 is positioned in the roll bar 36 (see FIG. 22 ), the wedge 92 of the down limit stop 88 rides in an elongated channel 110 (FIG. 5B) of the roll bar 36 .
The roll-bar-end support wheel 86 also includes an alignment groove 112 . The alignment groove 112 accommodates an alignment tongue 114 (FIG. 5B) comprising an integral part of the roll bar 36 . The alignment groove 112 , when slipped over the alignment tongue 114 , forces the roll-bar-end support wheel 86 to rotate in unison with the roll bar 36 . Also visible in FIG. 5A on the roll-bar-end support wheel 86 are alignment ribs 116 . As may be clearly seen, these alignment ribs 116 are slightly tapered to facilitate easy insertion of the roll-bar-end support wheel 86 into the end of the roll bar 36 during assembly of the apparatus 10 for covering an architectural opening. A smooth barrel 118 is supported at the center of the roll-bar-end support wheel 86 by a plurality of spokes 120 . The left end of the smooth barrel 118 includes an annular bearing surface 122 , which rides in a channel 124 (FIG. 6A) on the inside surface, as depicted, of the skew adjustment plate 66 , adjacent the cylindrical housing 64 . Also visible in FIG. 5A is a complimentary channel 126 and its side walls 128 , which accommodate the elongated channel 110 (FIG. 5B) of the roll bar 36 in the assembled head rail 22 .
Referring now to FIGS. 5A and 6A, additional details concerning the skew adjustment plate 66 are provided. The left-hand side of the skew adjustment plate 66 , as depicted, includes the arcuate threaded surface 84 previously described. The cylindrical housing 64 projects from the right side of the skew adjustment plate 66 and is integrally molded in the preferred embodiment with the skew adjustment plate 66 . A bore 132 passes completely through the skew adjustment plate 66 and the center of the cylindrical housing 64 . Referring in particular to FIG. 6A, the right side, as depicted, of the skew adjustment plate 66 includes a substantially annular channel wall 134 defining the substantially annular channel 124 . Two support wheel locks 138 are arranged on the surface of the cylindrical housing 64 . When the roll-bar-end support wheel 86 is slid into position over the cylindrical housing 64 and is fully seated so that the annular bearing surface 122 of the roll-bar-end support wheel 86 is against the skew adjustment plate 66 , the support wheel locks 138 , which are located approximately 180° apart on the surface of the cylindrical housing 64 , snap over the annular ledge 527 visible in FIGS. 5A and 24C to rotatably lock the roll-bar-end support wheel 86 into position. When the roll-bar-end support wheel 86 is thus positioned over the cylindrical housing 64 , the arcuate arm 94 of the down limit stop 88 rides in the substantially annular channel 124 visible in FIG. 6 A. The arcuate arm 94 riding in this channel 124 is also clearly depicted in FIG. 24 A. Locking fingers 140 are molded into the distal end of the cylindrical housing 64 (FIG. 6 A). When the head rail 22 is fully assembled as depicted in FIGS. 3A, 3 B, and 4 , for example, the locking fingers 140 are engaged by the four locking lugs 142 depicted on the left end in FIG. 5 B.
Referring now to FIG. 5B, the components of the threaded shaft 72 are described next. In the preferred embodiment, the threads on the threaded shaft are left-handed threads. The left end, as depicted, of the threaded shaft 72 comprises a head 144 . On the interior of the head 144 are the two short interlocking tabs 70 , which engage the interlocking channels 68 on the plunger 46 (see FIG. 5A) after the head rail 22 is assembled. Moving outward radially from the interlocking tabs, an annular abutment surface 146 is next encountered. As may be seen, for example, in FIG. 17, this annular abutment surface rides against the inward side of the spring retention ring 62 . Moving further out radially on the left-hand end, as depicted in FIG. 5B, of the threaded shaft 72 , the four locking lugs 142 are next present. These four locking lugs 142 , which are positioned at substantially 90° intervals around the circumference of the annular abutment surface 146 , engage the locking fingers 140 of the cylindrical housing 64 to facilitate adjustment of the maximum amount of retraction of the covering 12 that is possible. The four locking lugs 142 project leftward, in FIG. 5B, from a finger seat 148 , which is annular in configuration. The reader is referred, for example, to FIG. 19, which shows the locking fingers 140 of the cylindrical housing 64 resting against the finger seat 148 located on the head 144 of the threaded shaft 72 when the head rail 22 is assembled and is not being adjusted. Finally, on the back side, as depicted in FIG. 5B, of the head 144 of the threaded shaft 72 is a stopping ledge 150 . The function of the stopping ledge 150 , which may also be clearly seen in FIGS. 18 and 19, will be described in further detail below.
Referring again to FIG. 5B, the next component encountered is the internal, roll-bar-support wheel 152 . This internal, roll-bar-support wheel 152 may also be seen in at least FIGS. 3A, 3 B, 4 , and 22 . The internal, roll-bar-support wheel 152 includes an internally threaded barrel 154 . This threaded barrel 154 makes it possible to thread the internal, roll-bar-support wheel 152 onto the threaded shaft 72 adjacent the wheel 152 in FIG. 5 B. The threaded barrel 72 is supported by a plurality of barrel support spokes 156 which extend radially between the outer surface of the threaded barrel 154 and the outer ring 157 of the internal, roll-bar-support wheel 152 . The outer ring 157 of this wheel 152 is not completely rounded. In particular, contact ribs 158 are present on the outer surface of the outer ring 157 . When the internal, roll-bar-support wheel 152 is inserted into the roll bar 36 , these contact ribs 158 ride on the inner surface of the roll bar 36 and help ensure that the alignment of the internal, roll-bar-support wheel 152 is correct. Also present on the outer surface of the outer ring 157 is an alignment groove 160 . The alignment groove 160 accommodates the alignment tongue 114 running down the inside of the roll bar 36 parallel to the longitudinal axis of the roll bar 36 . When the internal, roll-bar-support wheel 152 is properly inserted into the interior of the roll bar 36 , the alignment tongue 114 rides in the alignment groove 160 , which helps ensure that the internal, roll-bar-support wheel 152 and the roll bar 36 rotate in unison. The outer ring 157 of the internal, roll-bar-support wheel 152 also includes a complimentary channel 162 and side walls 164 , which accommodate a similar elongated channel 110 and its corresponding channel side walls 165 formed integrally with the roll bar 36 . Thus, when the internal, roll-bar-support wheel 152 is properly inserted into the interior of the roll bar 36 , the alignment tongue 114 is trapped within the alignment groove 160 , and the elongated channel 110 of the roll bar is similarly captured in the complimentary channel 162 in the internal roll-bar-support wheel 152 . Also visible on the internal roll-bar-support wheel 152 depicted in FIG. 5B is an intercepting ledge 166 . If the internal, roll-bar-support wheel 152 is threaded far enough onto the threaded shaft 72 , the intercepting ledge 166 of the roll-bar-support wheel 152 will impact on the stopping ledge 150 of the threaded shaft 72 . This interaction is described further below with reference to FIGS. 18 and 19.
Next, depicted in the upper half of FIG. 5 B and in the lower leftmost portion of FIG. 5B are fragmentary portions of the roll bar 36 . The primary features of the roll bar 36 , including the alignment tongue 114 and the elongated channel 110 have been described previously.
The remaining components depicted in FIG. 5B (namely the screw 168 , drive member 170 , clutch coil spring 172 , and mounting hub 174 ) cooperate with several components depicted in FIG. 5C to rotatably support the right-hand end, as depicted, of the roll bar 36 . These components include a break away operating cord system 176 substantially identical to that described in co-pending applications Ser. No. 09/050,507, filed Mar. 30, 1998, which disclosure is incorporated in the present application as though fully set forth herein. The reader is referred to that prior application for further details concerning the construction and operation of the break away cord mechanism in addition to the disclosure provided in the present application. The drive member 170 (FIG. 5B) includes a generally cylindrical main body 178 having a plurality of generally radial support ribs 180 projecting from an outer surface of the cylindrical main body 178 . One of the support ribs includes an alignment groove 182 , which is similar to the alignment groove 160 previously described in connection with the internal, roll-bar-support wheel 152 . When the drive member 170 is inserted into the right end, as depicted, of the roll bar 36 and is properly aligned, the alignment tongue 114 , which is an integral part of the internal surface of the roll bar 36 , rides in the alignment groove 182 , thereby forcing the drive member 170 and roll bar 36 to rotate in unison. A tapered barrel 184 is suspended by a plurality of barrel support spokes 186 extending between the exterior surface of the tapered barrel 184 and the internal surface of the generally cylindrical main body 178 of the drive member 170 . At the right-hand end, as depicted, of the drive member 170 is a drive wheel 188 . The drive wheel 188 includes alternate radially extending teeth 190 , which define a channel 192 between them. As shown in other figures (e.g., FIG. 8 ), the channel 192 accommodates an operating cord 193 .
The tapered barrel 184 suspended in the center of the generally cylindrical main body 178 does not extend the full length of the inside of the generally cylindrical main body 178 . Rather, as is clearly depicted in FIGS. 3A, 3 B, and 4 , for example, the tapered barrel 184 extends only approximately half way through the generally cylindrical main body 178 . Subsequently, the inside of the generally cylindrical main body 178 becomes larger. The diameter of this larger portion of the internal surface of the generally cylindrical main body 178 is designed to accommodate the clutch coil spring 172 depicted in FIG. 5 B. The internal surface of the generally cylindrical main body 178 is merely notched a sufficient amount to accommodate the clutch coil spring 172 . When the clutch coil spring 172 is properly installed, the internal surface of the spring 172 is substantially coplanar with the internal surface of the generally cylindrical main body.
A mounting hub 174 is the final component visible in FIG. 5 B. The mounting hub 174 has a central cylindrical axial passage 198 and includes a generally U-shaped longitudinally extending channel 200 . On the right-hand end, as depicted, of the mounting hub 174 is a bearing surface 202 . This bearing surface is substantially annular and rides on the inner ring-like bearing surface 204 (FIG. 5C) located on the inward side of the relatively flat base of the right end cap 26 when the head rail 22 is fully assembled.
Even though FIG. 5B shows only one clutch spring 172 in the preferred embodiment there are two clutch springs placed back-to-back in the drive member 170 .
Referring now to FIG. 5C, additional components of the right end of the head rail 22 are depicted. First, a releasable mounting plate 206 is shown. This releasable mounting plate 206 includes a generally U-shaped notch 208 . This generally U-shaped notch 208 is defined by side edges 210 , 210 ′ that extend from the distal end of a pair of clamp arms 212 , 212 ′ toward a pair of horizontal lips 214 , 214 ′ and then around an arcuate segment 216 defining an enlarged recess area 218 . This enlarged recess area 218 and the horizontal lips 214 , 214 ′, conform to the shape molded into the rear side, as depicted, of the mounting hub 196 (see FIG. 6B, which shows the rear side of the mounting hub 174 ). The releasable mounting plate 206 also includes a pair of mounting blocks 220 on the peripheral edges of each clamp arm 212 , 212 ′. These mounting blocks 220 each define a pulley channel 222 that is substantially U-shaped. A pin hole 224 is located on the legs of the pulley channel and a shaft hole 226 is located in the base of the pulley channel 222 . During assembly, a pulley wheel 228 is mounted in each pulley channel 222 by inserting the shaft 229 of the pulley wheel 228 into the shaft hole 226 of the pulley channel 222 . Then, the operating cord 193 (FIG. 8) is threaded above the pulley wheel 228 between the upper portion of the mounting block 220 and the top of the pulley wheel 228 . Then, the pulley plate 300 , which comprises a pair of mounting pins 302 on its back side 303 and includes a shaft hole on its back side (not depicted) is positioned to rotatably secure the pulley wheel 228 in position in the pulley channel 222 . When the pulley plate 300 is properly positioned over the mounting block 220 , the top side 301 of the pulley plate is substantially coplanar with the top surface 305 of the semi-circular guide plate 304 .
The lock plate 306 depicted in FIG. 5C may be used to disable the break-away feature of the operating cord 193 . The lock plate 306 is slid into position after the other components of the break away operating cord system are assembled. When properly positioned, the upstanding legs 308 of the lock plate 306 prevent the two clamp arms 212 , 212 ′ of the releasable mounting plate 206 from permitting the releasable mounting plate 206 from releasing. Since it may be difficult to remove the lock plate 306 after it has been inserted, the lock plate 306 includes an elongated slot 310 . If the lock plate 306 is difficult to remove, a flat-blade screwdriver may be inserted into the elongated slot 310 to facilitate removal of the lock plate 306 .
Various details of the inner surface of the right end cap 26 are visible in FIG. 5 C. Protruding from the relatively flat base 311 of the right end cap 26 is a tapered support shaft 312 . This tapered support shaft 312 supports the mounting hub 174 and the drive member 170 as shown in FIG. 4, for example. Extending substantially parallel to the tapered support shaft is the stop arm 314 . A pair of abutment surfaces 316 are visible on each side of the right end cap 26 . These abutment surfaces 316 are impacted by the abutment surfaces 213 on the clamp arms 212 , 212 ′, one of which is visible on the releasable mounting plate depicted in FIG. 5 C. Also visible in FIG. 5C is a top wall 318 , which is an integral part of the right end cap 26 . When the head rail 22 is fully assembled, as depicted in FIG. 1, for example, an end portion 400 of the top wall abuts a corresponding surface on the arcuate cover plate 28 . The back side of the arcuate cover plate 28 is supported by the arcuate, plate-like projection 402 depicted in FIG. 5 C. This arcuate, plate-like projection 402 is integrally molded as a part of the right end cap 26 in the preferred embodiment. Finally, a cord guide surface 404 is also depicted in FIG. 5C as being integrally formed on the back side or internal side, as depicted, of the right end cap 26 .
When the break away clutch system is completely assembled, it appears as depicted in FIGS. 4, 7 , and 8 , for example. FIG. 7 depicts a cross-sectional view taken along line 7 — 7 of FIG. 4 . Clearly visible in FIG. 7 are the abutment surfaces 213 on each of the clamp arms 212 , 212 ′ of the releasable mounting plate 206 in proximity to the corresponding abutment surfaces 316 of the right end cap 26 . FIGS. 7 and 8 are included in the present application primarily for context. For additional details and explanation concerning the assembly and operation of the break away clutch mechanism, the reader is referred to co-pending application Ser. No. 09/050,507, which has been incorporated herein by reference.
Referring now to FIGS. 9, 10 , 11 , 12 , 13 , 14 , 15 , and 16 , the bottom rail 20 of the present invention is next discussed. The bottom rail 20 , an isometric view of which is clearly shown in FIG. 1, comprises a bottom plate 412 , a compression plate 414 , a pair of end caps 416 and an optional weight 418 . FIG. 9 is a fragmentary cross-sectional view of a portion of the bottom rail 20 taken along line 9 — 9 of FIG. 1 . FIG. 9 depicts the relationship between the left bottom rail end cap 416 , the first and second flexible sheets 14 , 16 , the compression plate 414 , and the optional weight 418 . As seen in FIGS. 9, 10 , and 11 , the bottom rail end caps 416 (the right end cap is not depicted but is the same as the left end cap) include an upper projection 500 and two lower projections 502 extending from the inside surface 504 of the end caps 416 . The upper projection 500 is shown in phantom in FIG. 9, but additional details concerning the upper projection 500 may be clearly seen in FIGS. 10 and 11. The two lower projections 502 depicted in FIG. 10 extend in the preferred embodiment approximately the same distance from the inside surface 504 of the rail end caps 416 as does the upper projection 500 . These three projections frictionally engage the compression plate 414 and the bottom plate 412 of the bottom rail 20 to removably secure the end caps 416 to the bottom rail 22 .
Referring in particular to FIG. 13, the bottom plate 412 is next described. As shown in FIG. 13, the bottom plate has a winged U-shape when viewed in cross-section perpendicular to the longitudinal axis of the bottom rail 20 . Two strips of gripping material 506 extend along the interior surface of the bottom plate 412 . These strips of gripping material 506 are substantially parallel to the longitudinal axis of the assembled bottom rail 20 . When the first and second sheets 14 , 16 arc trapped during bottom sheet assembly (see, for example, FIG. 16 ), the gripping material 506 helps hold the flexible sheet material in position. In the preferred embodiment, the bottom plate 412 itself is made from a plastic material, and the gripping material is a type of gummier, rubber-like material. Extending upward (leftward as depicted in FIG. 13) from the bottom plate 412 and continuing for the entire length of the bottom rail 20 in a longitudinal direction are a pair of inwardly projecting ledges 508 . The ledges 508 project inwardly from a distal end of a vertical wall 509 and are substantially perpendicular to the vertical wall 509 . The vertical walls 509 are attached at one end to the bottom plate 412 . A weight channel 510 is defined by the substantially rectangular pocket created between the undersides of the inwardly projecting ledges 508 and the inside surface of the bottom plate 412 . If the optional weight 418 were used, it is preferably placed in the weight channel 510 as shown in FIG. 15 . The weight 418 may be used to help the covering 12 extend more easily, and the optional weight could also assist in anti-skew adjustment. On the opposite sides of the substantially vertical walls 509 , are two other ledges 516 , 516 ′ extending toward the longitudinal edges 413 of the bottom plate 412 . Each of these latter two ledges 516 , 516 ′ also extend for the entire longitudinal length of the bottom plate 412 in the preferred embodiment. Each of these latter ledges 516 , 516 ′ also interlocks with a corresponding ledge 517 , 517 ′, respectively, on the compression plate 414 to secure the bottom plate 412 to the compression plate 414 .
Referring now to FIG. 12, the compression plate 414 in the preferred embodiment has a substantially arcuate cross-section. A pair of substantially vertical walls 512 extend from the underside of the compression plate 414 and extend for the entire longitudinal length of the compression plate 414 in the preferred embodiment. The distal edges 514 of each of the substantially vertical walls 512 comprises an interlocking ledge 517 , 517 ′. Each of these interlocking ledges 517 , 517 ′ corresponds with an interlocking ledge 516 , 516 ′, respectively, on the bottom plate 412 . In the preferred embodiment, the compression plate 414 is made from aluminum or some similar rigid material, while the bottom plate 412 is made from a flexible plastic material. Thus, when the compression plate 414 is forced toward the bottom plate 412 , the interlocking ledges 516 , 516 ′ on the flexible bottom plate 412 snap around the interlocking ledges 517 , 517 ′, respectively, on the substantially rigid compression plate 414 , thereby locking the two components together as shown in FIGS. 14 and 15, for example.
Referring now to FIG. 16, the assembly of the bottom plate 412 , compression plate 414 , and the covering 12 is described. As shown in FIG. 16, the first flexible sheet 14 and the second flexible sheet 16 of the covering 12 each has a trailing edge 518 extending below the lowest horizontal vane 18 connecting these two flexible sheets. To attach the bottom rail 20 to the covering 12 , the relatively rigid compression plate 414 is placed between the trailing edges 518 of the first and second flexible sheets 14 , 16 . Then, the bottom plate 412 is pressed toward the compression plate 414 while ensuring that the trailing edges 518 extending past the compression plate 414 are placed on top of the longitudinally extending strips of gripping material 506 affixed along the longitudinal edges 413 of the bottom plate 412 . With the trailing edges 518 of the two flexible sheets 14 , 16 positioned as shown in FIG. 16, the bottom plate 412 is pressed toward the compression plate 414 until the first and second interlocking ledge pairs 516 / 517 , 516 ′, 517 ′ snap together, as shown in FIG. 15 . When the bottom rail 20 has been properly assembled, the trailing edges 518 of the first and second flexible sheets 14 , 16 are trapped between the gripping material 506 and the interior surface of the compression plate 414 .
Referring now to FIGS. 17, 18 , 19 , 20 , and 21 , operation and adjustment of the control system hardware that controls the upper retraction limit is next described. FIG. 17 shows a cross section of the left-hand end of the assembled head rail 22 . As shown in FIG. 17, the plunger 46 is snapped together with the threaded shaft 72 , and the setting retention spring 60 is trapped between the spring retention ring 62 and the underside of the plunger head 48 . Tension within the setting retention spring 60 causes the spring to press against the spring retention ring 62 and the plunger head 48 , thereby biasing the plunger head 48 toward the left, which simultaneously biases the threaded shaft 72 to the left as depicted in FIG. 17 . When the threaded shaft 72 is thus biased to the left, as depicted, this causes the four locking lugs 142 on the head 144 of the threaded shaft 72 (see FIG. 5B) to engage the locking fingers 140 on the distal end of the cylindrical housing 64 of the skew adjustment plate 66 (see FIG. 5A for a clear view of the locking fingers 140 ). When in this configuration, the threaded shaft 72 is kept from rotating by the pressure between the four locking lugs 142 and the locking fingers 140 . Therefore, if the roll bar 36 is rotated in one of the directions indicated by the bent arrows 520 , 522 at the right side of FIG. 17, this causes the internal roll-bar-support wheel 152 to move left or right, as depicted in FIG. 17, parallel to the axis of rotation 196 of the roll bar 36 . Rotation of the roll bar 36 thus rotates the internal roll-bar-support wheel 152 , which must rotate substantially in unison with the roll bar 36 because of the interaction between the alignment tongue 114 and the alignment groove 160 (visible in FIG. 5B) and interaction between the elongated channel 110 and the complimentary channel 162 (also visible in FIG. 5 B). Since the internal roll-bar-support wheel 152 comprises a threaded barrel 154 that is threaded on the threaded shaft 72 , any rotation of the internal, roll-bar-support wheel 152 results in a proportional longitudinal movement of the internal roll-bar-support wheel 152 as the threaded barrel 154 rotates along the threaded shaft. For example, when the covering 12 is extended (i.e., when the roll bar 36 is rotated in the direction indicated by the arrow 522 in FIG. 17 ), the internal roll-bar-support wheel 152 is driven toward the right as depicted in FIG. 17 . This occurs because in the preferred embodiment, the threaded barrel 154 and the threaded shaft 72 have left-handed threads. Obviously, the length of the threaded shaft 72 is at least partially dependent upon the size of the covering 12 that must be unrolled (i.e., the number of rotations that the internal roll-bar-support wheel 152 will complete during extension of the covering). If the threaded shaft 72 is not sufficiently long, extension of the covering will eventually force the internal roll-bar-support wheel 152 to fall off the right end, as depicted, of the threaded shaft. Of course, one could implant a pin or shaft (not shown) perpendicular to the threaded shaft 72 near its free end in order to prevent the internal roll-bar-support wheel 152 from falling off the right end (as depicted in FIG. 17) of the threaded shaft 72 . Such a pin or shaft that stops the lateral or longitudinal movement of the internal roll-bar-support wheel 152 could act as a backup to the gravity lock disclosed herein and described further below.
FIGS. 18 and 19 each shows a fragmentary cross-sectional view along line 18 — 18 of FIG. 17 to demonstrate how the upper stop limit for the covering 12 is set. In FIG. 18, the covering 12 (shown in FIG. 1) is at least partially extended. This is apparent because the intercepting ledge 166 is displaced from the stopping ledge 150 since the internal roll-bar-support wheel 152 is displaced partway down the threaded shaft 72 . As the covering 12 is retracted (i.e., the roll bar 12 is rotated in the direction 520 indicated in FIG. 17 ), the threaded barrel 154 and, thus the internal roll-bar-support wheel 152 , moves to the left in FIGS. 18 and 19 until the intercepting ledge 166 on the edge of the threaded barrel 154 intercepts the stopping ledge 150 on the head 144 of the threaded shaft 72 . When the intercepting ledge 166 intercepts the stopping ledge 150 , no further retraction of the covering 12 may occur. Thus, if the stopping ledge 150 and the intercepting ledge 166 have met, but the covering 12 is not retracted as far as desired, it is necessary to adjust the relative position between the internal roll-bar-support wheel 152 and the threaded shaft 72 to prevent the intercepting ledge 166 from intercepting the stopping ledge 150 until the covering 12 is retracted the desired amount. Adjustment of this relationship between the internal roll-bar-support wheel 152 and the threaded shaft 72 is depicted in FIGS. 20 and 21.
FIGS. 20 and 21 show adjustment of the relative position of the internal roll-bar-support wheel 152 relative to the threaded shaft 72 . Referring first to FIG. 20, a screwdriver 524 is shown inserted in the screwdriver slot 58 (FIG. 5A) in the plunger head 48 . In order to gain access to the screwdriver slot, the access door 32 (visible in FIGS. 1 and 5A) has been removed, and the screwdriver 524 has been inserted through the access port 42 in the left end cap 24 . When the screwdriver 524 is forced with sufficient pressure into the screwdriver slot 58 in the plunger head 48 , this action compresses the setting retention spring 60 as the plunger 46 travels rightward as depicted in FIG. 20 . The plunger 46 and the threaded shaft 72 move in unison because of the interaction among several components, including the intermediate cylindrical portion 52 of the plunger, the interlocking channels 68 on the intermediate cylindrical portion 52 , the locking tabs 74 on the flexible arms 56 , the interlocking tabs 70 on the interior of the head 144 of the threaded shaft 72 , and the annular abutment surface 146 on the left end (as depicted in FIG. 5B) of the threaded shaft 72 . Thus, when the plunger 46 is driven rightward in FIG. 20, this simultaneously disengages the locking lugs 142 of the threaded shaft 72 from the interlocking fingers 140 of the cylindrical housing 64 of the skew adjustment plate 66 after the setting retention spring 60 has been compressed a sufficient amount. Once the interlocking lugs 142 are thus disengaged from the locking fingers 140 , rotation of the screwdriver 524 directly rotates the threaded shaft 72 . Thus, if the roll bar 36 remains motionless, this rotation of the threaded shaft 72 will force the internal roll-bar-support wheel 152 to move left or right, depending upon the direction of rotation of the screwdriver 524 . For example, if the screwdriver 524 is rotated in a first direction 523 while the roll bar 36 is kept from moving, the internal roll-bar-support wheel 152 will be pulled to the left in FIG. 20 by the interaction between the threads of the threaded barrel 154 and the threads on the threaded shaft 72 . Similarly, if the screwdriver 524 is turned in the second direction 525 while the roll bar 36 is prevented from rotating, the internal roll-bar-support wheel 152 will be pushed to the right in FIG. 20 by the interaction between the threaded barrel 154 and the threaded shaft 72 . By making these adjustments, which increase or decrease the number of threads between the left edge of the internal roll-bar-support wheel 152 and the head 144 of the threaded shaft 72 , it is possible to adjust the number of rotations that the roll bar 36 is permitted to go through before the intercepting ledge 166 on the internal roll-bar-support wheel 152 intercepts the stopping ledge 150 on the back side of the finger abutment ring 149 on the head 144 of the threaded shaft 72 . When the pressure driving the screwdriver 524 rightward in FIG. 20 is released, the setting retention spring 60 drives the plunger 46 and threaded shaft 72 to the left in FIG. 20 until the four locking lugs 142 engage locking fingers 140 on the cylindrical housing 64 , and the tips of the locking fingers 140 rest against the finger seat 148 (FIG. 5B) of the finger abutment ring 149 . Once the interlocking lugs 142 are locked into the locking fingers 140 , the threaded shaft 72 again becomes effectively fixed to the left end cap 24 and, thus, remains stable during rotation of the roll bar 36 . FIG. 21 is a fragmentary view taken along line 21 — 21 of FIG. 20 and depicts disengagement of the locking lugs 142 (two of which are depicted) from the locking fingers 140 .
FIG. 22 is a partial cross-sectional view taken along line 22 — 22 of FIG. 20 through the center of the internal roll-bar-support wheel 152 . The threaded barrel 154 of the internal roll-bar-support wheel 152 is shown as threaded onto the threaded shaft 72 , the edge of the threads shown in phantom as a ring around the threaded shaft 72 . Placement of the internal roll-bar-support wheel 152 within the roll bar 36 is also clearly visible in FIG. 22 . The alignment tongue 114 is shown as riding in the alignment groove 160 , and the complimentary channel 162 of the internal roll-bar-support wheel 152 is shown accommodating the elongated channel 110 built in to the roll bar 36 . The wedge 92 of the down limit stop 88 is also visible riding on the outside of the roll bar 36 in the elongated channel 110 . The threaded barrel 154 is supported by a plurality of barrel support spokes 156 . Although spokes 156 are used in the preferred embodiment, clearly the spokes 156 could be replaced by solid material or the number of barrel support spokes 156 could be increased or decreased at the whim of the designer. Several layers of the covering 12 are shown as still being wound around the roll bar 36 in FIG. 22, and a portion of the covering 12 has been unwound and is hanging down from the right-hand side, as depicted, in FIG. 22 .
Referring now to FIGS. 23A, 23 B, 24 A and 24 B, operation of the extension limit (gravity lock) in the present invention is described next. FIG. 23A is a fragmentary cross-sectional view taken about line 23 A— 23 A in FIG. 4 . Clearly visible in FIG. 23A is the left end cap 24 , the arcuate cover plate 28 , a portion of the roll bar 36 , the roll-bar-end support wheel 86 with the down limit stop 88 (FIG. 5A) mounted thereon, and a portion of the covering 12 . As shown by the direction arrow 91 in FIG. 23A, the roll bar 36 is rotating clockwise and extending the covering 12 comprising the first flexible 14 , the second flexible sheet 16 , and the horizontal vanes 18 . As depicted in FIG. 23A, the covering 12 is nearing complete extension. The interior side of the first flexible sheet 14 is pressing against the outer surface 102 of the wedge 92 on the down limit stop 88 , thereby keeping the wedge 92 from rotating about its mounting tang 90 . FIG. 24A shows the covering and roll bar 36 in approximately the same position from the opposite direction since FIG. 24A is a partial cross-sectional view taken about line 24 A— 24 A in FIG. 4 . In FIG. 24A it is clearly visible that the flexible sheet 14 pressing against the outer surface 102 of the wedge 92 is keeping the arcuate arm 94 within the semi-annular channel 124 (see also FIG. 6A) defined between the semi-annular channel wall 134 and the annular bearing surface 122 (FIG. 5A) on the roll-bar-end support wheel 86 .
FIG. 23B is similar to FIG. 23A; however, rotation of the roll bar 36 has been stopped by the down limit stop 88 and the covering 12 is in its fully extended configuration. When the roll bar 36 rotates from the position shown in FIG. 23A to that shown in FIG. 23B, no covering material remains on the roll bar 36 to press against the outer surface 102 of the wedge 92 and keep the down limit stop 88 from rotating about the mounting tang 90 . Therefore, shortly after being in the position shown in FIG. 23 A and shortly before reaching the position shown in FIG. 23B, gravity causes the down limit stop 88 to rotate about its mounting tang 90 to the position shown in FIG. 23 B and in FIG. 24B, which shows the same position from the opposite side. With the down limit stop 88 thus rotated, the leading edge 100 of the arcuate arm 94 impacts the edge of the semi-annular channel wall 134 since the arcuate arm 94 of the down limit stop 88 is no longer forced to remain within the semi-annular channel 124 by the pressing of the covering material on the outer surface 102 of the wedge 92 . When the leading edge 100 of the arcuate arm 94 impacts the semi-annular channel wall 134 , as depicted most clearly in FIG. 23B, the trailing edge 106 of the wedge 92 is simultaneously driven into a side wall 165 of the elongated channel 110 in the roll bar 36 . Thereby, any further downward motion of the covering 12 toward the extended position is prevented. When the roll bar 36 is rotated in the opposite direction to that depicted by the direction arrow 91 in FIG. 23A in order to retract the covering 12 by winding it back on to the roll bar 36 , the opposite edge 135 (FIG. 24B) of the semi-annular channel wall 134 impacts the outer edge 98 of the arcuate arm 94 , thereby rotating the down limit stop 88 counterclockwise as depicted in FIG. 24B about the mounting tang 90 and pushing the arcuate arm 94 back into the semi-annular channel 124 defined between the semi-annular channel wall 134 and the annular bearing surface 122 of the roll-bar-end support wheel 86 . Then, as the roll bar 36 continues to retract the covering 12 and completes its first full rotation, the down limit stop 88 is prevented from rotating about its mounting tang 90 since a layer of the covering 12 will then be present to press against the outer surface 102 of the wedge 92 during further retraction of the covering 12 .
FIG. 24C is a fragmentary cross-sectional view taken about line 24 C— 24 C of FIG. 24 B. This figure clearly shows how the support wheel locks 138 , which in the preferred embodiment is an integral part of the cylindrical housing 64 on the skew adjustment plate 66 (see, e.g., FIG. 6 A), snap behind the annular ledge 527 on the inside of the otherwise smooth barrel 118 suspended in the center of the roll-bar-end support wheel 86 by a plurality of spokes 120 . When the roll-bar-end support wheel 86 is slid onto the cylindrical housing 64 of the skew adjustment plate 66 , the support wheel locks 138 are flexed toward the axis of rotation 196 of the roll-bar-end support wheel 86 until the roll-bar-end support wheel 86 is slid sufficiently far onto the cylindrical housing 64 that the support wheel locks 138 can trap the support wheel 86 onto the cylindrical housing 64 by springing out behind the ledge 527 . Also clearly visible in FIG. 24C is the method of attaching the down limit stop 88 to the roll-bar-end support wheel 86 . When the mounting tang 90 is pushed sufficiently into the mounting hole 108 on the support wheel 86 , the locking tabs 96 on the distal end of the mounting tang 90 snap past a ridge 526 on the inside of the mounting hole 108 where the mounting hole diameter increases slightly.
Referring next to FIGS. 3B, 5 A, 6 A, and 25 , the control system components that permit one type of skew adjustment available with the present invention are described next. As shown in FIG. 3B, if the left end cap 24 is incorrectly mounted higher than the right end cap 26 , for example, a skew angle 528 will be present between an imaginary horizontal line 530 and a second imaginary line 532 extending between the top of the right end cap 26 and the top of the left end cap 24 . This skew angle 528 can be compensated for or corrected by turning the threaded skew adjustment plug 76 in the plug bed 78 (FIG. 6A) by inserting a screwdriver 524 (FIG. 3B) through the access hole 80 (most clearly visible in FIG. 6 A). When the skew adjustment plug 76 is rotated, the threads on the skew adjustment plug 76 , which engage the arcuate threaded surface 84 (FIGS. 5 A and 3 B), molded into the skew adjustment plate 66 , drive the skew adjustment plate 66 upward or downward, depending on the direction of rotation of the skew adjustment plug 76 . The skew adjustment plate 66 is capable of moving up and down relative to the left end cap 24 since the front vertical edge 534 and the rear vertical edge 536 (see FIG. 6A) of the skew adjustment plate 66 ride in complimentary channels 82 molded onto the interior surface of the left end cap 24 (FIG. 6 ). Since the cylindrical housing 64 of the skew adjustment plate 66 moves the axis of rotation of the roll bar 36 via the interaction between the cylindrical housing 64 , the roll-bar-end support wheel 86 , and the roll bar 36 , as the skew adjustment plate 66 is driven upward or downward by rotation of the skew adjustment plug 76 , the entire left end (as depicted in FIG. 3B) of the roll bar 36 moves upward or downward. It is thereby possible to position one end of the roll bar 36 relative to the other end of the roll bar 36 without having to move the end caps 24 , 26 , which may be fixed relative to a mounting surface by mounting brackets 30 (see FIG. 1 ). FIG. 25 provides a view of the skew adjustment plate 66 in position in the channels molded on the inward surface of the left end cap 24 . The skew adjustment plug 76 is pinched between the arcuate threaded surface 84 of the skew adjustment plate 66 and the plug bed 78 (FIG. 6A) of the left end cap 24 . The skew adjustment plug 76 is pinched with sufficient pressure that the skew adjustment plate 66 will not move due merely to the weight of the roll bar 36 and covering 12 , but the skew adjustment plug 76 is not pinched so hard that desired skew adjustment is difficult to achieve.
Although preferred embodiments of this invention have been described above, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. For example, each of the support wheels 86 , 152 could be made with more or fewer spokes or they could be made with no spokes to support the central barrels, whether threaded or unthreaded. Also, in the preferred embodiment, the threaded shaft 72 and the threaded barrel 154 in the internal-roll-bar support wheel 152 are left-hand threaded. If desired, a right-hand thread could be used, but the covering 12 may be required to roll on the roll bar 36 from the opposite side from that depicted in the enclosed drawings, or the control system components that make it possible to control the maximum retraction and maximum extension of the covering could be incorporated into the right-hand end of the head rail 22 . In the break away operating cord system depicted in the present application, a single clutch coil spring 172 is shown in FIG. 5B, but more than one clutch coil spring could be incorporated into this portion of the control system without deviating from the scope of the present invention. The applicant has obtained favorable results from using two clutch coil springs. Also, as depicted in the drawings and discussed above, the covering 12 comprises two flexible sheets 14 , 16 with a plurality of horizontal vanes 18 extending between them. Any type of roll up covering, however, could be used in conjunction with the control system components of the present invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. | A control and suspension system for a retractable covering mounted on a rotating element includes an apparatus for mechanically limiting over-extensions of the covering and an apparatus for mechanically limiting over-retractions of the covering. The apparatus for limiting over-retraction includes a threaded shaft and an internal, roll-bar-support wheel treaded on the threaded shaft. An intercepting ledge comprising part of the internal, roll-bar-support wheel, and a stopping ledge comprising part of the threaded shaft. Over retraction of the covering is prohibited when the intercepting ledge impacts the stopping ledge. The apparatus for limiting over-extension includes a roll-bar-end support wheel having a down limit stop pivotally mounted thereto. When the covering material is fully extended, the limit stop rotates away from the roll-bar-end support wheel and impacts a substantially annular channel wall associated with an end cap, thereby preventing further rotation of the roll bar and thus further extension of the covering. The control and suspension system also includes an apparatus to compensate for any undesirable skewing of the covering that might occur. The skew adjustment apparatus includes a skew adjustment plate that is slidably mounted in channels on an end cap. A threaded skew adjustment plug is threadingly engaged with the skew adjustment plate such that rotation of the skew adjustment plug moves the skew adjustment plate. Finally, the control and suspension system also includes a bottom rail that attaches to the bottom of the covering by trapping a portion of the covering between a compression plate and a bottom plate. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/832,074, filed Aug. 21, 2015, which claims priority to U.S. Provisional Application No. 62/040,182, filed Aug. 21, 2014. U.S. Application No. 14/832,074 is also a continuation-in-part of U.S. Application No. 14/292,881, filed May 31, 2014, now U.S. Pat. No. 9,140,005, issued Sep. 22, 2015, which claims priority to U.S. Provisional Application No. 61/830,257, filed Jun. 3, 2013. Each of the above patent applications is incorporated by reference herein in its entirety to provide continuity of disclosure.
TECHNICAL FIELD
[0002] The present invention relates generally to a corner bead for cementitious fireproofing of structural steel members and, more particularly, to a device that is self-aligning in installation and allows the accurate gauging of the thickness of the fireproofing material along three surfaces.
BACKGROUND OF THE INVENTION
[0003] In the art of a corner bead for fireproofing structural steel, prior approaches conventionally include a v-bend corner bead having adjustable legs (flanges). This type of corner bead is mostly used in the plastering and stucco trades. The previously utilized corner bead is constructed of wires welded into a lattice that is v-shaped in section as shown in FIG. 1 .
[0004] In installation, the longitudinal base wires of the v-shaped corner bead are attached with a tie wire either onto a metal lath or onto a wire mesh, and further attached to the steel member to be fireproofed as shown in FIG. 2 . At best, this allows for distribution of the fireproofing material along two surfaces after a complex negotiation of the correct height of the two flanges; to wit, to establish the correct fireproofing thickness, one must establish the correct height of the vertex by shrinking or expanding the distance between the legs (flanges) of the corner bead defined by the vertex. Using this technique, the alignment of the corner bead with the adjacent surface is difficult and great skill is required to install the corner bead for fireproofing structural steel.
[0005] The prior art includes many problems, including the difficulty of properly adjusting the traditional corner bead to the adjacent surface, the uneven application of fireproofing material, and the lack of a dam for the wet cement material. Despite these well-known and long-existing problems, and a readily apparent market for a solution, the prior art does not disclose or suggest a viable, cost-effective solution to the aforementioned problems of the prior art.
[0006] Accordingly, a need exists for an improved corner bead to avoid inaccuracy in gauging the thickness of the fireproofing material and to allow easy installation along three surfaces. An improved self-aligning double wire corner bead is inexpensive to manufacture and easy to install.
SUMMARY
[0007] The present invention provides a self-aligning, double wire corner bead that allows to make, in an accurate and quick manner, corners of a fireproofing material around structural steel members, said fireproofing material having uniform thickness around the structural steel member. This is accomplished by bending a single strip of welded wire fabric of pre-determined width along a plurality of longitudinally extending lines (axes) to provide a profile of a metal sheet having a plurality of dihedral angles, two wings of the desired width, a single wire membrane and a double wire membrane, said double wire membrane comprising a first leg and a second leg as substantially shown in FIGS. 4 and 5 .
[0008] The angle at which each wing meets the single wire membrane and a second leg of the double wire membrane of the device, respectively, determines the thickness of the fireproofing material distributed around the structural steel member along three surfaces. Further, said thickness may be modified by changing the width of each respective wing. The uniformity in thickness of the fireproofing material distributed around three surfaces of the structural steel member is achieved by bending the first wing and the second wing at approximately the same angle in relation to the single wire membrane and the second leg of the double wire membrane, respectively. The uniformity in thickness of the fireproofing material distributed around all surfaces of the structural steel member in a contour type application is achieved by using the same width of the single metal strip bent to create an identical single metal sheet profile for all corners of the structural steel member.
[0009] It is further an object of the present invention to provide an improved corner bead for fireproofing structural steel without the need of adjusting the legs.
[0010] Another object of the present invention is to provide novel means of installing the corner bead by easier attachment to the structural steel.
[0011] Another object of the present invention is to provide an improved technique for application of accurate thickness of fireproofing material along three surfaces under any construction condition for making said fireproofing of structural steel members.
[0012] A further object of the present invention is to provide a dam to form a roughened surface on the first application of fireproofing material until it hardens along three surfaces.
[0013] While satisfying these and other related objectives, the present invention provides an improved, self-aligning, double wire corner bead for fireproofing structural steel which is very competitive from a mere economic standpoint. The corner bead of the present invention consists of a single strip of welded wire fabric cut to a desired width for the fireproofing thickness and bent along a plurality of longitudinal axes to form a set of wings, a single wire membrane, and a double wire membrane, said double wire membrane having a first leg and a second leg, said first leg seamlessly becoming said second leg through a process of bending of said double wire membrane such that said first leg is substantially parallel to said second leg, and wherein said single wire membrane and said double wire membrane are attached by the attachment means to the lath distributed around the structural steel member.
[0014] In accordance with the present invention, the corner bead includes a single elongated strip of welded wire fabric of pre-determined width, said single strip of welded wire fabric comprising a set of flexible mesh strips as shown in FIG. 3 .
[0015] According to one embodiment of the present invention, the improved double wire corner bead allows each element of the bent wire mesh of the corner bead to perform different functions that are essential for the successful completion of the fireproofing process along three surfaces.
[0016] The single wire membrane and the double wire membrane provide a flat portion of a grid (mesh) through which pneumatic or screw type fasteners attach the mesh to the structural steel at the appropriate location. In addition, the double-wire membrane provides additional support for two wings positioned at the opposite corners of the steel structure member, hence facilitating one piece of wire mesh to cover two corners and three surfaces of the structure. This easy application establishes automatic alignment of the corner bead along three surfaces, eliminates the cumbersome process of shrinking or expanding the distance between the legs of the traditional bead, as well as provides only one strip of metal of the desired width to allow fireproofing of two corners of the steel structure member along three surfaces at the same time in a contour-method application of the fireproofing material.
[0017] The width of the set of wings and/or the angle at which the first and the second wing meet the single wire membrane and the second leg of the double wire membrane, respectively, determines the thickness of the fireproofing material distributed along three surfaces by providing a rigid screed edge along a nose. Therefore, the correct amount of fireproofing material is distributed adjacent to the corner bead creating a leveled application throughout the surface.
[0018] The width of the set of wings also provides a dam to form a roughened surface on the first application of the fireproofing material until the fireproofing material hardens. This forming action allows successive application of the cement material to the adjacent surface.
[0019] In another aspect, the present invention includes a method of manufacturing an improved self-aligning, double wire corner bead for fireproofing structural steel comprising a single strip of welded wire fabric cut to the desired width for the fireproofing thickness and bent along a plurality of longitudinally extending lines (axes) to form a profile of a metal sheet, a first longitudinal line to define a first wing and a single wire membrane extending laterally therefrom at a first angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other and wherein said single wire membrane is secured to a structural steel member and said first wing is configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the nose, a second longitudinal line to define said single wire membrane and a first leg of a double wire membrane extending from said single wire membrane in a continuous manner and at a second angle of approximately 90 degrees relative to each other, a third longitudinal line to define said first leg of said double wire membrane and a second leg of said double wire membrane such that said first leg is positioned substantially parallel to said second leg (the second leg substantially overlaps the first leg), and wherein said double wire membrane is secured to said structural steel member, and a fourth longitudinal line to define a second wing and said second leg of said double wire membrane, said second leg extending downwardly from said second wing at a third angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other, and wherein said third angle is substantially equal to said first angle.
[0020] In a further aspect, the present invention includes a method of finishing a set of corners for cementitious fireproofing in a contour application of a set of structural steel members, the method comprising the steps of: selecting a corner bead comprising a single strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent along a plurality of longitudinally extending lines, to provide a profile having a plurality of dihedral angles, wherein a first longitudinal line to define a first wing and a single wire membrane extending laterally therefrom at a first angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other and wherein, said single wire membrane is secured to a structural steel member and a first wing is configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the nose, a second longitudinal line to define said single wire membrane and a first leg of a double wire membrane extending from said single wire membrane in a continuous manner and at a second angle of approximately 90 degrees relative to each other, a third longitudinal line to define said first leg of said double wire membrane and a second leg of said double wire membrane such that said second leg is extending from said first leg of said double wire membrane in a continuous manner in such a way that said first leg is positioned substantially parallel to the second leg (the second leg substantially overlaps the first leg), and wherein said double wire membrane is secured to said structural steel member, and a fourth longitudinal line to define a second wing and said second leg of said double wire membrane, said second leg extending downwardly from said second wing at a third angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other, and wherein said third angle is substantially equal to said first angle.
[0021] A dihedral angle (also called a face angle) is the internal angle at which two adjacent faces of each section member of the double wire corner bead is delimited by the two inner faces, e.g., angle α 1 formed between adjacent faces of the first wing and the single wire membrane, angle α 2 formed between adjacent faces of the second wing and the second leg of the double wire membrane and angle β formed between adjacent faces of the single wire membrane and the first leg of the double wire membrane. The fourth angle created along the third longitudinal line between the first and the second leg of the double wire membrane is substantially zero (0) degrees so that the first leg and the second leg substantially overlap each other, and are approximately parallel, with respect to each other.
[0022] In another embodiment, the aim of the present invention is to provide a self-aligning corner bead which allows to make, in an accurate and quick manner, corners of the fireproofing material around structural steel members, said fireproofing material having uniform thickness around the structural steel. This aim is achieved owing to the fact that a strip of welded wire fabric having pre-determined width is bent along its longitudinal axis forming two wings of the desired width. The width of the second wing as well as the angle at which the two wings meet along the longitudinal axis determine the thickness of the fireproofing material strip disposed around the structural steel member along two surfaces. The uniformity in thickness of the fireproofing material distributed around the structural steel member is achieved by using the same width of the second wing bent at the same angle in relation to the first wing for all utilized corner beads, whether in a contour or a hollow-box type application.
[0023] It is further an object of the present invention to provide an improved corner bead for fireproofing structural steel without the need of adjusting the legs.
[0024] Another object of the present invention is to provide novel means of installation of the corner bead by easier attachment to the structural steel.
[0025] Another object of the present invention is to provide an improved technique for application of accurate thickness of fireproofing material along two surfaces under any construction condition for making said fireproofing of structural steel members.
[0026] A further object of the present invention is to provide a dam to form a roughened surface on the first application of fireproofing material until it hardens.
[0027] In satisfaction of these and related objectives, applicant's present invention provides an improved corner bead for fireproofing structural steel which is very competitive from a mere economic standpoint. The corner bead of the present invention consists of a strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent longitudinally to form an obtuse V-shaped device.
[0028] In accordance with the present invention, the corner bead includes an elongated strip of welded wire fabric of pre-determined width, said strip bent along its longitudinal axis to define a pair of laterally extending wings, said wings comprising a flexible mesh strip.
[0029] According to one embodiment of the present invention, the improved corner bead allows each wing of the corner bead to perform different functions that are essential for the successful completion of the fireproofing process along two surfaces.
[0030] The width of the first wing provides a flat portion of metal grid (mesh) through which pneumatic or screw type fasteners attach the mesh to the lath disposed over the structural steel at the appropriate location. This easy application establishes automatic alignment and eliminates the cumbersome process of shrinking or expanding the distance between the legs of the traditional bead.
[0031] The width of the second wing and/or the angle at which the first and the second wing meet determines the thickness of the fireproofing material along two surfaces. The location of the rigid screed edge along the plastic nosing allows the correct amount of material to be distributed alongside the corner bead creating a leveled application throughout the surface.
[0032] The width of the second wing also provides a dam to form a roughened surface on the first application of the fireproofing material until it hardens. This forming action allows successive application of the cement material to the adjacent surface.
[0033] In another aspect, the present invention resides in a method of manufacturing an improved corner bead for fireproofing structural steel comprising a strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent along the longitudinal axis to form an obtuse V-shaped device, said longitudinal axis to define a pair of wings extending laterally therefrom at an angle of approximately more than 90 disagrees but less than approximately 180 degrees relative to each other and, wherein said first wing is secured to a structural steel member through a lath, said lath disposed around the structural steel member to hold the fireproofing material to said structural steel member, and a second wing configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the plastic nosing.
[0034] In a further aspect, the present invention resides in a method of finishing the corners for cementitious fireproofing (whether in a hollow box or a contour application) of structural steel members, the method comprising: selecting a corner bead comprising a strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent along its longitudinal axis to form an obtuse V-shaped device, said longitudinal axis to define a pair of wings extending laterally therefrom at an angle of approximately more than 90 degrees but less than approximately 180 degrees relative to each other; said first wing attached by joining means (attachment means) for securing said corner bead's first wing to a lath or mesh previously attached to a structural steel member and a second wing configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the plastic nosing; attaching said first wing through said lath to the structural steel member; and applying successive layers of the fireproofing material to allow creation of the roughened cementitious surface, and tapering to the outward extending width of the second wing.
[0035] Applicant's approach to the problem described above is certainly simple, but it is equally unobvious. With over twenty years of experience in the field of fireproofing services, applicant is well educated on the challenges involved such as the difficulty of properly adjusting the traditional corner bead to the adjacent surface, the uneven application of fireproofing material, and the lack of dam for the wet cement material. Despite these well-known and long-existing problems, and a readily apparent market for a solution, no one has presented a viable, cost-effective solution such as applicant here provides.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a perspective view of a small section of a corner bead according to the prior art.
[0037] FIG. 2 is a cross-sectional schematic view of a fireproofing structure utilizing a prior art corner bead installed according to a contour method.
[0038] FIG. 3 is a perspective view of an exemplary small section of the corner bead of the present invention bent along a longitudinal axis and manufactured according to an embodiment of the present invention.
[0039] FIG. 4 is an enlarged cross-sectional schematic view of the self-aligning, double wire corner bead of the present invention.
[0040] FIG. 5 is a cross-sectional schematic view of a fireproofing structure utilizing a self-aligning, double wire corner bead of the present invention according to the contour method.
[0041] FIG. 6 is a perspective view of a small section of the corner bead manufactured according to one of the embodiments of the present invention.
[0042] FIG. 7 is a cross-sectional schematic view of the fireproofing structure utilizing a corner bead of the present invention according to the hollow-box method.
[0043] FIG. 8 is a cross-sectional schematic view of the fireproofing structure utilizing a corner bead of the present invention according to the contour method.
DETAILED DESCRIPTION
[0044] Referring to FIG. 3 , corner bead 10 includes a plurality of longitudinal ribs 16 arranged substantially parallel with respect to a plurality of longitudinal axes, including longitudinal axis A and to each other, and a plurality of transverse ribs 18 distributed between and extending substantially perpendicular to the plurality of longitudinal axes and the plurality of longitudinal ribs 16 . A set of void areas 20 is defined by the plurality of longitudinal ribs 16 and the plurality of transverse ribs 18 , such that each void area 20 is bounded by at least two longitudinal ribs 16 and at least two transverse ribs 18 . A section of corner bead 10 includes a single strip of welded wire fabric cut to a predetermined length L and a predetermined width W. The predetermined length L and the predetermined width W correspond to a predetermined fireproofing thickness.
[0045] In a preferred embodiment, corner bead 10 is made of a suitable metal, such as 16 gauge wire. Other suitable materials known in the art may be employed, including suitable plastics. In a preferred embodiment, corner bead 10 is a double welded wire fabric.
[0046] In a preferred embodiment, corner bead 10 has a set of bends integrally formed in corner bead 10 along the plurality of longitudinal axes. Any number of bends may be employed. Longitudinal axis A defines first wing 12 and single wire membrane 11 . First wing 12 and single wire membrane 11 form angle α 1 of approximately greater than 90 degrees, but less than approximately 180 degrees as further illustrated in FIGS. 4 and 5 . A set of edges of first wing 12 defines a substrate to which nose 14 is attached. Nose 14 , first wing 12 , and second wing 12 ′ (shown in FIG. 5 ) provide a rigid edge having a dam-like function, as will be further described below.
[0047] In a preferred embodiment, nose 14 is made of a suitable plastic, such as polyvinyl chloride. Other suitable materials known in the art may be employed.
[0048] Referring to FIG. 4 , corner bead 10 is bent along a plurality of longitudinal lines 41 , 42 , 43 , and 44 , to provide a substantially continuous profile having a plurality of dihedral angles. Longitudinal line 44 defines first wing 12 and single wire membrane 11 extending laterally therefrom at angle α 1 . Angle α 1 is approximately greater than 90 degrees, but less than approximately 180 degrees. Each of noses 14 is attached to first wing 12 and second wing 12 ′. Longitudinal line 42 defines single wire membrane 11 and leg 31 of double wire membrane 30 extending from single wire membrane 11 in a continuous manner. Single wire membrane 11 and leg 31 are separated by angle β. Angle β is approximately 90 degrees. Longitudinal line 43 defines leg 31 of double wire membrane 30 and leg 31 ′ of double wire membrane 30 . Leg 31 ′ is positioned substantially parallel to leg 31 . Leg 31 ′ substantially overlaps leg 31 . Longitudinal line 41 defines second wing 12 ′ and leg 31 ′ of double wire membrane 30 . Leg 31 ′ extends away from second wing 12 ′ at angle α 2 . Angle α 2 is approximately greater than 90 degrees, but less than approximately 180 degrees.
[0049] In use, the improved, self-aligning, double wire corner bead 10 of the present disclosure is utilized in a contour-like manner, surrounding a structural steel member with fireproofing material. Referring to FIG. 5 , double wire corner bead 10 is secured to structural steel member 24 . First wing 12 is configured to establish a desired thickness of fireproofing material 22 along two surfaces of the structural steel member by providing a rigid screed edge to which nose 14 is attached. Double wire membrane 30 is secured to structural steel member 24 , as will be further described below. Fireproofing material 22 surrounds the dimensions of the structural steel member 24 in a contour-like manner, tracing structural steel member 24 in all dimensions. The single strip of corner bead 10 allows uniform distribution of fireproofing material 22 along three surfaces, surfaces S 1 , S 2 , and S 3 .
[0050] Referring to FIGS. 4 and 5 , the width of the wings 12 and 12 ′ determines distances D 1 , D 2 , and D 3 , and defines generally planar surfaces S 1 , S 2 , and S 3 forming a set of corners of fireproofing material 22 distributed around structural steel member 24 . Similarly, any of distances D 1 , D 2 , and D 3 are optionally altered by changing angles a 1 and a 2 . Angles a 1 and a 2 are substantially equal and measure approximately greater than 90 degrees, but less than 180 degrees. Angle β measures approximately 90 degrees. For example, the smaller (less obtuse) angle α 1 is between first wing 12 and the single wire membrane 11 the longer distance D 1 is between lath 26 and surface S 1 , and the shorter distance D 3 is between lath 26 and surface S 2 . Similarly, the less obtuse angle α 2 is between second wing 12 ′ and leg 31 ′ of double wire membrane 30 , the longer distance D 2 is and the shorter distance D 1 is making distributed fireproofing material 22 thicker along surface S 3 in relation to a thinner strip of fireproofing material 22 along surface S 1 .
[0051] In a preferred embodiment, the determination of angles α 1 and α 2 should be such that a uniform thickness of fireproofing material 22 along surface S 1 is achieved.
[0052] In one embodiment, lath 26 is distributed around structural steel member 24 . Single wire membrane 11 is attached through lath 26 into structural steel member 24 by pneumatic fastener 28 at a single fastening position on single wire membrane 11 . Other joining or attaching means known in the art, such as welded pins or screws, may be employed.
[0053] In another embodiment, each of single wire membrane 11 and double wire membrane 30 is attached to structural steel member 24 by pneumatic fastener 28 at a single fastening position on double wire membrane 30 .
[0054] In another embodiment, leg 31 and leg 31 ′ of double wire membrane 30 are attached through lath 26 into structural steel member 24 by pneumatic fastener 28 at a single fastening position on double wire membrane 30 . Other joining or attaching means known in the art, such as welded pins or screws, may be employed. According to one embodiment of the present invention, lath 26 is optionally distributed along the entire perimeter of structural steel member 24 to be fireproofed (not shown). In another embodiment, lath 26 is distributed along a portion of the perimeter of structural steel member 24 .
[0055] In other embodiments, any number of fastening positions and locations may be employed.
[0056] The width of first wing 12 and second wing 12 ′ along with nose 14 attached to the outer edges of both wings serves as a dam during the process of fireproofing. Fireproofing material 22 is then sprayed onto lath 26 and screened off using the location of nose 14 to determine the finished thickness of fireproofing material 22 .
[0057] Referring to FIG. 5 , in a shop application, i.e., fireproofing material 22 is applied to structural steel member 24 in a pre-fabrication facility, the cementitious composition is sprayed or poured one layer at a time on a surface of lath 26 positioned horizontally. Structural steel member 24 is then rotated 90 degrees and the adjacent surfaces are positioned horizontally to allow easy application of fireproofing material 22 . With this process in place, each successive spraying is performed which allows hardening of fireproofing material 22 before the next rotation of structural steel member 24 . As can be seen, the dam-like functionality of corner bead 10 according to one embodiment of the present invention is critical as it provides an appropriate keying surface to bond the subsequent layers of fireproofing material 22 . Each structural steel member 24 is turned to uniformly apply the cementitious material to all surfaces.
[0058] It will be appreciated by those skilled in the art that any type of member may be employed.
[0059] In a field application on a job site, structural steel members 24 are erected into a structure prior to fireproofing, and all surfaces of structural steel member 24 may be sprayed or troweled onto the surface of lath 26 at the same time (not shown).
[0060] Referring to FIG. 6 in another embodiment, a corner bead structure comprising a strip of welded wire fabric 610 cut to the appropriate length L 2 and width ω for the fireproofing thickness and bent longitudinally to form a structure having a longitudinal axis A 2 , said longitudinal axis to define a first wing 611 and a second wing 612 , said first wing 611 and said second wing 612 forming an angle θ of approximately more than 90 degrees but less than approximately 180 degrees. The second wing's outer edge comprises a substrate forming a nose 614 , said nose 614 together with the second wing 612 providing a rigid edge of dam-like functionality.
[0061] As further shown in FIG. 6 , the corner bead structure (typically 16 gauge welded wires) comprises a plurality of longitudinal metal ribs 616 arranged in substantially parallel fashion to the longitudinal axis A 2 and to each other and the plurality of transverse metal ribs 618 disposed between and extending substantially perpendicular to the longitudinal axis A 2 and the longitudinal metal ribs 616 . A plurality of void areas 620 of the approximate size 0.5″×0.5″ are disposed between the longitudinal ribs 616 and the transverse ribs 618 , such that each said void area 620 is bounded by at least two longitudinal ribs 616 and at least two transverse ribs 618 .
[0062] In general, two methods of enveloping the structural steel member with the fireproofing material may be utilized. As shown in FIG. 7 , the cementitious fireproofing material 622 surrounds the dimensions of the structural steel in a hollow-box manner, leaving empty void areas 624 between the structural steel member 626 .
[0063] As shown in FIG. 8 , the cementitious fireproofing material 622 surrounds the dimensions of the structural steel member 626 in a contour-like manner, tracing the structural steel member 626 in all its dimensions.
[0064] As can be seen most clearly in FIGS. 7 and 8 , the second width W 2 of a second wing 612 determines the distances (D 1 ′ and D 2 ′) between the lath 628 disposed over the structural steel member 626 and the two planar surfaces, S 1 ′ and S 2 ′ forming a corner of the fireproofing material 622 disposed around the structural steel member 626 . Similarly, the distances, D 1 ′ and D 2 ′, may be altered by changing an angle θ at which the strip of the welded material with pre-determined width ω is bent along its longitudinal axis A 2 . For example, the smaller (less obtuse) the angle θ between the first wing 611 and the second wing 612 , the longer is the distance D 1 ′ between the lath 628 and the surface S 1 ′, and the shorter is the distance D 2 ′ between the lath 628 and the surface S 2 ′. Consequently, such change in the angle causes the strip of the fireproofing material 622 to be thicker along surface S 1 ′ in relation to the thickness of the fireproofing strip 622 along surface S 2 ′.
[0065] In a further development of the subject matter described with reference to FIGS. 6, 7, and 8 , the first wing 611 is attached through the lath 628 into the structural steel member by the pneumatic fastener 630 . Other contemplated joining (attaching) means are welded pins or screws. The second wing 612 along with the plastic nose 614 attached to the outer edge of the second wing 612 serves as a dam during the process of fireproofing. The fireproofing material is then sprayed onto the lath 628 and screeded off using the plastic nose's 614 location to determine the finished thickness of the fireproofing material.
[0066] In a shop application (i.e., fireproofing is applied in a facility of the applicant to individual steel members), the cementitious composition is sprayed or poured one at a time on one horizontal surface 632 of lath 628 as shown in FIG. 7 . The steel member 626 is then rotated 90 degrees and the adjacent surfaces become horizontal to allow easy application of the fireproofing material. With this process in place, each successive spraying is performed which allows hardening of the fireproofing material before the next rotation of the steel member. This is why the dam-like functionality of the corner bead according to one embodiment of the present invention is critical as it provides an appropriate keying surface to bond the subsequent layers of the fireproofing material. Each steel member is turned four times to uniformly apply the cementitious material to all surfaces.
[0067] In a field application (outside of applicant's facility), where the members are erected into a structure prior to fireproofing, all surfaces of the steel member may be sprayed or troweled onto the lath surfaces at the same time (not shown). The process is similar regardless of whether the contour or hollow-box application is utilized.
[0068] It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims, as interpreted in accordance with principles of prevailing law, including the doctrine of equivalents or any other principle that enlarges the enforceable scope of a claim beyond its literal scope. Unless the context indicates otherwise, a reference in a claim to the number of instances of an element, be it a reference to one instance or greater than one instance, requires at least the stated number of instances of the element, but is not intended to exclude from the scope of the claim a structure or method having more instances of that element than stated. The word “comprise” or a derivative thereof, when used in a claim, is used in a nonexclusive sense that is not intended to exclude the presence of other elements or steps in acclaimed structure or method. | A self-aligning corner bead for fireproofing structural steel, having a strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent longitudinally to form an obtuse V-shaped device is disclosed. A plastic nosing is installed along one edge. A method of finishing the corners for fireproofing of structural steel member using an improved corner bead includes the step of attaching the first wing of an obtuse V-shaped device through a lathe to the structural steel member utilizing pneumatic or screw type fasteners. The mesh structure of the second wing of the V-shaped device provides a dam to form a roughened surface on the first application of fireproofing material until it hardens. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/881,277 filed Apr. 24, 2013, which is a U.S. National Phase application of International Application No. PCT/GB2011/052084 filed Oct. 26, 2011, which claims the benefit of and priority to UK Patent Application No. 1018074.3 filed Oct. 26, 2010. The entire disclosures of U.S. application Ser. No. 13/881,277, International Application No. PCT/GB2011/052084, and UK Patent Application No. 1018074.3 are incorporated by reference herein.
BACKGROUND
This invention concerns improvements in and relating to fluid delivery devices including but not limited to taps. More especially the invention concerns a system and method for the installation of taps that allows the installation to be carried out from above a mounting surface on, for example a sink, washbasin, bidet, bath or the like.
When installing a tap, the incoming hot and cold water supplies must be isolated either centrally by closing off a stop-cock for the incoming water supply to the property or by closing isolating valves fitted either locally to a specific tap or to a group of taps. The tap is located on the mounting surface and an externally threaded shank extends through an opening in the mounting surface onto which a nut and washer is screwed to engage the underside of the mounting surface to locate and retain the tap in position. This is usually achieved by holding the tap in the correct orientation in one hand above the mounting surface and manually screwing the nut and washer onto the shank with the other hand from below the mounting surface with the other hand. The nut can be tightened with a spanner from below the mounting surface to firmly secure the tap in position. A supply pipe is then screwed onto the shank from under the mounting surface to connect the tap to a supply of hot or cold water. Mixer taps require separate connections to supplies of hot and cold water.
A disadvantage of the above method is that access to the underside of the mounting surface is often restricted. As a result, it can be difficult both to tighten the nut and washer so that the tap is firmly secured in position and to connect the supply pipe(s) to the tap in a fluid tight manner during installation. Furthermore, it can be difficult to rectify any leakage that occurs from the connection(s) following installation.
The present invention has been made from a consideration of the foregoing and seeks to overcome or at least mitigate one or more of the aforementioned problems and disadvantages of the prior art.
SUMMARY
According to one aspect of the invention there is provided a fluid delivery device for connection to a fluid supply through an aperture in a mounting surface, and a clamping assembly for securing the fluid delivery device to the mounting surface, the clamping assembly including retainer means adapted, in use, to pass through the aperture in a collapsed position and to move to an operative position after passing through the aperture, the retainer means being operable on tightening the clamping assembly from above the mounting surface to engage an underside of the mounting surface remote from the fluid delivery device and to engage a sidewall of the aperture.
By this invention, the clamping assembly can be fitted from above the mounting surface so that access to the underside of the mounting surface may not be required. The engagement of the retainer means with the underside of the mounting surface and with the sidewall of the aperture provides feedback to the installer of the clamping force while the clamping assembly is tightened. For example, the retainer means may engage the sidewall of the aperture after engaging the underside of the mounting surface so as to produce a step change in the force required to tighten the clamping assembly that provides feedback to the installer that the necessary clamping force has been achieved. In this way, the risk of overtightening the clamping assembly and causing damage to the mounting surface may be reduced.
In one preferred embodiment, the retainer means includes a pair of clamping arms. In other embodiments, the retainer means may comprise more than two clamping arms. The number and arrangement of clamping arms may be chosen according to requirements, for example the available space for installation, the type of fluid delivery device and fluid connections. The clamping arms may be disposed symmetrically with respect to the aperture so that the clamping force is distributed uniformly and evenly around the aperture.
Preferably, each clamping arm is connected to a clamping plate so as to pass through the aperture with the clamping plate from the topside of the mounting surface.
In one arrangement, each clamping arm is connected to the clamping plate for pivotal movement from the collapsed position to the operative position. In another arrangement, at least one clamping arm is fixed to the clamping plate in the operative position and at least one clamping arm is connected to the clamping plate for pivotal movement from the collapsed position to the operative position. Each pivotal clamping arm may move to the operative position under gravity. Alternatively or additionally a spring or other biasing member may be employed. In this way, each pivotal clamping arm automatically adopts the operative position after passing through the aperture.
Preferably, fastening means is provided to move the clamping plate towards the underside of the mounting surface to engage each clamping arm with the underside of the mounting surface.
Preferably, the fastening means includes an actuator such as a bolt threadably coupled to the clamping plate such that the clamping plate can move lengthwise of the bolt in response to rotation of the bolt. For example, the clamping plate may be prevented from rotating relative to the threadably coupled bolt so as to move towards the underside of the mounting surface as the bolt is rotated in one direction and to move away from the mounting surface as the bolt is rotated in the opposite direction.
Preferably, the bolt extends through the aperture and is rotatable to operate the retainer means from the topside of the mounting surface.
Preferably, each clamping arm is configured to provide feedback to the installer of the clamping force while the bolt is rotated. For example, each clamping arm may have a first portion that is engageable with the underside of the mounting surface and a second portion that is engageable with the sidewall of the aperture. The second portion may engage after the first portion so as to produce a step change in the force required to rotate the bolt that provides feedback to the installer that the necessary clamping force has been achieved. In this way, the risk of overtightening the clamping assembly and causing damage to the article providing the mounting surface, for example a basin or bath or sink, is reduced.
Preferably, at least one clamping arm, more preferably each clamping arm, is configured to grip the underside of the mounting surface and/or the sidewall of the aperture when the bolt is rotated so as to create locking forces that resist rotation of the clamping assembly. For example, one or more clamping arms may be provided with formations such as serrations or knurling that contact and grip the underside of the mounting surface and/or the sidewall of the aperture.
Alternatively or additionally, one or more clamping arms may be provided with a high friction material such as rubber, abrasive paper such as emery paper or other suitable elastomeric or polymeric material that contacts and grips the underside of the mounting surface and/or the sidewall of the aperture. The high friction material may be overmoulded on the clamping arm(s). The formations and/or high friction material can help to secure the fluid delivery device in a desired position and prevent the fluid delivery device rotating after installation. This may be of particular benefit where the mounting surface for the fluid delivery device is a ceramic or glass surface.
Preferably, the fluid delivery device includes a mounting element connectable to the fluid supply and a body element detachably connected to the mounting element.
Preferably, the mounting element is coupled to the clamping plate by the fastening means and is secured to the mounting surface when the fastening means is actuated to cause the clamping arms to engage the underside of the mounting surface as described previously.
Preferably, a more secure fixing of the fluid delivery device is provided by preventing or inhibiting relative rotation between the body element and each clamping arm. In one arrangement, relative rotation is prevented by each clamping arm co-operating with the mounting element. In another arrangement, relative rotation is prevented by each clamping arm co-operating with the body element. In either arrangement each clamping arm is preferably guided for axial movement relative to the mounting element or body element and is constrained from rotating relative to the mounting element or body element. For example, each clamping arm may be received in an axial keyway that allows the clamping arm to slide up and down without rotating.
The body element may comprise flow control means such as a tap or mixer housing a mechanism for controlling flow of water. The mounting element may comprise a fluid manifold base that is substantially concealed by the body element.
Preferably, the manifold base has an inlet connectable to the fluid supply and an outlet connectable to the body element.
Preferably, the mounting element includes an isolator valve assembly to isolate the fluid supply when the body element is detached from the mounting element.
Preferably, the isolator valve assembly is operable in response to attaching and detaching the body element.
Preferably, the body element is releasably attached to the mounting element by interengageable formations.
Preferably, the interengageable formations are engaged and disengaged by axial and rotational movement of the body element relative to the mounting element.
Preferably, the interengageable formations comprise a bayonet type connection.
Preferably the isolator valve assembly has an open position to connect the fluid supply to the body element when the body element is mounted on the mounting element and a closed position to isolate the fluid supply when the body element is removed from the mounting element.
Preferably, the isolator valve assembly moves between the open and closed positions in response to rotational movement of the body element relative to the mounting element.
Alternatively, the isolator valve assembly moves between the open and closed positions in response to axial movement of the body element relative to the mounting element.
According to another aspect of the invention there is provided a method of attaching a fluid delivery device to a mounting surface having a topside and an underside, the method comprising the steps of connecting the fluid delivery device to a water supply through an aperture in the mounting surface, providing a clamping assembly for securing the fluid delivery device to the mounting surface, positioning the fluid delivery surface on the topside of the mounting surface and passing retainer means of the clamping assembly through the aperture in a collapsed position to position the retainer means below the mounting surface whereupon the retainer means moves to an operative position, and operating the clamping assembly from the topside of the mounting surface to engage the retainer means with the underside of the mounting surface and with a sidewall of the aperture to secure and retain the fluid delivery device on the topside of the mounting surface.
Preferably, the clamping assembly is operable by rotating an actuator that extends through the aperture in the mounting surface.
Preferably, rotation of the actuator in one direction fastens the clamping assembly and rotation in the opposite direction unfastens the clamping assembly.
Preferably, the retainer means includes two or more clamping arms connected to a clamping plate and at least one clamping arm, more preferably each clamping arm, is pivotal between the collapsed position and the operative position for passage of the retainer means through the aperture in the collapsed position.
Preferably, the actuator comprises a rotatable member such as a bolt that threadably engages the clamping plate.
With this arrangement, each pivotal clamping arm can move to the operative position after passing through the aperture, for example under gravity or the action of a biasing member such as a spring, and the clamping plate is movable lengthwise of the rotatable member in response to rotation thereof to move the clamping arms towards the underside of the mounting surface.
Preferably, the clamping arms engage the underside of the mounting surface in a first stage of operation and engage the sidewall of the aperture in a second stage of operation. The sidewall acts as stop to limit movement of the clamping arms and results in an increase in force required to rotate the rotatable member that provides feedback to the installer of the required clamping force to prevent overtightening of the clamping assembly.
Preferably, at least one clamping arm, more preferably each clamping arm, is adapted to resist relative rotation between the clamping arm and the mounting surface. For example, the or each clamping arm may be provided with formations such as serrations or knurling and/or with a high friction material such as rubber to enhance the grip when tightening the clamping assembly.
According to another aspect of the invention there is provided apparatus for connecting a fluid supply to a fluid delivery device, the apparatus including a connector for connection to a fluid supply and a clamping assembly for securing the connector to a mounting surface, the clamping assembly including retainer means adapted, in use, to pass through an aperture in the mounting surface in a collapsed position and to move to an operative position after passing through the aperture, the retainer means being operable on tightening the clamping assembly from above the mounting surface to engage an underside of the mounting surface remote from the connector and to engage a sidewall of the aperture to secure the connector to the mounting surface.
The connector may be connectable to individual supplies of hot and/or cold water and/or to a combined supply of hot and cold water. The connector is preferably secured on the upper surface or top side of the mounting surface and is adapted for attaching a fluid delivery device such as a tap or mixer.
The clamping assembly may be as described in connection with the previous aspects of the invention.
According to a further aspect of the invention there is provided a fluid delivery device for connection to a fluid supply through an aperture in a mounting surface, and a clamping assembly for securing the fluid delivery device to the mounting surface, the clamping assembly being adapted, in use, to pass through the aperture in a collapsed position and to move to an operative position after passing through the aperture for engagement with an underside of the mounting surface remote from the fluid delivery device.
Preferably, the clamping assembly is arranged to produce a step change in an operating force required to tighten the clamping assembly that provides feedback to an installer that a required clamping force has been achieved. In this way, the risk of overtightening the clamping assembly and causing damage to the article providing the mounting surface, for example a basin or bath or sink, is reduced.
The clamping assembly may be as described in connection with previous aspects of the invention. The clamping assembly may move to the operative position under gravity.
According to another aspect of the invention there is provided a method of attaching a fluid delivery device to a mounting surface having a topside and an underside, the method comprising the steps of connecting the fluid delivery device to a water supply through an aperture in the mounting surface, providing a clamping assembly for securing the fluid delivery device to the mounting surface, positioning the fluid delivery surface on the topside of the mounting surface and passing the clamping assembly through the aperture in a collapsed position to position the clamping assembly below the mounting surface whereupon the clamping assembly moves to an operative position, and operating the clamping assembly from the topside of the mounting surface to engage the underside of the mounting surface to secure and retain the fluid delivery device on the topside of the mounting surface.
Preferably, the clamping assembly is arranged to produce a step change in an operating force required to tighten the clamping assembly that provides feedback to an installer that a required clamping force has been achieved. In this way, the risk of overtightening the clamping assembly and causing damage to the article providing the mounting surface, for example a basin or bath or sink, is reduced.
The clamping assembly employed may be as described in connection with previous aspects of the invention. The clamping assembly may move to the operative position under gravity.
According to another aspect of the invention there is provided a fluid delivery device comprising a mounting element for connection to a fluid supply and body element mounted on the mounting element for controlling discharge of fluid from the device, the body element being detachable from the mounting element without disconnecting the mounting element from the fluid supply, and the mounting element including an isolator valve assembly having an open position to connect the fluid supply to the body element when the body element is mounted on the mounting element and a closed position to isolate the fluid supply when the body element is removed from the mounting element, wherein the isolator valve assembly moves between the open and closed positions as the body element is attached to and detached from the mounting element.
Preferably, the body element is a push fit on the mounting element and is secured by rotating the body element relative to the mounting element.
Preferably, the body element is rotatable between a release position that allows the body element to be pushed on and lifted off the mounting element and a retained position that prevents the body element being lifted off the mounting element.
Preferably, the isolator valve assembly is opened and closed according to the direction of rotation of the body element at a position between the release position and retained position.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail by way of example only with reference to the accompanying drawings wherein:
FIG. 1 is an exploded view of a tap assembly according to a first embodiment of the invention;
FIG. 2 is a vertical section showing the manifold base and tap body in the normal operating position;
FIG. 3 is a vertical section showing the manifold base and tap body in the isolated position;
FIG. 4 is a vertical section showing the tap body detached from the manifold base;
FIG. 5 is a horizontal section showing the manifold base and tap body in the normal operating position;
FIG. 6 is a horizontal section showing the manifold base and tap body in the isolated position;
FIG. 7 is a horizontal section showing the manifold base and tap body in the tap release position;
FIG. 8 is a vertical section showing installation of the manifold base;
FIG. 9 is a vertical section showing the manifold base installed;
FIG. 10 is a perspective view of a tap assembly according to a second embodiment of the invention partially assembled; and
FIG. 11 is a perspective view of a tap assembly according to a third embodiment of the invention partially assembled.
DETAILED DESCRIPTION
Referring to FIGS. 1 to 9 of the drawings, a tap assembly 1 has a body element 3 detachably connected to a mounting element 5 connected to a pair of supply pipes 7 , 9 for hot and cold water. In this embodiment the body element 3 is a tap body provided with a flow control and/or mixing mechanism for the hot and cold water and the mounting element 5 is a fluid manifold base for delivering hot and cold water from the supply pipes 7 , 9 to the tap body.
The supply pipes 7 , 9 extend through an aperture 11 in a mounting surface 13 and engage inlets 15 , 17 in the underside of the manifold base 5 . The supply pipes 7 , 9 and inlets 15 , 17 may have mating screw threads to secure releasably the supply pipes 7 , 9 to the manifold base 5 . The supply pipes 7 , 9 may be provided with seals such as O-rings (not shown) mounted in grooves 19 , 21 co-operable with the inlets 15 , 17 to provide a watertight seal. Any other means of securing and sealing the supply pipes 7 , 9 may be employed. The mounting surface 13 may be a sink, washbasin, bidet, bath or any other suitable surface for mounting the tap assembly, for example a worktop. The mounting surface 13 may comprise a ceramic, glass, wood (including wood substitutes or composites) or any other suitable material for mounting the tap assembly 1 .
The manifold base 5 is seated on the topside of the mounting surface 13 and is releasably secured to the mounting surface 13 by a clamping assembly including retainer means for passage through the aperture 11 from the topside of the mounting surface 13 and operable on tightening the clamping assembly from the topside of the mounting assembly to secure the manifold base 5 to the mounting surface. As shown, the retainer means includes a clamping plate 23 and a pair of clamping arms 25 , 27 . The clamping plate 23 is located between the supply pipes 7 , 9 and the clamping arms 25 , 27 are pivotally connected to opposite ends of the clamping plate 23 . The clamping plate 23 has a central aperture 29 provided with a screw thread (not shown) that is engaged by a screw thread (not shown) on the lower end of a bolt 31 that extends through the manifold base 5 . The bolt 31 has a head 33 provided with a socket 35 for receiving a tool (not shown) to rotate the bolt 31 .
To secure the manifold base 5 to the mounting surface 13 , the supply pipes 7 , 9 are attached to the inlets 15 , 17 in the underside of the manifold base 5 . The clamping arms 25 , 27 are pivoted upwards to extend in the direction of the length of the bolt 31 to a closed or collapsed inoperative position in which the free ends of arms 25 , 27 are adjacent the bolt 31 and the manifold base 5 is then lowered towards the mounting surface 13 to pass the clamping plate 23 and clamping arms 25 , 27 through the aperture 11 in the mounting surface 13 in the direction of arrow A as shown in FIG. 8 .
When the clamping arms 25 , 27 clear the aperture 11 on the underside of the mounting surface, they pivot outwards under gravity in the direction of arrow B as shown in FIG. 9 to an open or extended operative position in which the free ends are spaced away from the bolt 31 and lugs 25 a , 27 a engage the mounting plate 23 to prevent further pivotal movement of the arms 25 , 27 . The clamping arms 25 , 27 are preferably configured so as to pivot to the operative position automatically on clearing the aperture 11 on the underside of the mounting surface 13 . For example, the shape and/or mass of the clamping arms 25 , 27 may be arranged so that the clamping arms 25 , 27 will adopt the operative position under gravity in the absence of a restraining force to retain the clamping arms 25 , 27 in the inoperative position. In a modification (not shown) the clamping arms may be urged towards the operative position by a biasing member such as a spring and movable to the collapsed position against the biasing force for passage through the aperture.
The free ends of the clamping arms 25 , 27 are provided with angle section formations 37 , 39 having faces 37 a , 37 b and 39 a , 39 b that extend normal to one another. In the open position, the faces 37 a , 39 a extend generally parallel to the underside of the mounting surface and the faces 37 b , 39 b extend generally normal to the underside of the mounting surface. The underside of the manifold base 5 is stepped to locate within the aperture 11 in the mounting surface 13 and a seal such as an O-ring (not shown) may be mounted in a groove 41 in the underside of the manifold base 5 to provide a watertight seal between the manifold base 5 and the mounting surface 13 around the aperture 11 .
The bolt 31 is then rotated to tighten the clamping assembly by inserting a tool (not shown) in the socket 35 . As the bolt 31 is rotated, the clamping plate 23 is prevented from rotating by the water supply pipes 7 , 9 with the result that the clamping plate 23 is lifted upwards in the direction of arrow C as shown in FIG. 9 towards the underside of the mounting surface 13 causing the clamping arms 25 , 27 to rise upwards until the faces 37 a , 39 a contact the underside of the mounting surface at the edge of the aperture 11 .
Further rotation of the bolt 31 to tighten the clamping assembly takes up any slack and a small sliding action of the clamping arms 25 , 27 occurs radially until the faces 37 b , 39 b contact the inner sidewall 11 a of the aperture 11 in the mounting surface 13 . The contact between the faces 37 a , 39 a and the underside of the mounting surface 13 and between the faces 37 b , 39 b and the inner sidewall of the aperture produces friction to prevent rotation of the manifold base 5 relative to the mounting surface 13 . Furthermore, contact between the faces 37 b , 39 b with the inner side wall 11 a of the aperture 11 locks the arms 25 , 27 and provides feedback to the user that the bolt 31 is sufficiently tight to secure the manifold base 5 in position. In this way, excessive tightening of the clamping assembly can be avoided. Controlling the clamping force may of particular benefit where the tap assembly 1 is secured to a surface that may be damaged by overtightening the clamping assembly, for example a ceramic or glass surface.
The grip to secure the manifold base 5 and resist relative rotation between the manifold base 5 and the mounting surface may be enhanced by appropriate design of the clamping arms 25 , 27 . For example, the contact faces 37 a , 39 a and/or the contact faces 37 b , 39 b may be formed or provided with a high friction material (not shown) to increase the grip. Where provided, the high friction material may be made of rubber or other suitable elastomeric or polymeric material or abrasive paper such as emery to increase friction. The high friction material may be overmoulded on the angle section formations 37 , 39 . Alternatively or additionally, where provided, the contact faces 37 a , 39 a and/or the contact faces 37 b , 39 b may be formed or provided with formations such as teeth, serrations or knurls (not shown) to increase the grip. The formations may be configured to penetrate the underside of the mounting surface 13 and/or the inner side wall of the aperture 11 to provide an interlock. The formations may be formed or provided in high friction material. Increasing the grip may be of particular benefit where the tap assembly 1 is secured to a ceramic or glass surface to prevent rotation of the tap assembly 1 after installation.
When the manifold base 5 is secured in position, the tap body 3 is lowered onto the manifold base 5 and secured by any suitable means. For example, a bayonet connection may be provided between the tap body 3 and manifold base 5 to secure releasably the tap body 3 to the manifold base 5 by a combination of axial and rotational movement of the tap body 3 relative to the manifold base 5 .
In this embodiment, a bayonet connection is provided by interengageable formations such as a lug 43 on the manifold base 5 that co-operates with a groove 45 in the inner surface of the tap body 3 . The groove 45 has a first section 45 a that extends in the axial direction from the end face of the tap body 3 to a second section 45 b that extends in the circumferential direction around the tap body 3 .
When connecting the tap body 3 to the manifold base 5 , the tap body 3 is positioned to align the first section 45 a with the lug 43 so that the lug 43 enters the first section 45 a as the tap body 3 is lowered onto the manifold base 5 . The lug 43 and groove 45 are configured so that the lug 43 aligns with the second section 45 b when the end face of the tap body 3 seats on the mounting surface 13 to cover and conceal the manifold base 5 . The tap body 3 is then rotated so that the lug 43 enters the second section 45 b to prevent the tap body 3 being lifted off the manifold base 5 . In this embodiment, the tap body 3 can be rotated through approximately 90 degrees until the lug 43 engages the end of the groove 45 . The groove 45 may be configured to provide any desired range of axial and/or rotational movement to engage the lug 43 to locate and retain the tap body 3 on the manifold base 5 .
When securing the manifold base 5 to the mounting surface 13 , the lug 43 is positioned so that, when attaching the tap body 3 to the mounting base 5 , the tap body 5 can be rotated to engage the lug 43 in the second section 45 b and locate the tap body 3 in the required position for discharge of water. The tap body 3 may be retained in the required position by frictional engagement between the tap body 3 and manifold base 5 . Alternatively or additionally, the tap body 3 may be locked in the required position by any suitable means, for example by tightening a grub screw 47 to engage a recess in the wall of manifold base 5 . The grub 47 could be replaced with any other suitable fastening means such as a roll pin, a dowel, a standard headed screw or a more complex system such as a locking ring provided with a lug which fits into grooves in the manifold base and the tap body to prevent rotation where linear movement of the ring disengages one of the lugs and allows rotation of the tap body relative to the manifold assembly.
When the tap body 3 is secured to the manifold base 5 , flow of hot water and cold water from the manifold base 5 to the tap body 3 is permitted and, when the tap body 3 is detached from the manifold base 5 , flow of water is prevented by any suitable means. For example, an isolation valve assembly may be provided in the manifold base 5 that is opened when the tap body 3 is connected to the manifold base 5 and closed when the tap body 3 is disconnected from the manifold base 5 . Alternatively, isolation valves may be provided in the supply pipes separate from the tap assembly to prevent fluid flow and allow the tap body 3 to be disconnected from the manifold base 5 .
In this embodiment, an isolation valve assembly is provided by an isolator plate 49 and an isolator plate seal 51 . The isolator plate 49 is mounted for rotation relative to the manifold base 5 between end positions defined by engagement of a lug 53 on the edge of the isolator plate 49 with opposite ends of a slot 55 in the sidewall of the manifold base 5 . The isolator plate 49 is retained by the bolt 31 and a bearing washer 56 is mounted on the bolt 31 between the isolator plate 49 and the bolt head to allow relative rotation between the bolt 31 and the isolator plate 49 . The isolator plate seal 51 seals between the underside of the isolator plate 49 and the manifold base 5 and is located in a channel 57 in the underside of the isolator plate 49 so as to rotate with the isolator plate 49 . The configuration of the isolator plate seal could be changed depending on the sealing requirements. The isolator plate seal could be replaced with a pair of ceramic plates.
Inlet ports 59 , 61 in the manifold base 5 connect the inlets 15 , 17 to a region between inner and outer rings 63 , 65 of the isolator plate seal 51 that prevent water leaking between the manifold base 5 and the isolator plate 49 at the inner and outer peripheries. The inner and outer rings 63 , 65 are joined together by a plurality of connecting webs. The webs seal around two outlet ports 67 , 69 in the isolator plate 49 and divide the region between the outlet ports 67 , 69 into three areas 71 a,b,c on one side of the ports and three areas 73 a,b,c on the other side. The outlet ports 67 , 69 extend above the isolator plate 49 and are received in a pair of inlet ports 75 , 77 in the tap body 3 when the tap body 3 is lowered onto the manifold base 5 so that the isolator plate 49 rotates with the tap body 3 . The outlet ports 67 , 69 are provided with seals such as O-rings (not shown) received in annular grooves 79 , 81 to provide a watertight seal with the inlet ports 75 , 77 in the tap body 3 . In this embodiment, the inlet ports 75 , 77 in the tap body 3 are provided with removable filters 83 , 85 that are retained in position by the outlet ports 67 , 69 of the manifold base 5 when the tap body 3 is lowered onto the manifold base 5 .
The isolator valve assembly controls the flow of water from the manifold base 5 to the tap body 3 . When the tap body 3 is connected to the manifold base 5 in the normal operating position shown in FIGS. 2 and 5 , the outlet ports 67 , 69 of the isolator plate 49 are connected to the inlet ports 75 , 77 in the tap body 3 and communicate with the inlet ports 59 , 61 in the manifold base so that water can flow freely from the manifold base 5 to the tap body 3 . The tap body 3 may be provided with a suitable mechanism (not shown) for discharge of hot water or cold water or a mixture of hot water and cold water.
If required, the tap body 3 can be detached from the manifold base 5 by rotating the tap body 3 relative to the manifold base 5 to align the first section 45 a of the groove 45 with the lug 43 on the manifold base 5 whereupon the tap body 3 can be lifted off the manifold base 5 . As the tap body 3 is rotated, the isolator plate 49 and isolator plate seal 51 rotate with the tap body 3 so that communication between the outlet ports 67 , 69 of the isolator plate 49 and the inlet ports 59 , 61 on the mounting base 5 is gradually reduced. After rotation of approximately 45 degrees from the normal operating position, the isolator plate seal 51 provides a fluid tight seal that isolates the outlet ports 67 , 69 from the inlet ports 59 , 61 as shown in FIGS. 3 and 6 to prevent flow of water from the manifold base 5 to the tap body 3 . In this position, the tap body 3 is still retained on the manifold base 5 by engagement of the lug 43 in the second section 45 b of the groove 45 and the inlet ports 59 , 61 open to sealed areas 71 a , 73 a between the manifold base 5 and the isolator plate 49 .
On continued rotation of the tap body 3 in the same direction, the lug 43 is aligned with the first section 45 a of the groove 45 . In this position, the inlet ports 59 , 61 open to sealed areas 71 b , 73 b between the manifold base 5 and isolator plate 49 as shown in FIG. 7 so that, when the tap body 3 is lifted off the manifold base 5 as shown in FIG. 4 , the isolator valve assembly is closed and prevents flow of water from the manifold base 5 . Confining the incoming supplies to the sealed areas between the outlet ports 67 , 69 when the isolator valve assembly is closed reduces the force of the inlet water pressure pushing the isolator plate 49 away from the manifold base 5 thereby reducing the risk of leakage between the isolator plate 49 and manifold base 5 .
The tap body 3 can be re-fitted by a reverse of the above procedure to remove the tap body 3 and the isolator valve assembly is opened and allows flow of water from the manifold base 5 to the tap body 3 as the tap body 3 is rotated relative to the manifold base 5 .
As will be appreciated, the clamping assembly is operated from the topside of the mounting surface and the isolator valve assembly is operated as the tap body is attached to and detached from the manifold base. This has a number of advantages including but not limited to
Access to the underside of the mounting surface to disconnect/reconnect the inlet water supplies and/or to unfasten/fasten the tap assembly may not be required The water supply to the tap assembly may not be required in order to service/replace the tap body. Separate isolators on the hot and cold inlets may not be required. Access to and operation of isolators in awkward places may not be required Removal of the tap body without isolating the inlet supplies may be avoided Additional tools or effort to isolate the water supplies may be avoided. Access to the serviceable items may be facilitated Access to filters for cleaning/replacement may be facilitated.
It will be appreciated that the clamping assembly may be employed without the isolator valve and two arrangements in which the isolator valve has been omitted are shown in FIGS. 10 and 11 . For convenience, like reference numerals are used to indicate similar features.
In FIG. 10 , the manifold base 5 has an integral sleeve 87 that extends within the aperture in the mounting surface (not shown) and is provided with opposed axially extending slots 89 (only one shown) in the outer surface in which the angle section formations 37 , 39 of the clamping arms 25 , 27 are received. The slots 89 provide a keyway for sliding movement of the angle section formations 37 , 39 in an axial direction while preventing relative rotation between the clamping arms 25 , 27 and the manifold base 5 .
In use, the angle section formations 37 , 39 slide upwards in the slots 89 to engage the underside of the mounting surface when the bolt 31 is rotated to fasten the clamping assembly as described previously. When the angle section formations 37 , 39 engage the underside of the mounting surface, further rotation of the bolt 31 causes the arms to slide outwards to engage the inner wall of the aperture as described previously and take up any slack so that the manifold base 5 is firmly located on the mounting surface. In this way, variations in the thickness (T) of the mounting surface can be accommodated.
Once the manifold base 5 has been secured, the tap body 3 is located on the manifold base 5 to prevent relative rotation and is axially secured to the manifold base 5 by any suitable means. For example, the tap body 3 may have one or more axial lugs (not shown) on the inner surface that locate in a corresponding recess 91 (only one shown) in the manifold base 5 to prevent relative rotation and may be axially secured by engagement of a grub screw (not shown) in an annular groove 93 in the manifold base 5 .
In FIG. 11 , the manifold base 5 has an integral sleeve 87 that extends within the aperture in the mounting surface (not shown) and is provided with opposed axially extending flats 95 (one only shown) in the outer surface and a pair of slots 97 , 99 providing access to the flats 95 from above the manifold base 5 . The slots 97 , 99 provide openings for four legs 101 (only three shown) that extend from the tap body 3 .
In use, the manifold base 5 is secured to the mounting surface (not shown) by rotating the bolt 31 to fasten the clamping assembly as described previously. The tap body 3 is then lowered onto the manifold base 5 so that the legs 101 pass through the slot 97 , 99 and extend either side of the angle section formations 37 , 39 to prevent rotation of the tap body 3 relative to the manifold base 5 . The tap body 3 may be axially secured to the manifold base 5 by engagement of a grub screw (not shown) in an annular groove 93 in the manifold base 5 .
As will be appreciated, restricting rotation of the tap body 3 as described and shown in FIGS. 10 and 11 provides a secure fixing for the tap body 3 . With this arrangement, the manifold base 5 has to be correctly positioned on the mounting surface as angular adjustment of the tap body 3 on the manifold base 5 to orientate the tap body 3 in the required direction is not permitted. However, it will be apparent that any adjustment to the mounted position of the tap body 3 can be achieved by detaching the tap body and releasing the clamping assembly sufficiently to rotate the manifold base to the correct position before re-tightening the manifold base 5 and attaching the tap body 3 .
It will be understood that the invention is not limited to the previously described embodiments which are capable of being modified without departing from the principles of the invention. For example, in the above embodiments, both clamping arms are pivotal between the collapsed position for passage through the aperture in the mounting surface to the operative position during installation. In a modification, one of the clamping arms may be pivotal between the collapsed position and the operative position and the other arm may be fixed for example, where sufficient clearance to pass through the aperture can be achieved. with one arm fixed and the other arm pivotal. Although in the above-described embodiments the clamping assembly is provided with two clamping arms, it will be understood that more than two clamping arms may be employed according to requirements. Where more than two clamping arms are provided, all the clamping arms may be pivotal between the collapsed position and the operative position or a combination of fixed and pivotal clamping arms may be employed. In the above-described embodiment, the fluid delivery device has a manifold and separate tap body attached to the manifold that allows the tap body to be attached to and removed from the manifold with the manifold secured to the mounting surface. It will be understood that this may not be essential and that the clamping assembly could be attached to the tap body to secure the tap body directly to the mounting surface without a separate manifold.
It will also be understood that the invention is capable of wider application. For example, in the previously described embodiment the tap assembly enables the user to select and discharge water having any temperature from full hot to full cold. However, the invention could easily be adapted for a tap which delivers only hot or cold water. This could be done by simply adding a sealing bung into the unwanted inlet port of the manifold base or by replacing the manifold base with one having only one inlet port. The invention could also be used for mounting other fluid delivery devices such as mixer valves for showers.
It will also be understood that the clamping assembly and isolator valve assembly may be provided together as shown and described in FIGS. 1 to 9 . Alternatively, the clamping assembly may be provided separate from the isolator valve assembly as shown and described in FIGS. 10 and 11 . Alternatively, the isolator valve assembly may be provided separate from the clamping assembly. The invention includes all such applications. | Apparatus and method for attaching a tap to a mounting surface ( 13 ) has a clamping assembly inserted through an aperture ( 11 ) in the mounting surface ( 13 ) and tightened from above the mounting surface ( 13 ). The clamping assembly has a pair of clamping arms ( 25, 27 ) that are mounted for pivotal movement from a collapsed position for passage through the aperture ( 11 ) to an operative position below the mounting surface ( 11 ). The clamping arms ( 25, 27 ) are operable on tightening the clamping assembly to engage in a first stage an underside of the mounting surface ( 13 ) remote from the fluid delivery device and to engage in a second stage a sidewall of the aperture ( 11 ) when continuing tightening. Thus a step change in an operating force is required that provides feedback to an installer that a required clamping force has been achieved. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to drilling rigs with erectable masts and substructures; in certain particular aspects, to such rigs that are mobile; and methods for moving a drilling rig.
2. Description of Related Art
The prior art discloses a variety of rigs used in drilling and various wellbore operations, including rigs that are mobile; for example, and not by way of limitation, U.S. Pat. Nos. 3,340,938; 3,807,109; 3,922,825; 3,942,593; 4,269,395; 4,290,495; 4,368,602; 4,489,526; 4,569,168; 4,837,992; 6,634,436; 6,523,319 and the references cited in these patents—all these patents incorporated fully herein for all purposes.
In many land drilling operations, land rigs are delivered to a site, assembled and then disassembled; including, in many cases, raising a rig mast to a vertical operational position. Often as an oilfield becomes mature, wells are drilled deeper into the earth to obtain production. Oil rigs are getting progressively larger to meet these needs. In the past, a 1500 hp rig was sufficient to handle most drilling. These rigs more recently have been supplanted by larger 2000 hp rigs. Currently, 3000 hp rigs are being made, but are not yet widely used. A 3000 hp rig typically has a 36 to 37 foot high drillfloor, a 156 foot clear height mast, a 1,500,000 pound hookload, a 1,300,000 pound rotary load, and a 1,000,000 pound setback load. Often large drilling rigs, e.g. in the Middle East, are transported between well sites by dismantling the rig into pieces that can be trucked between two well sites which can produce many time-consuming truckloads of rig components resulting in up to four additional weeks of rig downtime (the larger the capacity of the rig, the heavier the loads, and the number of loads also increases); and mounting the drilling module complete with mast on tires. One drawback of a tire-mounted drilling module is tire load capacity and overall rig height. Often, the largest tires that are used are 40×57 earthmover tires.
With certain current rig designs, the largest rigs that can be easily moved are 2000 hp rigs of a box style substructure. This style of design is conducive to even tire loading. A typical 3000 hp rig that has an evenly loaded box style substructure will be too tall to move with a 156 foot mast and a 37 foot drillfloor to get under the power line height restriction with current moving systems (e.g. in countries such as Kuwait where a typical maximum clearance for power lines is 161 feet from the ground to the top of the rig being transported). Anything taller than this will produce the potential for electrical arcing between the mast and the power lines if the rig is being towed on its tires.
Another common style of substructure is the slingshot substructure which is often used in large hookload application. The substructure folds down in order to easily access the drillfloor from the ground level, which aids in rig assembly. Often a substructure of this size is broken down into truck sized loads. Placing a wheeled moving system on certain rigs of this style may not be practical because it is not feasible to easily balance the wheel loads.
U.S. Pat. No. 3,922,825 discloses a rig with a stationary substructure base and a movable substructure base mounted thereon which is coupled to the stationary base and swings upright into an elevated position on a series of struts that are connected to the stationary base with swivel connections at each end. The movable base is otherwise stationary since neither the stationary base nor the movable base are mobile or repositionable without the use of an auxiliary crane or the like. The movable substructure base and the drill mast are raised with a winch mounted on an auxiliary winch truck.
U.S. Pat. No. 3,942,593 discloses a mobile well drilling rig apparatus which has a trailerable telescoping mast and a separate sectionable substructure assembly with a rig base, a working floor, and a rail structure. The mast is conveyed to the top of the substructure by rollers and is raised by hydraulic raising apparatus to an upright position. With such a system the the mast assembly can be relatively long when transporting it and the mast can be unstable during raising. This system uses drawlines and winch apparatus to raise the mast onto the working floor.
U.S. Pat. No. 6,523,319 discloses a drilling rig base and a lower mast section that are collapsible into a compact transportable position. The base is expandable in the field to support a drilling platform and equipment, and the telescoping mast is also expandable for supporting the crown block and cables of the drawworks. The rig may have a plurality of beams, the outer beams being collapsible to a transportable position for placing on a single truck or trailer, and the A-frame lower mast section which is collapsible to a transportable position for placing on a single truck or trailer. In one aspect, a mobile, collapsible drilling rig base and drilling platform are disclosed which haves: a base having a plurality of parallel beams; the beams being in a horizontal plane and including inner beams and outer beams: the outer beams being collapsible in said horizontal plane to a transportable position; and a drilling platform attached to the base that is elevatable above the base.
U.S. Pat. No. 6,634,436 discloses a mobile land drilling apparatus and method. The rig has a mobile telescoping substructure box. A lifting apparatus selectively supports the mobile telescoping substructure box unit in a raised position and lowered position. An extension cylinder further extends the mobile telescoping substructure box unit in telescopic extension. A stationary frame member and a telescoping frame member have a plurality of cables attached thereto for supporting the telescoping frame member when extended. A trolley winch allows completion of the rig assembly without an external crane.
U.S. Pat. No. 7,357,616 discloses oil rig capable of being at least partially disassembled to form at least two portions, such as a top half and bottom half, and an associated structure for transport. An oil rig top portion may be loaded onto a trailer for transport separate from a bottom portion. The trailer includes a bottom frame, a top frame, a structure operably associated with said bottom and top frames for moving the top and bottom frames away from and towards one another, and a moving means attached to the at least bottom frame to allow the trailer to be moved along the support surface. The trailer may be towed by a truck or other vehicle. In one aspect a method is disclosed for transporting an oil rig, including: disassembling the oil rig to form a top portion with a rig floor and a mast and bottom portion with a substructure; transporting the top portion separately from the bottom portion; transporting the rig floor on a trailer; raising a top surface of the trailer to accept the rig floor; and prior to the step of transporting the rig floor on the trailer, lowering the top surface of the trailer. In one aspect, a trailer is disclosed for moving a part of an oil rig along a support surface, the trailer having: a bottom frame; a top frame; a structure operably associated with the bottom and top frames for moving the top and bottom frames away from and towards one another and further operative to temporarily fix the position of the top and bottom frames with respect to one another, the structure having at least one hydraulic piston; an alignment mechanism affixed to one of the top and bottom frame, the alignment mechanism operative to align the top frame with a top surface of the oil rig; an I-beam affixed to the top surface and operative to facilitate loading the part of the oil rig onto the trailer; and a moving means attached to at least the bottom frame to allow the trailer to be moved along the support surface.
BRIEF SUMMARY OF THE INVENTION
The present invention, in certain aspects, discloses a mobile drilling rig with integral wheel assemblies selectively changeable from a drilling mode position to a moving mode position. In the moving mode position, the mobile drilling rig is movable on the wheel assemblies from one location to another.
In certain aspects, the present invention discloses a system that includes a land rig with an erectable substructure; an erectable mast; and movement apparatus on which the substructure is mounted for moving the rig from one location to another. In one aspect, the present invention discloses a mobile drilling rig with a base box, a plurality of wheel assemblies pivotably connected to the base box, each of the plurality of wheel assemblies selectively pivotable from a first position to a second position, the first position for moving the mobile drilling rig from a first location to a second location.
Accordingly, the present invention includes features and advantages which are believed to enable it to advance rig movement 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.
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.
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 the embodiments and aspects listed above and:
New, useful, unique, efficient, non-obvious drilling rigs, systems for moving them, and methods for moving them; and
Such systems in which a drilling rig has a plurality of wheel assemblies selectively movable into a moving mode to move the drilling rig from one location to another.
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.
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.
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.
Certain aspects, certain embodiments, and certain preferable features of the invention are set out herein. Any combination of aspects or features shown in any aspect or embodiment can be used except where such aspects or features are mutually exclusive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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 equivalent embodiments.
FIG. 1A is an end view of a drilling rig according to the present invention.
FIG. 1B is a side view of the drilling rig of FIG. 1A .
FIG. 1C is a top plan view of a rig floor of the drilling rig of FIG. 1A .
FIG. 1D is a side view of part of the drilling rig of FIG. 1A .
FIG. 1E is a top plan view of wheel assemblies and interconnecting structure of the drilling rig of FIG. 1A .
FIG. 1F is an end view showing the drilling floor of FIG. 1C in a raised position.
FIG. 2A is a side view of a part of the drilling rig of FIG. 1A showing a step in a method according to the present invention.
FIG. 2B is a side view of the drilling rig of FIG. 1A showing a step after the step shown in FIG. 2A .
FIG. 2C is a side front view of the drilling rig of FIG. 1A showing a step after the step shown in FIG. 2B .
FIG. 2D is a side view of the drilling rig of FIG. 1A showing a step after the step shown in FIG. 2C .
FIG. 2E is a side view of the drilling rig of FIG. 1A showing a step after the step shown in FIG. 2D .
FIG. 2F is a side view of the drilling rig of FIG. 1A showing a step after the step shown in FIG. 2E .
FIG. 2G is a side view showing the drilling floor of the drilling rig of FIG. 1A raised according to the present invention.
FIG. 3A is a top view of a wheel assembly of the drilling rig of FIG. 1A .
FIG. 3B is a side view of the wheel assembly of FIG. 3A .
FIG. 3C is a front view of the wheel assembly of FIG. 3A .
FIG. 4A is a front view of part of the rig of FIG. 1A .
FIG. 4B is a front view of a bearing pad of the rig of FIG. 1A .
FIG. 4C is a front view of the bearing pad of FIG. 4B .
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.
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.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides mobile drilling rigs, systems and methods for rig erection; and systems and methods for moving a drilling rig. This invention's teachings are applicable, inter alia, to any rig which has an erectable substructure.
FIGS. 1A and 1B show a system 10 according to the present invention which includes a drilling rig 12 with a mast 14 , a substructure 16 , and movement apparatus 20 supporting the substructure 16 , the mast 14 , and related equipment and structure. The mast 14 may be, as shown, a tilt top mast, or it may be any suitable known mast. The substructure 16 is erectable from a lowered position as shown in FIG. 1B to a raised position as shown in FIGS. 1A and 1D . The system 10 includes typical rig equipment and, apparatuses, e.g., but not limited to, a drawworks 1 , a rotary table 2 (see FIG. 1C ), a driller cabin/doghouse 3 , a setback floor 4 , a BOP stack 5 , a drill line spooler 6 , and hydraulic catheads 8 .
The movement apparatuses 20 (see, FIGS. 2G , 3 A- 3 C) include four wheel assemblies 30 which are pivotably mounted to a base box 18 at pivot points 19 . Each wheel assembly 30 has two wheels 35 each with a tire 36 and has a lug 31 selectively secured with a removable pin 17 a to a lug 17 projecting from the base box 18 . Stop members 15 abut top beams 32 of the wheel assemblies 30 when the wheel assemblies 30 pivot at the pivot points 19 to prevent further movement of the top beams 32 toward the substructure 16 .
Axles 33 which rotate in trunnions 32 of the wheel assemblies 30 have wheels 35 secured thereto. Each wheel 35 has a tire 36 (e.g., but not limited to 40×57, 76 ply tires). Optionally there is only one wheel for each wheel assembly each with one tire thereon at each of the four corners of a rig. A trunnion support 34 of each wheel assembly is rotatably secured at a wheel pivot 34 a to a trunnion load beam 37 which is secured to the base box 18 .
The movement apparatuses 20 (see, FIGS. 2G , 3 A- 3 C) include four wheel assemblies 30 which are pivotably mounted to a base box 18 at pivot points 19 . Each wheel assembly 30 has two wheels 35 each with a tire 36 and has a lug 31 selectively secured with a removable pin 17 a to a lug 17 projecting from the base box 18 . Stop members 15 abut top beams 37 of the wheel assemblies 30 when the wheel assemblies 30 pivot at the pivot points 19 to prevent further movement of the top beams 37 toward the substructure 16 .
The base box 18 includes base box spreaders 18 a (beams that interconnect boxes on each side of the rig) and roller tracks 18 c for scissors rollers (described below). Frame connection braces 18 b are secured between pairs of base box spreaders 18 a . Removable trunnion beam spreaders 37 a are connected between pairs of trunnion load beams 37 .
Four bearing pad apparatuses 40 are secured to the base box 18 in a raised position by pins 40 a . When the rig 12 is in a drilling mode (e.g. see FIGS. 1A and 2G ), the bearing pads 40 rest on the ground G. The bearing pads 40 have a limited travel length (e.g., see FIGS. 2B , 2 C). The bearing pads 40 are movable by cylinder apparatuses 70 (described below).
The substructure 16 supports a drillfloor 50 which includes a drillfloor skid 51 with ends 51 a and 51 b supported by drill floor skid supports 56 ; a driller's side floor box 52 ; a central drill floor 53 ; and an off driller's side floor box 54 . The drillfloor boxes 52 , 54 include roller tracks 55 for scissors rollers (described below). Drawworks support spreaders 57 extend between the drill floor boxes 52 , 54 .
The substructure 16 has four scissors apparatuses 60 , two front and two rear. Each front scissors apparatus has a two outer scissors 61 and two inner scissors 62 . Each rear scissors has two outer scissors 63 and two inner scissors 64 . The front and rear scissors parts are secured together with center pipe connections 65 . Rollers 66 are rotatably mounted at certain ends of the beams of the scissors 61 - 64 for movement in the tracks 55 (top rollers) or the tracks 18 c (bottom rollers). Top ends of the beams of the scissors 61 - 64 without rollers are pivotably secured to the drill floor boxes 52 and 54 at pivot points 59 and bottom ends of the beams of the scissors 61 - 64 without rollers are pivotably secured to the base box 18 at pivot points 18 p.
The substructure 16 is raised and lowered by hydraulic cylinder apparatuses 70 (one, two, three, four or more at each end; eight shown, two pairs at each corner) which are connected at their tops to lugs 58 on the drill floor boxes 52 , 54 and at their bottoms to connections 48 of the bearing pads 40 .
FIGS. 2A-2G illustrate a method according to the present invention for raising a drilling rig according to the present invention from a transport position to a drilling position.
As shown in FIG. 2A , the system 10 a , like the system 10 described above and like numerals indicate like parts, has been moved on its wheel assemblies 30 from an original location to the new location shown in FIG. 2A (e.g. towed by a truck or trucks with tow bars attached to the tow bar linkages 42 ). The substructure 16 (system 10 a shown partially; may include some or all of the structures and apparatuses shown in FIGS. 1A , 1 C and/or 1 D) is located over a proposed well site W. As shown, the substructure 16 has not yet been raised.
As shown in FIG. 2B , following removal of the pins 40 a , the bearing pads 40 are lowered using the hydraulic cylinders 70 . As shown in FIG. 2C the hydraulic cylinders 70 are extended to lift the substructure 16 , supported on the bearing pads 40 on the ground G. The pins 17 a are then removed to permit disconnecting the lugs 31 from the lugs 17 to free the wheel assemblies 30 for pivoting.
As shown in FIG. 2D , the substructure 16 (and whatever, not shown, is on the substructure 16 ) is lowered using the hydraulic cylinders 70 . The wheel assemblies pivot at wheel pivots 19 . As shown in FIG. 2E , the substructure 16 is lowered until it rests on the ground G (or rig mats if they are used), with the wheel assemblies pivoted sufficiently to permit the substructure 16 to rest on the ground G. At this point, if the mast is not already mounted on the drill floor boxes 52 , 54 , the mast may be placed in a horizontal position on the drill floor and raised to a vertical position. (i.e., the mast can be moved as a separate load). Pins 15 a which selectively secure the drill floor 50 and the base box 18 are removed so that the substructure 16 can be raised.
As shown in FIG. 2F , the substructure 16 and the drillfloor 50 (and whatever is on the drillfloor 50 ) are raised using the cylinders 70 . The scissors apparatuses 60 are moving with their rollers in tracks from the collapsed positions of FIG. 2E to the contracting positions of FIG. 2F .
FIG. 2G illustrates the substructure 16 raised to a desired height. The top roller ends of the beams of the scissors 61 - 64 are pinned with pins 67 to the drill floor boxes 52 , 54 and the base box 18 with pins 67 (e.g. hydraulic pins may be used).
It is within the scope of the present invention for the scissors apparatuses 60 to be folded up with the drillfloor pinned to the base box in the moving mode. Optionally the BOP stack or stacks can be removed for transport (e.g. at a 5 mph speed) using a known skidding-type BOP handling system or traditional BOP hoists to remove the stacks. At a 2.5 mph speed the BOP stack(s) may, optionally, stay onboard the rig in such a position to complement the tire loading at the four corners. The cylinders used to lift up the substructure may be the same cylinders used to raise the substructure base.
In one aspect four pairs of cylinders 70 are multistage power cylinder apparatus used with two cylinders located under each of four rig corners to raise the drillfloor and mast (if present) as one unit. The cylinders, optionally, are failsafe in that the safety factor of the hydraulics and cylinders is such that if one cylinder loses pressure, the system can still safely run with another cylinder holding the load in the same corner. If both cylinders in one corner lose pressure, then the structure, in one aspect, may still be safely lowered to the base box because the hydraulics and the cylinders have enough support ability built into them to prevent a catastrophic failure.
In one aspect the scissors apparatuses 60 are additional lifting apparatus for the BOP stacks in a cellar CR. The cellar CR can also, optionally, have spreaders with rails built in for the stack handler to roll onto from the truck bed.
The scissors apparatuses 60 are pinned at a drilling height (e.g. as in FIG. 2G ) using hydraulic latch pins 67 which secure the scissor apparatuses to the guide tracks 18 c and 55 . In one drilling position, the rig is typically raised to a maximum height, but, in one aspect, the inherent design of the scissors apparatuses 60 allow this substructure to operate over a much larger range of heights, e.g. from 28-29 feet to 36-37 feet, although a larger design according to the present invention can provide a maximum height to over 40 feet. For example, a smaller design of the scissors apparatuses 60 may be used to create a range of 15 feet to 25 feet for an operating height.
In certain aspects, for any sized rig according to the present invention, a mast can have its top section lay down to clear the power lines. This rig may include a top drive and torque track in place. Depending on the size of the rig selected, the transport height can be much lower for a smaller rig. For example, in one aspect, a shorter portable drilling rig provided according to the present invention still has a complete drilling module. The mast may also be removed completely and shipped separately in order for the system 10 a to achieve an even smaller minimum road height.
The scissors apparatuses 60 may be used in conjunction with any other sized drillfloor, large or small, tall or short, and other sized mast, in order to achieve a minimum road height and to help with clearance and stability for all families of scissor-type substructure drilling rigs. In cases where the BOP stack or other wellhead equipment is left on the well when the drilling rig (e.g. a rig 10 ) is ready for transport, the rig can be towed clear of the stack and then lowered to the transport height.
Systems according to the present invention, in certain aspects, aid in keeping the center of gravity of a rig in a horizontal plane at the same location in both drilling and transport modes (e.g. see FIGS. 1D and 1B ; FIGS. 2G and 2A ). This allows for quicker and easier rig moves with less down time for the operator, and a more evenly loaded and compact moving system design. The system, in certain aspects, also incorporates a relatively shorter wheelbase providing a more maneuverable drilling rig with a tighter turning radius, allowing for much easier transportation and location on well sites than certain current designs allow.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a mobile drilling rig including: a base box, a plurality of wheel assemblies pivotably connected to the base box, each of the plurality of wheel assemblies selectively pivotable from a first position to a second position, the first position for moving the mobile drilling rig from a first location to a second location. Such a system may include one or some, in any possible combination, of the following: a substructure connected to the base box; the substructure raisable above the base box; a raising system connected to the substructure and to the base box for raising the substructure above the base box; the raising system includes a plurality of powered cylinder apparatuses for raising and lowering the substructure; wherein the raising system includes a plurality of scissors apparatuses for bracing the substructure, the scissors apparatuses each with top ends connected to the substructure and bottom ends connected to the base box; the scissors apparatuses positionable in a collapsed configuration with the substructure lowered and in an extended configuration with the substructure raised; and the scissors apparatuses releasably securable in the collapsed configuration and in the extended configuration; wherein the plurality of scissors apparatuses includes four spaced-apart scissors apparatuses, each with two centrally connected scissors members; wherein the substructure has top roller tracks; the base box has bottom roller tracks; and each scissors apparatus has a first scissors member with a top roller movable in a top roller track and a second scissors member with a bottom roller movable in a bottom roller track; a plurality of bearing pads connected to the base box, each bearing pad of the plurality of bearing pads selectively movable down from the base box to contact ground therebeneath; the bearing pads movable by the powered cylinder apparatuses; each wheel assembly including a steering apparatus for steering the wheel assembly; a drill floor on the substructure; a mast on the drill floor; wherein the mast is selectively erectable with respect to the drill floor; wherein the mobile drilling rig has four corners; and the plurality of powered cylinder apparatuses includes four pairs of two powered cylinder apparatuses each; a pair of powered cylinder apparatuses at each corner of the rig; wherein a substructure is connected to the base box, the substructure raisable above the base box and wherein one powered cylinder apparatus alone of each pair can be used to raise and lower the substructure; and/or wherein the mobile drilling rig has a center of gravity maintainable in a horizontal plane during drilling and during rig movement.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a mobile drilling rig including a base box, a plurality of wheel assemblies pivotably connected to the base box, each of the plurality of wheel assemblies selectively pivotable from a first position to a second position, the first position for moving the mobile drilling rig from a first location to a second location, a substructure connected to the base box, the substructure raisable above the base box, a raising system connected to the substructure and to the base box for raising the substructure above the base box, the raising system includes a plurality of powered cylinder apparatuses for raising and lowering the substructure, and a plurality of scissors apparatuses for bracing the substructure, the scissors apparatuses each with top ends connected to the substructure and bottom ends connected to the base box, the scissors apparatuses positionable in a collapsed configuration with the substructure lowered and in an extended configuration with the substructure raised, the scissors apparatuses releasably securable in the collapsed configuration and in the extended configuration, the plurality of scissors apparatuses including four spaced-apart scissors apparatuses, each with two centrally connected scissors members, a plurality of bearing pads connected to the base box, each bearing pad of the plurality of bearing pads selectively movable down from the base box to contact ground therebeneath, the bearing pads movable by the powered cylinder apparatuses, each wheel assembly movably connected to the base box and including a steering apparatus for steering the wheel assembly, a drill floor on the substructure, a mast on the drill floor, and wherein the mast is selectively erectable with respect to the drill floor.
The present invention provides, therefore, in at least certain, but not necessarily all, embodiments a mobile drilling rig with a base box, a substructure connected to the base box, the substructure raisable above the base box, a raising system connected to the substructure and to the base box for raising the substructure above the base box, the raising system includes a plurality of powered cylinder apparatuses for raising and lowering the substructure, the raising system includes a plurality of scissors apparatuses for bracing the substructure, the scissors apparatuses each with top ends connected to the substructure and bottom ends connected to the base box, the scissors apparatuses positionable in a collapsed configuration with the substructure lowered and in an extended configuration with the substructure raised, and the scissors apparatuses releasably securable in the collapsed configuration and in the extended configuration. Such a rig may have one or some, in any possible combination, of the following: wherein the plurality of scissors apparatuses includes four spaced-apart scissors apparatuses, each with two centrally connected scissors members; wherein the substructure has top roller tracks, the base box has bottom roller tracks, and each scissors apparatus has a first scissors member with a top roller movable in a top roller track and a second scissors member with a bottom roller movable in a bottom roller track; a drill floor on the substructure, a mast on the drill floor, and wherein the mast is selectively erectable with respect to the drill floor.
The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for moving a mobile drilling rig, the method including: pivoting wheel assemblies pivotably connected to a base box of a rig from a drilling position to a movement position, the rig comprising a base box, a plurality of wheel assemblies pivotably connected to the base box, each of the plurality of wheel assemblies selectively pivotable from a first position to a second position, the first position for moving the mobile drilling rig from a first location to a second location; securing the wheel assemblies in the movement position, and moving the mobile drilling rig on the wheel assemblies. Such a method may include one or some, in any possible combination, of the following: a substructure connected to the base box, the substructure raisable above the base box, a raising system connected to the substructure and to the base box for raising the substructure above the base box, the method including raising with the raising system the substructure above the base box; wherein the raising system includes a plurality of powered cylinder apparatuses for raising and lowering the substructure; wherein the raising system includes a plurality of scissors apparatuses for bracing the substructure, the scissors apparatuses each with top ends connected to the substructure and bottom ends connected to the base box, the scissors apparatuses positionable in a collapsed configuration with the substructure lowered and in an extended configuration with the substructure raised, and the scissors apparatuses releasably securable in the collapsed configuration and in the extended configuration, the method including moving the scissors apparatuses from the collapsed configuration to the extended configuration as the substructure is raised; wherein the substructure has top roller tracks, the base box has bottom roller tracks, and each scissors apparatus has a first scissors member with a top roller movable in a top roller track and a second scissors member with a bottom roller movable in a bottom roller track, the method including moving the top rollers in the top roller tracks, and moving the bottom rollers in the bottom roller tracks; wherein a plurality of bearing pads are connected to the base box, each bearing pad of the plurality of bearing pads selectively movable with respect to the base box, the bearing pads in contact with ground during drilling and movable by the powered cylinder apparatuses, the method including raising the bearing pads above the ground to facilitate movement of the mobile drilling rig; wherein each wheel assembly including a steering apparatus for steering the wheel assembly, the method including steering each wheel assembly with its corresponding steering apparatus; wherein there is a drill floor on the substructure, a mast on the drill floor, and wherein the mast is selectively erectable and lowerable with respect to the drill floor, the method including lowering the mast to facilitate movement of the mobile drilling rig; wherein the raising system includes a plurality of powered cylinder apparatuses for raising and lowering the substructure, the mobile drilling rig has four corners, and the plurality of powered cylinder apparatuses includes four pairs of two powered cylinder apparatuses each, a pair of powered cylinder apparatuses at each corner of the rig, and wherein a substructure is connected to the base box, the substructure raisable above the base box and wherein one powered cylinder apparatus alone of each pair can be used to raise and lower the substructure, the method including operating only one powered cylinder apparatus of one pair of powered cylinder apparatuses during raising or lowering of the substructure; and/or wherein the mobile drilling rig has a center of gravity maintainable in a horizontal plane during drilling and during rig movement, the method including maintaining the center of gravity of the mobile drilling rig in a horizontal plane during drilling and during rig movement.
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 inventor may rely on the Doctrine of Equivalents to determine and assess the scope of the 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. 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. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements. | Mobile drilling rigs and methods for moving drilling rigs are disclosed which, in one aspect, include wheel assemblies connected to a rig which wheel assemblies are selectively movable from a rig drilling position to a rig movement position. 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). |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The present invention relates to toilet cleaning devices which may be concealed within the flush tank of a toilet, and more particularly to a foldable toilet plunger device which may be concealed and attached to the interior surface of a toilet.
BACKGROUND OF THE INVENTION
Toilet plungers and other cleaning devices have long been used to unblock and clean toilet drains. It is preferable to store such devices out of sight, since they are generally unsightly and unsanitary, but such devices are often difficult to store because of the limited amount of space in most bathrooms. Furthermore, the means of storage should securely support the cleaning devices and allow for drainage, yet allow them to be readily available when needed to clean or remove blockages in the drains.
Earlier efforts have attempted to respond to the storage and convenience-of-use problems, providing toilet plunger covers and/or combination toilet plunger covers and toilet plungers. For example, in U.S. Pat. No. 5,114,006 to Wilk, and U.S. Pat. Nos. 5,335,374 and 5,305,880 to Wilk et al., the toilet plunger housing is part of the toilet plunger. The Wilk ('006) combination toilet plunger and housing device has a housing with a slotted base which rests directly on the floor, wherein the plunger cup rests upon the slots when the plunger is in storage, and the same slots are used for grasping of the housing when the plunger is extended for use. Other embodiments of Wilk ('006) disclose the plunger cup resting on a removable base plate when the plunger is in a storage position. The '374 and '880 patents further expand upon this basic concept.
More recently, in U.S. Pat. No. 5,958,150 by Borger et al. disclosed a separate storage device which can be opened and closed without being manipulated directly by the user. The storage device also serves to partially conceal the plunger when closed and allows the plunger to drain while sitting in the device. Both the Borger and Wilk devices are stand-alone assemblies for housing the plunger apart from the toilet.
U.S. Pat. No. 2,701,702 by Deiderich, on the other hand, provides an accessory for use within a toilet flush tank which supplies deodorant or disinfectant and may also support a toilet brush. The accessory is preferably a metal wire apparatus which is supported by the overflow pipe. Thus use of toilet plungers is not disclosed in the '702 patent.
Thus, while there has been substantial effort in the design of bathroom accessory storage devices for toilet plungers and other cleaning devices, the art has not adequately responded to date with the introduction of a means for storing a toilet plunger or other cleaning device which securely stores the toilet plunger or other cleaning device in a concealed fashion that allows for drainage and ready access, while not occupying additional scarce bathroom space or presenting an unattractive visage. The present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
The concealed toilet cleaning system of the present invention provides a system for concealing and storing a toilet plunger within a toilet flush tank to allow for drainage and ready access to the plunger without occupying additional space within the bathroom or risking unsanitary and unsightly exposure to the toilet plunger when the toilet plunger is not in use. Furthermore, the present invention provides a toilet plunger device which can be more readily stored within a toilet flush tank. Additionally, the cleaning system of the present invention provides a method of storing and using a concealed toilet plunger or toilet brush.
Generally a holder is attached to the interior of the toilet flush tank in order to secure the toilet plunger out of sight within the toilet flush tank. The holder retains the plunger or other cleaning device securely so that it does not detach and drop into the toilet flush tank. Preferably, this holder is secured to the cover of the flush tank. Furthermore, in one embodiment, the toilet plunger is fashioned to include a pivot point behind the plunger cup to allow the toilet plunger to be folded so that it is more planar and can be more readily stored close to the surface of the interior of the toilet flush tank. The holder within the toilet flush tank can also be used to secure and conceal other toilet cleaning devices (ex. a toilet brush).
The present invention allows the toilet plunger to be concealed within the flush tank of a typical household toilet, thus allowing any household toilet to be readily converted into a storage device. Through use of a folding toilet plunger, the plunger can be much more readily stored within the toilet flush tank since it less bulky when folded. In particular, when folded it is much more planar and therefore adapted to be closely positioned to the toilet flush tank cover. In addition to preventing unsightly exposure to the toilet plunger, storage within the toilet flush tank is also more sanitary as it prevents contamination of the bathroom by waste material which may accumulate on the plunger cup. Storage within the toilet flush tank also facilitates the drying of the toilet plunger by allowing residual moisture to drain into the lower portion of the toilet flush tank.
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 design of other structures and systems for carrying out the several purposes of the present invention. 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 present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and aspects of the invention will be apparent from the description of embodiments illustrated by the following accompanying drawings:
FIG. 1 is a perspective view of a toilet flush tank where the cover has been lifted to reveal an attached toilet plunger; and
FIG. 2 is a perspective view of a toilet plunger with an elongated handle and pivoting plunger cup.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a concealed toilet cleaning system. Generally, the cleaning system of the present invention includes a toilet cleaning device and a holder 16 for releasably securing the toilet cleaning device to an interior surface of a toilet flush tank 12 . The toilet cleaning device of the present invention normally comprises a handle 24 and a cleaning attachment, such as a plunger cup 26 or a toilet brush (not shown).
A concealable toilet plunger storage system in accordance with an embodiment of the present invention will now be described with reference to FIGS. 1 and 2 . Referring to FIG. 1 , a conventional toilet 10 is shown, focusing on the upper toilet flush tank 12 . Both components are typically made of porcelain, though many other materials with similar properties can be used. The toilet flush tank contains the water reservoir and apparatus necessary to operate the toilet. Toilet flush tanks are typically provided with a toilet flush tank cover 14 which enables easy access to the toilet flush tank for maintenance or other purposes.
An embodiment of the toilet plunger 20 of the present invention is shown in FIG. 1 secured to the bottom surface of the toilet flush tank cover 14 . While it is preferable to secure the toilet plunger to this surface, as this surface provides the most ready access, the use of other surfaces within the toilet flush tank for mounting the toilet plunger 20 are also envisioned, as other surfaces will allow the toilet plunger 20 to be securely stored in an inconspicuous location while allowing drainage and satisfying various other criteria. The typical toilet flush tank 12 contains a flush mechanism and a float device (not shown), which present potential obstacles to the toilet plunger 20 . Thus, it is most preferable to position the toilet plunger 20 so that the plunger cup 26 is positioned over the float device, as there is typically more space available here than over the flush mechanism. Toilets that have anti-siphon ballcock devices rather than a float device will generally have a greater amount of space. When less room is available for the toilet plunger 20 , a light-duty 4″ plunger cup size can be used. As will be described below, the plunger is preferably capable of folding in order to take up less space within the toilet flush tank.
A holder 16 is used to secure the toilet plunger 20 to whatever portion of the toilet flush tank 12 surface is chosen. A wide variety of devices can serve as the holder 16 ; all that is necessary is to be able to attach the holder to the surface of the toilet and then use it to releasably grip the toilet plunger so that it can be positioned within the flush tank but withdrawn for use. The holder may be secured to the surface of the toilet flush tank 12 or the toilet flush tank cover 14 using a variety of adhesives, or other attachment means such as clamps, bolts, or screws Alternately, the holder 16 may be integrated into the surface of the flush tank 12 or flush tank cover 14 at the time of manufacture. In one embodiment, a Velcro® fastener with an adhesive backing may be used, as this allows the holder to be repositioned as needed. Preferably, the holder grips the handle of the plunger using friction and tension. There are a variety of hardware clips, such as roller jaw clips, that can be used to hold the toilet plunger 20 . A preferred holder 16 is a broom clip composed of a semi-rigid plastic or metal.
Referring to FIG. 2 , the toilet plunger 20 can be of a conventional type and is comprised of an elastomeric or resilient plunger cup 26 and an elongated handle 24 having one end attached to or inserted into cup 26 . As previously suggested, the cup 26 is made of an elastomeric or resilient material. Suitable cup materials include, but are not limited to, rubber, neoprene or any elastic polymer. A conventional plunger typically has a 6″ plunger cup and 20″ handle. However, any size cup or handle that can fit within the toilet tank can be utilized in the present invention. The handle 24 is preferably an elongated cylinder or rod, but many other shapes that transmit force and distance the user from the working cup 26 (i.e., function as a handle) can be used. The handle is preferably composed of a rigid material such as acrylic plastic which resists damage from moisture within the flush tank. Other suitable handle materials are metal, fiberglass, or water-resistant wood. Preferably, the handle 24 attaches to the cup 26 by means of a hinge 28 which allows the cup 26 to pivot so that the plane defined by cup 26 is parallel rather than perpendicular to the line formed by the handle 24 . In an alternate embodiment, the hinge 28 may include a locking mechanism to prevent the cup 26 from wobbling while being used. Once folded, the toilet plunger 20 will take up much less space within the toilet flush tank 12 . It is also preferable to sheath the cylindrical handle 24 in a elastomeric or rubber-like grip material 22 which makes it easier to securely hold the toilet plunger. In another embodiment, the handle of the toilet plunger 20 is designed so that it can be collapsed to reduce its length. For example, the plunger handle 24 could be made of several overlapping cylinders capable of telescoping into the outer cylinder for storage within the flush tank 12 .
To use the toilet plunger 20 , the toilet flush tank cover 14 is first lifted to reveal the toilet plunger 20 . The plunger 20 is then removed from its holder 16 , unfolded, and used to unblock the toilet. After use, the toilet plunger 20 is refolded and secured back to the holder 16 and the toilet flush tank cover 14 is replaced on the toilet flush tank 12 . A label, preferably one with a logo and made up of transparent plastic, can be used to designate the toilet as one with a concealed plunger, in order to alert a potential user to the plunger's presence.
Although the preferred embodiments of the invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | The present invention relates to a system for concealing a cleaning device such as a toilet plunger within a toilet flush tank. A modified toilet plunger has been designed to include a hinge so that the plunger cup can pivot on the end of the plunger handle, thereby taking up less space. The folded toilet plunger is secured to the inside of the toilet flush tank by a holder, preferably on the toilet flush tank cover, so that the toilet plunger is readily accessible yet out of sight and will drain into the toilet flush tank after use. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND OF THE INVENTION
The present invention relates generally to operations performed in subterranean wells and, in an embodiment described herein, more particularly provides a remotely actuatable plug apparatus.
It is common practice for plugs in subterranean wells to be serviced via intervention into the wells. For example, a plugging device may be latched in an internal profile of a tubular string using a slickline, wireline, coiled tubing, etc. The plugging device may then be retrieved also using a slickline, wireline, coiled tubing, etc.
However, it would be more convenient, and at times less expensive, to be able to remotely actuate a plugging device. For example, instead of mobilizing a slickline, wireline or coiled tubing rig, ceasing production if necessary, and entering the tubing string with equipment for retrieving a plugging device, it would be far more convenient and economical to merely apply fluid pressure to open a plug apparatus and thereby permit fluid flow through a portion of the tubing string. It would, therefore, be desirable to provide a plug apparatus which is remotely actuated.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with an embodiment thereof, a remotely actuated plug apparatus is provided which permits actuation of the apparatus by application of fluid pressure thereto. Methods of using a remotely actuated plug apparatus are also provided.
In broad terms, a plug apparatus is provided which includes an expendable plug member. The plug member initially blocks fluid flow through one of two flow passages of the plug apparatus. The plug member may be expended by applying a predetermined fluid pressure to one of the two flow passages.
In one aspect of the present invention, a flow passage is isolated from fluid communication with a portion of the plug member by a fluid barrier or a flow blocking member. Application of the predetermined fluid pressure to the flow passage, or another flow passage, ruptures the fluid barrier or displaces the flow blocking member, thereby permitting fluid communication between one or both of the flow passages and the plug member portion. In various representative embodiments of the invention, the flow passages may or may not be placed in fluid communication with each other, and either of the flow passages may by placed in fluid communication with the plug member portion.
In another aspect of the present invention, fluid may be delivered to the plug member portion by a fluid source located within the well, or at the earth's surface. The fluid source may be interconnected to the plug apparatus by a line extending externally to the tubing string in which the plug apparatus is connected. The line may also extend through a well tool interconnected in the tubing string between the fluid source and the plug apparatus.
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
FIGS. 1A&1B are cross-sectional views of successive axial portions of a first plug apparatus embodying principles of the present invention;
FIGS. 2A&2B are cross-sectional views of successive axial portions of a second plug apparatus embodying principles of the present invention;
FIGS. 3A&3B are cross-sectional views of successive axial portions of a third plug apparatus embodying principles of the present invention;
FIG. 4 is a schematicized view of a first method of using a remote actuated plug apparatus, the method embodying principles of the present invention; and
FIG. 5 is a schematicized view of a second method of using a remote actuated plug apparatus, the method embodying principles of the present invention.
DETAILED DESCRIPTION
Representatively illustrated in FIGS. 1A&1B 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 some respects to plug apparatus described in U.S. Pat. Nos. 5,479,986 and 5,765,641, the disclosures of which are incorporated herein by this reference. Specifically, the plug apparatus 10 includes a generally tubular housing assembly 12 configured for interconnection in a tubing string, a flow passage 14 extending generally axially through the housing assembly, and a plug member 16 which blocks fluid flow through the flow passage, but which is expendable upon contact between a fluid and a portion 18 of the plug member. As used herein, the term "expend" means to dispense with or to make no longer functional. For example, the plug member portion 18, or a portion thereof, may be dissolvable in the fluid, may otherwise react with the fluid, etc., so that the plug member portion is no longer able to block fluid flow through the flow passage 14. In the embodiment representatively illustrated in FIGS. 1A&1B, the plug member portion 18 is a compressed mixture of salt and sand which is isolated from contact with fluid in the flow passage 14 by elastomeric end closures 20, but it is to be clearly understood that the plug member portion may be made of any other material and may be otherwise configured without departing from the principles of the present invention.
A fluid passage 22 is formed in the housing assembly 12 for providing fluid communication between a port 24 positioned externally on the housing assembly and the plug member portion 18. When fluid is delivered through the fluid passage 22 to the plug member portion 18, in a manner described more fully below, the plug member portion becomes weakened, so that the plug member 16 is no longer able to block fluid flow through the flow passage 14. A conventional rupture disk 26 or other fluid barrier may be installed between the port 24 and the fluid passage 22, so that a predetermined fluid pressure must be applied to the port 24 to rupture the rupture disk and permit fluid communication between the port and the plug member portion 18 through the fluid passage 22.
Note that the port 24 is formed in a conventional tubing connector 28 which also retains the rupture disk 26 and is threadedly installed externally in the housing assembly 12. It is to be clearly understood that the connector 28 is not necessary in a plug apparatus constructed in accordance with the principles of the present invention, for example, the port 24 could be formed directly on the housing assembly 12 and the rupture disk 26 could be eliminated or otherwise retained relative to the housing assembly.
The connector 28 is configured for connection of an external flow passage or line thereto for application of a predetermined fluid pressure to the rupture disk 26 to rupture it and deliver fluid to the plug member portion 18, as described more fully below. However, the flow passage or line could also extend internally within the housing assembly 12, or be placed in fluid communication with the fluid passage 22 via an appropriately designed connection between the plug apparatus 10 and an external fluid source. Thus, it may be readily appreciated that it is not necessary for the fluid passage 22 to be in fluid communication with a line or flow passage external to the housing assembly 12.
When the plug member 16 is expended, permitting fluid flow through the flow passage 14, note that the flow passage 14 will be placed in fluid communication with the fluid passage 22. This may be desirable in some instances, such as when it is desired to inject fluid into the flow passage 14 via the fluid passage 22 after the plug member 16 has been expended. A check valve (not shown) could be installed to prevent fluid flow from the flow passage 14 into the line or other flow passage connected to the port 24. However, it is not necessary for the flow passage 14 and fluid passage 22 to be placed in fluid communication after the plug member 16 is expended, in keeping with the principles of the present invention.
Representatively illustrated in FIGS. 2A&2B is another plug apparatus 30 embodying principles of the present invention. Elements of the plug apparatus 30 which are similar to elements previously described are indicated in FIGS. 2A&2B using the same reference numbers, with an added suffix "a".
In the plug apparatus 30, the port 24a is formed directly externally in the outer housing assembly 12a, and no rupture disk 26 is utilized to block fluid communication between the port 24a and the fluid passage 22a. However, a tubing connector 28 could be installed in the outer housing assembly 12a, and a rupture disk 26 or other fluid barrier could be utilized, without departing from the principles of the present invention.
Instead of the rupture disk 26, the plug apparatus 30 utilizes a sleeve 32 sealingly and reciprocably disposed within the housing assembly 12a to isolate the fluid passage 22a from fluid delivery thereto. As viewed in FIG. 2A, the sleeve 32 is in an upwardly disposed position relative to the housing assembly 12a, in which the sleeve prevents fluid flow between the fluid passage 22a and the port 24a, and between the fluid passage 22a and the flow passage 14a. The sleeve 32 is releasably secured in this position by shear pins 34.
When a predetermined fluid pressure is applied to the port 24a, the shear pins 34 will shear, and the fluid pressure will downwardly displace the sleeve 32 relative to the housing assembly 12a. Such downward displacement of the sleeve 32 places openings 36 formed through the sleeve in fluid communication with openings 38 formed in the housing assembly 12a, thereby permitting fluid communication between the flow passage 14a and the fluid passage 22a. Fluid in the flow passage 14a may then flow through the openings 36, 38 and through the fluid passage 22a to the plug member portion 18a.
Note that, in the plug apparatus 30, the fluid passage 22a is placed in fluid communication with the flow passage 14a when fluid is delivered to the plug member portion 18a. Additionally, the port 24a is not placed in fluid communication with the fluid passage 22a. Thus, although the predetermined fluid pressure is applied to the port 24a to expend the plug member 16, it is the flow passage 14a which is placed in fluid communication with the plug member portion 18a. However, the port 24a could be placed in fluid communication with the flow passage 14a and/or fluid passage 22a without departing from the principles of the present invention. For example, one or more seals providing sealing engagement between the sleeve 32 and the housing assembly 12a could be disengaged from sealing engagement with the sleeve and/or the housing assembly when the sleeve 32 is displaced downwardly.
Referring additionally now to FIGS. 3A&3B, a plug apparatus 40 embodying principles of the present invention is representatively illustrated. Elements of the plug apparatus 40 which are similar to elements previously described are indicated in FIGS. 3A&3B using the same reference numbers, with an added suffix "b".
The plug apparatus 40 is similar in many respects to the plug apparatus 30 described above, in that a predetermined fluid pressure may be applied to the port 24b to shear the shear pins 34b and thereby downwardly displace a sleeve 42 within the housing assembly 12b, permitting fluid communication between the flow passage 14b and the fluid passage 22b. However, in the plug apparatus 40, a predetermined fluid pressure may also be applied to the flow passage 14b to shear the shear pins 34b and downwardly displace the sleeve 42.
Note that the sleeve 42 of the plug apparatus 40, unlike the sleeve 32 of the plug apparatus 30, presents an upwardly facing piston area 44 in fluid communication with the openings 38b. Thus, when fluid pressure is applied to the flow passage 14b, that fluid pressure also biases the sleeve 42 downward. The predetermined fluid pressure which may be applied to the flow passage 14b to shear the shear pins 34b may be the same as, or different from, the predetermined fluid pressure which may be applied to the port 24b to shear the shear pins, depending upon the respective piston areas on the sleeve 42.
When a predetermined fluid pressure is applied to the port 24b or flow passage 14b, the shear pins 34b will shear, and the fluid pressure will downwardly displace the sleeve 42 relative to the housing assembly 12b. Such downward displacement of the sleeve 42 places the openings formed through the sleeve in which the shear pins 34b are installed in fluid communication with the openings 38b, thereby permitting fluid communication between the flow passage 14b and the fluid passage 22b. Fluid in the flow passage 14b may then flow through the openings 38b and through the fluid passage 22b to the plug member portion 18b.
Note that, in the plug apparatus 40, the fluid passage 22b is placed in fluid communication with the flow passage 14b after fluid is delivered to the plug member portion 18b. Additionally, the port 24b is not placed in fluid communication with the fluid passage 22b. Thus, although a predetermined fluid pressure is applied to the port 24b or the flow passage 14b to expend the plug member 16b, it is the flow passage 14b which is placed in fluid communication with the plug member portion 18b. However, the port 24b could be placed in fluid communication with the flow passage 14b and/or fluid passage 22b without departing from the principles of the present invention. For example, one or more seals providing sealing engagement between the sleeve 42 and the housing assembly 12b could be disengaged from sealing engagement with the sleeve and/or the housing assembly when the sleeve 42 is displaced downwardly.
Referring additionally now to FIG. 4, a method 50 of utilizing a remote actuated plug apparatus is representatively illustrated. In the method 50, a remote actuated plug apparatus 52 is interconnected as a part of a tubular string 54 installed in a subterranean well. The plug apparatus 52 may be similar to one of the above-described plug apparatus 10, 30, 40, or it may be another type of remote actuated plug apparatus.
Another well tool 56 may be interconnected in the tubular string 54. In the method 50 as depicted in FIG. 4, the well tool 56 is a hydraulically settable packer of the type well known to those skilled in the art. The packer 56 is positioned between the plug apparatus 52 and the earth's surface. It is to be clearly understood, however, that the well tool 56 may be a tool or item of equipment other than a packer, and it may be otherwise positioned in the well, without departing from the principles of the present invention.
A control line or other type of flow passage 58 is connected to a conventional fluid source, such as a pump (not shown), at the earth's surface. The term "fluid source" as used herein means a device or apparatus which forcibly transmits fluid, such as a pump, a pressurized accumulator or another fluid pressurizing device. The line 58 extends downwardly from the earth's surface, extends through the packer 56, and connects externally to the plug apparatus 52, such as at the ports 24, 24a, 24b described above. Of course, the line 58 or other type of flow passage could be internally disposed relative to the tubular string 54, could be formed in a sidewall of the tubular string, etc., without departing from the principles of the present invention. For example, in the packer 56, the flow passage 58 could be formed in a sidewall of a mandrel of the packer.
With the plug apparatus 52 initially preventing fluid flow through the tubular string 54, fluid pressure may be applied to the tubular string to set the packer 56 in the well, and then fluid pressure may be applied to the line 58 to open the plug apparatus to fluid flow therethrough. If the plug apparatus 52, like the plug apparatus 40 described above, is actuatable by application of fluid pressure to the tubular string 54, the line 58 may not be necessary, and the plug apparatus may be set up so that the predetermined fluid pressure needed to open the plug apparatus is greater than the fluid pressure needed to set the packer 56. Alternatively, the packer 56 could be settable by application of fluid pressure to the line 58, and the plug apparatus 56 could be actuated by application of fluid pressure to the line greater than that needed to set the packer. As another alternative, the packer 56 could be settable by fluid pressure in the line 58, and the plug apparatus 52 could be actuatable by fluid pressure in the tubular string 54. Thus, it will be readily appreciated that the plug apparatus 52 permits increased versatility in wellsite operations, without requiring intervention into the well for its actuation.
Referring additionally now to FIG. 5, another method 60 embodying principles of the present invention is representatively illustrated. Elements shown in FIG. 5 which are similar to elements previously described are indicated in FIG. 5 using the same reference numbers, with an added suffix "c".
Note that, in the method 60, the line 58c does not extend to a fluid source at the earth's surface. Instead, the line 58c extends to a fluid source 62 installed in the well as a part of the tubular string 54c. The fluid source 62 may be a pump, hydraulic accumulator or differential pressure-driven piston of the type well known to those skilled in the art. Additionally, the fluid source 62 may apply fluid pressure to the line 58c in response to receipt of a signal transmitted thereto from the earth's surface or other remote location, such as another location within the well.
The fluid source 62 could include a pump or other fluid pressurizing device coupled with the tubular string 54c for supplying the predetermined fluid pressure to actuate the plug apparatus 52c. For example, a slickline, wireline, coiled tubing, or otherwise-conveyable fluid pressurizing device could be positioned in the tubular string 54c and coupled therewith. An example of such a fluid pressurizing device is described in U.S. Pat. No. 5,492,173. Another fluid pressurizing device is the model DPU available from Halliburton Energy Services, Inc. of Dallas, Tex. The DPU or other fluid pressurizing device may be engaged with the tubular string 54c, such as via an internal latching profile, to form the fluid source 62 and to place the DPU in fluid communication with the line 58c. The DPU could then be actuated to provide pressurized fluid, which is then delivered to the plug apparatus 52c via the line 58c.
Of course, many modifications, additions, deletions, substitutions and other changes may be made to the various embodiments of the present invention described herein, which would be obvious to a person skilled in the art, and these changes are contemplated by the principles of the present invention. For example, in the method 60, the fluid source 62 could be positioned between the packer 56c and the plug apparatus 52c, and could be attached directly to the plug apparatus. 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 and associated methods are provided for remotely actuating a plug apparatus in a subterranean well. In a described embodiment, a plug apparatus has a plug member blocking fluid flow through one of two flow passages of the plug apparatus. A predetermined fluid pressure applied to one of the flow passages permits the plug member to be expended from the plug apparatus. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The priority of U.S. Provisional Application 60/673,933, filed on Apr. 22, 2005, is hereby claimed and the specification thereof is incorporated herein by reference. This application and U.S. Pat. Nos. 6,260,623, 6,427,777 and 6,622,792, which are incorporated herein by reference, are commonly assigned to KMK Trust.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable.
FIELD OF THE INVENTION
[0003] The present invention is directed to an apparatus and method for improving the formation of multiple lateral wells in new and pre-existing wellbores, and positive, selective reentry of each lateral well.
BACKGROUND OF THE INVENTION
[0004] Several advantages are provided by drilling relatively high angle, deviated or lateral wells from a generally common wellbore such as a) access to the regular oil and gas reserves without additional wells being drilled from the surface, b) avoiding unwanted formation fluids, c) penetration of natural vertical fractures, and d) improved production from various types of formations or oil and gas reserves. Additionally, reentry of one or more lateral wells is often required to perform completion work, additional drilling, or remedial and stimulation work. Thus, lateral wells have become commonplace from the standpoint of new drilling operations and reworking existing wellbores.
[0005] Ordinarily, lateral well completion and/or reentry requires expensive downhole wireline surveys to accurately position the diverter or whipstock which is used to direct the boring or completion tool through a wall of a generally vertical wellbore into the adjacent formation. Without a survey, the lateral well formed may not be accurately recorded for purposes of reentry. For example, U.S. Pat. Nos. 4,304,299; 4,807,704; and 5,704,437 each describe a method and/or apparatus for producing lateral wells from a generally vertical common wellbore using conventional techniques and tools. In each instance, one or more lateral wells may be produced at a different depth and location in the common wellbore and reentered. Consequently, the whipstock must be repositioned at the new depth and location. Each time the whipstock is repositioned at a different depth and location, the change in depth and lateral orientation relative to a point of reference is recorded. In many applications using conventional threaded connections, the exact depth and location of each lateral well formed cannot be accurately or efficiently recreated using the same system and technique. As a result, a downhole directional survey is necessary to relocate the exact depth and location of each lateral well upon reentry.
[0006] Recognizing the disadvantages of the foregoing techniques, U.S. Pat. No. 2,839,270 and, more recently, U.S. Pat. No. 5,735,350 address the need for a more accurate method and/or apparatus for producing and reentering lateral wells without the need for a directional survey. For example, U.S. Pat. No. 2,839,270 describes a technique for selectively forming a lateral well through a wall of a common wellbore at a predetermined depth and lateral orientation by means of a supporting apparatus which includes apertures formed at predetermined locations in the supporting apparatus. The apertures determine the relative depth and lateral orientation of each lateral well and are prefabricated according to the particular common wellbore in which the supporting apparatus is installed. The whipstock is then positioned using one or more specially designed latches which engage a corresponding aperture designed for receipt of the respective latch.
[0007] Similarly, U.S. Pat. No. 5,735,350 describes a method and system for creating lateral wells at pre-selected positions in a common wellbore by means of a diverter assembly having a plurality of locator keys specially designed to engage a corresponding nipple formed in the wellbore casing having a unique profile. Although this technique may be employed in new and existing wells, it is expensive and, in some instances, inappropriate because the prefabricated keys and nipples are permanently and integrally formed according to the particular formation characteristics of the common wellbore in which the system is installed.
[0008] More recently, a system and method for use in a completed wellbore lined with casing was described in U.S. Pat. No. 6,427,777. This system uses a directional survey to position an anchor at a predetermined depth and lateral orientation relative to a longitudinal position and lateral position of the desired lateral well. Because a directional survey is used to position the anchor after the casing is set and secured, the exact location of a pre-formed opening in the casing is difficult to find. And, because the system is designed for completed wellbores, the system typically requires running equipment in the wellbore which is different than the equipment used to line and secure the wellbore with casing. Finally, the casing must be milled with a different type of bit than the bit used to drill through the formation when the system is used in a completed wellbore without pre-formed openings in the casing. As a result, the system must be run in the wellbore twice to form each lateral well.
SUMMARY OF THE INVENTION
[0009] The present invention meets the above needs and overcomes one or more deficiencies in the prior art by providing an apparatus for adjusting alignment between one section of a tubular assembly and another section of the tubular assembly. The apparatus comprises a first coupler coupled to one section of the tubular assembly and a second coupler coupled to another section of the tubular assembly. The first coupler includes a plurality of grooves equidistantly spaced about the circumference of the first coupler. The second coupler includes a plurality of teeth equidistantly spaced about the circumference of the second coupler, wherein each tooth is cooperatively engaged with a corresponding groove from the plurality of grooves. The first coupler and the second coupler are fully engaged to prevent rotational movement therebetween at a first position and are partially engaged to prevent incremental rotational movement therebetween at a second position.
[0010] In another embodiment, the present invention provides a packer for use in forming a lateral borehole through the wall of a wellbore. The packer comprises a first passage having an opening in an upper portion of the packer and a side opening in the packer and a second passage having an opening in the upper portion of the packer and an opening into the first passage for fluid communication between the first passage opening in the uppoer portion of the packer and the second passage opening in the upper portion of the packer.
[0011] In yet another embodiment, the present invention provides a method for forming a lateral borehole through a wall of a wellbore with a packer having a first passage in fluid communication with a second passage. The method comprises: i) setting the packer at a predetermined depth and azimuth; ii) positioning a flexible boring tool through the first passage and a side opening in the packer; iii) forming the lateral borehole with the flexible boring tool; and iv) pumping a fluid through the second passage and a portion of the first passage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention is described in detail below with reference to the attached drawing figures, wherein:
[0013] FIG. 1 . is an elevational view of a tubular assembly illustrating the adjustable coupling apparatus and the packer of the present invention in partial cross-section.
[0014] FIG. 2A is a cross-sectional view of the packer illustrated in FIG. 1 .
[0015] FIG. 2B is a cross-sectional view of the packer illustrated in FIG. 1 and a flexible boring tool inserted there through into a formation.
[0016] FIG. 3A is an elevational view of the adjustable coupling apparatus illustrated in FIG. 1 , fully engaged.
[0017] FIG. 3B is an elevational view of the adjustable coupling apparatus illustrated in FIG. 1 , partially engaged.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] In the description which follows, like parts are marked throughout this description in drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated, in scale or in schematic form, in some details of conventional elements may not be shown in the interest of clarity and conciseness.
[0019] FIG. 1 is an elevational view of a tubular assembly 100 shown in partial cross-section and illustrates one embodiment of the present invention. The tubular assembly 100 may be used in both new and preexisting well environments and is generally shown within a main well bore 112 that has been drilled generally vertically into a surface 114 of the earth in a conventional manner. The well bore 112 extends generally vertically downward into an area of the formation 116 where it may also be desired to induce or inject fluids. In this embodiment, the well bore 112 is generally vertical, however, may extend in other non-vertical directions approaching horizontal. The main casing 118 may be set and secured in the well bore 112 with a cement liner 120 in a conventional manner or in the manner described in U.S. Pat. No. 6,622,792. Generally, the casing 118 comprises multiple segments that may be connected at the surface 114 , wherein each connection forms a casing joint 117 , as the casing 118 is lowered into the well bore 112 . Preferably, at least one of the casing segments includes a preformed opening or window 119 in the casing 118 . The opening 119 may be covered by a fiberglass mesh (not shown) or any other substantially impermeable material to prevent the cement liner 120 from compromising the annulus between the drill string 132 and the casing 118 .
[0020] The tubular assembly 100 comprises a first anchor 122 , an orienting member 124 , an extension member 126 , a packer 128 and a second anchor 130 . The first anchor 122 may include a conventional packer design or it may be designed in the same manner as the anchor described in U.S. Pat. No. 6,427,777. The first anchor 122 may be positioned within the well bore 112 at a predetermined position using a drill string 132 comprising segments of connected drill pipe. The predetermined position of the first anchor 122 may be determined by any conventional survey means, such as a directional down hole survey of the formation 116 to determine the depth (longitudinal position) and azimuth (lateral orientation) of the first anchor 122 . A conventional directional survey of the well bore 112 therefore, should reveal the longitudinal position and lateral direction of each region or area of the formation 116 where hydrocarbons may be found. Based upon the survey results, the appropriate number of lateral boreholes may be determined at a given depth and azimuth. The casing 118 may include multiple preformed openings, like opening 119 , which may be aligned with each corresponding area of the formation 116 where a lateral borehole is desired. Thus, the casing 118 and the first anchor 122 may be made up and lowered into the well bore 112 until the opening 119 is generally aligned with an area of the formation 116 where a lateral borehole is desired. The longitudinal position and lateral orientation of the opening 119 may be generally aligned with an area of the formation 116 where a lateral borehole is desired by reference to a longitudinal reference point and lateral reference point located on the first anchor 122 in the manner described in U.S. Pat. No. 6,427,777. If, however, the casing 118 does not include opening 119 , then the first anchor 122 and the casing 118 may be made up and lowered into the well bore 112 adequately below an area of the formation 116 where a lateral borehole furtherest from the surface 114 is desired.
[0021] Once the casing 118 and the first anchor 122 are set and secured in the well bore 112 , the orienting member 124 , the extension member 126 , the packer 128 and the second anchor 130 may be lowered into the well bore 112 until the orienting member 124 is slidably engaged within the first anchor 122 . The first anchor 122 may be modified to include the longitudinal reference point and the lateral reference point in most applications after the first anchor 122 is permanently secured.
[0022] The side opening 129 in the packer 128 may be aligned with the opening 119 in the casing 118 using the extension member 126 . Alternatively, the side opening 129 in the packer 128 may be generally positioned at a predetermined longitudinal position and lateral orientation corresponding with a preferred area of the formation 116 where a lateral bore hole may be desired. The extension member 126 includes one end 158 connected to the orienting member 124 and another end 154 connected to the packer 128 . The length of the extension member 126 may be varied by using one or more shorter or longer drill pipe segments 156 . Each unilateral connection 140 maintains lateral orientation and alignment between the orienting member 124 and the side opening 129 in the packer 128 . Each unilateral connection 140 and drill pipe segment 156 may be designed and made up in the manner described in U.S. Pat. No. 6,427,777. An adjustable coupling device 134 permits the lateral orientatin of the packer 128 to be adjusted in preselected increments as more particularly described in reference to FIGS. 3A and 3B .
[0023] The packer 128 may therefore, be positioned at any predetermined depth and lateral orientation by using the first anchor 122 , the orienting member 124 and the extension member 126 . The first anchor 122 and the orienting member 124 may therefore, be constructed and operated in the same manner as the anchor and the orienting member described in U.S. Pat. Nos. 6,427,777 and 6,662,792. Alternatively, the first anchor 122 and the orienting member 124 may be constructed and operated in the same manner as the bridge plug and orienting device described in U.S. Pat. No. 6,260,623. A second anchor 130 may be positioned above the packer 128 for additional stability, if necessary. The second anchor 130 may include another packer and/or slips, which may be integral with, or connected to, the packer 128 .
[0024] Referring now to FIGS. 2A and 2B , cross-sectional views of the packer 128 are illustrated with ( FIG. 2B ) and without ( FIG. 2A ) a flexible boring tool 200 . The flexible boring tool 200 may include a conventional drill bit or a fluid jet nozzle at a distal end 204 for use in forming a lateral bore hole 202 through the cement liner 120 , a wall of the well bore 112 and into the formation 116 . The flexible boring tool 200 may be positioned at the lower end of a coil tubing string. In the event that a fluid jet nozzle is preferred at the distal end 204 the flexible boring tool 200 , the fluid jet nozzle may be designed and operated in the manner described in U.S. Pat. No. 6,260,623 to bore through and/or stimulate the formation 116 with one of a fluid and another fluid.
[0025] The packer 128 includes a first passage 206 for receipt of the flexible boring tool 200 and at least one of the fluid and the another fluid. The first passage 206 has an opening 208 centrally positioned in an upper portion of the packer 128 and a side opening 129 . The first passage 206 may extend from the first passage opening 208 in the upper portion of the packer 128 to the surface 114 of the well bore 112 through the drill string 132 . The packer 128 also includes a second passage 210 for receipt of one of the fluid and the another fluid. The second passge 210 has an opening 212 in the upper portion of the packer 128 and an opening 214 into the first passage for fluid communication between the first passage opening 208 in the upper portion of the packer 128 and the second passage opening 212 in the upper portion of the packer 128 . The second passage opening 214 into the first passage 206 may be closer to the side opening 129 than to the first passage opening 208 in the upper portion of the packer 128 .
[0026] The packer 128 may be expanded to engage the side opening 129 of the packer 128 with the lateral bore hole 202 . The packer 128 may be expanded with a sealing element 216 , which substantially prevents the fluid, the another fluid and/or formation cuttings from passing between the formation 116 and an annulus between the casing 118 and the drill string 132 .
[0027] The second passage opening 214 into the first passage 206 is positioned to direct at least one of the fluid and the another fluid toward the first passage opening 208 in the upper portion of the packer 128 . One of the fluid and the another fluid therefore, enters the second passage opening 212 in the upper portion of the packer 128 and exits through the first passage opening 208 in the upper portion of the packer 128 for controlling at least one of a plurality of entrained cuttings from the formation of the lateral bore hole 202 and a hydrostatic pressure between the well bore 212 and the lateral bore hole 202 . A check valve 218 may be positioned in the second passage 210 near the second passage opening 212 in the upper portion of the packer 128 to prevent one of the fluid and the another fluid from circulating away from the second passage opening 214 into the first passage 206 toward the second passage opening 212 in the upper portion of the packer 128 .
[0028] The fluid and the another fluid may comprise at least one of a liquid and a gas that are introduced through the drill string 132 to the second passage opening 212 in the upper portion of the packer 128 and the flexible boring tool 200 . The fluid and the another fluid therefore, may or may not comprise the same fluid.
[0029] The selection of the fluid and the another fluid may depend on the desire to control the velocity and the volume of entrained formation cuttings flowing through the first passage 206 and/or the hydrostatic pressure between the well bore 112 and the lateral bore hole 202 . For example, selection of a heavier fluid raises the hydrostatic pressure. Conversely, selection of a lighter fluid lowers the hydrostatic pressure. A gas, such as oxygen or nitrogen, or a combined liquid and gas (foam) may therefore, be used as the fluid or the another fluid in the second passage 210 to lower the hydrostatic pressure. A liquid or a gel, however, may be preferred to carry more formation cuttings and reduce the slip of such cuttings. As the velocity of the fluid or the another fluid is increased through the second passage 210 , more formation cuttings may be carried (entrained) through the first passage 206 .
[0030] In another embodiment, the packer 128 may comprise a third passage 220 for receipt of one of the fluid and the another fluid. The third passage 220 has an opening 222 in the upper portion of the packer 128 and an opening 224 into the first passage 206 for fluid communication between the third passage opening 222 in the upper portion of the packer 128 and the first passage opening 208 in the upper portion of the packer 128 . The third passage 220 may be used to improve the velocity and the volume of entrained cuttings flowing from the formation of the lateral bore hole 202 through the first passage 206 and control the hydrostatic pressure between the well bore 112 and the lateral bore hole 202 in the same manner as described in reference to the second passage 210 .
[0031] In this embodiment, for example, the first passage 206 may comprise an independent passage throughout the full length of the drill string 132 , while the second passage 210 and the third passage 220 may be limited to the packer 128 . The one of the fluid and the another fluid may be introduced through the flexible boring tool 200 , which returns, with the formation cuttings, through the first passage 206 in the drill string 132 to the surface 114 of the well bore 112 in FIG. 1 . The one of the fluid and the another fluid may also be introduced through the second passage 210 and the third passage 220 , which returns, with the formation cuttings, through a portion of the first passage 206 in the drill string 132 to the surface 114 of the well bore 112 in FIG. 1 . The one of the fluid and the another fluid may be introduced through the annulus between the casing 118 and the drill string 132 to the second passage opening 214 and the third passage opening 222 in the upper portion of the packer 128 . In this manner, the fluid and/or the another fluid may originate from the same, or separate, source(s) and return through the first passage 206 in the drill string 132 to the same source at the surface 114 of the well bore 112 in FIG. 1 .
[0032] The packer 128 may therefore, be used to form the lateral bore hole 202 through a wall of the well bore 112 by first setting the packer 128 at a predetermined depth (longitudinal position) and azimuth (lateral orientation) as described in reference to FIG. 1 . The side opening 129 of the packer 128 is initially aligned with the opening 119 in the casing 118 . The flexible boring tool 200 is then positioned through the first passage 206 and the side opening 129 in the packer 128 . If milling through the casing 118 is unnecessary, then the flexible boring tool 200 may be fitted with a drilling bit or fluid jet nozzle at its distal end 204 that is capable of forming the lateral bore hole 202 through a preferred area of the formation 116 . In one embodiment, the fluid jet nozzle may be used to form the lateral bore hole 202 by introducing one of a fluid and another fluid through the fluid jet nozzle attached to the distal end 204 of the flexible boring tool 200 at a high velocity to form the lateral bore hole 202 . As the lateral bore hole 202 is formed, formation cuttings and one of the fluid and the another fluid are forced through the lateral bore hole 202 and the side opening 129 of the packer 128 into the first passage 206 . The sealing element 216 substantially prevents formation cuttings and one of the fluid and the another fluid from entering the annulus between the casing 118 and the drill string 132 .
[0033] In order to facilitate entrainment of the formation cuttings and one of the fluid and the another fluid into the first passage 206 , one of the fluid and the another fluid may be introduced through the second passage 210 and a portion of the first passage 206 , between the second passage opening 214 into the first passage 206 and the first passage opening 208 in the upper portion of the packer 128 , at a sufficient velocity to entrain the formation cuttings and at least one of the fluid and the another fluid through the first passage opening 208 in the upper portion of the packer 128 , away from the side opening 129 in the packer 128 . Introducing one of the fluid and the another fluid through the second passage 210 and the portion of the first passage 206 may also control hydrostatic pressure between the well bore 112 and the lateral bore hole 202 .
[0034] Once the lateral bore hole 202 is formed, the process may be repeated as described to form multiple lateral bore holes, at the same depth or longitudinal position, without removing the packer 128 from the well bore 112 . The packer 128 may therefore, be used to entrain formation cuttings, control hydrostatic pressure and/or drill in underbalanced conditions.
[0035] Referring now to FIGS. 3A and 3B , elevational views of the adjustable coupling apparatus 134 are illustrated in a fully engaged first position ( FIG. 3A ) and a partially engaged second position ( FIG. 3B ). The adjustable coupling apparatus 134 may be used to align the packer 128 with an opening in the casing 118 or preferred lateral orientation to form a lateral bore hole without removing the packer 128 from the well bore 112 . The adjustable coupling apparatus 134 therefore, may be used to adjust alignment between one section of the tubular assembly 100 connected to one end 138 of the adjustable coupling apparatus 134 and another section of the tubular assembly 100 connected to another end 136 of the adjustable coupling apparatus 134 . The adjustable coupling apparatus 134 includes a first coupler 300 coupled to the one section of the tubular assembly 100 at the another end 136 , and a second coupler 304 coupled to the another section of the tubular assembly 100 at the end 138 . The first coupler 300 includes a plurality of grooves 302 equidistantly spaced about a circumference of the first coupler 300 . The second coupler 304 includes a plurality of teeth 306 equidistantly spaced about a circumference of the second coupler 304 . Each tooth 306 is cooperatively engaged with a corresponding groove 302 .
[0036] In FIG. 3A , the first coupler 300 and the second coupler 304 are fully engaged at a first position by a force 308 . The first coupler 300 and the second coupler 304 are restricted from rotational movement at the fully engaged first position. In FIG. 3B , the first coupler 300 and the second coupler 304 are partially engaged at a second position by a force 312 . The first coupler 300 and the second coupler 304 may be incrementally rotated in a clockwise direction 310 at the partially engaged second position. Alternatively, the adjustable coupling apparatus 134 may be designed to permit full engagement between the first coupler 300 and the second coupler 304 by a force in a direction opposite to the force 308 illustrated in FIG. 3A . Likewise, the adjustable coupling apparatus 134 may be designed to permit partial engagement by a force in a direction opposite to the force 312 illustrated in FIG. 3B . The adjustable coupling apparatus 134 may also be designed to permit incremental rotational movement between the first coupler 300 and the second coupler 304 in a counter-clockwise direction, instead.
[0037] The first coupler 300 and the second coupler 304 therefore, permit rotational alignment in a single direction between the one section of the tubular assembly 100 and another section of the tubular assembly 100 . The first coupler 300 and the second coupler 304 are therefore, longitudinally movable between the first position illustrated in FIG. 3A and the second position illustrated in FIG. 3B . The adjustable coupling apparatus 134 enables the packer 128 to be used with the flexible boring tool 200 to form multiple equidistantly spaced lateral bore holes at the same depth or longitudinal position within the well bore 112 . As illustrated in reference to FIG. 1 , additional lateral bore holes may be formed at other depths or longitudinal positions by removing the tubular assembly 100 and adjusting the length of the extension member 126 . Accordingly, the tubular assembly 100 may be utilized to form multiple lateral bore holes through a wall of the well bore 112 at multiple lateral positions at the same or different longitudinal positions (depths) in preexisting or new well bores with fewer runs and fewer tools.
[0038] Because the tubular assembly 100 comprises many conventional or standard components, this tubular assembly 100 costs less to manufacture than any alternative systems, which may require specially designed casing and other components manufactured in accordance with the specific requirements of the particular site and well bore. Additionally, the tubular assembly 100 , and use thereof, may be employed in new and preexisting well bores using the same components, which substantially reduces production costs.
[0039] While preferred embodiments of the present invention have been illustrated in detail, it is apparent that modifications and adaptations of the preferred embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention as set forth in the following claims. | An apparatus and method for improving multilateral well formation and reentry are disclosed. The apparatus comprises a tubular assembly, which includes an adjustable coupling device and a packer. The method comprises the use of the tubular assembly. |
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This application is a continuation in part of U.S. patent application Ser. No. 10/922,126 filed Aug. 16, 2004, which is hereby incorporated by reference.
BACKGROUND
1. Field of the Invention
The present invention relates to an apparatus for cleaning swimming pools, spas, and hot tubs, reflection pools, and other water features.
2. Description of the Related Art
Outdoor swimming pools are often exposed to sources of contamination. Leaves and sticks fall from surrounding trees, grass clippings eject from lawn mowers, and dirt and other trash are commonly near a swimming pool. Wind blows the grass, sticks, dirt, and other trash into the swimming pool, making the pool unsanitary and unpleasant to swim in.
To help maintain proper sanitation, swimming pools commonly include a circulation pump and filter system. The circulation pump draws water from the pool, pumps the water through a filter, and then returns the water to the pool. A strainer is typically installed where the circulation pump draws water from the swimming pool. The strainer is designed to strain leaves and other debris from the water in order to protect the circulation pump.
When many leaves and debris fall into the swimming pool, the pool requires additional cleaning beyond the installed filter system. Many pool-cleaning devices are available to move along the swimming pool bottom and lift debris from the bottom. Some pool-cleaning devices are categorized as suction type pool cleaners; other pool-cleaning devices are categorized as pressure type pool cleaners.
Present suction type pool cleaners typically use the swimming pool's circulation pump to develop suction, and some use the swimming pool's filter system to remove debris. Typical examples of suction type pool cleaners include U.S. Pat. No. 4,849,024 to Supra, U.S. Pat. No. 5,720,068 to Clark, and U.S. published patent application 2003/0208862 to Henkin. However, suction type pool cleaners that use the pool's filter system can put a heavy burden on the circulation pump and filter system. As leaves and debris accumulate in the strainer, the flow of water to the circulation pump is reduced. The strainer must be cleaned out repeatedly to prevent clogging, which reduces suction and potentially can cause harm to the circulation pump. In addition, circulation pumps typically need to be primed, which is inconvenient and time consuming for the operator. Because of the demands on the circulation pump, present suction type pool cleaners commonly have low suction and are limited in their ability to pick up heavy debris such as pebbles or sand. When the swimming pool's filter system is used to remove debris, the additional load on the filter makes filter maintenance and cleaning more frequent.
Pressure type pool cleaners operate on pressurized water that is supplied to the pool cleaner through a hose. The pressurized water is used to drive blades of a turbine that induce a flow of pool water into a collection bag. Some pressure type pool cleaners use a booster pump to generate added water pressure because the circulation pump used in many swimming pools does not create sufficient water pressure for effective cleaning. Typical examples of pressure type pool cleaners include U.S. Pat. No. 5,933,899 to Campbell, U.S. Pat. No. 5,930,856 to Van Der Meyden, and U.S. Pat. No. 4,558,479 to Greskovics. While all of the pool-cleaning devices and systems available have furthered the art of swimming pool cleaning, none of the known prior art addresses a pool cleaner that can quickly and efficiently remove a large quantity of debris from a swimming pool or other water feature. There remains a need for a powerful and efficient pool cleaning system and apparatus that does not rely on the circulation pump and filter system of the swimming pool for its power, is easy to use, and which is inexpensive to maintain.
SUMMARY OF THE INVENTION
In response to the foregoing concerns, the present invention provides an apparatus for cleaning swimming pools, spas, fountains, and other water features. One embodiment of the pool cleaning apparatus includes a pump with an inlet and an outlet, suited to pump a mixture of contaminants (such as leaves and pebbles) and liquid (such as water). A gasoline or electric engine is coupled to the pump to drive the pump. The pump provides suction to draw the mixture of contaminants and liquid into a vacuum wand that is connected to the pump inlet. The vacuum wand is designed to lift debris and water from the bottom of a swimming pool and may be configured with a long handle, or may be configured to move about the bottom of a swimming pool automatically when the pump is operating.
The mixture of contaminants and liquid entering the pump inlet are expelled through the pump outlet into a transfer pipe, then through a filtering device. The filtering device includes a trap to strain large debris and items such as leaves, grass clippings, worms, coins, and pebbles, and a primary filter for straining smaller particles, such as sand, algae, small bugs, and dirt. The filtered water flows out of the filtering device through a discharge hose, and back into the swimming pool. In one embodiment, the primary filter comprises a permeable foam or fibrous material. In a further embodiment, the pool cleaning apparatus includes a pump with an inlet and an outlet, and a filtering device with an inlet and an outlet. A vacuum wand is attached to the inlet of the filtering device. The outlet of the filtering device is attached to the pump inlet. In this embodiment, suction from the pump draws a mixture of contaminants and liquid from a pool of water through the vacuum wand and through the filtering device comprising a leaf trap and a filter, where the contaminants are filtered out. The suction of the pump then draws filtered water from the filtration device through the pump. The filtered water is expelled out of the pump outlet and back to the pool.
In one embodiment, the pool cleaning apparatus is mounted to a cart or hand truck so that the apparatus is portable, and may, during swimming season, be attachable to an above ground pool where it functions both as a water purification system and as a pool cleaner. In another embodiment, the pool cleaning apparatus is permanently installed pool-side, where it functions both as a water purification system, and as a pool cleaner.
The following description sets forth in detail certain illustrative embodiments of the invention, these being indicative of but a few of the various ways in which the principles of the present invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view in partial cross section of a first embodiment of the pool cleaning apparatus;
FIG. 2 is a side elevational view in partial cross section of a vacuum wand for the pool cleaning apparatus;
FIG. 3 is a side perspective view in partial cross section of a trap for the pool cleaning apparatus;
FIG. 4 is a side perspective view of a first embodiment of the pool cleaning apparatus;
FIG. 5 is a side perspective view of a second embodiment of the pool cleaning apparatus;
FIG. 6 is a partially elevated perspective view of the pool cleaning apparatus, reflecting a third embodiment of the invention, showing the operation of the invention.
FIG. 7 is a perspective view of the pool cleaning apparatus shown in FIG. 6 showing the front right side thereof;
FIG. 8 is a perspective view of the pool cleaning apparatus shown in FIG. 7 , showing the back left side thereof;
FIG. 9 is an exploded view of the filtration device located on the pool cleaning apparatus shown in FIG. 8 ;
FIG. 10 is a cross section of the filtration device shown in FIG. 9 , with arrows illustrating the flow of water through the filtration device;
FIG. 11 is a top view of the filtration element contained in the filtration device of the third, fourth, fifth, and sixth embodiments described herein;
FIG. 12 is a perspective view of the fourth embodiment of the pool cleaning apparatus, showing the front right side thereof;
FIG. 13 is a cross section of the filtration device shown of the pool cleaning apparatus shown in FIG. 12 , with arrows illustrating the flow of water through the filtration device;
FIG. 14 is a partially elevated perspective view of the pool cleaning apparatus shown in FIG. 7 , reflecting the fifth embodiment of the invention, depicting the annexation thereof to an above-ground swimming pool;
FIG. 15 is a top schematic view of the pool cleaning apparatus, reflecting the sixth embodiment of the invention, depicting the incorporation thereof into the filtration and cleaning system of a pool or water feature;
FIG. 16 is a top schematic view of the general set up of the pool cleaning apparatus shown in FIG. 15 , showing a diagram of the pump, motor, filtration device, heater, mineral filterchlorine pack combination unit, water control valves and water control unions;
FIG. 17 is an exploded view of the filtration device depicted in FIGS. 6-10 and 12 - 16 , showing the modified frame on which the filtration device is mounted;
FIG. 18 is a partially elevated perspective view depicting the modified basket which is used with the filtration and cleaning system shown in FIGS. 14 and 15 ;
FIG. 19 is a partially elevated perspective view of the suction disc, showing tapering nipple and gasket, which covers the pool drain during cleaning; and
FIG. 20 is an exploded view of a pump.
DETAILED DESCRIPTION
As used in this specification and the appended claims, the word debris means particles and substances that contaminate pool water, including larger items such as, but not limited to, leaves, grass clippings, worms, trash, coins, and pebbles, and smaller particles such as, but not limited to, sand, algae, small bugs, and dirt.
Referring to FIGS. 1 and 4 , a first embodiment of the pool cleaning apparatus of the present invention includes a pump 1 that has a pump inlet 2 and a pump outlet 4 . The pump 1 is driven by a motor 6 , and is configured to pump a mixture of contaminants and liquid. A vacuum wand 8 is illustrated in FIG. 2 . The vacuum wand 8 includes a hose 10 , an intake aperture 12 , and a handle 14 . The hose 10 is connected to the pump inlet 2 , whereby the pump 1 can draw a mixture of contaminants and liquid from a pool of water through the intake aperture 12 and into the pump inlet 2 . The pump 1 expels the mixture of contaminants and liquid through the pump outlet 4 into a transfer pipe 13 . The mixture of contaminants and liquid flow through the transfer pipe 13 to a trap inlet 16 , located inside of a filtering device 18 .
The filtering device 18 includes a vessel 20 and a lid 22 . The lid 22 is secured to the vessel 20 by a lid clamp 24 . Inside the vessel 20 , the mixture of contaminants and liquid discharge through the trap inlet 16 into a trap 26 .
The trap 26 is situated to strain larger contaminants such as leaves and pebbles out of the mixture. Referring to FIG. 3 , the trap 26 includes one or more peripheral surfaces 28 defining a container shaped to capture debris. The peripheral surfaces 28 include a plurality of holes or perforations to allow water to flow through the trap 26 but to retain contaminants such as leaves and pebbles inside of the trap 26 . The trap 26 is removable for cleaning when the lid 22 is opened. In one embodiment, trap 26 further comprises an access door 30 . The access door 30 is hinged to allow the operator to push the access door open as shown by position 30 a . The access door may be spring loaded to hold the access door 30 closed.
The partially separated liquid mixture passes through a primary filter 32 . The primary filter 32 is a permeable foam or fibrous material in one embodiment. The primary filter 32 acts to further separate contaminants from the liquid before the liquid is expelled through a discharge hose 34 . In a normal operation, the discharge hose 34 returns filtered water back to the pool of water.
In one embodiment, the filtering device 18 sits on a base 36 . In another embodiment, the filtering device 18 includes features to sit without a base 36 .
In one embodiment, the foregoing components are mounted to a cart 38 , which has wheels 40 and a cart handle 42 . The cart 38 makes the pool cleaning apparatus portable.
A second embodiment is illustrated in FIG. 5 . The second embodiment includes a filtering device 44 with a filtering device inlet 46 and a filtering device outlet 48 . The hose 10 of the vacuum wand 8 is connected to the filtering device inlet 46 . The second embodiment includes a pump 1 , with a pump inlet 2 and a pump outlet 4 . The pump inlet 2 is connected to the filtering device outlet 48 . The pump outlet 4 is connected to a discharge hose 50 . The pump 1 is driven by a motor 6 and is sized so that the suction from the pump 1 will draw a mixture of contaminants and liquid from a pool of water through the intake aperture 12 , through the hose 10 , and through the filtering device 44 . The filtering device 44 removes the contaminants from the mixture, and filtered water passes through the filtering device outlet 48 and into the pump inlet 2 . The filtered water is expelled through the pump outlet 4 and through the discharge hose 50 .
In the first embodiment, the pump 1 is a pass through pump suited to transferring a mixture of debris and liquid. In one embodiment, the pass through pump 1 is a type of pump commonly known in the art as a trash pump, which is configured to pass a mixture of debris and liquid. A trash pump has benefits over a regular pump because a trash pump is more durable and reliable for water that contains debris such as leaves and small pebbles. In the first and second embodiments, the pump 1 is self-priming.
In one embodiment, the motor 6 is a gasoline engine. Gasoline engines of this type are commonly available from manufacturers such as Briggs and Stratton or Honda and are well known in the art. Other types of engines or motors may be used as well. Some embodiments of the pool cleaning apparatus may use a suitable electric motor, or might operate with an engine of an alternate fuel, such a diesel engine.
The design of the filtering device 18 includes a method for removing the trap 26 . As the trap 26 fills with leaves or other contaminants, it will become clogged, reducing the effectiveness of the apparatus. By unlatching the lid clamp 24 , the operator can open the lid 22 . Once the lid 22 is opened, the trap 26 can be removed and cleaned.
The primary filter 32 may be comprised of a permeable foam or fibrous material. The permeable foam or fibrous material is removable when the lid 22 is open for cleaning or replacement. The operator can remove the permeable foam or fibrous material and clean it with a garden hose.
The handle 14 on the vacuum wand 8 is elongated so the operator can reach to the bottom of a swimming pool. The intake aperture 12 and hose 10 are of large enough diameters to draw in water with leaves and small sticks. In alternate embodiments, the vacuum wand 8 does not have the elongated handle 14 . Instead, the vacuum wand 8 is designed to automatically move around the bottom of the pool when the pump is operating. Automatic propulsion of pool-cleaning devices is disclosed in U.S. Pat. No. 4,835,809 to Roumagnac and U.S. Pat. No. 5,933,899 to Campbell, which are herein incorporated by reference.
In another embodiment, the pool cleaning apparatus is mounted onto a cart 38 with wheels 40 . The wheels 40 may be suited to roll over grass and gravel. The cart 38 has four wheels 40 , but other designs could utilize two or three wheels 40 in alternate configurations. In alternate embodiments, the water filtrating system is permanently installed next to a pool of water and does not use a cart 38 .
Many backyard pools have narrow walks with tight turn radiuses through which the homeowner may need to maneuver. Pool ladders, planters, plants, and other structures present added obstacles. For improved maneuverability and weight, the cart 38 may be a two-wheel hand truck, and additional embodiments are shown below to more clearly depict the various embodiments associated with the two-wheel version of the apparatus.
Referring to FIGS. 6-11 and 15 , a third embodiment of the invention, includes the pass through pump 1 that has a pump inlet 2 and a pump outlet 4 , and a motor 6 . The pass through pump is configured to pass debris directly through the pump. The motor may be gas or electric. In this embodiment, the motor 6 is electric. Electric power is often available pool side, the electric motor is quieter and generally maintenance free, and electric power may be cheaper than gasoline. Nonetheless, a gas engine may be utilized where it is impractical to use electric power, such as where the operator is in the business of cleaning pools, and must provide his own power.
In one embodiment, the pass through pump 1 has a semi-open to open (depending on the size of solids being passed), clog-resistant impeller, which allows leaves and debris to pass through the pump 1 without getting caught therein. In this embodiment, the pass through pump 1 uses a pump style commonly known in the art as a trash or semi-trash pump, which is configured to pass a mixture of debris and liquid. If the pump 1 does not come with an internal mechanism for maintaining pump prime, then a check valve 137 having a check valve inlet 138 and a check valve outlet 139 may be fitted onto the pump inlet 2 to maintain prime. A tapering plastic nipple 101 is fitted onto the check valve inlet 138 .
The vacuum wand 8 or an automatic vacuum wand 402 fits onto the tapering plastic nipple 101 during operation. Leaves and debris enter the vacuum wand 8 through an aperture 12 in the brush head which is a part of the vacuum wand 8 . In one embodiment, the brush head is hingedly attached to the elongated handle 14 , and is removable from the elongated handle 14 .
Referring now to FIG. 10 , water containing leaves and debris are drawn through the vacuum wand 8 and the pump 1 , and through a transfer pipe 113 into a filtration device 718 . In this embodiment, the filtration device 718 features a water tower design. The filtration device 718 comprises a modified leaf trap 726 and a filter 732 . Water laden with leaves and debris enters the filtration device 718 through a filtration device inlet 746 , which may be positioned beneath the filter 732 , and enters a vessel 720 through an inlet tube 102 . The inlet tube 102 extends into a leaf trap spout 900 positioned to dispense the water laden with leaves and debris into the modified leaf trap 726 . In this embodiment, the inlet tube 102 is positioned vertically within the filtration device 718 , passing through the center of the vessel 720 and the filter 732 . In the embodiment of FIG. 10 , the central inlet tube 102 is connected to the outlet of the pump by way of the transfer pipe 113 and the inlet 746 .
The vessel 720 has a side wall having a positive stop 104 around its perimeter and a gasket 105 around the positive stop 104 , and the inlet tube 102 has a tube flange 144 . A flange gasket 145 may be placed on the tube flange 144 to seat and seal against the filter 732 . As illustrated in FIGS. 9 and 10 , the modified filter 732 sits on the gasket 105 and positive stop 104 , and the flange gasket 145 and tube flange 144 .
The filter 732 comprises a filter container 729 having peripheral surfaces, and a recess 112 , as shown in FIG. 9 . The filter 732 may have one or more handles 115 to aid in its removal from the vessel 720 . As illustrated in FIG. 11 , the filtration element 114 has apertures and slits that enable it to fit over the handles 115 and the inlet tube 102 . In alternate embodiments, the filtration element 114 may be shaped to fit around the handles 115 and the inlet tube 102 . The filter 732 and the filtration element 114 are held securely to the vessel 720 by a flange nut 103 , which screws unto the inlet tube 102 .
The filter container 729 may be manufactured from a metal or plastic material, or a stainless steel screen suitable for housing a filtration element 114 . The filter container 729 may be manufactured by thermoplastic injection molding, or by other techniques, and may comprise one or more apertures for allowing the flow of water through the filter container 729 of the filter 732 .
In the embodiment depicted in FIG. 10 , the filtration element 114 is positioned in the recess 112 of the filter 732 . In this embodiment, the filtration element 114 is a fibrous polymer filtration element comprising polyester fibers. In alternate embodiments, other thermoplastic or polymer fibers may be used in the filtration element 114 , producing a product that filters fine particles and is conducive to backwashing. In one embodiment having a polyester fiber filtration element, particles that are greater than 5-10 microns are removed by the filtration element 114 without any noticeable reduction in flow.
In one embodiment, the leaf trap 726 is omitted, and the filter 732 comprises the filter element 114 .
The leaf trap 726 has surfaces 728 comprising a screen suitable for catching leaves and debris. The modified leaf trap 726 may be manufactured from a plastic, or a metal such as stainless steel, or a combination of plastic and metal. The modified leaf trap 726 may match the interior shape of the vessel 720 . In the embodiment exemplified by FIG. 9 , the vessel 720 and the modified leaf trap 726 have a round shape, with the diameter of the modified leaf trap 726 being approximately ⅛ of an inch smaller than the inside diameter of the vessel 720 . Debris which passes through the modified leaf trap 726 is trapped in the filter 732 . It is contemplated that the leaf trap 726 may be larger in diameter than the filter 732 .
As depicted in FIGS. 9 and 10 , the central inlet tube 102 passes through the center of the modified leaf trap 726 , and having an outlet 146 extending into the leaf trap spout 900 . The modified leaf trap 726 rests on the periphery of the filter 732 , which in turn sits on the positive stop 104 . The leaf trap has two or more leaf trap handles 116 that are used to remove it from the vessel 720 , and during cleaning operations.
In one embodiment, the filter container 729 comprises a stainless steel screen having apertures larger than ⅛ of an inch. A lower peripheral edge of the filter container 729 rests on the gasket 105 on the positive stop 104 , sealing the filter 732 against the side wall around the perimeter of the vessel. In the embodiment of FIG. 10 , the positive stop 104 orients the filter 732 in a substantially horizontal orientation.
The operator may invert the filtration element 114 to backwash the filtration element 114 inside the filtration device 718 without the use of garden hose or other external water source. When the filter 732 is removed, the modified leaf trap 726 may also be inverted inside the vessel 720 during backwashing. Alternately, the operator may backwash the filtration device 718 with a garden hose.
As illustrated in FIGS. 7 and 9 , the vessel 720 has an access opening, closed by a lid 722 . The lid 722 comprises a lid gasket 106 , and one or more hold down latches 109 to tighten the lid 722 against the lid gasket 106 . Hold down bumpers 107 protect the vessel 720 during loosening of hold down latches 109 . A lid handle 108 is used to gain access to the interior of the vessel 720 . The vessel 720 contains a drain 111 to remove water during cleaning or storage. In the embodiment of FIG. 7 , the lid 722 is hingedly attached to the vessel 720 by one or more hinges 141 .
As illustrated in FIGS. 9 and 10 , water, leaves and debris enter the filtration device 718 from the pump 1 , enter into the transfer pipe 113 , then pass into the filtering device inlet 746 , through the central inlet tube 102 , into the leaf trap spout 900 , and upward, to an area under the lid 722 . From there, water laden with leaves and debris starts to flow downward, into the modified leaf trap 726 , where larger debris is strained out. The water flows downward through the filtration element 114 of the filter 732 , out of the vessel 720 through the filtering device outlet 748 , through the discharge tube 734 , and back into the pool or water feature. As shown in FIG. 6 , a discharge extension tube 35 may be attached to the discharge tube 734 to more effectively return treated water back to the source. This embodiment may be described as a “pressurized vessel” water filtration system, and may use a pressure gauge 110 to measure the pressure that is in the vessel 720 .
Referring to FIGS. 6-8 , the filtration device 718 may be fastened onto the hand truck 123 by one or more vessel support brackets 130 . In one embodiment, the vessel support brackets comprise threaded rods and nuts to secure the filtration device to the hand truck 123 . A longitudinal support bracket 131 may be used to support the filtration device 718 , and to prevent the filtration device from falling forward. In the embodiment of FIG. 7 , anti-slip grips 121 cover the handles, and one or more rubber lid bumpers 125 support the hingedly attached lid 722 when in an open position.
A vacuum wand pole clip 135 may be provided as shown in FIG. 7 , to hold the pole and to free up the operator's hands as needed. The vacuum wand pole clip 135 comprises a knob 136 that is used to adjust the position of the vacuum wand pole clip 135 . The discharge extension tube 35 may be held to the hand truck 123 by one or more discharge extension tube clips 117 .
Further, many home owners like to sweep off their pool deck and walkways. Consequently, some of the embodiments may feature a broom holder 119 , and a broom boot 120 . It is also possible to wrap the vacuum hose 10 onto the hand truck 123 by securing the brush head component of the vacuum wand 8 into the brush head holder 140 , wrapping the hose 10 around the hand truck handles and the vacuum hose hook 124 , and finally, by securing the end of the hose 10 unto the hose clip 122 . During cleaning, the modified leaf trap 726 , the flange nut 103 and the filter 732 , may be placed onto small hooks 129 .
The hand truck 123 may be made with an elongated toe plate 126 , which accommodates the motor 6 , and a carrying case 128 suitable for keeping chlorine, water testing devices, cleaners, a priming cup, and other objects fit for operating the apparatus, and for pool maintenance. Two handles 127 are located on the either side of the toe plate which assists in lifting the pool cleaning apparatus. In one embodiment, the hand truck 123 comprises flat-free tires 740 and a vibration insulator 132 to make the apparatus more suitable for use on hard surfaces such as concrete. The motor 6 is operated by a control box 133 having a ground fault interrupter (GFI), which prevents accidental shocks. An electrical cord 134 supplies power to the motor 6 .
In another embodiment, which is illustrated in FIG. 12 , the vessel supply tube 202 , is connected to the filtering device inlet 746 , the check valve outlet 139 is connected to the vessel supply tube 202 , and the plastic nipple 101 is attached to the check valve inlet 138 . A pump supply tube 204 is attached to the pump inlet 2 and the filtering device outlet 748 . A small discharge tube 203 having a shut-off valve 201 , is attached to the pump outlet 4 . The shut-off valve 201 , is useful in maintaining prime of the vessel 720 and the pump 1 , as needed. The lid may be fitted with a vacuum gauge 200 that measures the vacuum pressure in the vessel 720 .
Referring to FIGS. 12 and 13 , in this embodiment (and with the attachment of a vacuum wand 10 as previously disclosed) water laden with leaves and debris is pulled from the pool/water feature 400 through the vacuum hose, through the tapering plastic nipple 101 , the check valve 137 and the vessel supply tube 202 , through the filtering device inlet 746 into the central inlet tube 102 , upward toward the lid 722 ; then it is pulled downward through the modified leaf trap 726 , removing larger debris, into the filtration element 114 and filter 732 , which removes dirt and smaller particles, through the filtering device outlet 748 , into the pump supply tube 204 , into the pump inlet 2 and pump 1 , out of the pump outlet 4 , through the small discharge tube 203 , and back into the pool/water feature.
In the embodiment depicted in FIG. 12 , hard objects, such as small stones and coins, are filtered out before they reach and possibly damage the pump. This embodiment is useful for use in reflection pools and fountains, and situations where it is difficult to see the type of debris that is being removed. It is generally necessary to prime the vacuum wand, vessel, and pump to create suction to clean the water feature. A shut-off valve may be used in priming the apparatus. This embodiment may be described as a “vacuum vessel” pool cleaner.
A fifth embodiment is depicted in FIG. 14 , and may be described as a portable water filtration and cleaning unit. Such an embodiment could be used on a seasonal basis with an above-ground pool 313 . In this embodiment, the pressurized vessel type pool cleaner of FIG. 7 is adapted for use with an above-ground pool. The embodiment depicted in FIG. 14 , may also employ the “vacuum vessel” type pool cleaner shown in FIG. 12 instead of the “pressurized vessel” type pool cleaner. Nonetheless, the “pressurized vessel” type pool cleaner may be easier to prime.
In adapting the “pressurized vessel” type pool cleaner for use with an above-ground pool 313 , as shown in FIG. 14 , it is necessary to refer to FIGS. 14 , 6 , 15 , 18 , and 19 , which correspondingly depicts a portable water filtration and cleaning system attached to an above-ground pool 313 , a vacuum wand 8 , a self-propelled vacuum wand 402 , a modified basket 310 , and a suction disc 404 .
The above-ground pool 313 is equipped with a skimmer 308 having a drain 309 . Polymer tubing 311 is attached to the drain 309 , which transports unfiltered water and leaves and debris 405 out of the modified basket 310 which is housed in the drain 309 , through polymer tubing, and through water control valves 300 and a check valve 137 into the pump 1 . A modified basket 310 , having apertures large enough to pass leaves and debris but not larger objects that may clog the polymer tubing 311 , is useful in this embodiment. The polymer tubing 311 may be made from polyvinyl chloride or other suitable material. Then, untreated water enters the filtration device 718 , wherein leaves and debris are removed, as discussed above. Clean water exits the filtration device 718 , the discharge tube 734 and the discharge extension tube 35 . Treated (or untreated) water may be drained from the waste water discharge tube 301 , by the adjusting the flow of the water with water control valves 300 . Treated water flows through a heating unit 302 which may be solar, electric, or other, by entering in at the heater inlet 303 , where it is heated, and then flows out of the heater outlet 304 , into a mineral filter/chlorine pack combination unit 305 , where the treated water enters the filter/chlorine pack inlet 306 , is treated, and exits through the filter/chlorine pack outlet 307 . Treated water is then pushed back toward the pool via polymer tubing. A check valve 137 is connected to the polymer tubing 311 to prevent possible flooding of the filtration device 718 when the motor 6 is turned off. Treated water then enters the pool or water feature through return jets 312 .
The fifth embodiment operates on a full-time basis to circulate, sanitize, and treat water during the season; however, it is also capable of operating as a pool cleaner by inserting a suction disc 404 over the drain 309 , and using a vacuum wand 8 as illustrated in FIG. 6 , to remove leaves and debris that have sunken to the bottom of the above-ground pool. This eliminates the need for a homeowner to separately purchase an above-ground pool cleaner. Alternatively, cleaning may be accomplished by using a self-propelled vacuum wand 402 , as illustrated in FIG. 15 . The pool cleaning apparatus may be removed for winter storage, and reattached in spring. Finally, the apparatus may be backwashed as discussed herein.
The pool cleaning apparatus which is the subject of this invention, may also be permanently mounted pool side. In a permanent installation, the apparatus may be used as the pool's primary filtration system and also as a cleaner. This sixth embodiment would also eliminate the need for a homeowner to separately purchase and install a filtration system and a pool cleaner, and may be installed when the pool is being constructed. FIG. 15 illustrates a typical pool/water feature 400 , equipped with the skimmer 308 and the drain 309 . The modified basket 310 fits down into the drain. The modified basket 310 is made with larger holes, approximately ¾ inches in diameter to allow for the passage of leaves and debris which would otherwise clog the common unmodified basket having apertures which are approximately ⅛ th of an inch in diameter. The polymer tubing 311 is used as a conduit to circulate debris laden and treated water through the pool cleaning system. During circulation and filtration, unfiltered water is drawn by the pump 1 from the pool/water feature 400 . Water exits the skimmer 308 and the drain 309 . Larger objects such as sticks and small balls, which may get stuck in the polymer tubing 311 , are removed by the modified basket 310 . Water enters the polymer tubing 311 , and is carried to the check valve 137 if the pump does not have an internal check valve. The check valve 137 helps to keep the pump, which is self-priming, primed.
The motor 6 should be electric since it would be running on a full-time basis, and a 1 or 2 hp electric motor is generally suitable for an approximately 40 feet by 20 feet pool or water feature. In this embodiment, the pump 1 is configured to allow for the passage of leaves and debris without damaging internal mechanisms of the pump. In this embodiment, the pump 1 has an open or semi-open clog-resistant impeller 800 . Water and debris leave the check valve 137 , enter the pump inlet 2 , and is pumped through and out the pump outlet 4 . Water leaves the pump 1 and passes through the polymer tubing 311 toward the filtration device 718 . The system has water control unions 401 which gather and distribute the flow of treated or untreated water. There are also various water control valves 300 which shut off, and controls the direction and flow of water.
Water enters the filtration device 718 where leaves and debris 405 are removed by the modified leaf trap 726 and smaller particles are removed by the filter 732 and the filtration element 114 as shown in FIG. 10 . Filtered water then leaves the filtration device 718 and flows toward a waste water discharge tube 301 , which may be used to drain the pool, and to aid in backwashing operations as described below. Treated water then enters a heating unit 302 which may be solar, electric, or other, circulates, and further enters the mineral filter/chlorine pack combination unit 305 which adds water stabilizing minerals and chemicals, including chlorine, to the treated water before the same is returned to the pool/water feature 400 . Treated water enters and exits a water control union 401 by the polymer tubing 311 and enters the pool via return jets 312 .
The permanently mounted or installed apparatus is capable of manual cleaning and removal of leaves and debris 405 , by putting a suction disc 404 over the drain 309 , and attaching the end of the vacuum hose 10 unto the aperture of the suction disc 404 as shown in FIGS. 19 and 15 . Alternatively, the pool/water feature 400 may be cleaned by a self-propelled vacuum wand 402 which may be more appropriate for larger pools/water features. The automatic vacuum hose 710 , which tends to be less stiff than the vacuum hose 10 , goes over suction disc 404 . It may be necessary to prime the vacuum hose 10 , or the automatic vacuum hose 710 and or the pump 1 to create suction and cleaning of pool walls and floors.
The pool cleaning apparatus may be permanently mounted pool-side, as shown in FIG. 15 . This may be accomplished by pouring the concrete over the modified frame 403 and allowing the concrete to set-up, forming a concrete base 407 ; or by the use of hardware such as bolts, screws and nuts. The modified frame 403 has 2 rubber lid bumpers 125 , small hooks 129 on which to hang the modified leaf trap 726 , the filter 732 , and other objects. Also, the modified frame 403 has a brush head holder 140 , and a hose clip 122 , so that the vacuum wand 8 may remain pool-side. Power to the motor 6 is supplied pool side by an electrical power source 406 .
The present invention utilizes a self-priming pump. During cleaning and use, air may get into the vacuum hose 10 causing a loss of prime. In that situation, a self priming pump would quickly re-prime so that operation of the apparatus may continue. FIG. 20 illustrates a pump 1 , which comprises a clog-resistant impeller 800 (which may be partially to completely open, depending on the size of the leaves, debris, and solids being passed), housed inside a volute 801 , with the volute 801 designed to extend to the pump inlet 2 , with the said volute 801 having a flapper valve 802 which is in contact with the pump inlet 2 . This design is capable of creating a greater vacuum which helps to more quickly regain prime. Ideally, the pump will only need an initial prime at the beginning of the season. The pump 1 may be designed so that some water will remain therein after use. The small amount of water which stays in the pump should be sufficient to prime a dry vacuum hose 10 , and to begin suction and cleaning my merely turning on the pump 1 . This pump 1 also contains a drain 118 , a drain plug 804 , a pump fill 805 which helps with the initial priming of pump 1 , a pump fill plug 803 , and a pump outlet 4 . The pump 1 shown in FIG. 20 eliminates the need to separately purchase a check valve 137 , because the flapper valve 802 located inside the pump 1 , functions to keep water inside the pump 1 , and to maintain and regain prime. Priming of the pump may be achieved in many ways, including putting water into the inlet tube 102 opening when the lid 722 is open, via the pump fill 805 , by submerging the hose into the water being cleaned to remove air, and by putting the end of the vacuum hose 10 , or automatic vacuum hose 710 , over the return jets 312 to fill the hose 10 with water, thereby removing air.
The modified leaf trap 726 , and the filtration element 114 , are capable of being backwashed by inverting them in the filtering device (the filtration element 114 is inverted and placed in the filter 732 ), securing the lid 722 to the vessel, and starting the motor 6 . Leaves, debris, and dirt will then leave the filtration device through the discharge tube 734 , or the waste water discharge tube 301 , depending on the embodiment being used. The filter container 729 has peripheral surfaces containing sufficiently large apertures that allow dirt and debris trapped in the filtration element 114 to wash away. Alternately, the filtering device, leaf trap, filter, and filtration element may be cleaned by spraying and washing these components with a garden hose or other suitable source of water.
Although the principles, alternate embodiments, and operation of the present inventions have been described in detail herein, this is not to be construed as being limited to the particular illustrative forms disclosed. It will thus become apparent to those skilled in the art that various modifications of the embodiments herein can be made without departing from the spirit or scope of the invention as defined by the appended claims. | A pool cleaning apparatus is provided that employs a pump and a filtering device. An engine or motor drives the pump. The pump draws water and debris into the pool cleaning apparatus through a wand. The pump moves the water through the filtering device to remove debris. The filtering device comprises a vessel having a sealable lid. The vessel contains a tube for transporting water and debris into the vessel, a leaf trap for catching debris, a primary filter of polyester fiber, and a positive stop having a gasket. The primary filter sits on the gasket, with the leaf trap resting above the primary filter. Both the leaf trap and the primary filter have a hole through which the tube extends, and handles. The primary filter houses a filtration element which is washable and disposable. The pool cleaning apparatus may be mounted onto a cart, or be permanently installed. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
This invention relates to a partition construction, and particularly to a combination of sections of partition adjoined by a plurality of clips, and the structure of the partition at such junctions.
BACKGROUND OF THE INVENTION
Non-progressive demountable partitions have been constructed heretofore with partition corners which are formed by extending one of the two walls forming the corner all the way to where the wall corner is desired and then abutting the end of the second wall against the side of the first wall, adjacent the end of the first wall. Preferably, the two walls would abut such that the wallboard on one side of the second wall overlapped the end of the first wall. A small angular elongate corner trim would then be affixed over the ends of the boards at the corner.
SUMMARY OF THE INVENTION
The present invention is directed to structure wherein two or more sections of a partition are connected by a plurality of clips of hollow short sections of extruded metal, each of which are connected to metal studs located at the ends of the partition sections, and each of which have means for affixing a partition height section of wall trim over the junction. A novel partition corner consists of two sections of partition disposed at 90° to each other, with each section having a metal stud located at or near the end of the section. Short hollow clips are affixed to each of the two end studs, as by screw heads engaging stud webs, preferably at three vertically spaced apart locations, affixing the two partition sections permanently in their closely spaced 90° relationship. An elongate piece of outside corner trim is then mounted over the outside corner thus formed and affixed to the clips, and an elongate section of inside corner trim is mounted over the inside corner thus formed and affixed to the clips.
It is an object of the present invention to provide an improved means for constructing partitions.
It is a further object to provide a novel clip for joining sections of partitions.
It is a still further object to provide an improved partition, having sections adjoined by a novel hollow short clip which engages adjacent metal studs.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will be more readily apparent when considered in relation to the preferred embodiments as set forth in the specification and shown in the drawings in which:
FIG. 1 is a horizontal sectional view of a partition corner constructed in accordance with the invention.
FIG. 2 is an isometric view of a pair of studs disposed at 90° to one another and adjoined by a novel hollow short clip, preparatory to applying wallboard and corner trim in the process of constructing the corner structure of FIG. 1.
FIG. 3 is an isometric view of the studs and clip of FIG. 2 showing the attachment of the clip to web of a stud by a screw head inserted through a hole in the stud web.
FIG. 4 is a horizontal sectional view of an intersection of one partition wall with the middle of a second partition wall.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-3, there is shown a first partition wall 10 and a second partition wall 12 which are adjoined at a corner structure 14. Corner structure 14 includes three short hollow corner clips 16 (only one shown) which are located at vertically spaced positions in the corner structure, preferably spaced apart 29 inches, center to center.
Each clip 16 is attached to a stud 18 of wall 10 and to a stud 20 of wall 12, and thus clips 16 physically connect the two walls 10 and 12.
The studs 18 and 20 are of similar construction, each including a central web 22 and a pair of flanges 24 extending perpendicularly from each side edge of a central web 22. Central webs 22 have openings, or knockouts, 26 for passage therethrough of utilities or reinforcing channels, not shown. Webs 22 preferably have an additional small opening 28 located every 29 inches, which may be in the form of a keyhole.
Each clip 16 is a short section, about six inches long, of a thin walled aluminum extrusion, having two sides 30 and 32 disposed at a 90° angle one to the other. Approximately centered in each of the two sides 30 and 32 is a hole 34 through which extends a washer headed machine screw 36. The threaded end 38 of screw 36 extends inwardly of sides 30 and 32, and has thereon a square nut 40, which is restrained from being rotated when screw 36 is rotated by a pair of inwardly extending ribs 42.
The small openings 28 on each of studs 18 and 20 are located at equal heights, and each clip 16 is attached to the two studs 18 and 20 by inserting the heads of the two screws 36 through the openings 28 of the two studs. The clip 16 is then moved downward until the threaded end 38 engages the bottom of each opening 28. Screws 36 are then tightened in nuts 40, firmly locking together the clip 16 and the two studs 18 and 20.
Gypsum wallboard 43 is then applied to both sides of both walls 10 and 12, and screw 37 attached to the two studs 18 and 20, and the clips 16.
In the preferred embodiment, each clip 16 is formed of six sides. Connecting perpendicular sides 30 and 32 is a narrow diagonally extending side 44 having means for receiving and holding an elongate inside corner trim 46. The other half of clip 16 includes two perpendicularly disposed sides 48 and 50 between which there is a diagonally extending side 52 having means for receiving and holding an elongate outside corner trim 54.
The means for holding the inside corner trim 46 and the outside corner trim 54 includes a pair of outwardly extending, spaced apart, ratchet arms 56 on each of the diagonal sides 44 and 52 and a pair of inwardly extending barbed arms 58 on each of the corner trims 46 and 54. The barbed arms 58, in each combination, fit closely between the ratchet arms 56. Once engaged, the outwardly extending barbs 60 engage the inwardly extending ratchet teeth 62, and the corner trims 46 and 54 are relatively permanently held in place.
The ratchet teeth 62 have a height of about 0.030 inch and are located every 1/16 inch, providing adjustability to the placement of the corner trims 46 and 54 in case a vinyl or cloth sheet, to match the facings on the wallboard 43, is wrapped around the corner trim and under the side edges.
Each corner clip 16 consists essentially of a continuous wall, forming the six sides, which is of a thickness of about 0.050 to 0.060 inch. Ribs 42 and ratchet arms 56 have an average thickness of about 0.040 to 0.050 inch.
Referring to FIG. 4, there is shown a first partition wall 70, a second partition wall 72 and a third partition wall 74, which are all adjoined at a wall intersection 76. Intersection 76 includes three short hollow intersection clips 78 (only one shown) which are located at vertically spaced positions in the intersection structure, preferably spaced apart 29 inches, center to center.
Each clip 78 is attached to a stud 80 of wall 70, to a stud 82 of wall 72 and to a stud 84 of wall 74. Clips 78 physically connect the three walls 70, 72 and 74, forming a 90° intersection of wall 72 with two walls 70 and 74, which are in line with one another.
Each clip 78 is a short section, about six inches long, of a thin walled aluminum extrusion having three sides 86, 88 and 90, each of which has a hole 92 through which extends a washer headed machine screw 94. The threaded end has a square nut 96 which is restrained from being rotated when screw 94 is rotated by a pair of inwardly extending ribs 98.
Small openings 100 on each of studs 80, 82, 84 are located at equal heights. Each clip 78 is attached to the three studs by inserting the heads of the three screws 94 through the openings 100 of the three studs. The clip 78 is then moved downward until the screw 94 engages the bottom of each opening 100. Screws 94 are then tightened in nuts 96, firmly locking together the clip 78 and the three studs 80, 82, 84. Gypsum wallboard is then applied to both sides of walls 70, 72, 74, and screw-attached to studs 80, 82, 84.
In the preferred embodiments, clip 78 has the three perpendicularly disposed sides 86, 88, 90 connected by diagonally extending sides 102, 104, each having a pair of outwardly extending, spaced apart, ratchet arms 106. Engaged between each pair of ratchet arms 106 are a pair of inwardly directed barbed arms 108 on each of two elongate inside corner trim 110.
On the opposite side of clip 78 there is a flat wall 112, with two opposed, outwardly directed ratchet arms 114, holding therebetween two inwardly directed barbed arms 116 of a flat elongate face trim 118.
Having completed a detailed disclosure of the preferred embodiments of my invention so that those skilled in the art may practice the same, I contemplate that variations may be made without departing from the essence of the invention or the scope of the appended claims. | A partition wall in which a plurality of sections are adjoined by a plurality of vertically spaced apart hollow clips having a tightenable screw protruding from each to which a section of wall is to be affixed, with each screw head being placed through a hole in the web of a metal stud near the end of each wall section, with the screw head screwed tight against the stud web material. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
The field of the invention is installing and cementing well liners and providing a circulation system for formation treatment, conditioning, or gravel packing.
BACKGROUND OF THE INVENTION
Oil and gas operators often drill wells in formations that require treatment of the producing formation or gravel packing to ensure optimum production. In past installations, such treatment or gravel packing was not attempted until after a well liner was positioned and cemented in place. The liner and its cement seal served to isolate the producing formation, or pay zone, from other zones above the pay zone so that there was no cross-contamination or fluid and material loss during treatment or gravel packing.
Presently, the liner cementing and formation treatment or gravel packing are accomplished as separate steps, requiring multiple equipment runs into the well bore. First, the well bore is drilled to the point where the liner will be seated. The liner is lowered into position and cemented into place. After the cement has set, a second, smaller diameter drill string is used to drill beyond the cemented liner into the pay zone. The drill string is removed and a circulation system is lowered into the pay zone for treatment or gravel packing of the pay zone. This system is expensive and time-consuming because it requires multiple trips in and out of the hole and multiple drilling runs.
In some cases, a single hole can be drilled into the pay zone, and the liner and production strings lowered in a single trip. However, these situations only occur when there is no need to treat the formation or gravel pack the production string, and the production string can utilize large-opening slotted or perforated production casing. The liner can be cemented into position and the well brought on line without multiple trips in and out of the hole because there is little or no danger of formation contamination or debris plugging the production casing. When formation treatment or gravel packing is required, large-opening production casing cannot be used and this simpler, one-pass approach is unavailable due to the danger of formation damage or plugging the small openings in the production screens.
It is an object of this invention to allow a single drilling operation to complete the well bore into the pay zone when formation treatment or gravel packing is required.
It is a further object of this invention to allow simultaneous insertion of cementing apparatus and formation treatment or gravel packing apparatus into the well bore.
It is a further object of this invention to allow cementing operations without danger of contaminating or clogging either the formation or production equipment installed below the cementing apparatus.
SUMMARY OF THE INVENTION
An apparatus and method is provided that allows an operator to drill a well into a formation requiring treatment or gravel packing in a single pass, then to lower, position, and set the drill-in liner and production strings simultaneously. The invention allows cementing of the drill-in liner prior to any treatment or gravel packing, and provides an integral circulation system to allow formation treatment or gravel packing of the production string. Once treatment or gravel packing is completed, the invention provides mechanical fluid loss control as the circulation system is pulled out of the hole.
The invention comprises a liner assembly, a cementing assembly, and a circulation and production assembly. After the well bore has been drilled into the pay zone, the three assemblies are assembled at the surface and lowered into the well bore. The circulation and production assembly includes the shoe and production screens, with a wash pipe inserted into the interior of this string to provide circulation control during formation treatment or gravel packing.
The cementing assembly includes a cementing valve and means of isolating the annulus of the cementing assembly from the annulus of the circulation and production assembly. During cementing operations, the isolation means is used to prevent cement flow down into the pay zone. The bottom of the liner assembly connects to the top of the cementing assembly, so that cement pumped through the cementing assembly is forced upward to encase and seal the liner in position. "Cement" as used herein includes using cement or other means of achieving a seal between liner and the well bore.
Once the cementing operation is completed, the cementing wash pipe is withdrawn and a new wash pipe is lowered into position to connect to the circulation and production assembly wash pipe. Formation treatment or gravel packing is carried out to prepare the well to be brought on line. When the treatment or gravel packing is completed, the entire wash string is withdrawn. Mechanical means, such as a knock out isolation valve, provides mechanical fluid loss control to prevent fluid backwash in the production assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-E is a partially cut away drawing of the outer equipment string for one embodiment of the one trip cement and gravel pack system.
FIGS. 2A-F is a partially cut away drawing of the inner equipment string for one embodiment of the one trip cement and gravel pack system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1A-E, one embodiment of the outer equipment string 10 of the one pass cement and gravel pack system is shown. The outer equipment string 10 comprises an outer liner assembly 12, an outer cementing assembly 14, and an outer circulation assembly 16.
The outer liner assembly 12 comprises a liner packer 18, such as Baker Product No. 296-14, a liner hanger 20, such as Baker Product No. 292-50, and a liner 22. The liner packer 18, the liner hanger 20, and the liner 22 are normally used in lining and cementing operations, and those skilled in the art will recognize that the particular specifications for these will vary depending on the conditions of the installation.
The outer cementing assembly 14 is in fluid communication with the outer liner assembly 12 and comprises a first seal bore extension 28, such as Baker Product No. 449-40, a cementing valve 30, such as Baker Product No. 810-80, a second seal bore extension 32, such as Baker Product No. 449-40, an external casing packer 34, such as Baker Product No. 301-13, and a third seal bore extension 36, such as Baker Product No. 449-40. Slip-on fluted centralizers 38 may be used to position the outer cementing assembly 14 and to protect the external casing packer 34 from premature setting during insertion into the well bore 40.
The outer circulating and production assembly 16 is in fluid communication with the outer cementing assembly 14 and comprises casing joints 42, a seal bore 44, a perforated extension 46, a lower seal bore 48, a knock-out isolation valve 50, pre-pack screens 52, flapper valves 54, a first O-ring seal subassembly 56, a slotted liner 58, a second O-ring seal subassembly 60, and a set shoe 62, such as a double "V" set shoe.
Referring to FIGS. 2A-F, one embodiment of the inner equipment string 110 of the one pass cement and gravel pack system is shown. The inner equipment string comprises an inner liner assembly 112, an inner cementing assembly 114, and an inner circulation assembly 116.
The inner liner assembly 112 comprises a lift nipple 118, such as Baker Product No. 265-20, a packer setting dog subassembly 120, such as Baker Product No. 270-09, a liner setting tool 122 such as Baker Product No. 265-88, a first wash pipe 124, and a ported landing subassembly 126, such as Baker Product No. 276-04. Seals 128 and 130 isolate a port 132 on the ported landing subassembly 126.
The inner cementing assembly 114 is in fluid communication with the inner liner assembly 112 and comprises a second wash pipe 136, a first seal assembly 138, a slurry placement indicator 140, such as a Baker Model "E," Baker Product No. 445-56, a circulating valve 142, such as a Baker Model "S2P," Baker Product No. 445-66, a closing tool 144, such as a Baker Model "HB," a second seal assembly 146, an indicating collet assembly 148, such as Baker Model "A," Baker Product No. 445-34, and an opening tool 150, such as Baker Model "HB."
The inner circulation assembly 116 is installed coaxially with the outer circulation and production assembly 16. The inner circulation assembly 116 comprises a crossover tool 152, such as Baker Product No. 445-72, a low bottom hole pressure flapper valve 154, an anchor seal assembly 156, and a third wash pipe 160.
Referring to FIGS. 1A-E and 2A-F, the well bore 40 is initially drilled to the depth at which the liner 22 is to be begun. The outer casing 64 is lowered into the well bore 40 and cemented into position. The well bore is then completed, drilling to the final position desired in the pay zone. The one trip cementing and gravel pack system is initially assembled at the surface with the inner equipment string 110 coaxial with and inside the outer equipment string 10 and lowered into position so that the set shoe 62 is in the pay zone at the bottom of the well bore 40. A ball 164 is dropped into the well bore 40 so that it will be caught by the ported landing subassembly 126. Once caught, the ball 164 blocks the fluid flow, allowing internal pressure to be built up from the surface. Seals 128 and 130 prevent the fluid from flowing in the annulus between the inner equipment string 110 and the outer equipment string 10. The increased fluid pressure is forced against the liner hanger 20 to set it. After the liner hanger 20 is set, the port 132 in the ported landing subassembly 126 is closed and the ball 164 is released. If the ported landing subassembly 126 is a type such as Baker Product No. 276-04, these actions are accomplished by further increasing the pressure in the inner equipment string 110, forcing the port 132 to close and breaking a shear pin to release the ball 164. The ball 164 is pumped to the circulating valve 142.
The circulating valve 142 must trap the ball and seal off fluid flow from the region below the circulating valve 142. If the circulating valve 142 is a valve such as a Baker "S2P," the ball 164 is caught on a teflon seat. The teflon seat flexes to form a tight seal between the teflon seat and the ball 164, preventing fluid flow into the region below the teflon seat. Several smaller balls are embedded in the teflon seat and act to hold the ball 164 in position. Once the ball 164 is in position against the teflon seat, fluid flow from above the ball is diverted through a circulating valve port 143.
The first seal assembly 138 is initially positioned inside of the third seal bore extension 36. When the ball 164 lands on the teflon seat, the fluid overpressure is prevented from releasing upwards in the inner equipment string 110 by the first seal assembly 138, and is instead forced downward into the inner circulation assembly 116. This positioning protects the external casing packer 34 from damage due to the fluid overpressure.
After the ball 164 is captured, the inner equipment string 110 is raised to position the first seal assembly 138 inside of the second seal bore extension 32, and the second seal assembly 146 inside the third seal bore extension 36. As the inner equipment string 110 is raised, the indicating collet assembly 148 locates onto the third seal bore extension 36, providing a weight indication on the inner equipment string 110 to indicate position. In this position, the circulating valve port 143 is aligned with the external casing packer 34. The external casing packer 34 is pressure set in accordance with the procedure for the specific model used.
When the external casing packer 34 is set, the internal equipment string 110 is again raised, positioning the first seal assembly 138 in the first seal bore extension 28, and the second seal assembly 146 in the second seal bore extension 32. As the inner equipment string 110 is raised, the indicating collet assembly 148 locates onto the second seal bore extension 32, providing a weight indication on the inner equipment string 110 to indicate position. In this position, the circulating valve port 143 is aligned with the cementing valve 30. Cement is pumped through the cementing valve 30 to fill the annulus between the liner 22 and the well bore 40. If the inner equipment string 110 is raised too far, the cementing valve 30 may be accidentally closed. If the cementing valve 30 is accidentally closed, the inner equipment string 110 may be raised further to use the opening tool 150 to reopen the cementing valve 30.
The slurry placement indicator 140, such as Baker Model "E," comprises a seat and a bypass. When the last of the cement is pumped into the well bore 40 at the surface, a wiper plug 166, such as Baker Product No. 445-56 is pumped on top of the cement and followed with completion fluid to force the cement through the circulating valve port 143. When it reaches the slurry placement indicator 140, the wiper plug 166 seats in the seat of the slurry placement indicator 140, causing a temporary rise in pressure at the surface to notify the surface crew of the location of the wiper plug 166. The increase in pressure forces the bypass in the slurry placement indicator 140 to open, relieving the pressure increase and allowing completion of the cementing operation.
When the cementing operation is completed, the inner equipment string 110 is again raised to use the closing tool 144 to close the cementing valve 30. After pressure testing to insure proper closure of the cementing valve 30, the inner equipment string 110 is lowered until the packer setting dog subassembly 120 engages the liner packer 18. Weight is applied to the inner equipment string 110 to set the liner packer 18.
After the completion of the cementing operation and setting the liner packer 18, the inner liner assembly 112 and the inner cementing assembly 114 of the inner equipment string 110 are raised sufficiently to allow reverse circulation to clean out any excess cement. The inner liner assembly 112 and the inner cementing assembly 114 are then pulled out of the well bore 40. The removed inner liner assembly 112 and the inner cementing assembly 114 may be replaced with a wash pipe which can be connected to the inner circulation assembly 116 for formation treatment or gravel packing operations.
To treat the formation or gravel pack in preparation for production, a wash pipe is run back into the well and engaged onto the inner circulation assembly 116 using conventional fishing equipment. A second ball 168 is dropped into the well bore 40 and is caught by the crossover tool 152. Once caught, the second ball 168 blocks fluid flow in the interior of the inner circulation assembly 116, causing an increase in liquid pressure. The increased pressure exposes the gravel pack port 170.
If the crossover tool 152 is a valve such as Baker "S2P," the second ball 168 is caught on a teflon seat. The teflon seat flexes to form a tight seal between the teflon seat and the second ball 168, preventing fluid flow into the region below the teflon seat. Several smaller balls are embedded in the teflon seat and act to hold the second ball 168 in position. Once the second ball 168 is in position against the teflon seat, fluid flow from above the ball is diverted through the gravel pack port 170.
The crossover tool 152 is initially positioned between the seal bore 44 and the lower seal bore 48, so that fluid flowing out of the crossover tool 152 flows out of the perforated extension 46 and downward into the pay zone, across the knockout isolation valve 50, pre-pack screens 52, flapper valves 54, first O-ring seal subassembly 56 and into the slotted liner 58. The fluid returns up the third wash pipe 160, through the by-pass in the crossover tool 152, and returns to the surface. This circulating position allows fluids to be pumped across the pay zone to treat or gravel pack as required.
Once sufficient circulation is achieved, the inner circulation assembly 116 is raised, pulling the anchor seal assembly 156 into the seal bore 44 and the lower seal bore 48, thereby isolating the perforated extension 46. In this position, the gravel pack port 170 is above the seal bore 44, allowing excess fluids to be reversed or circulated out of the well bore 40.
After the completion of treatment or gravel packing, inner circulation assembly 116 is separated from the anchor seal assembly 156. The inner circulation assembly 116, without the anchor seal assembly 156, is withdrawn from the well bore 40, leaving the anchor seal assembly 156 in position so that it permanently isolates the perforated extension 46.
As the inner circulation assembly 116 is removed, the knock-out isolation valve drops 50 into position to prevent the fluid in the inner circulation assembly 116 from flooding into the outer circulation and production assembly 16. | An apparatus and method is provided that allows an operator to drill a well into a formation requiring treatment or gravel packing in a single pass, then to lower and position the liner and production strings simultaneously. The invention allows cementing of the liner prior to any treatment or gravel packing, and provides an integral circulation system to allow formation treatment or gravel packing of the production string. Once treatment or gravel packing is completed, the invention provides mechanical fluid loss control as the circulation system is pulled out of the hole. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
TECHNICAL FIELD
Method and device for environmentally friendly ramming under water
The invention relates to a method and a device for the environmentally friendly driving of material to be rammed under water.
Offshore ramming work is carried out under water to establish foundations, for example, for drilling platforms and wind turbines. For wind turbines, large monopiles with a diameter of more than four meters are rammed into the seabed. This ramming results in an underwater noise input not to be overlooked, which can have a negative impact on the marine fauna, for example, the sense of direction of sea mammals can be impaired.
The object of the present invention is therefore to reduce the noise input into the environment with ramming work, in particular under water.
To reduce the noise input, a water-free working chamber is known from DE 2915542 C2, in the interior of which working chamber the pile is arranged. However, this measure presupposes that the working chamber is designed for the high underwater pressures at greater water depths and is correspondingly heavy.
A device for reducing the noise emission of a driven pile is known from DE 2514923 C2, during the driving of which into the ground, the pile is covered over its entire length by a folding jacket of flexible material.
The disadvantage of a device of this type is that it is not suitable for the rough conditions at sea, because the casing can be easily damaged during handling.
DISCLOSURE OF THE INVENTION
The object of the invention is to disclose a method and a device that is sufficiently robust for carrying out offshore ramming work and thereby substantially reduces the noise input into the water.
The method object is attained in that the ram and the pile are surrounded by a sound-insulating tubular flooded sleeve.
The device object is attained in particular by a machine, in particular a ram, for driving piles or the like, the device being covered by at least one sound-insulating fixed sleeve that is flooded.
The flooding is preferably carried out by the surrounding water, whereby differences in pressure are equalized so that the sleeve advantageously is subject to little static load.
In the embodiment of the device it is provided for the sleeve to be tubular, which advantageously reduces the expenditure for producing the sleeve.
Since the wall of the sleeve comprises a sound-insulating material, the noise emission is reduced by absorption directly at the point of origin.
The damping can be further improved if the sound-insulating material of the wall is embodied in an open-pore and/or closed-pore manner. With the closed pores, the pore content can be selected such that it improves the sound-insulating properties of the material.
Particularly good damping effects result if the wall has a thickness that is less than a quarter of the sound wavelength, preferably in the order of magnitude of a quarter.
The properties of the sleeve can be adapted to the specific conditions of use by a sandwich-like structure of the sleeve wall, if the wall of the sleeve has an outer shell and preferably is connected thereto. The outer shell thus protects the sleeve and additionally can fulfill static functions in that it gives the sleeve the necessary rigidity.
If furthermore the wall of the sleeve has an inner shell, preferably is also connected thereto, the inner shell can provide an additional protection from damage and additionally increase the mechanical rigidity.
A different oscillatory behavior of the two shells results because the materials and/or the thickness of the inner shell and outer shell are embodied differently, so that the material of the sleeve to which the shells are connected can even better damp the oscillations occurring.
The damping properties of the material can be better adjusted with the measure that the pores are filled with gas and/or with a liquid that is different from water.
The handling of the entire sleeve is advantageously simplified in that the sleeve comprises individual length sections that are preferably connected to one another in a telescoping manner and/or the sleeve is assembled from at least two segments divided in the axial direction. The segments can also be embodied as half-shells so that the sleeve can be opened in a hinged manner for assembly reasons. In the hinged open state the sound-insulating tube or the sleeve can be placed around the material that is to be rammed and subsequently closed again. The objective thereby is to minimize the crane height in the case of a sequential placement of the material to be rammed and of the sound insulation in great water depths. If the material to be rammed is placed first and if there is neither a telescoping unit nor a segmentation in the axial direction, the entire sound-insulating tube would have to be lifted over the material to be rammed or vice versa.
The sound emission can be further reduced if an upper end of the sleeve is embodied closed by a cover.
It is advantageously provided for piles that may not have sufficient inherent stability, that the sleeve has at least one damping guide element for guiding a pile.
These guide elements can dampen additionally in a particularly advantageous manner if at least one guide element is arranged outside self-vibrating nodes of the pile.
Since the machine and sleeve are embodied as a unit to be handled jointly, no additional hoisting machines are necessary at the building site. The ramming work can be carried out with the existing building site equipment.
The invention is described by way of example in a preferred embodiment with reference to a drawing, wherein further advantageous details can be taken from the figures of the drawing.
Functionally identical parts are thereby provided with the same reference numbers.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures of the drawing show in detail:
FIG. 1 : A diagrammatic axial section through the device according to the invention;
FIG. 2 : The detail x from FIG. 1 in three alternative embodiments, and
FIG. 3 : A view of the arrangement according to FIG. 1 , but with a segmentation in the axial direction instead of in a telescoping embodiment.
DETAILED DESCRIPTION
In FIG. 1 the sound-insulating sleeve 2 according to the invention encloses the pile 6 , on which the machine, i.e., the ram 1 , is located at the upper end. The inner diameter of the sound-insulating sleeve 2 embodied as a tube must therefore be greater than the largest outer diameter of the machine. The sound-insulating sleeve 2 is placed on the ground 7 or suspended in a suitable suspension with the machine 1 as one unit. The material to be rammed is supported in the sleeve 2 by means of guides 15 in a suitable manner if the construction of the material to be rammed or sleeve is not inherently stable due to its length. The tube or the sleeve can be open at the top and at the bottom or closed by means of a cover 14 . In a closed version, the supply lines 8 to the machine 1 and the material to be rammed 6 to be installed require a suitable feed-through. The sound-insulating sleeve 2 can be used above water as well as under water. It can comprise one piece or several sections 13 , 13 ′ that are assembled in a suitable manner. A telescoping embodiment is particularly space-saving.
FIG. 2 shows three alternatives a, b and c of the wall 3 of the sound-insulating sleeve 2 . In variant a the tube is of a composite material, i.e., a combination of a carrier material 5 , which determines the rigidity of the tube 2 , as an outer shell 10 , and a sound-absorption material 4 that fills the clearance between the inner shell 11 and outer shell 10 of the tube 2 . For underwater applications the enclosing material must withstand the ambient pressure so that the sound-absorption material 4 is not compressed under the pressure and thus loses its sound-insulating effect. The carrier material 5 itself can likewise have a sound-insulating effect and can also be used without additional sound-absorption material 4 as a sound-insulating sleeve pursuant to variant c. If the sound-absorption material is pressure-stable, it is sufficient to connect the sound-absorption material to the carrier material, pursuant to variant b. The sound-absorbing properties can be adjusted in wide ranges through the type and size of the pores 12 and the filling thereof. It is particularly effective if the thickness 9 of the outer shell and the thickness 9 ′ of the inner shell are different, because this results in a different oscillatory behavior. A particularly dimensioned wall thickness 17 of the insulating material and/or of the shells also has an advantageous effect.
The sleeve can also be embodied from more than three layers in an analogous manner, without leaving the extent of protection of the invention.
FIG. 3 shows a view of the arrangement according to FIG. 1 , but with a segmentation made in the axial direction instead of in a telescoping embodiment. In the case drawn the segment shells 18 , 18 ′ are asymmetrically divided and provided with flanges 19 . The segment shells can be detachably connected by hooks 20 mounted on the flanges, which hooks engage in corresponding openings of the mating flange. Alternatively, two segment shells can also be connected by hinges (not shown), so that one of the shells can be easily opened and closed again like a door for assembly purposes.
LIST OF REFERENCE NUMBERS
1 Machine, ram
2 Sound-insulating sleeve
3 Wall
4 Sound-absorption material
5 Carrier material
6 Material to be rammed
7 Ground
8 Supply lines
9 , 9 ′ Thickness of the shell
10 Outer shell
11 Inner shell
12 Pores
13 , 13 ′ Section
14 Cover
15 Guide element
16 Opening
17 Wall thickness
18 , 18 ′ Segment
18 Flange
19 Hook | The present invention relates to a method and a device for environmentally friendly ramming under water. To reduce the noise input under water, the machine and the material that is to be rammed are surrounded by a fixed flooded sleeve. The sleeve advantageously has a sandwich-like structure. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
FIELD OF THE INVENTION
[0001] The present invention relates to the field of strip doors used primarily for providing a flexible barrier across entry and exit openings in commercial and industrial facilities and equipment.
BACKGROUND OF THE INVENTION
[0002] Vertically hanging plastic strips arranged side-by-side, or in an overlapping arrangement, are used in many industrial and commercial applications to provide a flexible barrier to air, insects, noise, vapors, moisture, etc. A strip door system, which provides such barrier, only minimally disrupts the passage of product, personnel or vehicles through a doorway, or the like, as the vertically hanging plastic strips are easily bent to provide an opening for entry or exit. An important application for strip door systems, which provide a significant savings in energy consumption, is on openings into freezers and coolers in warehouse facilities, food processing areas, restaurants, etc.
[0003] Strip door systems are typically assembled by hanging a plurality of flexible plastic strips, having a width of 8-16 inches and a thickness of 0.060 to 0.160 inches, which are produced from PVC material. The strips typically are hung to span a vertically oriented plane, such as between side jams of a doorway. The strips typically have an overlap of 25-100%, for example, for a 50% overlap, on a given strip, 25% of its width, at each edge, would be overlapped with an adjacent strip.
[0004] The vertically hanging strips are usually hung from a uniformity spaced series of studs disposed at or near a header of a doorway. The studs are most often fixed to a plate, or the like, to form a hanger, and the hanger is attached to the header or a wall above the doorway. Many different hangers are known for hanging the plastic strips.
[0005] FIG. 1 shows a known flexible strip door system for describing a general configuration of a strip door system in which a hanger of the present invention would be used. In FIG. 1 , an opening 1 in wall 2 is provided with a flexible plastic strip door 3 having elongated flexible plastic strips 4 arranged in an overlapping pattern with areas of overlapping indicated at 5 . The strips 4 are hung from a hanger 6 having protruding studs 7 arranged in a uniform spacing along the length of the hanger. The plastic strips 4 have uniformily spaced apertures 8 , along an upper portion, which correspond in spacing with the studs 7 of the hanger. The spacing arrangement of the studs and the apertures allow for overlap of 25 to 100%, or no overlap, wherein edges of the strips are placed abutting edges of adjacent strips.
[0006] The system depicted in FIG. 1 has an overlap of about 50%, that is 50% of each strip is overlapped by other strips. Although not shown, some type of retaining means is necessary to prevent the strips from sliding off the studs when the strips are encountered by personnel or equipment passing through the opening. In U.S. patent application Ser. No. 10/406,527 entitled “Flexible-Strip Hanger for a Strip Door System and Method of Making Same”, filed Apr. 3, 2003, a hinged cover prevents the plastic strips from sliding off the studs.
[0007] Plastic strip door systems, as described above are very durable as they can be subjected to heavy usage by personnel or equipment passing through them. In particular, fork lifts or other commercial and industrial type equipment often subject the plastic strips to harsh usage, including tearing away of the strips, if caught on such equipment or caught on the product being moved. Such harsh usage, as well as normal everyday usage, necessitates the plastic strips being replaced from time to time. Because of the typical locations of the hangers, that is at a location requiring the use of a ladder, and/or at cold or below freezing environments, replacement is often difficult and dangerous, and can require the use of more than one person to carry out the replacement.
[0008] One known hanger has spaced studs on a backing plate along with a strip retaining bar, which requires the use of tools to secure the bar in place. Another known hanger, although it requires no tools for installing the strips, relies solely on studs having an enlarged end to prevent the strips from sliding off. In such a system an aperture in the plastic strip, which slides over the stud, must be very accurately formed so as to fit over the stud, yet be retained by the enlarged end. In the same system, a strip having the properly sized aperture can be difficult to slide over the enlarged end, if the material of the strip is at a low temperature in a cooler or freezer application. Many retaining systems are known, however they all have undesirable features.
OBJECTS OF THE INVENTION
[0009] It is the object of the present invention to provide a hanger for plastic strips of a strip door system which is of durable construction and configured for convenient initial installation.
[0010] It is another object of the present invention to provide a hanger which enables easy replacement of worn or damaged plastic strips, without the use of hand tools.
[0011] It is still another object of the present invention to provide a hanger having a positive retaining device to prevent the plastic strips from sliding off the studs, which does not rely solely on an enlarged portion of a stud and the elasticity of the plastic strip.
[0012] It is yet a further object of the present invention to provide an adjustable effective stud length to better accommodate plastic strips of various thicknesses arranged to have various amounts of overlap.
SUMMARY OF THE INVENTION
[0013] The present invention is a hanger for use in a strip door system for supporting vertically hanging flexible plastic strips, wherein each strip has a row of uniformity spaced apertures along an upper end portion. The hanger has an elongated backing plate portion for attaching the hanger to a structure above an opening, a plurality of uniformily spaced studs fixed along the length of the backing plate, for supporting the plastic strips by engagement through the strip apertures, and an elongated retaining plate for locking with the studs to prevent the engaged strips from sliding off the studs. Each stud has a plurality of locking means along its length for locking the retaining plate with the studs so as to provide an adjustable effective stud length between the backing plate and the retaining plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention will become more readily apparent from the following description of preferred embodiments thereof, shown, by way of example only, in the accompanying drawings, wherein:
[0015] FIG. 1 is a prior-art strip door system wherein flexible plastic strips having uniformily spaced apertures are supported on a hanger having uniformily spaced protruding studs;
[0016] FIGS. 2A and 2B are respectively, a front view and an end view of a backing plate of a first embodiment of the invention;
[0017] FIGS. 3A and 3B are respectively, a front view and an end view of a retaining plate of the invention;
[0018] FIGS. 4A and 4B are respectively, a front view and an end view of the backing plate of FIGS. 2A and 2B , having the retaining plate of FIGS. 3A and 3B in an engaged position;
[0019] FIGS. 5A and 5B are respectively, a front view and an end view of the retaining plate of FIGS. 3A and 3B as disposed when sliding the retaining plate onto studs of the backing plate;
[0020] FIGS. 6A and 6B are respectively, a front view and an end view of the hanger of the first embodiment of the invention having flexible plastic strips in place on the hanger;
[0021] FIGS. 7A and 7B are respectively, a front view and an edge view of a retaining disc of the invention;
[0022] FIGS. 8A and 8B are respectively a front view and an end view of the hanger of the first embodiment of the invention having the flexible plastic strip in place on the hanger and retaining discs in place on studs of the hanger.
[0023] FIGS. 9A and 9B are respectively, a front view and an end view of a backing plate of a second embodiment of the invention, for use when mounting the hanger on a header;
[0024] FIGS. 10A and 10B are respectively, a front view and an end view of a universal backing plate of a third embodiment of the invention, for either wall or header mounting of the hanger.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIGS. 2A and 2B show a front view and an end view, respectively, of an elongated backing plate of the first embodiment of the invention. The three embodiments of the invention, discussed below, are distinct only in the shape of the backing plate which is provided for mounting: 1) on a vertically oriented wall above an opening, 2) on a horizontally oriented header of an opening, and 3) on either a vertically oriented wall or a header of an opening.
[0026] The first embodiment, shown in FIGS. 2A and 2B , is for use in mounting on a wall above an opening which is to be provided with a strip door system. Shown is an elongated backing plate 9 of the hanger having apertures 10 for attaching the hanger to a vertically oriented wall above an opening to which the strip door is to be installed. Protruding from a front face 11 of the backing plate are a plurality of uniformity spaced studs 12 for supporting the flexible plastic strips of the strip door system. Apertures provided along a top portion of each strip are slid over the uniformily spaced studs to install the strips on the hanger. The studs, which preferably have a cylindrical shape, feature annularly shaped grooves 13 spaced along the length of each stud. The grooves have a major diameter D, which corresponds to the surface of the stud, and a minor diameter d as measured at the base of a groove. To insure a tight attachment to the backing plate, the studs preferably extend through the backing plate 9 and have a head portion 14 which rests against back face 15 of the backing plate. Any known means, such as a press fit, brazing, or the like, can be used to maintain a tight attachment of the studs to the backing plate. Preferably the backing plate includes bent portions, such as at 16 and 17 to give rigidity to the backing plate and to provide a spacing for the head portions 14 of the studs. The hanger can be of any length required to span the opening being addressed.
[0027] FIGS. 3A and 3B show an elongated retaining plate 18 of the hanger which prevents the installed flexible plastic strips from sliding off studs 12 . Retaining plate 18 features apertures 19 , having a minor portion 20 , and a major portion 21 which communicate with each other. Apertures 19 have centerlines 22 which correspond in spacing with center lines 23 of the studs of backing plate 9 . The apertures 19 of retaining plate 18 are configured such that the major portion of the aperture is slideable along the length of the studs, and the minor portion is slideable into one of the grooves 13 , but not slideable along the length of the stud. Thus the grooves of the studs act as a locking means for the retaining plate 18 .
[0028] FIGS. 4A and 4B show the retaining plate 18 in an engaged position, that is minor portions 20 of the apertures are seated in the grooves 13 of the studs 12 . FIGS. 5A and 5B show retaining plate 18 in a state whereat the major portion 21 of the aperture is being slid over the stud 12 to a position at which the retaining plate 18 is aligned with a groove 13 of the stud, and whereat by solely the force of gravity, the retaining plate 18 becomes locked on the stud 12 by engagement of the minor portion 20 of the aperture with the groove 13 as shown in FIGS. 4A and 4B .
[0029] As indicated earlier, a plurality of grooves are disposed along the length of each stud. Such arrangement enables the use of various thicknesses of plastic strips in either an overlapping or non-overlapping side-by-side hanging pattern. FIGS. 6A and 6B show the hanger of the invention having plastic strips 23 hanging from the studs 12 in an overlapping arrangement. As shown in FIG. 6B , having retaining plate 18 in a selected groove 13 of the stud provides an effective stud length, as measured between the backing plate 9 and the retaining plate 18 , such that the strips are prevented from moving backward and forward along the length of the stud. The spacing of the grooves need not be uniform along the length of the stud, however all of the studs of a hanger must have the same groove pattern. As can be seen in FIG. 6B , if thinner or thicker plastic strips are desired, or if no overlap is desired, the various grooves provide for flexibility by enabling an adjustment of the effective length of each stud. The grooves preferably have side walls which are perpendicular to the central axis of the stud, so as to more securely hold the retaining plate. As in the backing plate 9 , a bend 25 is provided in the retaining plate 18 in order to provide rigidity. When the retaining plate is engaged in the grooves 13 of the studs along the length of the hanger, normal passage through the strip door will not cause disengagement.
[0030] As an added safety feature, a retaining disc, 26 , as shown in FIGS. 7A and 7B can be used with the backing plate 9 and the retaining plate 18 . Referring to FIGS. 8A and 8B , the retaining disc 26 is shown as disposed on stud 12 . The retaining disc 26 is fabricated of a material having elasticity, yet some stiffness, in order that an aperture 27 formed in the retaining disc can be slid over a stud and be retained by elastic forces in a groove of the stud, that is one of the same grooves used for the retaining plate 18 . Preferably the aperture 27 is formed to have a diameter corresponding to the diameter d of the base of the groove. The disc is positioned on the stud, extending downward to contact a ridge 29 along a bottom portion of the retaining plate as shown in FIGS. 8A and 8B . Preferably the disc 26 has a thickness approximately equal to a width of the grooves to assure that the disc hangs vertically downward without a clearance between the disc and the groove with would enable easy movement of the disc away from its preferred vertical orientation. The disc 26 is placed in the groove which is adjacent to the groove occupied by the retaining plate. Also, in order to facilitate use of the retaining disc, a tab 28 extending from the body of the disc, is provided. In use of the invention, at least one of the retaining discs is used to assure that the retaining plate, due to an occurrence other than normal use of the strip door, does not move upwardly so as to become disengaged from the studs. The elimination of upwardly movement is assured by the disc 26 making contact with the ridge 29 .
[0031] FIGS. 9A and 9B show a front view and an end view respectively of a second embodiment of the invention for use in mounting a hanger to a horizontally oriented header of a doorway, for example. Shown in FIGS. 9A and 9B is backing plate 30 having a portion 31 , which is oriented horizontally when installed, which can be attached to a horizontally oriented surface for installation. Apertures 32 are provided to facilitate the installation. In the second embodiment, shown in FIGS. 9A and 9B all remaining features and operation are as described in the description of the first embodiment.
[0032] FIGS. 10A and 10B show a front view and an end view respectively of a third embodiment of the invention, which can be used for mounting the backing plate 33 to either a horizontally or vertically oriented surface. The backing plate 33 provides apertures 34 in portion 35 and web 36 of the backing plate 33 . In the third embodiment, shown in FIGS. 10A and 10B , all remaining features and operation are as described in the description of the first embodiment.
[0033] In all of the embodiments of the invention, because of the typically moist environment of the installation, galvanized steel or stainless steel is the preferred material for the components, however other materials are available in practice of the invention. The backing plate and retaining plate are preferably formed of 10 to 20 gauge sheet material. The studs preferably have a diameter of ¼-⅜ inches and a length of ¾-1¼ inches. The depth of the grooves is preferably about 0.07 inch.
[0034] While specific materials, dimensional data, etc. have been set forth for purposes of describing embodiments of the invention, various modifications can be resorted to, in light of the above teachings, without departing from Applicant's novel contributions; therefore in determining the scope of the present invention, reference shall be made to the appended claims. | A hanger for plastic strips having uniformity spaced apertures along an end portion thereof, to form a strip door across an opening. Uniformily spaced studs are provided on a mountable backing plate to support the plastic strips. A retaining plate retains the strips on the studs which have locking means along the length thereof, so as to provide an adjustable effective length for each of the studs. |
You are an expert at summarizing long articles. Proceed to summarize the following text:
BACKGROUND
[0001] The present invention relates generally to operations performed in conjunction with a subterranean well and, in an embodiment described herein, more particularly provides a method whereby a latch profile is installed in a tubular string.
[0002] It is common practice to set a packer (or another anchoring device, such as a liner hanger or hanger/packer) in a casing string in a parent wellbore prior to drilling a branch wellbore. The packer provides a secure platform to which a whipstock may be attached during the processes of milling through the casing and drilling the branch wellbore. The packer also seals against the casing, which may be used to provide pressure isolation for a zone of the parent wellbore below the intersection with the branch wellbore, or which may aid in preventing debris from falling down in the parent wellbore.
[0003] Various types of packers have been used for this purpose—permanent packers, retrievable packers, hydraulically set packers, mechanically set packers, etc. Nevertheless, all of these various types of packers share a common disadvantage in that they restrict access and flow through the parent wellbore. If full bore access to the parent wellbore below the branch wellbore intersection is desired after the branch wellbore is drilled, the packer must be unset and retrieved from the well (which is many times quite difficult to accomplish), or the packer must be milled through or washed over (which is quite time-consuming).
[0004] Because of this wellbore restriction due to the use of packers in multilateral wellbore drilling, multilateral wells are typically constructed from bottom up. That is, a first branch wellbore is drilled from a parent wellbore, then a second branch wellbore is drilled from the parent wellbore at a location above the intersection between the parent and first branch wellbores, then a third branch wellbore is drilled from the parent wellbore at a location above the intersection between the parent and second branch wellbores, etc. This situation unnecessarily limits the options available to the operator, such as to drill the branch wellbores in another, more advantageous, sequence or to drill a previously unplanned branch wellbore below another branch wellbore, etc.
[0005] In addition, a packer relies on a gripping engagement with the casing using slips. This gripping engagement may fail due to the severe forces generated in the milling and drilling operations. Such gripping engagement also provides limited radial orientation of the packer relative to the casing, so if the gripping engagement is ever relieved (such as, by unsetting the packer), any subsequent radial orientation relative to the casing (for example, to re-enter the branch wellbore) will not be able to benefit from the original orientation of the packer.
SUMMARY
[0006] In carrying out the principles of the present invention, in accordance with an embodiment thereof, a method is provided in which a latch profile is installed in a tubular string after the tubular string is positioned in a well. The method permits an apparatus such as a whipstock to be secured in the tubular string. The latch profile may provide for radial orientation of the apparatus.
[0007] In one aspect of the invention, the latch profile is formed on an expandable latch structure which is conveyed into the tubular string. The latch structure is then expanded outward, thereby securing the latch profile to the tubular string. For example, the latch structure may deform the tubular string when it is expanded outward, thereby recessing the latch structure into an interior surface of the tubular string and leaving full bore access through the tubular string. Bonding agents, such as adhesives and sealants may be used to bond the latch structure to the tubular string.
[0008] In another aspect of the invention, the latch profile may be formed on the interior surface of the tubular string by creating recesses on the interior surface.
[0009] The recesses may be formed in a predetermined pattern, so that an apparatus engaged therewith will be secured relative to the tubular string and radially oriented relative to the tubular string.
[0010] In yet another aspect of the invention, the latch profile may be formed on the interior surface of the tubular string by cutting into the interior surface to create the recesses. For example, cutting tools such as drills or mills may be used. If the recesses extend through a sidewall of the tubular string, thereby forming openings through the sidewall, sealant may be injected into the openings to prevent fluid flow therethrough.
[0011] In still another aspect of the invention, the latch profile may be installed in the tubular string using any of the methods summarized above, and then an apparatus may be operatively engaged with the profile in a single trip into the well. This may be accomplished by attaching the apparatus to a latch profile installation assembly and conveying these together into the well.
[0012] 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 a representative embodiment of the invention hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic cross-sectional view of a first method embodying principles of the present invention;
[0014] [0014]FIG. 2 is a schematic cross-sectional view of the first method of FIG. 1, wherein further steps of the method have been performed;
[0015] [0015]FIG. 3 is a schematic cross-sectional view of a second method embodying principles of the present invention;
[0016] [0016]FIG. 4 is a schematic cross-sectional view of a third method embodying principles of the present invention; and
[0017] [0017]FIGS. 5A & B are schematic cross-sectional views of a fourth method embodying principles of the invention.
DETAILED DESCRIPTION
[0018] Representatively illustrated in FIG. 1 is a method 10 which embodies principles of the present invention. In the following description of the method 10 and other apparatus and methods described herein, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used only 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., and in various configurations, without departing from the principles of the present invention.
[0019] As depicted in FIG. 1, a casing string 12 has been positioned in a parent wellbore 14 and has been cemented therein. The casing string 12 could be any type of tubular string, such as a string of liner, etc., and the parent wellbore 14 could be any type of wellbore, such as a branch wellbore, a vertical, horizontal or deviated wellbore, etc., in keeping with the principles of the invention. In addition, the terms “cemented”, “cement”, “cementing”, etc. as used herein are intended to encompass any means of securing and sealing the casing string 12 in the wellbore 14 . For example, materials such as epoxies, gels, resins, polymers, elastomers, etc., as well as cementitious materials, may be used for this purpose.
[0020] After the casing string 12 has been cemented in the wellbore 14 , a latch profile 16 is installed in the casing. Representatively, the latch profile 16 is used in the method 10 to position a whipstock assembly 18 at a location in the casing string 12 where it is desired to drill a branch wellbore. However, it is to be clearly understood that the latch profile 16 may be used for any of a large variety of purposes other than positioning the whipstock assembly 18 , without departing from the principles of the invention. For example, the latch profile 16 could be used to position a device for re-entering the branch wellbore after it is drilled and the whipstock assembly 18 is retrieved from the well, the latch profile could be used to position a flow control device, such as a plug or valve, to control fluid flow in the parent and/or branch wellbores, etc.
[0021] The whipstock assembly 18 includes a whipstock 20 having an upper deflection surface 22 , a wiper or seal 24 and one or more keys, lugs or dogs 26 for engagement with the latch profile 16 . The deflection surface 22 is used to deflect cutting tools, such as mills and drill bits, to drill the branch wellbore outward from the parent wellbore 14 . The seal 24 is used to prevent debris from fouling the latch profile 16 or from falling down into the parent wellbore 14 therebelow. The keys 26 are complementarily shaped relative to the profile 16 and may be continuously radially outwardly biased, or they may be selectively actuated to extend outward into engagement with the profile when desired.
[0022] As used herein, the term “whipstock” is used to designate any type of deflection device which may be used in a well to deflect an object from one wellbore to another.
[0023] Attached to a lower end of the whipstock assembly 18 is a running tool 28 . The running tool 28 is used to install the latch profile 16 in the casing 12 . Specifically, the running tool 28 is used to outwardly expand a latch structure 30 on which the latch profile 16 is internally formed.
[0024] The latch structure 30 may be a circumferentially continuous generally tubular shaped structure with the latch profile 16 formed on an interior surface thereof. However, it is to be understood that the latch structure 30 could be otherwise shaped and configured. For example, the latch structure 30 could be made up of multiple segments each of which is displaced outward to expand the latch structure. If the latch structure 30 is circumferentially continuous, it may be expanded outward by circumferential stretching.
[0025] Carried externally on the latch structure 30 is a bonding agent 32 . The bonding agent 32 may be an adhesive for securing the latch structure 30 to the casing 12 , or the bonding agent may be a sealant for forming a seal between the latch structure and the casing. Of course, the bonding agent 32 could be an adhesive sealant, and separate adhesive and sealant could also be used. In addition, other means of securing the latch structure 30 to the casing 12 (for example, thermal welding, piercing of the casing, deploying a spear-type device to connect and secure the latch structure to the casing, etc.), and other means of sealing between the latch structure and the casing, may be used without departing from the principles of the invention.
[0026] However, it should be understood that the bonding agent 32 is not necessary in the method 10 , since the latch structure 30 could be secured and/or sealed to the casing 12 by contact therebetween. For example, a metal to metal seal may be formed between the latch structure 30 and the casing 12 when the latch structure is expanded outward into contact with the casing.
[0027] The latch profile 16 is preferably of the type known to those skilled in the art as an orienting profile. That is, once installed in the casing string 12 , the latch profile 16 will serve to radially orient an apparatus engaged therewith relative to the casing string. For example, the whipstock assembly 18 will be radially oriented so that cutting tools are deflected off of the deflection surface 22 in a desired direction to drill the branch wellbore when the whipstock assembly is operatively engaged with the latch profile 16 . Of course, other types of profiles may be used for the latch profile 16 in keeping with the principles of the invention.
[0028] The running tool 28 includes an actuator 34 and a conically-shaped wedge 36 . The actuator 34 is used to displace the wedge 36 through the latch structure 30 to thereby outwardly expand the latch structure. The actuator 34 may be any type of actuator, such as a hydraulic, mechanical, explosive or electrical actuator.
[0029] As depicted in FIG. 1, the whipstock assembly 18 and running tool 28 are conveyed into the casing string 12 on a tubing string 38 . Any form of conveyance may be used in place of the tubing string 38 . For example, a wireline or slickline could be used. Furthermore, note that the tubing string 38 may be a segmented or a continuous tubing string, such as a coiled tubing string.
[0030] Referring additionally now to FIG. 2, the method 10 is representatively illustrated after the latch structure 30 has been expanded outward. Upward displacement of the wedge 36 by the actuator 34 has outwardly expanded the latch structure 30 so that the casing string 12 is plastically deformed, outwardly deforming a sidewall of the casing. The latch profile 16 is thereby secured to the casing string 12 .
[0031] Note that a minimum inner diameter of the latch structure 30 is substantially equal to the minimum inner diameter of the casing string 12 . Thus, the latch structure 30 permits full bore access through the casing string 12 . However, the latch structure 30 could have an inner diameter smaller than the inner diameter of the casing string 12 , without departing from the principles of the invention.
[0032] The bonding agent 32 adheres the latch structure 30 to the casing string 12 and/or forms a seal between the latch structure and the casing string. If the latch structure 30 is made up of individual segments, the bonding agent 32 may prevent the segments from falling inwardly.
[0033] The whipstock assembly 18 has been lowered in the casing string 12 , so that the keys 26 operatively engage the latch profile 16 . This engagement secures the whipstock 20 and radially orients the whipstock relative to the casing string 12 .
[0034] The seal 24 is received in an upper bore of the latch structure 30 . This engagement between the seal 24 and the latch structure 30 may serve to prevent fouling of the latch profile 16 and/or prevent debris from falling into the parent wellbore 14 below the whipstock assembly 18 .
[0035] Note that the latch profile 16 has been installed and the whipstock assembly 18 has been engaged with the latch profile in only a single trip into the casing string 12 . This enhances the economical performance of the method 10 . However, it should be understood that the latch profile 16 could be installed and an apparatus engaged therewith in multiple trips into the casing string 12 , without departing from the principles of the invention.
[0036] Referring additionally now to FIG. 3, another method 40 embodying principles of the present invention is representatively illustrated. In the method 40 , a latch profile 42 made up of multiple spaced apart recesses 44 , 46 is installed in a casing string 48 after the casing string is positioned in a wellbore 50 . Specifically, the recesses 44 , 46 are formed in the casing string 48 by plastically deforming the casing string using a forming apparatus 52 .
[0037] The forming apparatus 52 includes dies 54 , 56 which are outwardly extendable to engage an interior surface of the casing string 48 . On the left hand side of FIG. 3, the dies 54 , 56 are depicted in retracted positions thereof. On the right hand side of FIG. 3, the dies 54 , 56 are depicted in extended positions thereof, forming the recesses 44 , 46 on the interior surface of the casing string 48 by plastically deforming a sidewall of the casing string.
[0038] The dies 54 are circumferentially continuous (i.e., ring-shaped), so that the recesses 44 are also circumferentially continuous. The die 56 is not circumferentially continuous, but produces the discreet recess 46 at a particular desired radial orientation on the casing string 12 . The recesses 44 are used to secure an apparatus (such as the whipstock assembly 18 described above) against axial displacement through the casing string 48 , and the recess 46 is used to radially orient the apparatus relative to the casing string.
[0039] Thus, the recesses 44 , 46 are arranged in a predetermined pattern, so that an apparatus subsequently engaged therewith will be secured and radially oriented relative to the casing string 48 . For example, the whipstock assembly 18 described above could have keys, dogs or lugs carried thereon in a complementarily shaped pattern to operatively engage the recesses 44 , 46 . Preferably, the recess 46 would be engaged when the whipstock assembly 18 is properly radially oriented relative to the casing string 48 .
[0040] As depicted in FIG. 3, the forming tool 52 is conveyed into the casing string 48 on a wireline 58 , but any other type of conveyance could be used. The forming tool 52 may be hydraulically, mechanically, explosively or electrically actuated to extend the dies 54 , 56 outward. However, it should be understood that the forming tool 52 may be actuated in any manner, and may be configured in any manner to produce any desired pattern of recesses, in keeping with the principles of the invention.
[0041] Referring additionally now to FIG. 4, another method 60 embodying principles of the present invention is representatively illustrated. In the method 60 , a cutting apparatus 62 is used to cut into an interior surface of a casing string 64 positioned in a wellbore 66 . Specifically, cutting tools 68 are outwardly extended from the apparatus 62 to form recesses 70 in the interior surface of the casing string 64 .
[0042] On the left hand side of FIG. 4 the cutting tools 68 are depicted in retracted positions thereof, and on the right hand side of FIG. 4 the cutting tools are depicted in extended positions thereof. There may be only one of the cutting tools 68 , which may be used multiple times to cut corresponding multiple recesses 70 , or there may be the same number of cutting tools as recesses to be cut, etc.
[0043] The cutting tools 68 may be drill bits, mills, keyway cutters, or any other type of cutting tool. Alternatively, the cutting tools 68 could be nozzles for a high pressure water jet. In that case, it would not be necessary to outwardly extend the cutting tools 68 from the apparatus 62 in order to cut into the casing 64 . Water jet cutting of the casing 64 may be preferred for cutting a detailed profile into the casing 64 .
[0044] As depicted in FIG. 4, the recesses 70 are preferably cut in a predetermined pattern, so that an apparatus (such as the whipstock assembly 18 described above) subsequently engaged therewith will be secured and radially oriented relative to the casing string 64 . That is, the whipstock assembly 18 or other apparatus may be provided with keys, lugs or dogs arranged in a complementarily shaped pattern to operatively engage the recesses 70 . The pattern of recesses 70 thus make up the latch profile installed by the cutting apparatus 62 . Preferably, the recesses 70 are operatively engaged when the whipstock assembly 18 or other apparatus is radially oriented in a desired direction relative to the casing string 64 .
[0045] The recesses 70 may extend through a sidewall of the casing string 64 , so that they form openings through the casing sidewall. In that case, it may be desired to prevent fluid flow through the openings. A sealant 72 may be injected through the openings 70 for this purpose. For example, the sealant 72 may be an epoxy, polymer, resin, cement, or any other type of sealant.
[0046] As depicted in FIG. 4, the cutting apparatus 62 is conveyed into the casing string 64 by a wireline 74 . However, it is to be understood that any type of conveyance may be used in place of the wireline 74 . For example, a tubing string could be used to convey the apparatus 62 .
[0047] As with the running tool 28 described above, the forming tool 52 and/or the cutting apparatus 62 may be conveyed into a well attached to an apparatus which is to be operatively engaged with the latch profile installed by the forming tool or cutting apparatus. For example, the whipstock assembly 18 could be attached to the forming tool 52 when it is conveyed into the casing string 48 , or the whipstock assembly could be attached to the cutting apparatus 62 when it is conveyed into the casing string 64 . Thus, the latch profiles installed by the forming tool 52 and the cutting apparatus 62 may be operatively engaged by an apparatus, such as the whipstock assembly 18 , in a single trip into the well.
[0048] Referring additionally now to FIGS. 5A & B, another method 80 embodying principles of the invention is representatively illustrated. In the method 80 , an expandable latch structure 82 having a latch profile 84 formed internally thereon is conveyed into a casing string 86 , in a manner similar to that described above for the method 10 . The latch structure 82 is preferably generally tubular and circumferentially continuous, but could be circumferentially segmented if desired.
[0049] The latch structure 82 has a layer of a bonding agent 88 on the external surface of the latch structure. The bonding agent 88 may be similar to the bonding agent 32 in the method 10 . The bonding agent 88 is used to adhere and/or seal the latch structure 82 to the casing string 86 . Suitable materials for the bonding agent 88 may be elastomers, epoxies, other polymer compositions, resins, cements, other sealants, other adhesives, etc.
[0050] However, it should be understood that the bonding agent 88 is not necessary in the method 80 , since the latch structure 82 could be secured and/or sealed to the casing string 86 by contact therebetween. For example, a metal to metal seal may be formed between the latch structure 82 and the casing string 86 when the latch structure is expanded outward into contact with the casing string.
[0051] The profile 84 may be an orienting profile, that is, equipment (such as the whipstock 20 described above) operatively engaged with the profile is rotationally oriented relative to the casing string 86 , as well as being secured axially and rotationally thereto. Alternatively, or in addition, the latch structure 82 may include a laterally inclined upper surface go (known to those skilled in the art as a “muleshoe”) for rotationally orienting and securing the equipment. Preferably, the latch structure 82 is rotationally oriented relative to the casing string 86 prior to expanding the latch structure in the casing string.
[0052] The latch structure 82 is depicted in FIG. 5A in its radially compressed, or unexpanded, configuration. The latch structure 82 is depicted in FIG. 5B in its radially expanded configuration, with the bonding agent 88 contacting and securing and/or sealing the latch structure to the casing string 86 . A conical wedge 92 may be displaced through the latch structure 82 to expand the latch structure radially outward, or other means may be used for this purpose.
[0053] As depicted in FIG. 5B, the latch structure 82 in its expanded configuration has a minimum diameter therethrough which is somewhat less than the inner diameter of the casing string 86 . However, the latch structure 82 may be further radially outwardly expanded to recess the latch structure into the inner wall of the casing string 86 (similar to the manner in which the latch structure 30 is recessed into the casing 12 in the method 10 ) in which case the latch structure 82 could have a minimum diameter substantially equal to, or at least as great as, the casing inner diameter.
[0054] Of course, a person skilled in the art would, upon a careful consideration of the above description of representative embodiments of the invention, readily appreciate that many modifications, additions, substitutions, deletions, and other changes may be made to these specific embodiments, and such changes are contemplated by the principles of the present invention. For example, a latch profile may be installed in a casing string using a combination of various forming and cutting methods. Accordingly, the foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims and their equivalents. | A method of installing an internal latch profile in an existing tubular string does not require the use of a packer. In a described embodiment, a method of latch installation includes the step of deforming an interior surface of the tubular string after the tubular string is positioned in a well. In another described embodiment, a method of latch installation includes the step of cutting into the interior surface of the tubular string. |
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RELATED APPLICATION DATA
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 60/935,851, filed Sep. 4, 2007, entitled “Hybrid Retainer Sleeve For Tool Inserted into Block”, the entire contents of which are incorporated herein by reference.
FIELD
The present disclosure relates to a sleeve for retaining a tool in a block. More particularly, the present disclosure relates to a retainer sleeve that fits about the shank of a tool and is inserted into a bore of a block to form an assembly. The retainer sleeve incorporates both a friction fit and a rear retaining feature.
BACKGROUND
In the discussion of the background that follows, reference is made to certain structures and/or methods. However, the following references should not be construed as an admission that these structures and/or methods constitute prior art. Applicant expressly reserves the right to demonstrate that such structures and/or methods do not qualify as prior art.
Mining and construction machines are being designed with progressively faster cutter drum and chain speeds. These advancements are making it more difficult to retain tools in their respective holders, such as a tool block or a bore of a rotating drum. For this reason, friction sleeve retainers are becoming less effective in retaining tools. Many industries are starting to progress towards rear retention to hold tools in holders.
Rear retainers are typically used in applications where the user needs maximum retention. These retainers are separate, loose parts that are inserted in a retaining feature, such as a groove, on the portion of the tool shank that projects beyond the rear of the tool block.
Rear retainers have certain limitations. Rear retainers can be difficult to assemble and remove due to limited access behind the holder. In order to assemble a typical external retainer onto a tool, a certain amount of clearance is required between the rear of the holder and the groove in the tool shank. This clearance can allow unnecessary freedom of movement between the tool and holder, causing an unwarranted amount of slapping between the tool shoulder and face of the holder. This slapping can cause excessive wear in the bore and on the face of the holder, reducing the lifetime of both parts.
Certain retainers require special tools (for example, snap rings require special pliers) while others require excessive force (for example, cut washers) during installation and removal. Due to the elastic memory of these retainers, during removal many retainers are prone to “pop” off in any given direction. This can make the removal of these “projectile” retainers dangerous on the job site as well as cumbersome to use if one loses the retainer and needs to find a replacement.
SUMMARY
An improved sleeve utilizing two methods of retention—a friction fit as well as a rear retainer—has advantageous performance characteristics as well as improved ease of use.
An exemplary embodiment of a sleeve for retaining a tool in a block comprises a hollow cylindrical body having a first end, a second end and a connecting surface therebetween arranged axially, a first axially extending slit in the connecting surface extending from the first end to the second end, at least one second axially extending slit in the connecting surface extending from the second end to a termination point between the first end and the second end, and a projected portion offset from the second end, wherein the sleeve at the projected portion projects radially outward with a radius larger than a radius of an outer diameter of the hollow cylindrical body, and wherein the termination point is axially closer to the first end than the projected portion.
Another exemplary embodiment of a sleeve for retaining a tool in a block comprises a hollow cylindrical body having a first end, a second end and a connecting surface therebetween arranged axially, a plurality of sections arranged circumferentially at the second end, and a projected portion offset from the second end, wherein the hollow cylindrical body is circumferentially compressible, and wherein each of the plurality of sections is independently radially compressible.
An exemplary embodiment of a mining machine comprises a rotatable member, and one or more tools mounted on the rotatable member, wherein the one or more tools are mounted with a sleeve including a hollow cylindrical body having a first end, a second end and a connecting surface therebetween arranged axially, a plurality of sections arranged circumferentially at the second end; and a projected portion offset from the second end, wherein the hollow cylindrical body is circumferentially compressible, and wherein each of the plurality of sections is independently radially compressible.
An exemplary embodiment of a tool and block assembly comprises a block including a body having a bore extending axially from a first side to a second side, a tool including a body having a head and a shank, and a sleeve positioned about the shank, wherein the sleeve includes a hollow cylindrical body having a first end, a second end and a connecting surface therebetween arranged axially, a plurality of sections arranged circumferentially at the second end, and a projected portion offset from the second end, wherein at least a portion of the connecting surface has a friction fit with the bore, wherein the projected portion contacts the block to urge the sleeve rearward, and wherein the tool is rotatable.
An exemplary embodiment of a method of mounting a rotatable tool in a bore of a holder comprises securing the tool in the bore with a sleeve that provides both a friction fit and a rear retention feature.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWING
The following detailed description can be read in connection with the accompanying drawings in which like numerals designate like elements and in which:
FIG. 1 is a cross-sectional view of an exemplary embodiment of a tool assembly including a tool, a hybrid retainer and a holder.
FIG. 2 is an isometric view of an exemplary embodiment of a hybrid retainer sleeve.
DETAILED DESCRIPTION
An exemplary embodiment of a tool in a block is schematically illustrated in FIG. 1 . The tool 2 includes a body 4 having a head 6 and a shank 8 . The head 6 includes a front surface 10 and a side surface 12 . The side surface 12 extends axially rearwardly from the front surface 10 toward a shoulder 14 . The side surface 12 can be of various forms from being oriented substantially perpendicular to a central axis 16 of the body 4 to being oriented at an angle α to the central axis 16 (the angle α opening rearward), and combinations thereof and the form of the side surface 12 can be planar, concave, convex or combinations thereof. The side surface shown in FIG. 1 is an example of a concave form. A cutting tip 20 is attached to the front surface 10 of the head 6 . The cuffing tip 20 is made from a hard material. A suitable hard material for the cutting tip 20 is cemented carbide. An exemplary composition of the cemented carbide includes 6-12 wt. % Co and balance WC.
The block 30 can have any suitable shape, generally adapted to the mining machine on which it is mounted and adapted to the tool which it supports. An exemplary embodiment of a block 30 includes a body 32 having a bore 34 extending axially from a first side 36 to a second side 38 . The bore 34 can be smooth along its inner diameter, albeit the bore 34 can be stepped, i.e., have variation in the inner diameter along its length, or the bore 34 can include an internal groove. An example of a stepped bore is shown in FIG. 1 with a first portion 40 and a second portion 42 . Other stepped bore arrangements are disclosed in U.S. Pat. Nos. 7,234,782 and 5,302,005, the entire contents of which are incorporated herein by reference. An example of a bore with an internal groove is disclosed in U.S. Pat. No. 4,484,783, the entire content of which is incorporated herein by reference. The block 30 has a mounting surface 44 at a third side. The mounting surface 44 is adapted for mounting to a rotatable drum of a mining machine or other rotatable member of a construction machine, tunneling machining or trenching machine, such as Sandvik model MT720 tunneling machine or Voest-Alpine's Aline Bolter Miner ABM 25.
A sleeve 50 is arranged about at least a portion of the shank 8 inserted into the bore 34 of the block 30 . An exemplary embodiment of a sleeve is shown in FIG. 2 . The sleeve 50 includes a hollow cylindrical body 52 having a first end 54 , a second end 56 and a connecting surface 58 therebetween arranged axially. The cylindrical body 52 can have any suitable form, such as an elliptical cylindrical body or a right circular cylindrical body. In an exemplary embodiment, the sleeve 50 is formed from a spring steel.
The sleeve 50 includes a plurality of slits formed by the removal of at least some material from the hollow cylindrical body 52 . Each of the slits interrupts the generally continuous surface of the hollow cylindrical body 52 .
A first axially extending slit 60 in the connecting surface 58 extends from the first end 54 to the second end 56 . The first axially extending slit 60 allows circumferential compression of the sleeve 50 from a first circumference at a first radial distance to a second circumference at a second radial distance. At the first circumference, the edges 62 of the first axially extending slit 60 are separated by a distance (D 1 ); at the second smaller circumference, the edges 62 of the first axially extending slit 60 are separated by a distance (D 2 ). The distance D 1 is greater than the distance D 2 . The distance D 2 can be zero, i.e., the edges contact each other, along at least a portion of the axial length of the edges 62 . During circumferential compression, the general cylindrical form of the sleeve 50 holds, but the circumference is reduced. Similarly, the first axially extending slit 60 allows circumferential expansion of the sleeve 50 from the first circumference at the first radial distance to a larger third circumference at a third radial distance, where the separation distance of the edges 62 is increased along at least a portion of the axial length of the edges 62 .
At least one second axially extending slit 70 in the connecting surface 58 extends from the second end 56 to a termination point 72 between the first end 54 and the second end 56 . The at least one second axially extending slit 70 divides the second end 56 into a plurality of sections 74 arranged circumferentially at the second end 56 . The at least one second axially extending slit 70 allows radial compression of each of the plurality of sections 74 from a first radial distance to a second radial distance. The radial compression for any one section 74 can be independent from any other section 74 . At the first radial distance, the edges 76 of the at least one second axially extending slit 70 associated with one section 74 are separated by a distance (d 1 ) from the edges of adjacent sections 74 ; at the second radial distance, at least a portion of the edges 76 of the at least one second axially extending slit 70 associated with the one section 74 are separated by a distance (d 2 ) from the edges of adjacent sections 74 . The distance d 1 is greater than the distance d 2 . The distance d 2 can be zero, i.e., the edges contact each other, along at least a portion of the axial length of the edges 76 . Typically, the portion where the edges contact will be the portion closest to the second end 56 . Similarly, one or more of the sections 74 can be moved radially outward from a first radial distance to a larger third radial distance, where the separation distance of the edges 76 is increased along at least a portion of the axial length of the edges 76 . During the compression or expansion, the radial distance of any one of the sections 74 varies, either alone of in conjunction with other sections 74 , depending on the forces applied to the sections 74 . Therefore, one section 74 can have a reduced radial distance while an adjacent section can have an unchanged or increased radial distance. When all of the plurality of sections 74 move at the same time in the same direction, i.e., radially inward or radially outward, the sections effectively move to reduce or increase the circumference in that portion of the sleeve 50 .
The sleeve 50 includes a projected portion 80 . The sleeve 50 at the projected portion 80 projects radially outward with a radius larger than a radius of an outer diameter of the hollow cylindrical body 58 . The projected portion 80 is offset from the second end 56 . For example, the projected portion 80 can be in the sections 74 , with the termination point 72 of the second axially extending slit 70 axially closer to the first end 54 than is the projected portion 80 . The projected portion 80 can have any suitable geometric form. In an exemplary embodiment and as shown in FIGS. 1 and 2 , the projected portion is hemispherical. In other exemplary embodiments, the geometric form can be a circumferentially arranged series of bumps, an angled surface or any other protrusion, as long as the radius of the sleeve 50 at the projected portion 80 is the larger than the radius on the sleeve 50 that would contact the inner surface of the bore when assembled.
As shown in FIG. 1 , the shank 8 of the tool 2 is inserted into the bore 34 of the block 30 from the first side 36 . The sleeve 50 is positioned about the shank 8 with the connecting surface 58 between the shank 8 and the surface of the bore 34 . The second end 56 of the sleeve 50 , up to and including the projected portion 80 , extends past the bore 34 on the second side 38 of the block 30 with the projected portion 80 of the sleeve 50 abutting the second side 38 .
The sleeve utilizes two methods of retention—a friction fit as well as a rear retention.
A friction fit for the sleeve 50 is established by the contact between the connecting surface 58 and the surface of the bore 34 . The connecting surfaces 58 are pushed radially outward against the surface of the bore 34 by a spring-like action of the sleeve 50 . The spring like-action occurs because the static-state diameter of the sleeve is larger than the diameter of the bore. When the projected portion 80 of the sleeve 50 exits the bore 34 on the second side 38 of the block 30 , the connecting surface 58 of the sleeve 50 expands to the diameter of the bore 34 . The elastic properties of the sleeve 50 provide for friction retention when installed. Note that the sleeve is depicted in FIG. 1 as being located in only a portion of the bore 34 . That is, there is a portion of the shank 8 within the bore 34 that has the sleeve 50 arranged about it and there is another portion of the shank 8 within the bore 34 that does not have a sleeve 50 arranged about it. However, the sleeve 50 can occupy any length or longitudinally extent of the bore 34 .
A rear retention for the sleeve 50 is established by the projected portion 80 abutting the second side 38 . The geometry of the projected portion 80 urges the tool 2 into the bore 34 of the block 30 , i.e., in an axial rearward direction (R). During use, as the tool 2 tries to kick out (and drag the sleeve 50 with it due to the second end 56 of the sleeve 50 contacting stop surface 90 located at the end of the shank 8 ), the angle (α) that starts the projected portion 80 provides, along with the elastic forces of the sleeve, a resistive force that urges the sleeve 50 (and therefore the tool 2 ) rearward (R). This maximizes tool retention and minimizes slapping between the first side 36 of the block 30 , i.e. the face, and the shoulder 14 of the tool 2 .
By combining the holding features of a sleeve retainer with retention properties of a rear style retainer, the retention power for the sleeve is increased over designs using only one a friction fit and rear style retainer. The increased retention is more than enough to overcome the vibrations and centrifugal forces inherent in current and planned machine designs.
When assembling the tool 2 into the block 30 , the sleeve 50 is preassembled about the shank 8 . This can be accomplished, for example, by sliding the sleeve 50 , typically in an expanded state, over the stop surface 90 of the shank 8 . Once the sleeve 50 is past the stop surface 90 , the sleeve 50 returns to the static state. The stop surface 90 prevents the sleeve 50 from coming off the shank unless the sleeve 50 is expanded by some means.
When inserted into the bore 34 , the preassembled sleeve 50 is compressed by the surface of the bore 34 bearing on the projected portion 80 . In the area of the projected portion 80 , the shank 8 has a reduced radius or other accommodation, such as a slot, groove, trench or taper, to allow the sleeve 50 to compress as needed to pass the increased radius of the projected portion 80 through the bore 34 .
In an exemplary embodiment, a customer receives the tool 2 with the sleeve 50 already assembled. Thus, the tool 2 comes ready for installation with no loose pieces. Because the tool 2 comes with the sleeve 50 in place, installation is very simple. By using a standard dead-blow hammer, the tool 2 is knocked into the block 30 (or similar holder). Once the projected portion 80 of the sleeve 50 exits the bore 34 on the second side 38 of the block 30 , the sleeve 50 expands. The projected portion 80 behaves as a rear retainer and the connecting surfaces 58 act as a friction fit, locking the tool 2 in its block 30 without inhibiting rotation.
This retention method can be used with blocks that have internally grooved bores or smooth bores. Internally grooved bores are not needed for this sleeve, although they will not diminish the performance of the tool or the retention method. When an internally grooved bore is present, the connecting surface of the sleeve bridges the groove. During insertion of the sleeve in a grooved bore, the projected portion may expand into the groove. However, additional force can be used to recompress the sleeve and to continue insertion until the projected portion exits the bore on the second side of the block.
Although 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 department from the spirit and scope of the invention as defined in the appended claims. | A sleeve utilizing two methods of retention—a friction fit and a rear retention feature—is disclosed. The sleeve includes a circumferentially compressible portion that provides a friction fit when inserted into a bore and includes a projected portion around an end circumference that is used to mate with the rear of a tool block and urges the sleeve (and the tool) rearward. The disclosure also relates to a tool and block assembly, a method of retaining a tool in a holder and a mining machine incorporating the sleeve. |
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] The present application claims the benefit of and priority as available under 35 U.S.C. §§ 119-21 to the following U.S. patent application (which is incorporated by reference in the present application): U.S. Provisional Patent Application No. 60/461,089 titled “POST HOLE DIGGER” filed Apr. 8, 2003.
BACKGROUND
[0002] The present invention generally relates to post hole diggers. The present invention more specifically relates to a post hole digger that enables a user to conveniently produce a vertical hole in the ground with minimal interference between the post hole digger and the sides of the vertical hole.
[0003] It is generally known to provide a post hole digger for digging holes within the earth for placement of a post therein. Traditional post hole diggers include two concave blades that face one another to form a cylindrical region generally about six inches in diameter. The blades are pivotally connected to one another proximate the top portion of the blades. Extending from each blade is a fixture or cap supporting a shaft handle extending approximately four feet in height. The blades are spaced apart from one another such that each shaft is proximate the inner surface of each of the blades. By thrusting the blades into the ground, the earth is secured between the blades by moving the upper end of the handles away from one another forcing the blades to pivot about the pivot toward one another.
[0004] As the hole becomes deeper, the pivoting motion of the blades results in the shafts contacting the edge of the hole proximate the top of the hole. This minimizes the pivoting motion of the blades and thereby reduces the amount of dirt that can be pulled out with each pivoting motion of the shafts. As a result, a user is often forced to widen the width of the hole in order to accommodate the shafts. This can result both in excess effort from the user, as well as an increased use of cement and/or other type of filling for the hole. Further, the use of the fixtures extending from the blades to support the shafts can often interfere with the sight line of the user with respect to the blades, thereby inhibiting free visual access to the hole during use of the post hole digger. Additionally, the traditional wood and plastic handles or shafts are subject to breaking near the fixture that holds them. Further, the nuts and bolts that connect the handles to the fixtures typically loosen during use.
[0005] Accordingly, it would be advantageous to provide a post hole digger that allows for full pivoting of the blades relative to one another while minimizing the contact between the shafts and the upper edge of the hole. It would also be advantageous to provide a post hole digger that enables a user to dig deeper post holes without having to increase the diameter of the hole opening as the depth of the hole increases. It would also be advantageous to provide a post hole digger that enables a user to close the blades of the post hole digger without having the handles or shafts wider than the diameter of the top of the hole. It would also be desirable to provide a post hole digger having shafts with a configuration that maximizes the sight line of the post hole digger. It would also be desirable to provide a post hole digger having a handle arrangement and blade attachment that minimizes the chances of the handles breaking or loosening during use.
[0006] It would be advantageous to provide a post hole digger or the like of a type disclosed in the present application that provides any one or more of these or other advantageous features. The present invention further relates to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objects and features of the disclosed embodiments are accomplished will be described in the following specification or will become apparent to those skilled in the art after they have read this specification. Such other ways are deemed to fall within the scope of the disclosed embodiments if they fall within the scope of the claims which follow.
SUMMARY
[0007] One embodiment of the invention relates to a post hole digger. The post hole digger comprises a first shaft pivotally coupled at a pivot to a second shaft, the first shaft and the second shaft each comprising an upper end, a lower end, and a central portion having a central axis, and a first blade coupled to the first shaft at the lower end of the first shaft and a second blade coupled to the second shaft at the lower end of the second shaft. The central axis of the first shaft and the central axis of the second shaft generally define a plane when the first blade and the second blade are provided in an open configuration. The first blade and the upper end of the first shaft are located on a first side of the plane when the first blade and the second blade are provided in the open configuration. The second blade and the upper end of the second shaft are located on a second side of the plane when the first blade and the second blade are provided in the open configuration. The upper end of the first shaft and the upper end of the second shaft may be pivoted away from one another to position the blades in a substantially closed configuration.
[0008] Another embodiment of the invention relates to a post hole digger. The post hole digger comprises a first handle pivotally coupled to a second handle, the first handle and the second handle each having a longitudinal axis, and a first blade coupled to the first handle and a second blade coupled to the second handle. The first blade and the second blade are configured to pivot from an open configuration to a closed configuration by pivoting the first handle and the second handle away from one another. The first handle and the second handle extend along a plane defined generally by the longitudinal axis of the first handle and the longitudinal axis of the second handle when the first blade and the second blade are in the open configuration. The first blade and the second blade are generally parallel to the plane and spaced apart from the plane when provided in the open configuration.
[0009] Another embodiment of the invention relates to a method of producing a post hole digger. The method comprises providing a first shaft pivotally coupled to a second shaft, the first shaft and the second shaft comprising an upper end, a lower end, and a central portion having a longitudinal axis, and providing a first blade coupled to the first shaft and a second blade coupled to the second shaft. The method comprises configuring the first blade and the second blade to pivot from an open configuration to a closed configuration by pivoting the upper ends of the first shaft and the second shaft away from one another. The method comprises configuring the central portions of the first shaft and the second shaft to extend along a plane generally defined by the longitudinal axis of the first and second shaft when the first blade and the second blade are in the open configuration. The method comprises configuring the first blade and the second blade to be generally parallel to the plane and spaced apart from the plane when provided in the open configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a front perspective view of a post hole digger according to an exemplary embodiment.
[0011] [0011]FIG. 2 is a side view of the post hole digger according to an exemplary embodiment.
[0012] [0012]FIG. 3 is a front view of the post hole digger according to an exemplary embodiment.
[0013] [0013]FIG. 4 is a top view of the post hole digger according to an exemplary embodiment.
[0014] [0014]FIG. 5 is a front view of a shaft of the post hole digger according to an exemplary embodiment.
[0015] [0015]FIG. 6 is a side view of the shaft of the post hole digger according to an exemplary embodiment.
[0016] [0016]FIG. 7 is a plan view of a pivot bearing of the post hole digger according to an exemplary embodiment.
[0017] [0017]FIG. 8 is a side view of the pivot bearing of the post hole digger according to an exemplary embodiment.
[0018] [0018]FIG. 9 is a side view of the post hole digger in the closed position according to an exemplary embodiment.
[0019] [0019]FIG. 10 is a side view of a post hole digger according to an alternative embodiment.
DETAILED DESCRIPTION
[0020] Before explaining a number of preferred, exemplary, and alternative embodiments of the invention in detail, it is to be understood that the invention is not limited to the details or methodology set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or being practiced or carried out in various ways. It is also to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
[0021] A system (shown as a post hole digger 10 ) for digging holes within the earth (e.g., for the placement of posts, fences, poles, etc.) is shown in FIG. 1 according to a preferred embodiment. Post hole digger 10 may be operated by a user to dig deeper, more uniform diameter post holes without having to widen the upper portion of the hole. Post hole digger 10 enables a user to close the blades of the post hole digger 10 without having the handles or shaft wider than the diameter of the top of the hole.
[0022] Referring to FIG. 1, post hole digger 10 includes a pair of shafts 12 and a pair of blades 14 attached to shafts 12 . Shafts 12 are pivotally attached at a pivot 16 . Referring to FIGS. 2, 3 and 5 , each shaft 12 includes a grip 18 , a central portion 20 , an upper end 22 , and a lower end 24 . Each shaft 12 further includes an upper transition 26 between grip 18 and central portion 20 and a lower transition 28 extending from the lower end 24 of the central portion 20 of shaft 12 . As shown in FIGS. 1-3 and 9 , shafts 12 may be attached to pivot 16 along central portion 20 proximate lower transition 28 . According to various alternative embodiments, shafts 12 may be attached to pivot 16 at any suitable point along shafts 12 . The lower end 24 includes an engagement face or surface 30 that is directly connected to each respective blade 14 . According to an exemplary embodiment, engagement surface 30 may be formed by flattening the lower portion of shaft 12 . According to an alternative embodiment, the lower portion of shaft 12 may be cut to provide the beveled profile of engagement surface 30 .
[0023] [0023]FIGS. 2 and 4 show the post hole digger 10 in a non-extended or stowed configuration (e.g., the blades 14 are in an open position). When in the non-extended configuration, and as shown in FIGS. 2 and 4, the longitudinal axis of each of central portions 20 of shafts 12 define a plane 32 which also extends through the central axis of pivot 16 . Grip 18 and engagement surface 30 of each shaft 12 are both located on the same respective side of plane 32 . As shown in FIG. 4, a second plane 34 is perpendicular to plane 32 and to the central portion of each blade 14 . Second plane 34 extends through each grip or handle 18 as well as through pivot 16 and is perpendicular to the central axis of pivot 16 . Upper and lower transitions 26 , 28 of each shaft 12 extend from plane 34 at a predefined angle toward central potion 20 (and plane 32 ).
[0024] According to an exemplary embodiment, as shown in FIG. 6, the upper transition 26 may include a compound angle such that handle 18 is spaced a predetermined distance from an edge of the central portion 20 of post hole digger 10 . For example, length 88 a between the edge of grip 18 and the edge of central portion 20 may be approximately 2 inches. As shown in FIG. 5, length 88 b between the edge of grip 18 and the edge of central portion 20 may be approximately 1 inch. Similarly, lower transition 28 includes a compound angle such that engagement surface 30 is a predetermined distance from an edge of central portion 20 of post hole digger 10 . For example, as shown in FIG. 6, length 88 c between the edge of engagement surface 30 and the edge of central portion 20 may be approximately three inches. As shown in FIG. 5, length 88 d between the edge of engagement surface 30 and the edge of central portion 20 may be approximately one inch.
[0025] Referring to FIGS. 2 and 4, the blades are in the open position. According to an exemplary embodiment, the handles 18 may spaced approximately two to four inches apart from one another when in the open position as shown by length 88 e. Of course the exact distance between the handles may vary according to various exemplary embodiments. According to an exemplary embodiment, both of the handles fit within a cylindrical plane defined by the shape of the blades 14 .
[0026] Referring to FIGS. 7 and 8 pivot 16 will be described in greater detail. Pivot 16 includes a pair of bearings 36 . Each bearing 36 includes a bearing surface 38 . Bearing surface 38 may include either a coating or a separate material 40 being corrosion resistant, non-rusting, and having a low coefficient of friction. Each bearing 36 further includes a pin 42 extending therefrom that is received in a corresponding slot 44 on the other bearing 36 . This pin and slot arrangement limits the rotation of the bearings relative to one another and as a result limits the rotation of blades 14 . Slot 44 allows bearing 36 to pivot a predefined angle from the vertical. According to an exemplary embodiment, slot 44 is configured to allow bearing 36 to pivot between 10 and 35 degrees from the vertical. According to a preferred embodiment, slot 44 is configured to allow bearing 36 to pivot about 20 to 25 degrees from the vertical, and more preferably about 22.5 degrees from the vertical.
[0027] According to an exemplary embodiment, bearing 36 includes an arcuate inner surface 46 located opposite bearing surface 38 that is proximate shaft 12 . In one embodiment, each bearing 36 is welded to the outer surface of each respective shaft 12 such that inner surface 46 is adjacent shaft 12 . According to an exemplary embodiment, a pivot pin 48 need only extend through bearings 36 and not necessarily through shafts 12 . In an alternative embodiment, pivot pin 48 extends through each shaft 12 and through each opening 50 extending through each bearing 36 . According to various alternative embodiments, it is also possible to both weld bearing 36 to each shaft as well as to have pivot pin 48 extend through the shafts. Regardless of whether the bearing is welded to or mechanically attached to shafts 12 , the bearing surface 38 preferably rotates within plane 34 .
[0028] Referring to FIG. 9 post hole digger 10 is shown in a fully closed position (e.g., the post hole digger 10 is located within a hole in the ground). According to an exemplary embodiment, the post hole digger may be configured such that if the hole is six inches in diameter or equal to the distance between blades 14 when the blades are in the open position, then the outside of shafts 12 would contact the upper edge of the hole when the hole is 32 inches deep. According to this embodiment, if the hole is twelve inches in diameter, shafts 12 would contact the upper edge of the hole when the hole is 48 inches deep.
[0029] To operate the post hole digger 10 , a user grasps and hold grips 18 in the non-extended position shown in FIGS. 2 and 4. The user may then thrust the blades 14 into the ground. As shown in FIG. 9, the user may move the grips away from one another so that shafts 12 pivot about pivot 16 and blades 14 close and grip the soil therebetween. The user may then lift the post hole digger 10 out of the hole while continuing to pull the grips 18 apart. Once the post hole digger 10 is removed from the hole, the user may move the grips toward one another so that shafts 12 pivot about pivot 16 and blades 14 move apart from one another, thereby releasing the soil from between the blades 14 .
[0030] According to various exemplary embodiments, the assemblies and components of the post hole digger may be constructed from various different materials. According to a preferred embodiment, the assemblies and components of the post hole digger may be constructed from materials that are durable, substantially non-corroding, and light weight. For example, a variety of plastics (e.g., high-impact), polymers, rubber, etc. may be used for construction or assembly of the grip. Using rubber or plastic offers several advantages including that the grip may be constructed in a variety of different colors, surface finishes, textures, opacity, etc. According to various exemplary embodiments, a variety of suitable materials may be used for other components (such as the shafts and blades) of the post hole digger, including metals, alloys, composites, aluminum, stainless steel, fiberglass, wood, etc. Further, various parts of the post hole digger may be constructed and assembled as a single integrally formed piece or may be constructed and assembled from multiple parts.
[0031] It is important to note that the construction and arrangement of the elements of the post hole digger as shown in the various embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g. variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter disclosed in this application. For example, referring to FIG. 10, a pivot 52 may be located below or proximate the upper edge of blades 14 . Further the lower transition portion 54 may be formed of a separate component that is welded to or mechanically attached to the central portion of the shafts. Accordingly, all such modifications are intended to be included within the scope of the present invention. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In any claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions. | A post hole digger for producing a hole in the ground comprising a first handle pivotally coupled to a second handle and a first blade coupled to the first handle and a second blade coupled to the second handle. The first handle and the second handle extend along a plane defined generally by a longitudinal axis of the first handle and a longitudinal axis of the second handle when the first blade and the second blade are in the open configuration. The first blade and the second blade are generally parallel to the plane and spaced apart from the plane when provided in the open configuration. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a portable floor system and in particular to an improved locking assembly and mounting system for the locking assembly.
[0003] 2. Description of the Prior Art
[0004] Portable floors generally have a number of interlocking, rectangular sections or panels and are used for providing an extended hard surface that may be set up over carpeting or other surfaces on a temporary basis, by joining the floor sections together in an edge-to-edge relationship. Locks or other connectors are provided along the edges of the panels to secure the adjacent panels together to form the extended floor surface.
[0005] Portable floors are used for a variety of purposes and are particularly useful in the hospitality and entertainment industry. It is often desired to provide a temporary smooth hard surface for dancing or other activities that can be removed so the space may be used for other activities. Floors are usually connected together in an edge-to-edge fashion with releasable locks along their edges. A portable floor of this general type is disclosed in U.S. Pat. No. 3,310,919, which discloses floor panels with each floor panel having an extruded tongue section along certain edges and a complementary extended groove section along certain other edges. The adjoining sections can be fitted together in an edge-to-edge relationship by a tongue and groove arrangement and held in place by threaded locking screws mounted above the grooves to engage notches in the tongue members. Although the portable floor disclosed in that patent has been successful in providing a convenient and efficient portable floor, further improvements are possible.
[0006] Another patent showing portable floors is U.S. Pat. No. 6,128,881. Cam-type rotary locks having complementary male and female members on the edge of the panels are used to engage and lock the panels together in proper alignment. Although the cam-type rotary locks are an improvement, there are challenges with mounting such locks. As weight is a concern in the portable floor panels, it is often desired to utilize a panel construction having a light weight core panel to reduce overall weight. Although using core materials such as foam, honeycomb or balsa wood aids in reducing weight, these materials are not suitable as a mounting structure. Prior methods of mounting the rotary locks to the floor panel with a core that provides little support is difficult. Moreover, such systems are difficult to replace when failure occurs. Typically, a portion of the core is removed and a wood block is inserted for mounting by joint connector nuts and bolts or mounting using standard wood screws. Such a system requires a precise alignment for a joint connector bolt inserting into a complementary joint connector nut having a complementary orifice. Great precision is required for aligning the nuts and bolts. Moreover, such systems using either wood screws or joint connector require drilling of a pilot hole. Improper positioning of such pilot holes may ruin the panel during the manufacturing process.
[0007] In addition, such systems are difficult to repair should failure occur. Although the rotary locks are generally held by at least two screws or joint connector bolts, they typically have four mounting holes. However, due to the proximity between the holes, if failure occurs, the adjacent hole is typically too close to the position of the failure to allow for repair and mounting of a separate joint connector nut and bolt.
[0008] A further problem is the precise alignment that is required and the special manufacturing methods needed to align all of the various elements. The anchoring block and the rotary lock member are also spaced apart with light weight core material or alternate fill material between the elements when mounted so that when force is applied, the material between the wood block and the lock member can collapse, which can lead to failure and/or misalignment.
[0009] Another problem with portable floors is alignment of wood grain surfaces to provide continuity. Due to imprecise manufacturing, floors that have aligned wood grains have been difficult to achieve. It can be appreciated that a method that provides for properly aligning and orienting the wood grain so that the pattern on the top surface is consistently placed so that each panel has an identical appearance and aligns with any other panel improves overall appearance of the floor system.
[0010] It can be seen that a new portable floor system using new and improved portable floor panels is needed that overcomes the problems related to locking assemblies and their mounting. Such a system should provide for simple and easy insertion and manufacture of the floor panel and the locking devices. Such a system should also eliminate soft core material between the locking member and the anchoring element. Such a system should also improve alignment and provide a light weight anchor that is easily replaced should failure occur. The present invention addresses these, as well as other problems associated with portable floor systems.
SUMMARY OF THE INVENTION
[0011] The present invention is directed to a portable floor system and in particular to a floor system wherein the individual floor panels have an improved mounting assembly for mounting the arrangement for the locking assemblies.
[0012] The portable floor system of the present invention provides a temporary floor surface that is suitable for dancing or other activities while providing multi-use capability for the space where the floor is removed. The present invention provides a portable floor having substantially rectangular floor panels connecting and locking along their edges to form a continuous extended floor surface. Along the edges of the floor are edge trim panels that provide a transition from the portable floor surface to the underlying surface.
[0013] Each of the floor panels includes a planar floor portion with an extruded edge section. These edges form complementary tongues and grooves for aligning the panels together. The panels are locked together by a cam-type rotary lock having complementary male and female members on the edges of adjacent panels. As the cam locks engage, the camming action tends to slide the panels relative to one another along the edges, thereby locking the panels together and ensuring a proper fit with no gaps between the panels. The present invention provides for a lightweight and easy to manufacture mounting arrangement for the locking assemblies. The lock members attach directly to an anchor element mounted into a slot formed in the floor panel. The anchor element is a light weight plastic element having holes receiving mounting screws that attach through the locking member directly to the anchor element. The direct mounting eliminates the need for making precise pilot holes as was needed with the prior art lock mounting systems. In addition, the direct abutment of the locking devices to the anchor element provides a stronger rigid mount that eliminates the sagging and compression that may occur if the soft core material between the lock and the mounting blocks of the prior art has pressure applied.
[0014] In addition to a sturdier mounting arrangement, the mounting system of the present invention is also easy to manufacture. A first slot for the anchor element is formed in the bottom of the panel and a second slot for receiving the lock is formed in the edge of the panel to intersect the first slot and form a continuous opening. This provides for mounting the lock member directly against the anchor element for additional support. Moreover, the pattern on the upper surface may be continuous panel to panel and the lock and anchoring elements are aligned off a particular indexing feature of the surface panels so that the various panels are precisely aligned and therefore, can form a continuous wood grain pattern from panel to panel over the entire floor.
[0015] The mounting arrangement also provides for easy replacement as damaged screws may simply be replaced by removing the anchor element and the lock and replacing the damaged pieces. It can also be appreciated that if a mounting screw or hole is stripped, an adjacent hole may be utilized for mounting, thus eliminating the need for replacement of the anchor element. Moreover, the present invention does not require any type of adhesive or special steps for mounting. The anchor element is a rigid light weight plastic material such as nylon, with much of the slot into which it inserts remaining empty so that the mounting system achieves weight savings over the prior art systems.
[0016] These features of novelty and various other advantages that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings that form a further 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
[0017] FIG. 1 is a top plan view of a portable floor system according to the principles of the present invention;
[0018] FIG. 2 is a bottom exploded perspective view of a floor panel for the portable floor system shown in FIG. 1 ;
[0019] FIG. 3 is a top view of the floor panel shown in FIG. 2 with portions removed to show the locking assembly;
[0020] FIG. 4 is a bottom perspective view with portions removed of two panels for the floor system shown in FIG. 1 joined together;
[0021] FIG. 5 is a side sectional view of a portion of the panel shown in FIG. 2 ;
[0022] FIG. 6 is top detail view of the floor panel shown in FIG. 2 showing the locking assembly;
[0023] FIG. 7 is a bottom perspective view of two locking assemblies shown in FIG. 6 and their mounting to the panels with the locking assemblies connected;
[0024] FIG. 8 is a top plan view of a portion of the panel shown in FIG. 2 showing slots for installation of the locking assembly;
[0025] FIG. 9 is a perspective view of the anchor element for the locking assembly shown in FIG. 6 ; and
[0026] FIG. 10 is a side elevational view of an anchor element shown in FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring now to the drawings, and in particular to FIG. 1 , there is shown a portable floor system, generally designated 10 . The floor system 10 includes a plurality of generally rectangular floor panels 12 joined in an edge-to-edge relationship to form an extended, continuous floor surface. Such panels generally include a lightweight planar portion 14 with an extruded edge elements including tongues 16 along two edges and grooves 18 along the other two edges. With this arrangement, the tongues 16 insert to the corresponding grooves 18 and provide engagement of the edges of adjacent panels.
[0028] Referring now to FIG. 5 , the planar portion 14 typically includes a light weight center core layer 20 , a hard bottom exterior layer 22 and a bottom inner support layer 24 . A top support layer 28 extends over the core layer 20 and a top exterior layer 26 covers the top support layer 28 . The top exterior layer 26 may have a pattern and in one embodiment, includes a wood grain pattern to give the impression of a hardwood floor. It can be appreciated that fewer or more layers may be utilized, depending upon the use, but should include a lightweight core layer 20 . Referring again to FIG. 1 , the wood grain layer 70 is a continuous repeating pattern and includes a designated indexing feature 72 that it utilized for positioning the necessary cuts and for positioning the edges of the panel and the so that the pattern is continuous from one panel 12 to the next.
[0029] Referring again to FIG. 1 , the floor system 10 also includes edge trim pieces 30 and 32 . The edge trim pieces 30 and 32 form a safe transition from the upper surface of the floor system 10 to the underlying ground or floor. The edge trim pieces 30 and 32 have either tongues or grooves (not shown) similar to the tongues and grooves of the extruded edge 16 and 18 and mate in a similar manner. As explained hereinafter, the edge trim pieces 30 and 32 have corresponding locking devices that also engage complementary locking devices of the floor system 10 .
[0030] Referring now to FIGS. 2, 3 and 4 , the floor panels 12 are shown with the planar portions 14 and the extruded edge members including tongues 16 and grooves 18 . The tongues 16 are along two adjacent sides while the grooves 18 are along the two adjacent opposite sides. The tongues 16 engage the complementary grooves 18 of adjacent panels 12 so that the edges of the floor panels 12 abut and the floor panels 12 form an extended continuous floor surface.
[0031] The floor panels 12 are connected to one another with lock assemblies 40 , as shown more clearly in FIG. 7 . Referring again to FIGS. 2-4 , the lock assemblies include female locks 42 and complementary male locks 44 . The complementary rotary locks 42 and 44 provide for pulling the edges together to ensure a tight fit. The female rotating cam lock devices 42 have a rotatable circular cam and mount at the center of the two edges having grooves 18 . The complementary male cam lock members 44 mount at the center of the edges having tongues 16 and receive and retain the rotary cam member when the lock is actuated and the cam member extends into the male lock member 44 . The female cam members 42 are actuated by rotating the cam with an Allen-type tool inserted into an orifice 64 in the upper surface of the floor panels 12 . When actuated, the cam pulls the cam lock devices 42 and 44 and therefore the floor panels 12 together to ensure that no gaps are formed in the floor 10 and a tight edge-to-edge connection is maintained between adjacent panels 12 .
[0032] Referring now to FIGS. 5-7 , the improved mounting arrangement of the lock assemblies 40 of the present invention is shown. The lock assemblies 40 include the bodies of the female and male lock members 42 and 44 that mount directly into slots 66 formed through the tongues 16 and grooves 18 of the edges and slots 62 formed in the planar panel portion 14 . The female lock devices 42 and the male lock devices 44 mount directly to an anchoring element 48 . The slots 62 are formed in the edges of the center core of the planar portion 14 . The anchoring element fits into a slot 60 , shown most clearly in FIGS. 2 and 8 . Mounting screws 46 extend through the back of the female and male locks 42 and 44 and into receiving portions 52 of the anchoring element 48 , shown most clearly in FIG. 9 . It can be appreciated that with this arrangement, the lock devices 42 and 44 mount directly to the anchoring element 48 and abut the anchoring element, thereby eliminating the less dense and poorly supporting material of the lightweight center layer 20 of the prior art. The anchoring element 48 provides added support for the lock members 42 and 44 . Moreover, installation is straight forward and requires no special tools or application of adhesive.
[0033] Should damage occur, repair is simple so that the panel 12 is not ruined. If a mounting screw 46 or orifice 52 is stripped, a new screw may simply be inserted into the adjacent unused receiving orifice 52 and no replacement parts are needed. It can be appreciated that if the anchoring element 48 or other elements do need to replacement, they are simply removed with a screwdriver and new lock devices 42 or 44 or anchoring elements 48 may be remounted without any adverse effect to the floor panel 12 .
[0034] The anchoring element 48 provides further advantages over the prior art wood mounting blocks. The anchoring elements 48 are preferably made of a sturdy but light weight plastic material such as nylon 6/6 or other suitable material well known in the art. The plastic material includes an upper flange 50 that extends slightly around the slot 60 and over a portion of the bottom of the floor panel 12 . Horizontal ribs 56 and vertical ribs 54 provide a sturdy support structure for the mounting portions 52 . As the anchoring element 48 provides much empty space, it provides weight savings over solid wood block mounting systems.
[0035] Forming of the slots 62 and 60 is accomplished quite simply with a router and is positioned to ensure a proper placement from an indexing feature 72 of the surface pattern 70 . The edges of planar portion 14 are formed at the same time as the slots 60 and 62 so that the slots 60 and 62 are precisely located to ensure proper alignment of the lock devices 42 and 44 . This also provides sufficiently precise alignment to ensure that the patterns that are configured for being continuous are consistently aligned and oriented to give an improved overall continuous natural wood grain or other floor appearance.
[0036] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A portable floor system having a plurality of floor panels configured for connection along abutting edges to form an extended floor surface. Each panel has a planar portion including a top surface, a core, and a bottom surface. Extruded edge portions include tongues along two edges and complementary tongues along the other two edges. Each edge also includes a panel connecting assembly along each edge, having a lock device extending from an edge into the core. The lock device mounts directly against an anchor element. The anchor element extends through the bottom surface and having a connector receiving portion. |
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This application claims priority to EP14153788.6, having a filing date of Feb. 4, 2014, the entire contents of which is hereby incorporated by reference.
FIELD OF TECHNOLOGY
The following relates to a hatch actuating arrangement for actuating a hatch of a hatch device, with the hatch device being adapted to be disposed or being disposed within a tower structure, particularly a tower structure of a wind turbine.
BACKGROUND
It is known that tower structures, such as tower structures of wind turbines, occasionally have to be entered by service personnel for maintenance, repair, or service works. The service personnel has to pass respective hatches or hatch devices axially dividing the tower structure in compartments or inner volumes within a respective tower structure. Respective hatches or hatch devices are usually provided at platforms being disposed within respective tower structures.
It is regulated that service personnel has to wear safety gear while climbing ascending and/or descending structures, such as ladders etc., within the tower structure. However, respective safety gear securing the service personnel close to the inner circumference of the tower structure regularly causes problems when conventional hatches or hatch devices have to passed since it is hardly possible to reach the hatch and being safely secured at the same time.
Usually, the only possibility to reach respective hatches is to temporarily detach the safety gear. However, this compromises safety regulations as well as the safety of the service person as he might fall through the opened hatch.
SUMMARY
As aspect relates to providing a hatch actuating arrangement for actuating a hatch of a hatch device allowing an eased actuating of the hatch, particularly without the necessity to detach respective safety gear.
A further aspect relates to a hatch actuating arrangement for actuating a hatch of a hatch device, with the hatch device being adapted to be disposed or being disposed within a tower structure, particularly a tower structure of a wind turbine, comprising:
a hatch device adapted to be disposed or being disposed between two axially adjacent inner volumes of a tower structure, the hatch device comprising a hatch, with the hatch being movably supported between an open position, in which a passageway between the two inner volumes is not obstructed, and a closed position, in which a passageway between the two inner volumes is obstructed, a hatch actuating means for actuating the hatch with the hatch actuating means being movably supported relative to the hatch device, wherein the hatch actuating means is coupled with the hatch in such a manner that by moving the hatch actuating means towards the hatch device, a force is applied to the hatch which force moves the hatch in its open position or secures the hatch in its open position.
Embodiments of the invention relate to a special hatch actuating arrangement. The hatch actuating arrangement generally serves for actuating, i.e. particularly opening, a hatch of a hatch device. As initially mentioned, respective hatches or hatch devices are typically provided with respective (closed or partially closed) platforms provided at different axial positions or height levels, respectively, within tower structures, i.e. particularly tower structures of/for wind turbines.
The essential components of the hatch actuating arrangement according to embodiments of the invention are a hatch device and a hatch actuating means.
The hatch device is adapted to be disposed or mounted between two axially adjacent inner volumes of a tower structure, i.e. particularly a tower structure of/for a wind turbine. The hatch device is usually disposed or mounted with respective platforms provided within respective tower structures. Hence, respective inner volumes within a tower structure are essentially confined by respective hatch devices defining certain height levels within the tower structure.
The hatch device comprises at least one hatch. The hatch is movably, i.e. particularly pivotably, supported between an open position and a closed position. The open position is generally defined in that a passageway between two axially adjacent inner volumes of the tower structure provided with the hatch actuating arrangement is not obstructed, i.e. possible for a person. The closed position is generally defined in that a passageway between two axially adjacent inner volumes of the tower structure provided with the hatch actuating arrangement is obstructed, i.e. not possible for a person. The movable, i.e. particularly pivotable, support of the hatch may be realised by hinges, pivot joints, or the like.
The hatch actuating means serves for actuating, i.e. particularly opening, the hatch. The hatch actuating means is movably supported relative to the hatch device, i.e. the hatch actuating means may be moved in a direction towards the hatch and in an opposite direction thereto. The movable support of the hatch actuating means may be realised by guiding means such as guidances etc.
The hatch actuating means is typically translationally movably supported between two end positions, whereby the hatch is positioned in its closed position when the hatch actuating means is positioned in its first end position and the hatch is positioned in its open position when the hatch actuating means is positioned in its second position.
Respective motions of the hatch actuating means are typically vertically orientated relative to ground. I.e., the trajectory of the motion of the hatch actuating means typically runs perpendicularly relative to a horizontal plane. Hence, respective motions of the hatch actuating means are typically axially orientated with reference to the centre axis of a tower structure provided with the hatch actuating arrangement. However, it is also possible that motions of the hatch actuating means are inclined. I.e. the trajectory of the motion of the hatch actuating means may also extend with a certain inclination (angle) relative to a horizontal plane.
According to embodiments of the invention, there exists a coupling between the hatch of the hatch device and the hatch actuating means. The coupling of the hatch and the hatch actuating means is realised in such a manner that by moving the hatch actuating means towards the hatch device, a force is applied to the hatch which force moves the hatch in its open position or secures the hatch in its open position. The force applied to the hatch is typically a tensile force.
Thus, the coupling between the hatch actuating means and the hatch allows for a coupled movement of the hatch actuating means and the hatch. A coupled movement means that a motion of the hatch actuating means relative to the hatch device, i.e. particularly towards the hatch device, result in a motion of the hatch from its closed position to its open position. Thereby, the vector of the motion of the hatch actuating means towards the hatch device is typically oppositely directed to the vector of the force applied to the hatch.
In the mounted state of the hatch actuating arrangement, i.e. in the state in which the hatch actuating arrangement is mounted within a respective tower structure, the hatch actuating means typically has to be moved in, particularly axially or vertically, downward direction in order to create and apply the force on the hatch.
The inventive principle allows for an eased actuation of hatches of respective hatch devices since in order to actuate, i.e. particularly open, the hatch, only the hatch actuating means has to be moved towards the hatch device resulting in an opening of the hatch. Hence, when providing a tower structure with the hatch actuating arrangement according to embodiments of the invention, a person only has to move the hatch actuating means towards the hatch device when he is willing to open the hatch. Moving the hatch actuating means towards the hatch device is in any case possible, i.e. particularly possible when wearing respective safety gear.
The inventive principle works with all kinds of hatches, i.e. particularly single- or multipart hatches, the latter comprising a number of separate hatch segments (cf. double wing hatches, for instance).
According to an embodiment of the invention, the hatch actuating means comprises an actuating element. The actuating element may be provided as an actuating bar, an actuation rod, or the like. Generally, it is preferred that the actuation element has an elongate geometry or shape.
According to a further embodiment of the invention, coupling is achieved by means of a coupling means, whereby the coupling means is coupled to an or the actuating element of the hatch actuating means at a first coupling point and the coupling means is coupled to the hatch at a second coupling point. The coupling means generally serves for establishing a mechanical coupling between the hatch and an actuating element of the hatch actuating means. Thereby, mechanical coupling includes form- and/or force- and/or material fit couplings. The coupling means may be built as a band, a rope, a wire, or the like.
Thereby, a first coupling point establishes a mechanical coupling of the coupling means with the actuating element and a second coupling point establishes a mechanical coupling of the coupling means with the hatch. The first coupling point is typically provided at a free end of the actuating element with the free end facing towards the hatch device. The second coupling point is typically provided at a top side of the hatch with the top side facing towards the actuating element.
According to a further embodiment of the invention, the coupling means is guided along a deflecting means, the deflecting means being adapted to deflect the course of the coupling means between the two coupling points by a certain degree. The deflecting means serves for deflecting, i.e. typically inverting, the course of the coupling means between the two coupling points. The course of the coupling means is typically deflected by 180°. Thus, the deflecting means also allows for the fact that motions of the hatch actuating means towards the hatch device result in (essentially oppositely) directed motions of the hatch from its closed in its open position. The deflecting means is therefore, (at least functionally) interposed between the hatch actuating means and the hatch. The deflecting means may be provided as a deflecting roll or a deflecting pulley, for instance.
The hatch actuating means, particularly the actuating element, is movably supported relative to the deflecting means. Hence, the deflecting means is typically not disposed at the hatch actuating means, but with a different component. The deflecting means is fixed at a given position, i.e. the position of the deflecting means cannot be changed.
According to a further embodiment of the invention, the weight of the hatch actuating means is such that a weight force equal or less than the force applied to the hatch when moving the hatch actuating means towards the hatch device is created. Hence, the weight of the hatch actuating means may act as a counterweight allowing for an eased transfer of the hatch from its closed position in its open position.
Particularly, when the weight of the hatch actuating means is chosen in such a manner that it equals the force which has to be applied to the hatch in order to transfer it from its closed position in its open position, a balance of forces may be realised between the weight force of the hatch actuating means and the force which is necessary for actuating, i.e. opening, the hatch. Hence, the force for moving the hatch actuating means and thereby, opening the hatch may be held comparatively small. If the weight force of the hatch actuating means is less than the force which is necessary for actuating, i.e. opening, the hatch, the hatch will always tend to automatically return to its closed position.
According to a further embodiment of the invention, the hatch actuating means comprises at least one connecting means for connecting the hatch actuating means to the inside of a tower structure and/or a further component provided within a tower structure. The connecting means of the hatch actuating means serve for connecting the hatch actuating means to a tower structure and/or a further component provided within a tower structure. A respective component provided within a tower structure may be an ascending and/or descending means such as a ladder, for instance. Thereby, the hatch actuating means is typically disposed in close proximity to a respective ascending and/or descending so that a person climbing the ascending and/or descending may easily reach the hatch actuating means despite the fact that he is “constrained” by wearing safety gear.
Embodiments of the invention also relates to a tower structure, particularly a tower structure of/for a wind turbine. The tower structure comprises at least one hatch actuating arrangement as previously specified.
Embodiments of the invention also relates to a wind turbine, comprising a tower structure as previously specified.
Both regarding the tower structure and the wind turbine all annotations regarding the hatch actuating arrangement apply in analogous manner.
BRIEF DESCRIPTION
Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:
FIG. 1 shows a principle drawing of a hatch actuating arrangement in a first position according to an exemplary embodiment of the invention.
FIG. 2 shows a principle drawing of a hatch actuating arrangement in a second position according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1, 2 both show a principle drawing of a hatch actuating arrangement 1 according to an exemplary embodiment of the invention. The hatch actuating arrangement 1 serves for actuating, i.e. particularly opening, a hatch 2 of a hatch device 3 . Both the hatch actuating arrangement 1 and the hatch device 3 are provided within a tower structure (not explicitly shown) of a wind turbine (also not explicitly shown).
The hatch actuating arrangement 1 comprises a hatch device 3 , the latter comprising the hatch 2 . The hatch device 3 is provided with a platform 4 provided at a certain height level within the tower structure. Hence, the hatch device 3 and the platform 4 , respectively, axially divide the tower structure in respective axially adjacent inner volumes 5 , 6 . A first inner volume 5 is located above the hatch device 3 or platform 4 , respectively, a second inner volume 6 is located below the hatch device 3 or platform 4 , respectively.
The hatch 2 is movably, i.e. pivotably, supported between an open position (cf. FIG. 2 ) and a closed position (cf. FIG. 1 ). The open position of the hatch 2 is defined in that a passageway between the two volumes 5 , 6 is not obstructed by the hatch 2 , i.e. a person can pass from the first inner volume 5 to the second inner volume 6 , and vice versa. The closed position of the hatch 2 is defined in that a passageway between the two volumes 5 , 6 is obstructed by the hatch 2 , i.e. a person cannot pass from the first inner volume 5 to the second inner volume 6 , and vice versa.
The movable or pivotable support of the hatch 2 is realised by a hinge joint, i.e. a hinge 7 which interconnects the hatch 2 with the platform 4 .
The hatch actuating arrangement 1 further comprises a hatch actuating means 8 . The hatch actuating means 8 comprises an elongate actuating element 9 in the shape of an actuating bar. The hatch actuating means 8 , i.e. the actuating element, is vertically movably supported in a direction parallel to the centre or longitudinal axis of the tower structure (cf. double arrow 10 ).
Respective motions of the hatch actuating means 8 and the actuating element 9 , respectively are vertically orientated relative to ground. I.e. the trajectory of the motion of the hatch actuating means 8 and the actuating element 9 , respectively runs perpendicularly relative to a horizontal plane. Hence, respective motions of the hatch actuating means 8 and the actuating element 9 , respectively are axially orientated with reference to the centre axis of the tower structure.
The movable support of the hatch actuating means 8 and the actuating element 9 , respectively is established by upper and lower guiding means 11 , i.e. linear guidances, allowing for linear/translational motions of the hatch actuating means 8 and the actuating element 9 , respectively in the axial or vertical direction.
Therefore, the hatch actuating means 8 comprises connecting means (not explicitly shown) for connecting the actuating element 9 to the inside of the tower structure, i.e. particularly to an ascending and/or descending means 12 in the shape of a ladder vertically extending within the tower structure. Connection of the actuating element 9 to the ascending and/or descending means 12 may be realised by bolted and/or welded connections, for instance.
The hatch actuating means 8 , i.e. particularly the actuating element 9 , also allows for an extra support of a person climbing the ascending and/or descending means 12 .
A safety rail 13 for interconnecting with safety gear, such as a safety harness or the like, worn by personnel climbing the ascending and/or descending means 12 is provided with the ascending and/or descending means 12 .
A mechanical coupling of the actuating element 9 and the hatch 2 is provided by a coupling means 14 in the shape of a metal wire. As is discernible, the coupling means 14 is coupled to the actuating element 9 at a first coupling point 15 and to the hatch 2 at a second coupling point 16 . The first coupling point 15 is provided at the free end of the actuating element 9 with the free end facing towards the hatch device 3 . The second coupling point 16 is provided at a top side of the hatch 2 with the top side facing towards the free end of the actuating element 9 .
As is further discernible, the coupling means 14 is guided along a deflecting means 17 in the shape of a deflecting roll. The deflecting means 17 is interposed in the course of the coupling means 14 between the two coupling points 15 , 16 . The deflecting means 17 allows for a deflection of the course of the coupling means 14 between the two coupling points 15 by 180°. I.e., the deflecting means 17 inverts the course of the coupling means 14 .
The deflecting means 17 is stably mounted with the lower guiding means 11 and cannot be vertically moved. However, the hatch actuating means 8 and the actuating element 9 , respectively are movably relative to the deflecting means 17 .
The hatch actuating arrangement 1 as specified above allows for an eased actuation of the hatch 2 . In order to actuate, i.e. particularly open, the hatch 2 , the hatch actuating means 8 , i.e. particularly the actuating element 9 , has to be moved vertically downward towards the hatch device 3 . This motion of the actuating element 9 results in a vertically upwardly directed tensile force (cf. arrow 18 ) applied to the hatch 2 and consequently, an opening of the hatch 2 .
Thus, coupling of the hatch 2 and the hatch actuating means 8 is realised in such a manner that by moving the actuating element 9 vertically downward towards the hatch device 3 , a force is applied to the hatch 2 which force moves the hatch 2 in its open position or secures the hatch 2 in its open position.
Thereby, coupling between the hatch actuating means 8 and the hatch 2 allows for a coupled movement of the actuating element 9 and the hatch 2 . The coupled movement particularly allows that vertically downwardly directed motions of the actuating element 9 relative to the hatch device 3 , i.e. particularly vertically downwardly towards the hatch device 3 , result in a motion of the hatch 2 from its closed position to its open position. Thereby, the vector of the motion of the actuating element 9 towards the hatch device 3 is oppositely directed to the vector of the force applied to the hatch 2 .
As is discernible when comparing FIG. 1, 2 , it can be said that the hatch actuating means 8 or the actuating element 9 , respectively is translationally movably supported between two end positions. Thereby, the hatch 2 is positioned in its closed position when the hatch actuating means 8 or the actuating element 9 , respectively is positioned in its first end position (cf. FIG. 1 ) and the hatch 2 is positioned in its open position when the hatch actuating means 8 or the actuating element 9 , respectively is positioned in its second position (cf. FIG. 2 ).
All in all, a person climbing down the ascending and/or descending means 12 only has to move the actuating element 9 towards the hatch device 3 when he is willing to open the hatch 2 . Moving the actuating element 9 towards the hatch device 3 is in any case possible, i.e. particularly possible when the person wears respective safety gear.
In order to ease opening the hatch 2 , the weight of the actuating element 9 is chosen in such a manner that a weight force equal or less than the force applied to the hatch 2 when moving the actuating element 9 towards the hatch device 3 is created. Hence, the weight of the actuating element 9 acts as a counterweight allowing for an eased transfer of the hatch 2 from its closed position in its open position. In such a manner, the force for moving the actuating element 9 and thereby, opening the hatch 2 is held comparatively small. If the weight force of the actuating element 9 is less than the force which is necessary for actuating, i.e. opening, the hatch 2 , the hatch 2 will always tend to automatically return to its closed position.
Although the present invention has been described in detail with reference to the preferred embodiment, embodiments of the invention are not limited by the disclosed examples from which the skilled person is able to derive other variations without departing from the scope of the invention. | A hatch actuating arrangement for actuating a hatch of a hatch device, with the hatch device being adapted to be disposed or being disposed within a tower structure of a wind turbine. A hatch actuator being movably supported relative to the hatch such that a downward force upon the hatch actuator and a weight of the hatch actuator urges the hatch to rotate toward the open position; and wherein the hatch actuator is connected to and positioned proximate a side of a ladder above the hatch so that a user may open the hatch while upon the ladder above the hatch. |
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FIELD OF THE INVENTION
This invention relates to devices adapted to dispense a water soluble or dispersible additive into a flushable toilet cistern and bowl thereof. More particularly, the present invention relates to such a device having no moving part that is able to minimize the amount of additive that is flushed to waste and is present in the cistern water during quiescent periods, whilst maximizing the amount of additive present in the water of a toilet bowl after flushing.
BACKGROUND TO THE INVENTION
The prior art is replete with devices for use in dispensing an additive into a toilet cistern and a bowl thereof, which require no moving parts to facilitate their action. These range from relatively simple devices, such as those in which a block of additive material is held within a container having an opening into which the water in the cistern enters and dissolves or disperses the additive and by diffusion through the opening produces a concentration of additive in the cistern water, to relatively complex devices having air locks, baffles and the like to facilitate controlled delivery of additives.
An example of the latter mentioned type is disclosed in UK patent application No. GB2114623-A. Although dispensers of the latter type have the ability to provide a substantially constant concentration and volume of additive to the cistern and bowl, their complex design and resultant relative high costs generally have made these devices unattractive in large scale consumer use.
Similarly, whilst the relatively simple dispensers of the first mentioned kind have achieved wide consumer acceptance, because the additive is present in the cistern water, when a toilet is flushed, a substantial proportion of the additive will be flushed to waste. As the additive is generally required to produce an effect in the water of the toilet bowl, the amount of additive not remaining in the bowl after flushing is clearly wasted. Moreover, in most cases, the presence of additive in the cistern water during quiescent periods serves no useful purpose. Further, by allowing the relatively large volume of cistern water to remain in continuous contact with the additive during quiescent periods, this results generally in increasing concentration of additive in the cistern water with time.
To minimize the amount of additive wasted, additives have been incorporated into various solid matrices that allow the additive to be dissolved or dispersed in the cistern water at a controlled rate. Whilst this approach may achieve some reduction in the maximum concentration of additive in the cistern water, nevertheless, during prolonged quiescent periods, the concentration of additive in the cistern water will become excessive. More importantly, this approach will have no effect on the proportion of additive that is flushed to waste.
SUMMARY OF THE INVENTION
The present inventor has recognized these difficulties inherent in the prior art and in the present invention seeks to provide a dispenser that is relatively simple in design but which is able to minimize the proportion of additive that is flushed to waste, so that the major proportion of additive that is dispensed remains in the toilet bowl water after flushing.
Accordingly, the present invention consists in a passive dispenser for use in dosing a toilet bowl with an additive comprising a first chamber and a second chamber separated by a common wall having an opening therein, a second wall extending upwardly from a base of a second of the chambers and spaced apart from the common wall opening to define a cavity having an open upper end to permit fluid communication between the chambers, the first chamber being adapted to hold the additive, the second chamber having a filling means to admit water thereinto during filling of the cistern and a discharge means to discharge additive-containing water into the toilet bowl when a toilet is flushed.
DETAILED DESCRIPTION OF THE INVENTION
In order to allow water in the cistern to enter the dispenser, it is immersed in the cistern to an extent sufficient to ensure that when the cistern is full, water will enter the first chamber through the passage. This may be achieved by suspending the dispenser from an upper portion of the cistern, for example, from one of the sidewalls or cover. The first chamber must, however, always have an opening to the atmosphere through which water must not enter when the dispenser is placed in the cistern.
If the dispenser is to be suspended from a sidewall, a hanger having means to attach to an upper edge of a sidewall and apportion connectible to the dispenser may be used. Such a hanger will preferably be further adapted to permit the adjustment of the dispenser vertically in the cistern and hence the extent to which it will be immersed. This may be achieved through the use of an elongate portion dimensioned to co-operate with a connecting means on the dispenser in a manner such that the dispenser is adjustable therealong.
The additive may be in the form of a solid and if so, desirably it will be present in the form of a block in admixture, for example, with components to control the rate at which the additive is released into the surrounding water. Compositions for such blocks are well known in the art and require no elaboration in this specification. However, to assist in attaining the controlled release of additive, the dimensions of the block may be controlled together with its density.
In those cases where the additive is in the form of granules or the like, their size and density should be sufficient to prevent them from being carried over into the second chamber.
The additive may also be in the form of a gel, paste, emulsion, viscous dispersion, viscous solution, or dispersed or dissolved in water-immiscible liquid(s), provided that the additive in the form selected is capable of being dissolved or dispersed into the cistern water at an appropriate rate.
The additive itself may be a variety of substances present singularly or in combination. These include dyestuffs, fragrances, disinfectants, deodorants and the like. Depending on the nature of these substances, they may be dissolved or dispersed into the water contained within the first chamber.
The dispenser may be sold with or without the additive present in the chamber. Additive may also be sold separately to allow for replacement once the additive in a dispenser is used up.
The volume of additive-containing water dispensed will be determined by a number of factors, excluding the volume occupied by the additive in solid form. These are:
(a) the extent to which the dispenser is immersed, which will in turn determine the level of water in the chambers;
(b) the volume of the second chamber below the level of water therein; and
(c) the volume of the first chamber defined between the height of the second wall and the level of the water therein.
It is preferred that the chambers are formed side by side with the common wall dividing them. In this way, a common base may be used, from which the common wall upwardly extends. In such an arrangement, another upwardly extending wall may be formed around the periphery of the base.
The upper end of the second chamber may be closed by the use of a wall extending from the outer wall surrounding the first chamber to connect with the common wall.
The dimensions of the cavity formed between the walls, particularly the size of the opening in its upper end, will affect the diffusion of additive between the chambers. The rate of filling of the first chamber is not as critical as the control of the extent of diffusion. Clearly, if diffusion is excessive, then by further diffusion through the filling means and the discharge means into the cistern during quiescent periods, the effectiveness of the dispenser will be diminished.
The dimensions of the cavity will be such that the rate at which additive containing water is transferred from the first chamber to the second chamber when additive is dispensed is determined by the rate at which additive-containing water is dispensed through the discharge means. Provided that the rate of this transfer is the same or greater than the rate additive is dispensed, the dimensions of the cavity may be varied accordingly. However, as mentioned above, the dimensions of the passage should not be so large as to produce an unacceptable rate of diffusion.
The discharge means is preferably located at the lowest portion of the second chamber to maximize the efficiency of the discharge of additive and water. In an embodiment wherein the chambers have a common base, the discharge means comprises an aperture in a portion of the base of the second chamber. It will be appreciated that the dimensions of the aperture may be adjusted in accordance with the rate of discharge required.
To achieve maximum effectiveness of the dispenser of the invention, the dimensions of the aperture should be adjusted so that the rate of discharge is substantially less than the rate at which the level of water falls in the cistern during flushing. Most preferably, the rate of discharge should be such that the relatively concentrated additive-containing water held in the first chamber is dispensed into the cistern water immediately prior to emptying. In this way, a minimal amount of additive will be flushed to waste whilst a maximal concentration of additive in the toilet bowl water will be achieved.
The filling means must be located in a position that permits water to enter the second chamber when the cistern is full or during filling. Accordingly, the filling means may constitute an aperture located in an outer wall or in the base of the second chamber. If it is located in an outer wall, it will be located below the level of the water in the cistern when full.
Preferably, the filling means will also constitute the discharge means. Most preferably, such means will comprise an aperture in the base of the second chamber.
In use, the dispenser is partially immersed in the cistern water to a depth sufficient to cause water to enter the first chamber from the second chamber via the opening in the upper end of the cavity. Both of the chambers will be filled to a level somewhere above the height of the second wall, the exact level being determined by the extent of immersion.
At equilibrium, the level of water in the chambers of the dispenser and the cistern will be equal.
Once water enters the first chamber, additive will become dispersed or dissolved in the water. Some of the additive will diffuse into the water of the second chamber as the chambers are in fluid communication via the cavity. However, the concentration of additive in the water of the first chamber will be substantially greater than that of the second chamber.
When the cistern is emptied, water containing additive will be dispensed into the cistern water once the level of water in the cistern begins to fall. Discharge will continue until the level within the first chamber reaches the top of the second wall and the second chamber is empty. However, the greatest concentration of additive will be dispensed when the cistern is near empty. This will include the water from the first chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
Two embodiments of the invention will now be described with reference to the accompanying figures in which:
FIG. 1 is a perspective view of a dispenser of the invention;
FIG. 2 is a perspective sectional view about 2--2 of FIG. 1 (with the hanger removed);
FIG. 3 is an inverted plan view of a dispenser shown in FIG. 1; and
FIG. 4 is a perspective view of another embodiment of the dispenser of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The dispenser 10 comprises two chambers 11, 12 separated by a common wall 13. A wall 14 is spaced apart from an opening in wall 13 to form a cavity 15 having an open upper end.
In this embodiment, the volume ratio of chamber 11 to chamber 12 is 2.1:1, whilst the cross-sectional dimensions of the cavity 15 are 5×5 mm.
At an upper end of chamber 11 is an opening 16 to the atmosphere, through which a solid additive contained in the form of a block (not shown) is to be placed. In this embodiment, the block contains a dyestuff as additive.
In base 18 of chamber 12, there is a small, circular opening 17 that permits the discharge of water containing additive. The same opening 17 permits water to enter chamber 12. An opposing end 19 is closed.
In an opening 20, adjacent the open end 16 of chamber 11, there is a hanger 21 that permits the dispenser 10 to be located within a cistern. The hanger 21 has an elongated portion 22 dimensioned to fit within the opening 20. Notches, not shown, on the elongated portion allow the hanger to be positioned in the dispenser. At an upper end of the hanger 21 is a U-shaped portion 23 adapted to fit over the side of a cistern and be held there by a resiliently biassed portion 24.
All of the components of the dispenser 10, including the hanger 21, may be injection moulded using a thermoplastic material. The dispenser may be moulded with the hanger if it is, for example, aligned longitudinally as shown in FIG. 4.
In use, a block of solid additive is placed in chamber 11 prior to the immersion of the dispenser 10 in the water of a cistern. The hanger 21 is slid through opening 20, with the U-shaped portion 23 facing away from the chamber 11. The dispenser 10 is then immersed whilst the U-shaped portion 23 is placed over the upper edge of a wall of the cistern, being held there by the resilient bias of portion 24 acting on an inner surface of the wall.
By moving the dispenser 10 along the hanger 21, the position of the dispenser may be adjusted in the water until water enters chamber 11 through opening 17 and cavity 15.
The dispenser will then function as follows:
Once immersed, water will enter and fill chamber 12 through opening 17. When the water level reaches the top of wall 14, water will enter chamber 11 through cavity 15. Water will continue to enter chamber 11 until it reaches the level of the water in the cistern. The level of the water in the chambers 11, 12 will be somewhere above the top of wall 14, thereby ensuring that chambers 11, 12 will remain in fluid communication.
During immersion, additive will be dissolved or dispersed in the water in chamber 11. By virtue of the fluid communication with the water in chamber 12, some additive will diffuse into chamber 12. However, the concentration of additive will be substantially greater in chamber 11.
Naturally, the greater the contact time between the water held within chamber 11 and the additive block, the greater the resultant concentration of additive in the water.
During flushing, the water level falls in the cistern thereby causing the level of water in the dispenser to fall and additive to be dispensed. As the rate of discharge from opening 17 is substantially less than the rate of fall of water in the cistern, water containing additive from chamber 11 will be discharged when the cistern is near empty.
When the cistern is empty and discharge is completed, water will remain in chamber 11 to the height of wall 14. The volume of additive-containing water discharged will be equal to the volume of additive-containing water contained in chamber 12 together with the volume contained in chamber 11 above the top of wall 14.
The embodiment of the dispenser 10 of the invention shown in FIG. 4 is essentially as that described with reference to FIGS. 1, 2, 3, except that hanger 21 is affixed to a side of the dispenser by a lug 25. In this configuration, the dispenser and hanger may be injection moulded together in the one mould.
In use, the lug 25 is broken by twisting hanger 21. It is then inserted into opening 20 in the manner previously described. | A passive dispenser, adapted to be positioned in the cistern of a toilet, useful for dosing a toilet bowl with an additive such as a disinfectant, cleaning agent, colorant, perfume or the like, has a first chamber and a second chamber separated by a common wall having an opening therein, a second wall extending upwardly from a base of a second of the chambers and spaced apart from the common wall opening to define a cavity having an open upper end to permit fluid communication between the chambers, the first chamber being adapted to hold the additive, the second chamber having a filling means to admit water thereinto during filling of the cistern and a discharge means to discharge additive-containing water into the toilet bowl when the toilet is flushed. |
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REFERENCE TO PENDING APPLICATIONS
[0001] This application is not based upon any pending domestic or international patent applications.
FIELD OF THE INVENTION
[0002] The present invention is generally directed toward a method for attaching a self-contained keyhole weld fitting and apparatus. More specifically, the present invention provides an improved fitting and method of use providing a branch outlet which can be physically and sealably secured to an underground pipe while causing less disturbance to the earth above the pipe than using a traditional fitting and excavation.
BACKGROUND OF THE INVENTION
[0003] Additional outlets must often be added to underground pipelines or pipes. This is typically accomplished by creating an excavation from the earth's surface down to the pipe to be tapped. In locations where disturbance of the surface is not an issue an excavation is made which exposes the underground pipe and is large enough to accommodate a fitting along with a welder and his equipment. The fitting is temporarily held in place by various means while the welder physically and sealably secures the fitting by welding it to the exterior of the pipe. Once the fitting has been welded in place the means by which the fitting is temporarily held in place are removed. At this point an operation called a hot tap is carried out wherein a portion of the pipe is cut and removed such that the fitting is now in fluid communication with the interior of the pipe. This is accomplished while the pipe is under pressure carrying gas or liquids.
[0004] In many situations, such as pipes located under busy city streets, the surface disturbance caused by an excavation large enough to accommodate the fitting and welder are unacceptable. In these types of situations a much smaller excavation is created extending from the earth's surface down to just below the underground pipe being tapped. The excavation is deep enough to expose the lower surface of the pipe. The diameter of the excavation is typically just large enough to accommodate the fittings to be mounted on the pipe. A first portion of the fitting is seated on the lower surface of the pipe. The second portion of the fitting is then placed on a top portion of the pipe. The first and second portions are aligned with one another and secured to one another and the pipe using bolts. These bolt-on fittings are sealed to the pipe by elastomeric seals captured between the fitting and pipe. While these bolt-on fittings allow an underground pipe to be tapped with minimal disturbance to the surface, the elastomeric seals tend to deteriorate over time leading to leaks between the pipe and the fitting.
[0005] There is a long felt need in the pipeline industry for a fitting and method which would provide a permanent welded seal for a branch outlet while accessing the existing pipe using a keyhole excavation.
[0006] For additional information relating to excavation and fittings for tapping underground pipes, reference may be had to the following previously issued United States patents.
[0000]
Patent Number
Inventor
Title
847,594
McCreary
Hose or Pipe Mender
3,178,793
Rosengarten
Apparatus For Sealing Mains
Jr. et al.
4,323,526
Hilbush III
Method For Sealing Pipe Joints
4,610,439
Burghardt
Service Saddle U-Bolt Installation Holder
4,647,073
Kosaka
Clamping Device For Underground Pipes
4,832,069
Gale et al.
Tapping Subterranean Pipes
5,659,935
Lo-Pinto
Apparatus For Installing A Branch
et al.
Tapping On A Pipe
6,142,165
Wartel et al.
Method and Apparatus For Installing
A Branch Connector From
The Top Of An Excavation
6,669,406
Hutton et al.
Method and Apparatus For Underground
Connection of Pipe
6,705,801
Kiest Jr.
Apparatus and Method For Providing
Access To Buried Pipeline
7,001,106
Burnham
Installation of Service Connections
et al.
For Sensors or Transmitters In
Buried Water Pipes
2006/0002765
Hutton et al.
Tool Assembly With Universal Coupling
For Various Tools, For
Work On Underground Pipes
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention satisfies the needs discussed above. The present invention is generally directed toward a fitting and method of use which allows for tapping an underground pipe through a keyhole excavation which creates a minimum amount of disturbance to the earth's surface while also providing a welded connection and seal between the fitting and the pipe.
[0008] The fitting of the present invention uses a weld material which is placed between the fitting and the pipe. This weld material can then be activated from the earth's surface by applying an electrical charge across the fitting, weld material and pipe. The method for using the apparatus is to dig a keyhole excavation from the earth's surface to a depth sufficient to expose the pipe being tapped. The fitting is then placed on the pipe with the weld material captured between the fitting and the pipe. A power lead is attached to the fitting and a ground lead is attached to the pipe. An electrical charge is then applied to the power lead. This charge goes through the fitting, weld material and pipe and into the ground lead. Once the weld material has been activated it physically and sealably holds the fitting in place.
[0009] Further objects and features of the present invention will be apparent to those skilled in the art upon reference to the accompanying drawings and upon reading the following description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Preferred embodiments of the invention will now be described in further detail. Other features, aspects, and advantages of the present invention will become better understood with regard to the following detailed description, appended claims, and accompanying drawings (which are not to scale) where:
[0011] FIG. 1 is a cross-sectional view of an excavation showing the prior art fitting in place on an underground pipe.
[0012] FIG. 2 is a cross-sectional view of an excavation showing an embodiment of the fitting of the present invention in place on an underground pipe.
[0013] FIG. 3 is a cross-sectional view illustrating one embodiment of the layout of the insulators, weld material and fittings on a pipe.
[0014] FIG. 4 is a second embodiment of the layout of the insulators and weld material between the fitting and pipe.
[0015] FIG. 5 is an exploded cross-sectional view of a second embodiment of the fitting of the present invention.
[0016] FIG. 6 is an end view of a second embodiment of the present invention mounted on a pipe.
[0017] FIG. 7 is a side view of a second embodiment of the fitting of the present invention mounted on a pipe.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] For explaining the present invention in detail it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of the parts illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein are for the purpose of description and not of limitation.
[0019] Elements shown by the drawings are identified by the following numbers:
[0000]
20
Prior art fitting
22
Branch fitting
24
Pipe
26
First portion
28
Second portion
30
Bolts
32
Elastomeric seals
34
Keyhole excavation
36
Surface of earth
50
Fitting
52
Branch fitting
54
Pipe
56
First portion
58
Second portion
60
Weld material
62
Keyhole excavation
64
Excavation depth
66
Bottom (of excavation)
68
Top (of excavation)
70
Length of fitting
72
Insulators
74
Power lead
76
Hole
78
Ground lead
80
Plug
82
Hole
84
Earth's surface
90
Fitting
92
Tubular portion
94
Saddle-shaped contour cut
96
Weld material
98
Plug
100
Pipe
[0020] Referring to FIG. 1 , a prior art fitting 20 is used for attaching a branch outlet 22 to an underground pipeline or pipe 24 . The prior art fitting 20 has a first portion 26 and a second portion 28 held together by a plurality of bolts 30 . The second portion 28 also has a branch outlet 22 . The elastomeric seals 32 are located on the underside of the first and second portions 26 , 28 of the prior art fitting 20 and are shown in dashed lines.
[0021] In using the prior art fitting 20 , a keyhole excavation 34 is dug from the surface of the earth 36 exposing the pipe 24 . The size of the excavation 34 is depending upon the size of pipe 24 being tapped and to a certain extent, the depth of the pipe 24 . The excavation 34 must be deep enough to expose the bottom side of the pipe 24 so the first portion 26 of the fitting 20 can be placed underneath the pipe 24 . The second portion 28 of the fitting 20 is then placed on the top of the pipe 24 . A plurality of bolts 30 are used to secure the first and second portions 26 and 28 to one another. As the bolts 30 are tightened, the elastomeric seals 32 are compressed between the underside of the first and second portions 26 and 28 of the fitting 20 and the pipe 24 . This provides a seal between the first and second portions 26 and 28 of the fitting 20 and the pipe 24 . Once the fitting 20 is securely in place on the pipe 24 , the pipe 24 can be hot tapped so that a second pipe can be attached to the branch fitting 22 and provide an outlet for the gas or liquid flowing through the pipe 24 .
[0022] Turning to FIG. 2 , the fitting 50 of the present invention provides a branch fitting 52 for tapping into a pipe 54 . The fitting 50 also has a first portion 56 and a second portion 58 . The first and second portions 56 and 58 are secured and sealed to one another and to the pipe 54 by weld material 60 . The fitting 50 and pipe 54 are shown at the bottom of a keyhole excavation 62 . The depth 64 of the excavation 62 is dependent upon the depth of the pipe 54 . For the embodiment shown in FIG. 2 , the excavation 62 must be sufficiently deep to provide enough clearance between the pipe 54 and the bottom of the excavation 66 to allow for the first portion 56 of the fitting 50 to be placed on the pipe 54 . The width 68 of the excavation 62 is dependent upon the length 70 of the fitting 50 . The length 70 of the fitting 50 in turn is a function of the diameter of the pipe 54 .
[0023] FIGS. 3 and 4 show two variations of the detail of the weld material 60 once it is put in place. Turning now to FIG. 3 , the weld material 60 is disposed along the edges of the fitting 50 . Insulators 72 electrically isolate the fitting 50 from the pipe 54 . A power lead 74 passes through a hole 76 in the fitting 50 and is attached to the weld material 60 . A ground lead 78 is attached to the pipe 54 .
[0024] Turning now to FIG. 4 which shows another embodiment of the detailed joint layout used with the present invention. Here again the fitting 50 and the pipe 54 are electrically isolated from one another by insulators 72 . The weld material 60 extends along the outer edge of the fitting 50 with a triangular cross-section. The power lead 74 is attached to a plug 80 which is then secured to a hole 82 in the fitting 50 . The ground lead 78 is attached to the pipe 54 .
[0025] The method of the present invention involves digging a keyhole excavation 62 extending from the earth's surface 84 to an excavation depth 64 to expose a pipe 54 . The depth 64 of the excavation 62 should be sufficient to provide clearance between the bottom 66 of the excavation 62 and the pipe 54 . The diameter 68 of the excavation should be sufficient to expose enough of the pipe 54 to secure the fitting 50 . The first portion 56 of the fitting 50 is positioned on a lower surface of the pipe 54 . The second portion 56 of the fitting 50 is positioned on an upper surface of the pipe 54 in alignment with the first portion 56 . Welding material 60 is disposed along the edges of the first and second portion 56 and 58 of the fitting 50 such that it is between the fitting 50 and the pipe 54 . If necessary, one or more insulators 72 can be used to provide proper spacing between the portions 56 and 58 of the fitting 50 and the pipe 54 .
[0026] A power lead 74 is electrically connected to the fitting 50 and in turn the weld material 60 . This can be accomplished in several ways included, but not limited to, attaching the power lead 74 through a hole 76 in the fitting 50 and attaching it directly to the weld material 60 . This can also be accomplished by attaching the power lead 74 to a plug 80 which is seated in a hole 82 in the fitting 50 . A ground lead 78 is attached to the pipe 54 . The portions 56 and 58 of the fitting 50 is then physically and sealably secured to one another and the pipe 54 by passing an electrical charge through the power lead 74 into the weld material 60 through the pipe 54 and back to the ground lead 78 . The control of the electrical current being done from the surface of the earth 84 . The electrical charge melts the weld material 60 causing it to bond with the fitting 50 and the pipe 54 . Once the fitting 50 has been welded to the pipe 54 , the power lead 74 and ground lead 78 can be removed from the fitting 50 and pipe 54 . The pipe 54 and fitting 50 are then ready to be hot tapped. The hot tap operation from this point on is carried out in the same manner that is commonly practiced in the art today.
[0027] The actual joining of the fitting 50 and the pipe 54 can be accomplished by any one of several welding or braising techniques, including by way of example, shielded metal arc welding, exothermic brazing, thermit welding, electro slag welding and explosive welding. The composition of the weld material 60 can adapted to carry out these different types of welding.
[0028] For the shielded metal arc welding process the weld material 60 shown in the drawings would be similar to the composition of a welding rod. The arc would be initially struck on one point along the path of the weld material 60 . The arc would advance along the path of weld material melting the metal in the weld material 60 and releasing an inert shielding gas until the entire length of weld material 60 had been activated. The melted metal would fuse the fitting 50 and the pipe 54 together. Likewise the weld material 60 could also be a composition that would allow for exothermic brazing, thermit welding, electro slag welding or explosive welding.
[0029] FIGS. 5 , 6 and 7 show another embodiment of the apparatus of the present invention. The fitting 90 has a tubular portion 92 which terminates on one end with a saddle-shaped contour cut 94 . The contour cut 94 is configured to fit the external surface of a short length of exposed pipe 100 . Weld material 96 extends along the saddle-shaped contour cut 94 . The fitting 90 can also have a removable plug 98 sized to fit inside the tubular portion 92 of the fitting 90 .
[0030] In using this second embodiment of the fitting 90 , it is only necessary to dig an excavation to a depth which exposes the upper surface of the pipe 100 sufficient to position the saddle-shaped contour cut 94 on the pipe 100 . Then in a manner similar to that discussed for the first embodiment of the fitting 50 as shown in FIGS. 2 through 4 , a power lead is attached either to the fitting 90 or directly to the weld material 96 . A ground lead 78 is attached to the pipe 100 . Prior to activating the weld material 96 using an electrical charge, the plug 98 is placed in the interior of the tubular portion 92 of the fitting 90 . The plug 98 prevents weld material 96 from flowing into the interior of the tubular portion 92 .
[0031] With the plug 98 in place, the weld material 96 is activated using an electrical charge applied from the power lead 74 with the charge passing through the weld material 96 activating it. The weld material 96 physically and sealably secures the fitting 90 to the pipe 100 . The electrical charge then passes into the ground lead 78 . Once the power and ground leads 76 and 78 are removed from the fitting 90 and pipe 100 , they are ready for hot tapping. Here again the hot tapping is carried out in the method well known in the art.
[0032] The fitting 90 can also be used without the plug 98 in place by activating the weld material 96 in the same manner as when the fitting 90 is used with the plug 98 . When the fitting 90 is used without a plug 98 some of the weld material 96 will end up in the interior of the tubular portion 92 . The weld material 96 that works its way into the interior of the tubular portion 92 and might affect performance will be removed during hot tapping.
[0033] The weld material 96 shown in FIGS. 5 , 6 and 7 can be the same composition as any of the those discussed for the embodiment of the present invention shown in FIGS. 2 , 3 and 4 .
[0034] While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claims, including the full range of equivalency to which each element thereof is entitled. | A method of attaching a branch outlet fitting to a metal pipe buried beneath the earth's surface while causing reduced disturbance to the earth above the pipe, comprising digging a vertical excavation from the earth's surface to expose a short length of the pipe; positioning a first fitting portion on a lower surface of the pipe; positioning a second fitting portion on an upper surface of the pipe in alignment with the first fitting portion, the first and second fitting portions having welding material thereon adjacent the pipe surfaces and each other; and from the earth's surface, activating the welding material to physically and sealably secure the fitting portions to the pipe and to each other. |
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CROSS REFERENCES TO RELATED APPLICATIONS
The subject matter of this invention is related to my copending applications Ser. No. 915,829 and Ser. No. 915,830, filed concurrently herewith.
BACKGROUND OF THE INVENTION
It has long been a common practice in the well art to suspend an inner pipe, typically a casing string, concentrically within an outer member, typically an outer casing string or a wellhead member, by means of a hanger comprising a hanger member connected to the inner pipe and having a downwardly directed shoulder which engages an upwardly directed shoulder on the outer member as the inner pipe is run in. As the art developed, it became necessary to minimize the annular space between the inner and outer hanger members, and prior art workers have developed hangers employing a retractable hanger device carried by a mandrel on the inner pipe and capable of expanding into engagement with an outer hanger member when, as the inner pipe is run in, the mandrel reaches the outer hanger member. Pipe hangers of this type have become particularly important with the advent of offshore practices in which the hanger is located at the mudline and the outer pipe above the wellhead is of the same diameter as the outer casing below the wellhead and the annular space available for the hanger is relatively small. Such hangers sometimes employ an annular retractable hanger means in the form of a circular series of mutually independent segments with each segment being spring-biased outwardly as shown, for example, in U.S. Pat. No. 3,472,530 Fowler. In other prior-art devices of this type, the retractable hanger device is in the form of a split ring as seen, for example, in the following U.S. Pat. Nos.:
3,420,308--Putch
3,741,589--Herd et al.
3,800,869--Herd et al.
3,971,576--Herd et al.
3,974,875--Herd et al.
Though hangers of this general type have achieved considerable success, they still present problems which increase in severity as the annular space available at the hanger decreases and the weight of the pipe string to be suspended increases. It has proved difficult to design either an assembly of segments or on integral split ring which is dimensioned to be accommodated in the small annular space available, adequately strong to carry the heavy loads applied by the suspending pipe and, while adequately resiliently compressible to successfully enter the outer body from which the pipe is to be suspended, is yet effective to come automatically into full positive engagement with the outer body as landing of the string is completed. Further, hangers of this type require that the retractable hanger device, whether it be made up of a plurality of segments or be in the form of a split ring, be initially secured in releasable fashion to the mandrel in such fashion that, once releasable fashion that, once the retractable hanger device has engaged the outer body, further downward movement of the mandrel is possible to complete the operation. In some cases, the segments or the ring have been releasably secured to the mandrel by shear members, but this has the disadvantage that care must be taken to avoid portions of the shear member dropping into the annulus to become damaging debris, and it is therefore advantageous to employ other forms of releasable securing means. Such devices are practical with resilient retaining means such as disclosed in my copending application Ser. No. 915,830, for example. With releasable securing means of this general type, however, it is desirable to have at least a lower portion of the annular locking device be especially resilient and more easily distortable than is that portion of the device which actually supports the load of the suspended pipe. There has thus been a continuing need for improvement of devices of this general type.
OBJECTS OF THE INVENTION
One object of the invention is to provide hanger apparatus of the type described in which the annular resiliently contractable locking device carried by the mandrel includes two mutually independent annular means, one constituting the locking means and the other constituting the catching means.
Another object is to devise such a hanger apparatus wherein, as the combination of the mandrel and the resilient annular locking device is run down to the hanger body, that element carrying the active locking surfaces will be wholly within an annular recess in the mandrel.
A further object is to provide such an apparatus wherein that portion of the annular locking device which includes releasable means for securing the device to the mandrel can be made especially resilient.
SUMMARY OF THE INVENTION
Broadly considered, hanger apparatus according to the invention comprises an outer tubular hanger body, which can be carried by an outer string of casing, and which includes at its upper end an upwardly directed transverse annular camming shoulder and, below that shoulder, two axially spaced transverse annular inwardly opening grooves, the upper one of the grooves constituting a locking groove and the lower one of the grooves constituting a catching groove. The apparatus also includes a tubular hanger mandrel and a resiliently retractable annular locking device carried by the mandrel. The mandrel presents an elongated transverse annular recess and the locking device is disposed in the recess. At the lower end of the recess there is a transverse annular upwardly directed stop shoulder. At the upper end of the recess, the mandrel carries a downwardly directed transverse annular load-bearing shoulder. Spaced below the load-bearing shoulder, the mandrel has an annular surface of substantially smaller diameter than is the load-bearing shoulder, and the mandrel presents a downwardly and inwardly tapering actuating surface between the load-bearing shoulder and the smaller diameter surface. The annular locking device comprises a locking means, advantageously in the form of an axially short split ring, and a catching means, advantageously in the form of a split ring which, being separate from the locking ring, can be significantly more resilient than would be the combination of the two rings in an integral structure. The locking means presents a transverse annular outwardly projecting locking rib adapted to cooperate with the locking groove of the hanger body. The locking ring initially embraces the smaller diameter portion of the mandrel and is thus in a recessed, inactive position. Releasable retaining means secures the catching ring to the mandrel until, when the combination of the mandrel and locking device has been inserted downwardly into the hanger body, the catching ring engages the catching groove of the hanger body so that the locking device can no longer move downwardly. Continued downward movement of the mandrel causes the locking ring, which is now restrained from moving with the mandrel because the locking ring engages the upper end of the catching ring, to be expanded into engagement with the locking groove of the hanger body by the action of the downwardly tapering actuating surface presented by the mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the foregoing and other objects are achieved according to the invention can be understood in detail, one particularly advantageous embodiment of the invention will be described with reference to the accompanying drawings, which form part of the original disclosure in this application, and wherein:
FIGS. 1-1B are fragmentary longitudinal cross-sectional views illustrating a hanger apparatus according to the invention, the figures being sequential, progressing from illustration of initial contact of the locking device with the hanger body, in FIG. 1, to illustration of the hanger completely landed and locked, in FIG. 1B; and
FIG. 2 is a view, partly in longitudinal cross section and partly in side elevation, of the locking device of the apparatus of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, the hanger apparatus 1 of this embodiment includes a hanger body 2, a hanger mandrel 3 and a resilient annular locking device indicated generally at 4 and shown in detail in FIG. 2. In this embodiment, hanger body 2 is carried by an outer pipe 5, such as a string of casing, and the hanger body is tubular, with an outer diameter equal to that of casing 5. End portions b of body 2 are right cylindrical and have the same wall thickness as the casing, each end portion being rigidly secured, as by welding, to the end of a different joint of the casing string. An intermediate portion 7 of body 2, which extends for most of the length of that body, is substantially thicker than end portions 6 and projects inwardly, being bounded at its upper end by a frusto-conical camming shoulder 8 which tapers downwardly and inwardly to join the right cylindrical inner surface 9 of portion 7 in an annular corner 10. The lower end of intermediate portion 7 is defined by an upwardly and inwardly tapering frusto-conical surface 11. A plurality of circularly spaced longitudinal through bores 7a are provided in portion 7 to allow fluid flow through body 2.
Inner surface 9 of portion 7 is interrupted by an upper transverse annular inwardly opening groove 12 and, spaced therebelow, a lower transverse annular inwardly opening groove 13. Upper groove 12 serves as a locking groove and is defined by a frusto-conical upper wall 14, which tapers upwardly and inwardly, a right cylindrical bottom wall 15, concentric with the longitudinal axis of pipe 5, and a frusto-conical load-bearing lower wall 16 which tapers downwardly and inwardly. Upper wall 14 constitutes a camming shoulder and lower wall 16 constitutes a load-bearing shoulder. Lower groove 13 serves as a catching groove and has a frusto-conical upwardly and inwardly tapering upper wall 17, a right cylindrical bottom wall 18, concentric with the longitudinal axis of pipe 5, and a lower frusto-conical wall 19 which tapers upwardly and inwardly at a small angle, advantageously about 5°. Wall 17 constitutes a camming shoulder and wall 19 constitutes a catching shoulder. Walls 14, 16 and 17 are advantageously each disposed at an angle of 45° relative to the pipe axis.
Hanger mandrel 3 is an integral body having a right cylindrical outer surface 20 equal in diameter to the outer surface of inner pipe 21 to be suspended, typically a casing string. End portions 22 of the mandrel are of the same wall thickness as the inner pipe and are rigidly secured thereto, as by welding. An intermediate portion 23 of mandrel 3 has a right cylindrical inner surface 24 which extends for a substantial portion of the length of the mandrel and is of significantly smaller diameter than that of the inner surface of the end portions 22, surface 24 being jointed to the inner surfaces of end portions 22 by frusto-conical shoulders 25 and 26. Portion 23 of the mandrel is provided with a stepped annular outwardly opening recess 27 which extends longitudinally for most of the length of intermediate portion 23 and is long as compared to portion 7 of hanger body 2. The lower end of recess 27 is defined by a transverse annular stop shoulder 28 which faces upwardly and lies in a plane at right angles to the longitudinal axis of the mandrel. Shoulder 28 also forms the lower wall of a transverse annular outwardly opening retaining groove 29. Groove 29 has a cylindrical bottom wall 30, concentric with the longitudinal axis of the mandrel, and a transverse annular upper wall 31 which is frusto-conical and tapers downwardly and inwardly at a small angle relative to shoulder 28.
Recess 27 is further defined by a larger diameter right cylindrical surface 33, which commences at the upper wall 31 of groove 29, an upwardly and inwardly tapering frusto-conical surface 34 at the upper end of surface 33, a smaller diameter right cylindrical surface 35, which commences at the upper end of surface 34, a frusto-conical downwardly and inwardly tapering load-bearing shoulder 36 defining the upper end of recess 27, and a frusto-conical intermediate surface 37 which tapers at a small angle relative to the axis of the mandrel downwardly and inwardly to connect the inner periphery of shoulder 36 and the upper end of surface 35. Surface 37 constitutes an actuating surface as hereinafter described. Shoulder 36 is at an angle of 45° to the pipe axis so as to be parallel to load-bearing shoulder 16 of groove 12 when the mandrel and hanger body are concentric.
Shown in detail in FIG. 2, locking device 4 comprises an integral resilient metal ring 4a, constituting the locking ring of the device, and a second integral resilient metal ring 4b, constituting the catching ring of the device. Both rings are split throughout their lengths as indicated at 38a and 38b.
Locking ring 4a has a right cylindrical inner surface 39, two upwardly converging frusto-conical end surfaces 40 and 41, and a bottom end surface 42. The locking ring includes a transverse annular outwardly projecting locking rib 43 which is defined by upper surface 40, a right cylindrical outer surface 44, and a downwardly and inwardly tapering frusto-conical surface 45. Surfaces 41 and 45 extend at 45° to the longitudinal axis of the ring and constitute parallel load-bearing shoulders. Surface 40 extends at 45° to the longitudinal axis of the ring and constitutes a camming shoulder to coact with upper wall 14 of groove 12. In a location spaced below shoulder 45, ring 4a has an upwardly and inwardly tapering frusto-conical surface 46 which also is disposed at 45° relative to the axis of the ring and which intersects end wall 42. Ring 4a is short in comparison to surface 35 and the diameter of surface 39, when ring 4a is relaxed and undistorted, is such that the ring will slidably embrace surface 35. Thus, the normal relaxed diameter of surface 39 is significantly smaller than the diameter of load-bearing shoulder 36.
Catching ring 4b comprises an upper main body portion 47 and a dependent skirt 48. Body portion 47 has a transverse annular flat upper end surface 49 lying in a plane at right angles to the axis of the ring, a right cylindrical outer surface portion 50, and, at the outer periphery of end surface 49, an upwardly and inwardly tapering frusto-conical surface 51. Body 47 presents the transverse annular outwardly projecting catching rib 52, defined by surfaces 49, 50 and 51 and, at the bottom of surface 50, a downwardly directed frusto-conical surface 53 which tapers upwardly and inwardly at a small angle, advantageously 5°, to constitute a catching shoulder to cooperate with shoulder 19 of hanger body 2. Body portion 47 further comprises a right cylindrical outer surface 54 which extends downwardly from the inner periphery of shoulder 53, and a right cylindrical inner surface 55. At catching rib 52, the radial thickness of body portion 47 is equal to that of ring 4a at locking rib 43.
Skirt 48 is markedly thinner, and therefore markedly more resilient, than is body portion 47. The outer surface of the skirt is defined by upwardly and inwardly tapering frusto-conical surfaces 56, a right cylindrical outer surface portion 57 of the same diameter as surface 50, and a downwardly and inwardly tapering frusto-conical surface portion 58 which constitutes a camming surface to cooperate with the upper end of intermediate portion 7 of hanger body 2. The inner surface of skirt 48 is defined by upwardly and inwardly tapering frusto-conical surface 59, which intersects surface 55, a right cylindrical main inner surface portion 60, and a downwardly and inwardly tapering frusto-conical surface portion 61. Formed integrally with the skirt at the bottom end thereof is a transverse annular inwardly directed retaining flange 62 defined by a right cylindrical inner wall 63, which is concentric with the longitudinal axis of the ring, and inwardly converging upper and lower frusto-conical side surfaces 64 and 65. To increase its resiliency, skirt 48 is provided with a plurality of circumferentially spaced, longitudinally extending slits 66 each extending from surface portion 59 throughout the length of the skirt and opening through flange 62.
Flange 62 is dimensioned to be accommodated by groove 29 of mandrel 3. Ring 4b is installed on mandrel 3 before the mandrel is welded or otherwise secured to two joints of the inner pipe, installation being accomplished by expanding the split ring and slipping the ring over one end of the mandrel, the moving the ring axially until flange 62 is aligned with groove 29, at which point the ring is allowed to relax so that the inner periphery of flange 58 is disposed just within the mouth of groove 29, as seen in FIG. 1. Advantageously, an annular radially resilient sheet metal spring 67, FIG. 1, of generally U-shaped radial cross section, is disposed within groove 29 with the U of the spring opening upwardly, to maintain ring 4b approximately centered on the mandrel. When ring 4b is in its initial position on the mandrel, the juncture between surfaces 58 and 65 engages shoulder 28, and the inner surface 63 of flange 62 is in a position such that, if the mandrel is moved downwardly relative to ring 4b, the corner presented by surfaces 63 and 64 will engage the frusto-conical upper wall 31 of groove 29. The length of cylindrical surface 33 of the mandrel is such that the portion of the mandrel defined by the upper wall of groove 29, surface 33 and surface 34 can be accommodated between flange 62 and surface 59 of the skirt of ring 4b.
Installation of outer pipe 5 positions hanger body 2 at that location from which the inner pipe 21 is to be suspended. As the inner pipe is run in, locking device 4 remains in the position on mandrel 3 seen in FIG. 1, being retained by engagement of flange 62 in groove 29 and the fact that locking ring 4a, slidably embracing surface 35, has its bottom wall 42 engaged with upper end face 49 of ring 4b. As the intermediate portion 23 of the mandrel enters hanger body 2, surface 58 of the skirt of ring 4b engages the corner 10 presented at the inner periphery of camming shoulder 8 of body 2. Further downward movement of the inner pipe causes ring 4b to be compressed inwardly. Initially, such compression is concentrated in skirt 48, occurring both because of the relatively thin wall of the skirt and because of the provisions of slits 66. As downward movement of the inner pipe continues, such compression progresses until all of outer surface 57 of the skirt has passed into the bore of the hanger body. Further downward movement of the mandrel brings the corner defined by shoulder 53 and surface 50 into engagement with camming shoulder 8, and the main body portion 47 of ring 4b is also compressed and enters the bore of the hanger body. Throughout such downward movement, flange 62 remains engaged in groove 29 so that ring 4b is positively retained in its initial axial position relative to mandrel 3.
Continued downward movement of the combination of mandrel 3 and locking device 4 causes catching rib 52 to pass groove 12, and catching rib 52 passes downwardly to the location of catching groove 13. As rib 52 begins to mate with groove 13, catching shoulder 53 begins to overlap with catching shoulder 19 of the hanger body so that, as downward movement continues, shoulder 53 engages shoulder 19 and the taper of these two shoulders causes the two shoulders to coact to force ring 4 outwardly until, as seen in FIG. 1B, the catching rib is well engaged with the catching groove. Throughout such downward movement of the mandrel, locking ring 4a remains in place on surface 35 and in engagement with upper end face 49 of ring 4b.
Engagement of shoulder 53 with shoulder 19 stops ring 4b against further downward movement. At this stage, since rib 52 is mated with groove 13, ring 4b is free to relax fully. Continued downward movement of the mandrel forces upper wall 31 of groove 29 downwardly against upper surface 64 of flange 62 and causes flange 62 to ride out of groove 29 and to slidably embrace surface 33 of the mandrel, so that the mandrel is now free to move downwardly through rings 4a and 4b. Disengagement of flange 62 from groove 29 causes skirt to be resiliently distorted outwardly, tending further to assure proper mating of catching rib 52 in groove 13.
Downward movement of mandrel 3 now causes actuating surface 37 to enter locking ring 4a. Since the locking ring is held stationary, as to axial movement, because of its engagement with upper end face 49 of ring 4b, surface 37 acts to expand the locking ring progressively, with the juncture between surfaces 42 and 46 sliding outwardly along surface 49. Such expansion of ring 4a continues until rib 43 is fully engaged in locking groove 12 of hanger 2. Such engagement causes shoulder 45 of ring 4a to engage shoulder 16 of groove 12, with the result that shoulder 45 moves along shoulder 16 and rib 43 is fully inserted in groove 12. Ring 4a is thus elevated above ring 4b, so that downwardly acting loads are not transmitted from ring 4a to ring 4b. Finally, continued downward movement of the mandrel causes mandrel shoulder 36 to come into flush engagement with shoulder 41 of ring 4a, completing the locking action. At this stage, all downwardly acting loads applied by the mandrel act in a straight line at right angles to engaged shoulders 36, 41, 45 and 16, so that the full load is transmitted through ring 4a to hanger body 2.
When it is desired to recover the inner pipe string, applying an upward strain on that pipe string causes stop shoulder 28 of the mandrel to come into engagement with the lower end of ring 4b, flange 62 then again being free to enter groove 29. Accordingly, as the mandrel is moved upwardly with the pipe string, ring 4b is moved upwardly with the mandrel until surface 51 engages surface 17 and surface 56 engages surface 11. Ring 4b is therefore cammed inwardly until rib 52 disengages from groove 13. During initial upward movement of mandrel 3 and ring 4b, locking ring 4a remains generally in place. End face 49 of ring 4b then comes into engagement with the lower end face 42 of ring 4a, and ring 4a is forced to travel upwardly with the mandrel and ring 4b. As a result, camming surface 40 of ring 4a is forced against shoulder 14 of groove 12 and upward movement of the combination of rings 4a and 4b is resisted, movement of the mandrel continuing. As actuating surface 37 moves upwardly through ring 4a, ring 4a contracts to its normal, relaxed position, directly embracing cylindrical surface 35 of the mandrel. Rib 52 moves past groove 12 but ineffectually, shoulder 51 engaging shoulder 14 to cam ring 4b inwardly so that the ring moves upwardly and out of hanger body 2. Thus, the parts will have returned to the position illustrated in FIG. 1.
While catching shoulders l9 and 53 advantageously taper at an angle of about 5° relative to planes at right angles to the longitudinal pipe axis, the angle of taper of these shoulders can be 2°-10°, smaller angles having a reduced tendency to urge the catching ring 4b outwardly under downward loads, and larger angles having an increased danger of damage to the corners at the peripheries of the shoulders. While shoulders 36, 41, 45 and 16 are advantageously at 45°, the angle of taper of these shoulders can be 30°-60°, so long as all four shoulders are essentially parallel to each other. | In hanger apparatus of the type comprising a hanger mandrel carried by an inner pipe, an outer body which can be carried by an outer pipe, and a resiliently contractable annular locking device carried by the mandrel for locking the mandrel to the hanger body to suspend the inner pipe, the locking device comprises two independent annular resilient means, the upper one of which constitutes a locking means to cooperate with a locking groove in the hanger body and the lower one of which constitutes a catching means to cooperate with a catching groove in the hanger body below the locking groove. The two annular means are disposed in an outwardly opening annular recess presented by the mandrel. The invention has the advantage that the locking means, which may be a split ring, can be wholly within the mandrel recess as the mandrel is run down to the hanger body, the active outer surfaces of the locking ring thus being protected from being damaged during the trip down to the hanger body. A further advantage is that the catching device, being independent from the locking device, can be more resilient. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the general art of ladders, and to the particular field of accessories for ladders.
[0003] 2. Discussion of the Related Art
[0004] Many tasks require the use of an extension ladder to complete. Just about any work on or near the ceiling of a room will require a ladder.
[0005] Using a ladder while performing a task may require skill, balance and dexterity. These traits can, and are, generally acquired by workers and craftsmen. However, no matter how proficient a worker is, he must still have some part of his concentration directed to maintaining his balance on the ladder while competing a task.
[0006] For example, a paper hanger must balance on a ladder while feeding paper from a roll, applying adhesive, and keeping the paper in place. While many paper hangers successfully achieve these goals, it would make their jobs easier if one or more of these tasks could be carried out by an accessory.
[0007] Therefore, there is a need for an accessory for a ladder that will permit a worker to direct most of his concentration to completing the task.
[0008] More specifically, there is a need for an accessory for a ladder that will assist a paper hanger in directing as much of his concentration on the task of hanging paper as possible.
[0009] Any accessory that is intended to make a task easier should not require a great deal of work to set up, or its objective will be vitiated. Therefore, there is a need for an accessory for a ladder that will assist a paper hanger in directing as much of his concentration on the task of hanging paper as possible and which is easy to assemble and to disassemble from a ladder.
[0010] To be most effective, any accessory that is intended to hold work items on a ladder must hold those items in the most convenient location on the ladder where those items will be easily accessible to a worker balancing on the ladder. Otherwise, the objectives of the accessory may be defeated.
[0011] Therefore, there is a need for an accessory for a ladder that will assist a paper hanger in directing as much of his concentration on the task of hanging paper as possible and will locate the items needed for the task in a position that is most convenient for the worker.
PRINCIPAL OBJECTS OF THE INVENTION
[0012] It is a main object of the present invention to provide an accessory for a ladder that will permit a worker to direct most of his concentration to completing the task.
[0013] It is another object of the present invention to provide an accessory for a ladder that will assist a paper hanger in directing as much of his concentration on the task of hanging paper as possible.
[0014] It is another object of the present invention to provide an accessory for a ladder that will assist a paper hanger in directing as much of his concentration on the task of hanging paper as possible and which is easy to assemble and to disassemble from a ladder.
[0015] It is another object of the present invention to provide an accessory for a ladder that will assist a paper hanger in directing as much of his concentration on the task of hanging paper as possible and will locate the items needed for the task in a position that is most convenient for the worker.
SUMMARY OF THE INVENTION
[0016] These, and other, objects are achieved by an accessory that includes a trigger-operated clamp, a paper supporting roller, a masking tape holder, a paper cutter, and a tape cutter.
[0017] The accessory is easily clamped onto a rail of an extension ladder and will support paper and tape in position to be easily reached and easily manipulated by a worker balancing on the ladder. After a job has been completed, the accessory embodying the present invention is easily removed from the ladder.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0018] FIG. 1 is a perspective view of an accessory for use on a ladder during a paper hanging operation.
[0019] FIG. 2 is a side elevational view of an accessory for use on a ladder during a paper hanging operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description and the accompanying drawings.
[0021] Referring to the Figures, it can be understood that the present invention is embodied in an accessory 10 for use on a ladder to support paper and tape rolls on the rail of the ladder in a position that is convenient to a user.
[0022] Accessory 10 comprises a central support bar 12 which has a first end 14 , a second end 16 , a first side wall 18 , a second side wall 20 , and a longitudinal axis 22 which extends between first end 14 and second end 16 .
[0023] A tape roll-supporting unit 26 is mounted on second end 16 of central support bar 12 . Tape roll-supporting unit 26 includes an axle 30 mounted on support bar 12 and which extends between first and second side walls 18 and 20 of support bar 12 and transversely to longitudinal axis 22 of the support bar 12 . A first tape roll holder 32 is rotatably mounted on the axle 29 adjacent to first side wall 18 , and a second tape roll holder 34 is rotatably mounted on axle 30 adjacent to second side wall 20 of the support bar 12 .
[0024] Tape mounted on the tape roll-supporting unit 26 will be fed off the rolls in a manner known to those skilled in the art.
[0025] A tape cutter element 40 is mounted on support bar 12 and includes a first end 42 located adjacent to first side wall 18 of the support bar 12 , a second end 44 located adjacent to second side wall 20 of the support bar 12 , and a longitudinal axis 46 which extends between first end 42 and second end 44 of tape cutter element 40 and which is oriented to extend transversely of longitudinal axis 22 of support element 12 . A cutting edge 48 is on tape cutter element 40 and is used to cut lengths of tape in a manner known to those skilled in the art.
[0026] A paper roll holder element 50 is mounted on supporting bar 12 adjacent to first end 14 of the supporting bar 12 . Element 50 includes a mounting bolt 52 fixed to supporting bar 12 , a base element 54 in abutting contact with second side wall 20 of supporting bar 12 and is fixed to mounting bolt 52 .
[0027] A roller element 56 is rotatably mounted on mounting bolt 52 and paper rolls are supported on the roller element 56 in a manner known to those skilled in the art.
[0028] A paper control arm 60 has a first end 62 pivotally fixed to tape cutter element 40 and a second end 64 located adjacent to roller element 56 . As can be understood from the Figures, paper roll holder element 50 extends parallel to tape cutter element 40 .
[0029] A paper cutting blade 70 is mounted on first end 14 of supporting bar 12 and includes a first end 72 fixed to supporting bar 12 , a second end 74 , and a longitudinal axis 76 which extends between first end 72 and second end 74 of paper cutting blade 70 and which is oriented to be parallel to paper roll holder element 50 and to extend transversely to longitudinal axis 22 of supporting element 12 .
[0030] A paper cutting edge 78 is located on paper cutting blade 70 to cut paper drawn thereover in a manner known to those skilled in the art.
[0031] A ladder attachment unit 80 includes a main bar 82 slidably mounted on tape cutter element 40 adjacent to second end 44 of the tape cutter element 40 . Main bar 82 includes a first end 84 , a second end 86 , and a longitudinal axis 88 which extends between first end 84 and second end 86 of the main bar 82 and is oriented transversely of longitudinal axis 46 of tape cutter element 40 and transversely of longitudinal axis 22 of supporting element 12 .
[0032] Main bar 82 further includes a first edge 90 which is a top edge when ladder attachment unit 80 is in use, a second edge 92 which is a bottom edge when ladder attachment unit 80 is in use, a stop element 94 on second end 84 of the main bar 82 , and a first ladder-engaging clamp element 96 located on first end 84 of the main bar 82 .
[0033] A handle unit 100 is mounted on main bar 82 and includes a hand-held element 102 having a bore 104 defined therethrough and through which main bar 82 is slidably accommodated. Unit 100 further includes a trigger element 106 pivotally mounted on hand-held element 102 , and a second ladder engaging-clamp element 108 on the hand-held element 102 . Second ladder-engaging clamp element 108 is oriented to face first ladder-engaging element 96 with a rail of a ladder interposed therebetween when ladder attachment unit 10 is in use.
[0034] A mechanism 120 , such as a ratchet and pawl mechanism, or other such mechanism that is known to those skilled in the art, connects trigger element 106 to main bar 82 of ladder attachment unit 80 in a manner such that operation of the trigger element 106 causes the main bar 82 to move first ladder-engaging clamp element 96 toward second ladder-engaging clamp element 108 to clamp the rail of the ladder therebetween and mount unit 10 on the rail of the ladder.
[0035] Operation of unit 10 can be understood by one skilled in the art based on the teaching of the foregoing disclosure, and thus will not be discussed in detail. Unit 10 is located on the rail of a ladder in a chosen position, trigger element 106 is operated to draw clamp element 96 toward clamp element 108 and clamp the rail of the ladder therebetween. Paper is mounted on unit 50 and tape on unit 26 . Paper is drawn over cutting edge 76 and cut when a desired length of paper is drawn. Tape is drawn off tape rolls and cut using cutting edge 46 for use with the paper. When a job is completed, unit 10 can be disassembled from the ladder and moved to a position convenient for the next job.
[0036] It is understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangements of parts described and shown. | An accessory includes a handle-operated clamp and is mounted on a rail of a ladder, such as an extension ladder, to hold paper and tape in position to be easily accessed by a worker balancing on the ladder. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of pending U.S. patent application Ser. No. 12/959,044, filed on Dec. 2, 2010, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for repairing the wall of a manhole. More particularly, but not exclusively, it relates to a method and device for treating the wall of a manhole using a bladder and material capable of curing and hardening, such as a grout or thermoset resin. The bladder expands to conform to the wall of the manhole and the material capable of curing and hardening is disposed between the wall and the bladder or on the interior surface of the bladder.
Conventional manholes include a lower or bottom panel, a barrel having a relatively constant diameter adjacent the panel, a concentric or eccentric cone extending upwardly from the barrel, one or more adjusting rings to adjust the overall height of the manhole, and a casting frame on top of the adjusting rings to support an elevation substantially level with the surrounding pavement. The casting frame is preferably sealed to the uppermost adjusting ring to preclude or minimize water flow into the manhole. The cone and adjusting rings are commonly known as the manhole chimney. Most manhole structures are unique in size and shape with varying diameters and depths. Also, bricks often form a portion of the wall of the manhole.
Substandard construction methods can lead to damage or deterioration of the manhole structure. Thus the manhole is vulnerable, allowing water and subsidence of soil to enter the manhole, which eventually leads to a structural failure of the manhole.
One presently known method of repairing manholes is the placement of a coating of a cementitious grout onto the interior surface of the manhole wall. The grout is applied in an uncured state and is permitted to cure. Methods of applying the grout include troweling the grout onto the wall of the manhole after spraying or slinging the grout onto the wall of the manhole. The manhole wall must be clean and free from water leaking through the manhole walls. Here, it is necessary for a person to enter into the manhole to plug water leaking into the manhole. A final troweling step is usually required by a person entering the manhole in order to obtain the desired compaction, surface and thickness for the curable and/or hardenable material.
Additionally, resin, such as an epoxy, a polyurethane, polyuria or other thermo-set resins have been applied to manhole walls by spraying or slinging the polymer onto the manhole wall. The polymer requires the manhole wall to be clean and free from water leaking with a prepared surface adequate for adhering the polymer to the manhole wall.
Resin-coated sleeves have also been used for repairing a manhole chimney. However, to accommodate changes in diameter of the manhole, the use of an impermeable coating on the sleeve is problematic, as a substantial coating can prohibit the necessary stretching of the sleeve, because when the sleeve stretches, the coating becomes prone to delamination from the sleeve. Furthermore, applying a coating to a fabric sleeve and sealing the seam of a fabric sleeve increases the cost for producing the sleeve. As such, problems remain in the art and a need exists for an improved method and means for repairing the wall of a manhole.
SUMMARY OF THE INVENTION
It is therefore a principal object, aspect, feature or advantage of the present invention to provide an apparatus and method for repairing the wall of a manhole which improves over or solves the problems and deficiencies in the art.
Other objects, features, aspects, and/or advantages of the present invention relate to an apparatus and method which achieves the desired compaction, surface and thickness for the curable and hardenable material without troweling or otherwise requiring an operator to enter the manhole.
Further objects, features, aspects, and/or advantages of the present invention relate to a new method of repairing the wall of a manhole wherein the curable and hardenable material is applied to the wall and an impermeable coating is applied to the outer surface of the material.
Further objects, features, aspects, and/or advantages of the present invention relate to a new apparatus and method for repairing the wall of a manhole wherein an impermeable coating is mechanically bonded to the grout or other curable and hardenable material.
Still further objects, features, aspects, and/or advantages of the present invention relate to a new method of repairing the interior wall of a manhole wherein an impermeable coating is formed about the manhole wall and adhered thereto with a chemical bond, or in some cases a mechanical and a chemical bond.
Still further objects, features, aspects, and/or advantages of the present invention relate to a new method of repairing the interior wall of a manhole wherein a resin impregnated sleeve does not include an impermeable coating maximizing stretching of the sleeve, forming an impermeable coating to the resin impregnated sleeve by adhering an inflatable bladder to the resin impregnated sleeve as the resin cures.
A still further object, feature, aspect and/or advantage of the present invention relates to a method and apparatus for repairing the wall of the manhole that accommodates diameter changes along the wall.
Further objects, features, aspects, and/or advantages of the present invention relate to a method and apparatus for repairing the wall of a manhole wherein a pressurized, expandable bladder provides a clean dry surface onto which a curable and hardenable material is applied.
These and other objects, features, aspects, and/or advantages of the present invention will become apparent with reference to the accompanying specification and claims.
One aspect of the invention includes a method for repairing a wall of a manhole that obviates the need for a pre-formed liner. The method generally includes applying a material capable of curing and hardening to the wall of the manhole, positioning a bladder at least partially within the manhole, expanding the bladder under pressure against the wall of the manhole, allowing the material to cure and harden, and removing the bladder from the manhole.
In another aspect of the invention, a resin impregnated sleeve may optionally be used and the bladder is left within the manhole after the curing process. A bond is created between the resin and an exterior surface of the bladder after the resin impregnated sleeve is applied to the wall of the manhole and is allowed to cure and harden. In one form, the exterior surface of the bladder is uneven and adapted to be mechanically attached to the cured resin impregnated sleeve. In another form, the bladder is compatible for adhesion with the cured resin impregnated sleeve. Once the material cures and hardens, a mechanical bond and/or a chemical bond are created between the resin impregnated sleeve applied to the wall and the inflation bladder. The bladder is left bonded to the material on the wall of the manhole to create an impermeable coating.
Another aspect of the present invention includes a method of repairing a wall of a manhole wherein a bladder is positioned at least partially within the manhole and expanded under pressure against the wall of the manhole. A material capable of curing and hardening is then applied to the interior surface of the manhole and allowed to cure and harden. The bladder provides both an impermeable barrier and a clean dry surface on which to apply the curable and hardenable material.
Yet another aspect of the present invention relates to an apparatus for treating a wall of a manhole that includes a material capable of curing and hardening covering the wall of the manhole, a bladder is expanded outwardly with an exterior surface of the bladder being attached to the material on the wall of the manhole and wherein the exterior surface of the bladder creates a mechanical bond, a chemical bond, or both a chemical and mechanical bond with the material on the wall of the manhole.
In an alternative form, the apparatus includes a bladder expanded outwardly against the wall of the manhole and the material capable of curing and hardening covers an interior surface of the bladder.
The present invention as disclosed herein provides numerous advantages. For example, once a grout or other material capable of curing and hardening is applied to the wall of the manhole, no troweling by hand or similar operation is required to provide for the proper compaction, surface and thickness of the material. A pre-formed liner is not required to practice the invention. In embodiments wherein the bladder is not removed from the wall of the manhole, the bladder effectively becomes an impermeable barrier or coating to the manhole lining.
Still further yet, in those embodiments wherein the material capable of curing and hardening is sprayed or otherwise applied to the interior of an expanded bladder within the manhole, the bladder provides a clean surface onto which to adhere the material in addition to an impermeable barrier.
Still further yet, the use of an expandable bladder to press a curable and hardenable material against and into cracks and crevices in the wall of the manhole provides for a structurally sound repair not heretofore possible with the prior art spraying and troweling method.
These and other benefits and advantages of the invention will become apparent to those skilled in the art based on the following disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a manhole including a sprayer for applying a curable and/or hardenable material onto the manhole walls.
FIG. 2 is a sectional view of a manhole where an installation assembly is used in accordance with an embodiment of the present invention.
FIG. 3 is a sectional view of the manhole in FIG. 1 , showing a second view of the preferred embodiment of the present invention.
FIG. 4 is a sectional view according to line 4 - 4 of FIG. 3 .
FIG. 5 is a sectional view according to line 5 - 5 of FIG. 2 .
FIG. 6 is a sectional view similar to FIG. 5 of a modification of the present invention.
FIG. 7 is a sectional view similar to FIG. 5 of a further modification of the present invention.
FIG. 8 is a sectional view similar to FIG. 5 showing a further modification of the present invention.
FIG. 9 is a sectional view showing yet a further modification of the present invention.
FIG. 10 is a sectional view of the manhole of FIG. 1 showing another embodiment of the installation assembly of FIG. 2 .
FIG. 11 is a sectional view according to line 11 - 11 of FIG. 10 .
FIG. 12 is a sectional view of a manhole illustrating an alternative embodiment of the present invention.
FIG. 13 is a sectional view of a manhole illustrating an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A typical manhole 10 has a bottom panel 12 that has a run through 13 . The bottom panel 12 is attached to a barrel 14 , a cone section 16 , and a plurality of adjusting rings 18 . A casting frame 20 is mounted at the upper end of the manhole 10 . As can be seen in FIGS. 1, 2, 3, 10, 12, and 13 , the manhole 10 has a number of diameters D 1 , D 2 , D 3 , and D 4 , as well as irregularities in the wall usually formed of brick, which often become spaced from one another.
FIG. 1 shows the initial manhole 10 . A curable and/or hardenable material 42 is sprayed on the wall of the manhole 10 by a sprayer 50 . The material capable of curing and hardening may be a grout, a resin, a thermoset resin, a photocuring resin, or a cementious material. Sprayer 50 has an inside air supply 44 and an outside air supply 46 , which cause sprayer ribs 52 to rotate and throw the curable and/or hardenable material 42 outwardly in the direction of arrow 54 . The sprayer 50 has a feeder 48 which extends downwardly through sprayer 50 . The arrow 56 shows the movement of sprayer 50 in an upward and downward direction. A cementitious grout is preferred, but various construction grouts and resinous materials are suitable for use with the present invention, including resin grouts and thermoset resins such as epoxy resin.
FIGS. 2-4 show an embodiment of the invention. Attached to an upper rack 22 is the upper end 24 of an expandable bladder 26 which extends to a lower end 28 . The lower end 28 of the bladder 26 is attached to a lower rack 30 . The lower rack 30 is attached to the upper rack 22 by a post 32 that has a post section 34 telescopically received within a post section 36 , which has a pin 38 securing the post sections 34 , 36 together. There may be other post sections in addition to post sections 34 , 36 . A threaded end 40 is within the lower most post section 36 so as to secure the post 32 to the lower rack 30 . Alternatively, the bladder 26 may be attached to the upper rack 22 at the upper end 24 of the bladder 26 , and the lower end 28 of the bladder 26 may be closed by banding or otherwise sealing the lower end 28 . In such an alternative, the lower rack 30 and post 32 need not be used to install the bladder 26 into manhole 10 .
The bladder 26 is self-contained and therefore inflatable. The bladder 26 may generally be described as an inflatable, expandable, non-absorbent, fluid impervious film. The bladder 26 is preferably made of thermoplastic polyurethane or another thermoplastic material such as poly vinyl chloride or polypropylene. The bladder material should have a wall thickness of approximately 20-100 mils prior to expansion, which thins to approximately 10-80 mils when expanded against the wall. It is also preferable that the bladder not have a scrim reinforcement, so that the bladder can expand or stretch as necessary to accommodate changes in diameter of the manhole. As such, the bladder 26 may have a single, uniform diameter. With such a bladder, the diameter may be sized to be equal or less than the smallest cross section found within the manhole 10 , which is typically defined by the casting frame 20 and adjusting rings 18 .
An air inlet tube 39 extends through the upper rack 22 and is adapted to introduce air to inflate the bladder 26 . The air inlet tube 39 or a separate inlet may be used to introduce steam or another heated fluid when thermoset resins are used. Alternatively, a UV light may be integrated into the upper rack 22 so as to extend into the bladder 26 .
FIG. 5 shows the bladder 26 with an exterior surface 60 in contact with a curable and/or hardenable material 42 . As shown in FIG. 5 , there are no projections extending from the bladder 26 into the curable and/or hardenable material 42 , and consequently there is no mechanical bond. However a chemical bond exists between the bladder 26 and the curable and/or hardenable material 42 upon the curing and hardening of the material, forming an impermeable coating or barrier that becomes an integral part of the manhole. In order to exploit this feature of the invention, it is preferred to use a bladder material that is compatible for adhesion with the curable and hardenable material. A preferred combination to create a chemical bond is the use of an epoxy as the curable and hardenable material and the use of thermoplastic polyurethane as the bladder material. However, other combinations are within the scope of this invention. The bladder 26 as illustrated in FIGS. 6-9 is intended for use in applications where the bladder 26 remains fixed to the curable and/or hardenable material 42 after it cures and hardens, thus becoming an impermeable coating or barrier by a mechanical bond. Here, the exterior surface 60 is uneven and preferably includes a plurality of projections or protrusions. Referring to FIG. 6 , a surface 60 of the bladder 26 includes straight pointed projections 62 extending in opposite directions and embedded in curable and/or hardenable material 42 . FIG. 7 shows a plurality of curved pointed projections 64 , and FIG. 8 illustrates T-shaped projections 66 . All of these projections 62 , 64 and 66 provide a mechanical bond between the bladder 26 and the curable and/or hardenable material 42 , as the projections become embedded and trapped within the curable and/or hardenable material 42 once the curable and/or hardenable material cures and hardens. Projections having other shapes can be used to create a mechanical bond between the bladder 26 and curable and/or hardenable material 42 .
The projections depicted in FIGS. 6-8 may be formed when the bladder material is made by an extrusion process. In such a process, raw material for forming the bladder is extruded through a series of rollers and allowed to set. At least one of the rollers may be embossed with a texture to impart the projections onto the material.
FIG. 9 illustrates an alternative embodiment of the bladder 26 that is intended for use in applications where the bladder 26 remains fixed to the curable and/or hardenable material 42 after it cures and hardens, thus becoming an impermeable coating or barrier via a mechanical bond. In this embodiment, the mechanical bond is formed by the use of pores 67 within the bladder 26 . The pores 67 may be formed within the bladder material by an extrusion process or like as described above, or the pores 67 may be formed by stretching or abrading the material of the bladder 26 . The stretching may be performed by inflation and expansion of the bladder 26 after placement within the manhole. In operation, the pores 67 are formed within the material of the bladder 26 . The bladder 26 is expanded against a manhole wall. As the material of the bladder 26 stretches, the pores 67 open to accommodate the flow of curable and hardenable material within the pores 67 . The curable and hardenable material cures within the pores 67 and anchors the material of the bladder 26 to the wall of the manhole.
The method of repair illustrated in FIGS. 1-4 is as follows. First, the manhole 10 is sprayed by sprayer 50 , such as shown in FIG. 1 . The sprayer 50 is passed upwardly and downwardly as shown by arrow 56 until the surface area of the wall 43 is covered. The thickness may vary depending upon the condition of the manhole 10 .
The installation assembly, comprising the upper rack 22 , the optional lower rack 30 , and the bladder 26 , is inserted into the manhole 10 with the post 32 threaded into the lower rack 30 . Initially the bladder 26 hangs loose within the manhole 10 and is not in contact with the curable and/or hardenable material 42 . The bladder 26 is then inflated by introduction of a fluid into the fluid intake 39 . Because the bladder 26 is expandable, it moves into contact with the curable and/or hardenable material 42 as shown in FIG. 2 . The fluid can be hydraulic fluid, water, or air, and could be other fluids as well.
The bladder 26 presses against the curable and/or hardenable material 42 so as to smooth it and also to cause the curable and/or hardenable material 42 to press against the number of diameters D 1 , D 2 , D 3 , and D 4 (as well as other diameters) and to penetrate cracks and crevices in the wall of the manhole 10 . This is superior to troweling, which cannot achieve the same penetration of the curable and/or hardenable material 42 . Troweling also requires the operator to enter the manhole 10 . With the present method of operation, it is not necessary for an operator to enter the manhole 10 .
The curable and/or hardenable material is then cured and hardened within the manhole 10 . The curable and/or hardenable material may be cured by the accepted method known for curing the material. For example, the curable and/or hardenable material may be cured by the use of introducing steam within the bladder 26 for a thermoset resin or the introduction of a UV light or the like for a photocuring resin. Once the curable and/or hardenable material 42 has cured and hardened, the bladder 26 may be entirely removed from the manhole 10 or the portion contacting the curable and/or hardenable material 42 may be left in place. In applications where the bladder 26 is removed, it is preferable to use a non-stick bladder material as disclosed in U.S. Patent Publication No. 2009/0194183, which is incorporated herein by reference in its entirety. In such an embodiment, no projections or protrusions should be disposed on the exterior surface of the bladder 26 to ensure the bladder 26 does not stick to the curable and/or hardenable material 42 . Using this particular repair or treatment method, the curable and/or hardenable material is smoothed and penetrates cracks and crevices in the wall of the manhole 10 . However, it is preferred to leave the bladder 26 within the manhole 10 to use it as an impermeable coating or barrier. Here, the bladder 26 is cut adjacent the upper end 24 and the post is unthreaded from its attachment to lower rack 30 . The installation assembly, including the upper and lower rack 22 , 30 and the post 32 , is removed from the manhole 10 to form the manhole lining.
This leaves the manhole 10 as shown in FIG. 3 . A handle 96 with a knife 98 is inserted and the knife 98 cuts the bottom of the bladder 26 into a circular cutout 99 . The excess bladder material is removed from the bottom of the manhole 10 , and the resulting manhole 26 is shown in FIG. 4 . The handle 96 may or may not be utilized, as it allows an operator to stand outside of the manhole while cutting and removing excess material. Alternatively, the operator can enter the manhole 10 to cut and remove excess material. Alternatively, a saw, grinding tool, sander, or other cutting tool may be used to remove or smooth excess or unneeded portions of the bladder and cured material. It should also be noted that the FIGS. 3-4 illustrate where the bottom of the bladder is cut out around the periphery of the floor of the manhole 10 . However, the lining of the entire manhole floor need not be removed. As such, the knife 98 or other cutting tool may simply be used to remove the lower rack 30 and to reinstate access to the run through 13 . Similarly, the knife 98 or other cutting tool may be used to remove excess bladder and other material extending above the casting frame 20 of the manhole 10 after installation of the manhole lining.
As an alternative to positioning the stretchable material or bladder 26 in the manhole and then expanding it radially outwardly toward the manhole wall, it may also be inverted into the manhole. This is illustrated in FIG. 10 wherein an inverter 72 is self-contained within an above ground inverter 74 , and a bladder 82 is within the above ground inverter 74 and is reversed with its outside presented inwardly and its inside presented outwardly.
A plug 76 is inserted within and attached to the above ground inverter 74 . The plug 76 contains a fluid introducer 78 and a pull rope 90 having a lower end 92 and an upper end 94 . The upper end 94 extends through a hole in the plug 76 . Fluid introducer 78 may be used to introduce steam or another heated fluid where thermoset resins are used. In such an application, the use of a heated fluid will permit or encourage curing and/or hardening of the thermoset resin. Alternatively, a separate inlet or port may be integrated into the plug 76 to accommodate the use of a heated fluid.
A rigid ring 80 is placed within the casting frame 20 and an upper end 84 of the bladder 82 is attached to the rigid ring 80 . A lower end 86 of the bladder 82 is attached to a pull device 88 . The lower end 92 of the pull rope 90 is attached to the pull device 88 for embodiments where the bladder 82 is removed from the manhole 10 . The pull rope 90 may also be utilized for embodiments where the bladder 82 is left within the manhole 10 . In such applications, the pull rope 90 may be marked at the upper end 94 prior to the inversion process so that a technician may be able to determine when the bladder 26 is fully inverted into the manhole.
The bladder 82 is reversed or inverted into the manhole 10 with its inside presented outwardly and its outside presented inwardly. The inversion can be caused by a fluid (either gas, air, or hydraulics) that is introduced by the fluid introduction device 78 . The bladder 82 expands into contact with the curable and/or hardenable material 42 . If a photocuring resin is used with a UV light or the like, then the bladder 82 should be made from a translucent or semi-transparent material (as known in the art). This allows a UV light to be lowered into the manhole for curing.
The bottom portion of the bladder 82 can be cut out (as previously described) and removed from the manhole 10 by pulling on the end 94 of rope 90 . The remaining portion of the bladder 82 is left within the manhole 10 . The same modifications as shown in FIGS. 5-8 can be applied to the bladder 82 and the curable and/or hardenable material 42 to create a chemical bond 61 or a mechanical bond or both. Again, the inflatable bladder 82 or other stretchable material acts as a coating on the curable and/or hardenable material 42 .
A second embodiment is illustrated in FIG. 12 . In this embodiment, a manhole liner 100 is used as an alternative to the sprayer 50 and the bladder 82 is left in the manhole 10 to create an impermeable barrier on the walls of the manhole 10 . The manhole liner 100 is generally a fabric capable of being impregnated with a curable and hardenable material. The manhole liner 100 may be a stretchable sleeve that can be used to repair and renew manholes having various sizes. In one embodiment, the manhole liner 100 is a one-size fabric liner which stretches circumferentially to various diameters up to 150% of the unstretched diameter for use in manholes of varying sizes and shapes. U.S. Pat. No. 7,670,086 and U.S. Pat. App. No. 2010/0018631 describe such liners and are incorporated by reference in their entireties.
Where the bladder 82 is to be left within the manhole 10 by the use of a chemical bond, the bladder 82 is preferably constructed of a polyurethane and the curable and hardenable material is preferably an epoxy. However, other combinations of bladder material and material capable of curing and hardening are considered for use as long as they are compatible and conducive for adhesion. Where the use of a mechanical bond is desired, the material of the bladder 82 should include the projections or pores as described above.
In operation of the second embodiment, the manhole liner 100 is impregnated with a material capable of curing and hardening. The manhole liner 100 is then placed into the manhole 10 by attaching an upper portion 70 of the manhole liner 100 to a flange member 68 above the manhole 10 , adjacent the casting frame 20 . The manhole liner 100 is then inserted into the manhole 10 and placed against the walls of the manhole 10 by a bladder 82 that is used to expand the manhole liner 100 against the walls of the manhole. In the embodiment depicted in FIG. 12 , the bladder 82 is inverted into the manhole 10 by attaching the bladder 82 to an above ground inverter 74 , inserting the plug 76 , and providing a fluid to the bladder 82 using fluid introducer 78 . The pull rope 90 may be used to measure the depth of the bladder 82 as described above. The material capable of curing and hardening is allowed to cure and harden, providing a lining to the manhole 10 where the manhole liner 100 , the cured and hardened material, and the bladder 82 become an integral part of the manhole 10 . In embodiments where a chemical bond between the bladder 82 and the curable and/or hardenable material is desired, steam or heat may be introduced into the manhole 10 during the curing process to promote integration of the bladder 82 to the material capable of curing and/or hardening. Once the material is fully cured and/or hardened, areas of the lining that are unnecessary are cut away and removed from the manhole 10 .
It should be noted that FIG. 12 shows where the bladder 82 is placed into the manhole 10 by the use of an inversion process for the bladder 82 after the manhole liner 100 is attached to the casting frame 20 of the manhole 10 by the use of a flange member 68 . However, an inversion process is not required to practice this embodiment of the invention. Alternatively, the installation assembly as described in reference to FIG. 2 may be used to press the manhole liner 100 against the manhole walls. It should also be noted that all methods of the present invention should not be limited to the order of the recited steps. For instance, the manhole liner 100 may be impregnated with the material capable of curing and hardening before being placed into the manhole 10 . Alternatively, the material capable of curing and hardening may be placed onto the manhole walls, and the manhole liner 100 may be impregnated by the material capable of curing and hardening after insertion into the manhole 10 .
An alternative embodiment is illustrated in FIG. 13 . Here, the bladder 26 is inflated and expanded against the wall of the manhole 10 prior to applying a curable and/or hardenable material 42 . The curable and/or hardenable material 42 is applied to the interior surface 63 of the bladder 26 while the bladder is maintained under pressure and conforms to the wall of the manhole 10 . The curable and/or hardenable material 42 is then allowed to cure and harden, and portions of the bladder 26 are cut out and removed as previously described. In the illustrated embodiment, the sprayer is adapted to be an integral part of the installation assembly and the spray ribs 52 are movable along the post 36 between the lower rack 30 and the upper rack 22 .
This alternative embodiment has several advantages. The bladder 26 , preferably made of TPU with a wall thickness of 20-100 mils prior to expansion, provides a clean dry surface on which the curable and/or hardenable material is applied. The bladder also provides an impermeable barrier against the wall of the manhole that prevents ground water from washing away the curable and/or hardenable material and entering the manhole.
The invention has been shown and described above with the several embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives. | The present invention comprises a method and kit for repairing the wall of a manhole wherein a material capable of curing and hardening is adhered to the wall. An expandable bladder engages the curable and hardenable material and presses against and smoothes the material. The bladder may be chemically bonded. |
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BACKGROUND OF THE INVENTION
The present invention relates generally to a toilet flushing device with water saving features, and, in particular, to a toilet flushing device with a dual flush mechanism which uses a single handle and a single flush valve to effect both a short flush and a long flush. In addition, the present invention relates generally to a toilet trapway reseal device which selectively directs water from the reseal water hose into the tank overflow tube.
Various dual flush toilet mechanisms have been developed over the years for the purpose of providing the option of a full or long flush cycle for solid waste, or a short or partial flush cycle for liquid waste to save water during flushes that do not require the use of a full flush cycle. Conservation of natural resources such as water is important. Toilets which use less water to flush waste are most desirable.
Prior art dual flush mechanisms characteristically fall into two general categories. The first type of device includes dual flush mechanisms that utilize two separate flush valves. The flush valve used for the full flush is located at a lower level in the tank than the flush valve used for the short flush cycle. An example of this type of dual flush mechanism construction is found in Brown U.S. Pat. No. 1,960,864. Brown describes a dual flush valve operating device for a flush toilet wherein two trip lever arms of different lengths have a common fulcrum and are independently pivoted as the handle is rotated clockwise or counterclockwise.
The second type of dual flush mechanism characteristically includes two separate handles, one to effectuate the long flush and the other to effectuate the short flush. Activation of either handle causes a single flush valve in the tank to be raised to different heights. For example, Harney U.S. Pat. No. 4,881,279 describes a two-handle system wherein turning of the first handle results in a regular, full flush, and turning of the second handle results in a partial raising of the flush valve to actuate a short or partial flush. Harney uses a complicated system to effect the short flush cycle.
Lester U.S. Pat. No. 2,001,390 uses a clutch device on the rod of the flush valve to hold the flush valve in a partial raised position during the short flush cycle.
Most users are accustomed to a toilet with a single handle, and most toilets use a single flush valve as part of the toilet tank construction. Accordingly, an improved dual flush device for a toilet tank having a single flush valve actuated by a single handle for effecting either a short flush cycle or a long flush cycle is desired. It would also be desirable to provide such a dual flush device that can be retrofitted to a conventional toilet tank.
Another source of wasted water in a toilet tank occurs through the reseal water hose. After a toilet is flushed, the tank must be refilled with fresh water. In addition, some water must be supplied to the bowl or the trapway during refilling of the tank to insure that the trapway is resealed. In conventional toilets, the reseal water hose extends from the tank inlet water control and directs water into the tank overflow tube (which leads to the bowl or trapway) the entire time that the tank is refilling. This causes a waste of water since once the trapway is resealed, excess water will flow into the drain.
Furthermore, a dual flush device in the toilet tank complicates the water flow operation since two different refill patterns are required. Because the refill cycle after the long flush duration is greater than the short flush duration in a dual flush application, the volume of reseal water dedicated to insuring that the trapway in the toilet bowl is resealed after the long flush is typically greater than the volume of water dedicated to resealing the trapway during the short cycle. This may result in an underfilled trapway seal for the short flush which can create a health hazard. Yet, on the other hand, during the long flush, there is an overfilled trapway seal which wastes water that could have been better utilized, for example, for flushing solid waste and refilling the tank.
Prior art water reseal constructions have identified this problem of wasted water from the reseal hose and have attempted, in a less than completely satisfactory way, to provide a solution. For example, Lazar U.S. Pat. No. 5,341,520 describes a dual capacity toilet flusher where the end of the reseal hose is supported on a movable platform construction which selectively moves the refill hose horizontally away from the overflow tube when the bowl is refilling. Comparetti U.S. Pat. No. 4,910,812 describes a complicated toilet system wherein the overflow tube pivots out of the path of the reseal hose water during part of the flush cycle.
However, heretofore, an acceptable, reliable and simple reseal water hose assembly has not been provided which can permit the reseal water hose to direct water into the tank during part of the flushing cycle and thereafter permit the reseal water hose to direct water into the overflow tube to reseal the trapway, while providing the same amount of water during the long and short flush cycles.
Accordingly, an improved reseal water hose assembly that reduces unnecessary water consumption and assists in the filling of the toilet tank in order to effectuate a more efficient refill cycle is desired. In addition, a trapway reseal assembly that delivers an appropriate volume of reseal water to the trapway regardless of the flush cycle, and which can utilize the excess water flowing from the reseal hose by redirecting this water directly into the tank, is desired.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the present invention, a dual flush device for a toilet tank having a flush valve actuated by a pivotable actuation arm for effecting both a short flush cycle and a long flush cycle, is provided. The dual flush device includes a cam rotatably supported on the toilet tank adjacent the actuation arm. The cam, when rotated in a first direction, acts to press against and pivot the actuation arm to effect the long flush. When the cam is rotated in a second direction, the cam presses against and pivots the actuation arm to effect the short flush. The dual flush device also includes a lever pivotably supported with respect to the actuation arm between a first position out of blocking contact with the actuation arm and a second position where the lever blocks the actuation arm for a predetermined period of time when the cam is rotated in the second direction to hold the actuation arm in a partially raised position. A float is coupled to the lever for determining the predetermined period of time. The float acts to pivot the lever into the second position when the cam is rotated in the second direction.
In a preferred embodiment, the dual flush device includes a single handle for selectively rotating the cam in the first direction and the second direction.
According to another aspect of the present invention, a trapway reseal assembly is provided. A doughnut-shaped float rides along the overflow tube in the toilet tank with the changing water level in the tank. The end of a reseal water hose is supported on the float and selectively directs water into the overflow tube or the tank depending on the height of the float.
Accordingly, it is an object of the present invention to provide an improved toilet flushing device with water saving capabilities.
Another object of the present invention is to provide an improved dual flush device for use in a toilet tank that requires only a single flush valve actuated by a single handle for effecting both a short flush cycle and a long flush cycle.
Yet another object of the present invention is to provide an improved toilet construction that reduces unnecessary water consumption.
Still another object of the present invention is to provide an improved trapway resealing assembly.
Another object of the present invention is to provide an improved trapway resealing assembly for use in toilets with both a long flush cycle and a short flush cycle.
Yet another object of the present invention is to provide an improved trapway resealing assembly that reduces unnecessary water consumption and assists in the filling of the toilet tank in order to effectuate a more efficient refill cycle.
Still another object of the present invention is to provide an improved trapway resealing assembly that delivers an equal quantity of reseal water to the trapway regardless of the flush cycle and utilizes the unnecessary water flowing from the reseal tube by redirecting this water directly into the tank.
A still further object of the present invention is to provide a toilet flushing device with water saving features that can be retrofitted into a conventional toilet tank.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the constructions hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a front elevational view of a toilet with a toilet tank shown partially cut away having a dual flush mechanism and reseal water hose assembly constructed in accordance with a preferred embodiment of the present invention;
FIG. 2 is a top plan view of the toilet and tank of FIG. 1, with the tank cover removed;
FIG. 3 is a rear perspective view of the dual flush mechanism constructed in accordance with a preferred embodiment of the present invention;
FIG. 4 is an exploded perspective view of the dual flush mechanism depicted in FIG. 3;
FIG. 5 is a rear elevational view of the dual flush mechanism in accordance with the present invention, shown prior to the commencement of a flush cycle;
FIG. 6 is a rear elevational view of the dual flush mechanism in accordance with the present invention after the handle has been rotated to commence the long flush cycle;
FIG. 7 is a cross-sectional view taken along lines 7--7 of FIG. 6;
FIG. 8 is a rear elevational view of the dual flush mechanism in accordance with the present invention after the handle has been rotated to commence the short flush cycle;
FIG. 9 is a partial top plan view of the dual flush mechanism of FIG. 8;
FIG. 10 is a top plan view of the reseal water hose assembly constructed in accordance with a preferred embodiment of the present invention; and
FIGS. 11 through 14 depict the reseal water hose operation during the long and short flush cycles in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference is first made to FIGS. 1 and 2 of the drawings which depict a toilet, generally indicated at 20, having a toilet bowl 21 and a toilet tank 22. Toilet tank 22 includes a removable tank cover 23. Toilet tank 22 also includes a dual flush mechanism, generally indicated at 30, and a trapway reseal assembly, generally indicated at 50, both constructed in accordance with the present invention.
A water inlet control assembly 70 is provided in the tank for controlling the refilling of toilet tank 22 with fresh water after flushing has occurred. Some fresh water is supplied to a water reseal hose 52 during refilling of the tank. Tank 22 includes an overflow tube 24 which leads to bowl 21 or directly to the toilet trapway below the toilet. Tank 22 also includes a flush valve, generally indicated at 60, which provides a conduit for water to flow from tank 22 to bowl 21 when the toilet is flushed. Flush valve 60 includes a valve seat 62 and a pivotable flush valve flapper 64 which opens and closes the valve.
Reference is now made additionally to FIGS. 3 and 4 to describe the construction of dual flush mechanism 30. Dual flush mechanism 30, as described below in detail, is activated by a handle 32 on the outside of tank 22 which can be rotated in a counterclockwise direction in the direction of arrow A to effectuate a long or full flush cycle and in a clockwise direction in the direction of arrow B to effectuate a short or partial flush cycle.
Dual flush mechanism 30 includes an L-shaped pivotable actuation lever or arm 34 having a first arm 35 and a second arm 36. In a preferred embodiment, first arm 35 is longer than second arm 36. Free end 35a of first arm 35 of actuation lever 34 is coupled to flapper 64 of flush valve 60 through a chain or other flexible linkage 66. Free end 35a of first arm 35 may include several openings 33 spaced therealong to permit fastening of chain 66 thereto at a desired position. A separate flush valve float 67 is attached along chain 66 to hold flapper 64 open during the long flush cycle as described below in detail.
Dual flush mechanism 30 also includes a short flush lever 80 in the form of a pivotable L-shaped bellcrank. A partial flush float 84 is removably coupled to short flush lever 80 through a float rod 86, preferably using a threaded thumb nut 87, although other fastening devices can be used.
As can be seen, dual flush mechanism 30 may be mounted to toilet tank 22, preferably on a front wall thereof. Moreover, the exact position of the mounting can vary within reason, keeping in mind the importance of access to handle 32 and that dual flush mechanism 30 must not be mounted so as to cause interference with pre-existing structure in the conventional tank. In an exemplary embodiment, and as shown in FIG. 3, an opening is formed in the front wall of toilet tank 22 thereby permitting dual flush mechanism 30 to be mounted thereon by positioning the tank wall between a backing plate 38 and a threaded nut or other escutcheon 40. Backing plate 38 includes an opening 38a through which a shaft 31 which rotates with handle 32 extends. However, it is also contemplated that backing plate 38 may be formed as part of the inside wall of the toilet tank itself.
Handle 32 is coupled to dual flush mechanism 30 through shaft 31. A cam 42 in the form of an asymmetrical shoe having a first toe 43 and a second toe 44 is secured to shaft 31 using a screw or the like so as to be rotatable therewith. Cam 42 may be configured in alternate shapes such as a kidney bean shape, so long as cam 42 can operate to contact and lift actuation lever 34 when rotated clockwise and counterclockwise. However, it is noted that other forms of single handle actuation, such as different amounts of rotation, can be used to effectuate the different flush cycles.
In an exemplary embodiment, actuation lever 34 is pivotably supported by a pin 38b extending from backing plate 38. This mounting construction permits actuation lever 34 to be rotatable in a plane essentially parallel to backing plate 38. Arms 35 and 36 of actuation lever 34 may be constructed so as to be rigidly fixed together, or actuation lever 34 may be a unitary member. In addition, arm 35 may also be of a unitary member or may include a joint 78 which permits first arm 35 to be moveable horizontally with respect to second arm 36 to allow for different configurations. A pin 79, screw or the like is mounted as part of joint 78 to secure the sections of actuation lever 34 together.
It is noted that the dual flush mechanism of the present invention works best when free end 35a of arm 35 is positioned at least substantially over flush valve flapper 64. As described in greater detail below, when actuation lever 34 is raised, flush valve flapper 64 is pulled off of flush valve seat 62. Therefore, if free end 35a of arm 35 is positioned above lush valve flapper 64, flushing can be effectuated in a most efficient manner. By providing joint 78, first arm 35 can be rotated about joint 78 to position the free end of arm 35 as desired to avoid interference with other components in the tank.
Short flush lever 80 is pivotably coupled to backing plate 38 through a joint 81 using a dowel, screw or pin 85 or the like. Short flush lever 80 is pivotally coupled to backing plate 38 in a direction transverse to actuation lever 34. Short flush lever 80 includes two legs 82 and 83. Leg 83 is coupled to float rod 86. A partial flush float 84 may be slidably coupled to float rod 86 to permit accommodation in a pre-existing conventional toilet tank and to control the length of the short flush cycle. By permitting partial flush float 84 to be manually repositioned along float rod 86, the dual flush mechanism can be configured to operate in conventional toilets.
In addition, and as particularly shown in FIGS. 4 and 9, float rod 86 can be mounted to leg 83 in various orientations. In this regard, leg 83 has a star-shaped opening 87 to permit an end 86a of float rod 86 to be inserted therein in various positions. End 86a of float rod 86 may include wings 86b and 86c which are accommodated by hole 87. Once positioned, a thumb nut 87a can be used to hold the float rod in place.
A wall stop 90 is provided to prevent the over-rotation of cam 75 as discussed below.
As shown in FIGS. 3 and 5, which depict a pre-flush configuration when the tank is full, leg 82 of short flush lever 80 rests against second arm 36 of actuation lever 34 as float 84 tends to be lifted by the water level in the tank.
Reference is now made to FIGS. 5-7 to describe the operation of the dual flushing mechanism in accordance with the present invention to provide a long or full flush.
Such long or full flush is initiated by rotating handle 32 counterclockwise from the front in the direction of arrow A. This rotation of handle 32 causes shaft 31 to also rotate which in turn causes cam 42 to rotate in the same direction. This rotation causes the long toe 43 of cam 42 to contact an upper portion of second arm 36 of actuation lever 34 thereby raising first arm 35 which in turn pulls on chain 66 to raise flapper 64. Float 67 is accordingly pulled up to the lowering surface of the water W (FIG. 6). The angle through which actuation lever 34 can be rotated and the maximum height reached by arm 35 is limited by wall stop 90. Wall stop 90, shown in an arcuate shape by way of example only and not in a limiting sense, may be mounted to backing plate 38 or be formed integral therewith.
When handle 32 is rotated in the counterclockwise direction of arrow A (when viewed in FIG. 1), short toe 44 of cam 42 contacts the lower edge of wall stop 90 thereby preventing cam 42 and hence handle 32 from rotating any further. In this long or full flush condition, flush valve flapper 64 is shifted to its fully open or buoyant position thereby allowing the water in the tank to empty into the bowl to flush the bowl. As the water level in the tank drops, float 67 also lowers (but remains on the water surface). Actuation lever 34 also lowers to its original position. When the water level drops to a predetermined level, flush valve flapper 64 closes and reseals flush valve seat 62 in the conventional manner, thus terminating the full flush cycle. The tank then begins to refill.
As depicted in FIG. 3, in the pre-flush condition when the tank is full, leg 82 presses against the side of arm 36 of actuation lever 34 due to the buoyancy of flush float 84. As depicted in FIG. 7, when the long flush cycle begins, short flush lever 80 initially rotates towards handle 32 in the direction of arrow C and would appear to prevent actuation lever 34 from returning to its original position after the tank empties. However, it is to be understood that after the long flush cycle begins, the water level in the tank begins to fall as water in the tank is delivered through the flush valve to the bowl. The lowering of the water causes partial flush float 84 to also fall, thereby rotating short flush lever 80 away from handle 32 out of the path of arm 36 of actuation lever 34 before flush valve flapper 64 covers and seals flush valve seat 62. Therefore, it can be seen that the presence of the short flush lever 80 does not affect the long or full flush cycle.
Reference is now made to FIGS. 8-9 which illustrate the operation of the dual flushing mechanism of the present invention during the short flush cycle. A partial or short flush is initiated by rotating handle 32 in the clockwise direction of arrow B (as viewed in FIG. 1). The rotation of handle 32 rotates shaft 31 which causes short toe 44 of cam 42 to contact a lower portion of second arm 36 of actuation lever 34 thereby raising first arm 35 of actuation lever 34 to a second predetermined height, which is less than the predetermined height in the long flush.
The amount of rotation and height is also limited by wall stop 90. In the clockwise direction, toe 43 contacts the top of wall stop 90 to prevent the over-rotation of actuation lever 34. Accordingly, flush valve flapper 64 is not raised off of flush valve seat 62 as high as it is raised during the long full flush cycle operation. Moreover, since float 67 is not raised sufficiently to rise to the water surface, flush valve flapper 64 is held open only due to the tension of chain 66, rather than by the float buoyancy as in the full flush.
As soon as actuation lever 34 is raised, the buoyancy of partial flush float 84 causes leg 82 of short flush lever 80 to rotate towards handle 32 and press against the face of cam 42 as depicted in FIG. 9. When handle 32 is released, leg 82 of short flush lever 80 will contact the inner surface 36a of second arm 36 of actuation lever 34 so as to block further downward movement and maintain first arm 35 of actuation lever 34 in an elevated position allowing flush valve flapper 64 to be held in a partially open position permitting water to flow from the tank to the bowl.
However, after the commencement of the short flush cycle, the water level begins to fall. As the water level falls, partial flush float 84 lowers with the corresponding water level in the tank. At a predetermined water level, the partial flush float 84 will have fallen a sufficient distance to cause short flush lever 80 to rotate back, thus disengaging leg 82 from arm 36 of actuation lever 34, thereby permitting actuation lever 34 to rotate and lower which in turn permits flush valve flapper 64 to close and reseal, thereby terminating the partial or short flush cycle.
As water refills in the tank in the conventional manner, flush float 84 rises in the tank and leg 82 of short flush lever 80 rotates about its pivotal axis to reset itself for the next flush action.
By providing a dual flush mechanism which allows the user to select either a full or partial flush by selected rotation of a single handle to selectively activate a single flush valve, an improved dual flush mechanism that conserves water is provided. A full flush is obtained by the rotation of a single handle in the counterclockwise direction. This rotation causes the cam or shoe to contact an actuation arm, thereby lifting the flush valve from its seat. Upward movement of the actuation arm is limited by a stop.
For a partial flush, the handle is rotated in the clockwise direction. This rotation causes the cam to contact the actuation lever, but raises the actuation lever a lesser amount. Similarly, upward movement of the actuation arm is limited by the stop. Release of the handle allows the short flush lever to temporarily hold the actuation in a partial raised condition, thereby keeping the flush valve in an unseated position allowing water to flow from the tank to the bowl. As the water level in the tank drops, the partial flush float also drops disengaging the short flush lever from the actuation lever. This permits the actuation arm to return to its pre-flush position and reseat the flapper onto the flush valve seat. With the refilling of the tank, the partial flush float rises, rotating the short flush lever to contact the actuation lever in preparation for the next flush cycle.
Reference is now made particularly to FIGS. 10 through 14, which depicts trapway reseal assembly 50. Assembly 50 includes a reseal water hose 52 having a free end 52a which is coupled to a reseal float 54. In the preferred embodiment, reseal hose 52 is coupled to reseal float 54 by means of a clip 53 or the like. Reseal float 54 is preferably in the shape of a doughnut and slidably supported to ride along overflow tube 24. Overflow tube 24 may also include a retaining pin 55 (FIG. 10) which prevents reseal float 54 from disengaging from overflow tube 24. In addition, overflow tube 24 may include a splash guard 56 (FIG. 10) to assist in directing water flow from hose 52.
Reference is now made specifically to FIGS. 11 through 14 which illustrate the operation of trapway reseal assembly 50 in accordance with the present invention. In a pre-flush configuration when the tank is full, float 54 is in its uppermost position as shown in FIG. 11. At this position, free end 52a is positioned to direct water in overflow tube 24. However, no water is flowing in the pre-flush condition since the inlet valve of the water control is closed.
After a long or short flush cycle is commenced, as water in the tank empties into the toilet bowl, the reseal float begins to lower with the tank water level. Distance X shown in FIG. 11 shows the distance that the reseal float 54 drops during a short flush cycle, while distance Y show the drop distance for a long flush. Once float 54 drops to the level shown in FIG. 12, reseal hose 52 is below the rim of overflow tube 24 and water from the reseal hose will be directed into the tank.
As the tank refills after the flapper has closed, the reseal float will begin to rise. Water from hose 52 will continue to be directed into the tank until the float hits the level of FIG. 13 where water begins to be directed into the overflow tube. It is specifically noted that the point at which reseal water is first redirected into the overflow tube is the same after either flush cycle, thus ensuring the same quantity of reseal water dedicated to sealing the trapway. As the water continues to rise, reseal hose 52 is again directly over overflow tube 24 so as to cause water to flow directly into overflow tube 24 as shown in FIG. 14. Water will be directed into the overflow tube until the tank is full.
The trapway reseal assembly of the present invention provides for excess water from the reseal hose to be used for refilling the tank. In addition, essentially the same amount of water will be delivered through the overflow tube to the trapway regardless of the length of the flush.
By providing a trapway reseal assembly where the reseal hose is mounted on a float which rides along the overflow tube, an improved dual flushing toilet system that channels an equal volume of reseal water dedicated to sealing the trapway of the toilet is provided. Regardless of the flush cycle, by providing a trapway reseal assembly where water is directed by the position of a reseal float, which itself is positioned by the water level within the tank, an improved reseal assembly is provided.
It will thus be seen that the objects set forth above, and those made apparent from the preceding description are efficiently obtained and, since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | A toilet flushing mechanism includes a dual flush device for effecting both a short flush cycle and a long flush cycle in a toilet tank including a flush valve actuated by an actuation arm. A cam operable by a handle is rotatably supported adjacent the actuation arm. When rotated in a first direction, the cam acts to press against and pivot the actuation arm to effect the long flush. When rotated in the second direction, the cam acts to press against and pivot said actuation arm to effect the short flush. A lever is pivotably supported with respect to the actuation arm and pivots between a first position out of blocking contact with the actuation arm and a second position where the lever blocks return of the actuation arm for a predetermined period of time when the cam is rotated in the second direction. A float is coupled to the lever for determining the predetermined period of time. The float acts to pivot the lever into the second position when the cam is rotated in the second direction. |
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BACKGROUND OF THE DISCLOSURE
[0001] 1. Field of the Disclosure
[0002] The subject disclosure relates generally to oilfield drilling, and more particularly to bottom hole assemblies and tools for orienting a bottom hole assembly (BHA).
[0003] 2. Background of the Related Art
[0004] In conventional drilling, the BHA is lowered into the wellbore using jointed drill pipes or coiled tubing. Often the BHA includes a mud motor, directional drilling and measuring equipment, measurements-while-drilling tools, logging-while-drilling tools and other specialized devices. A simple BHA having a drill bit, various crossovers, and drill collars is relatively inexpensive, costing a few hundred thousand US dollars, while a complex BHA costs ten times or more than that amount.
[0005] Many drilling operations require directional control so as to position the well along a particular trajectory into a formation. Directional control, also referred to as “directional drilling,” is accomplished using special BHA configurations, instruments to measure the path of the wellbore in three-dimensional space, data links to communicate measurements taken downhole to the surface, mud motors, and special BHA components and drill bits. The directional driller can use drilling parameters such as weight-on-bit and rotary speed to deflect the bit away from the axis of the existing wellbore. In some cases, e.g. when drilling into steeply dipping formations or when experiencing an unpredictable deviation in conventional drilling operations, directional-drilling techniques may be employed to ensure that the hole is drilled vertically.
[0006] Direction control is most commonly accomplished through the use of a bend near the bit in a downhole steerable mud motor. The bend points the bit in a direction different from the axis of the wellbore when the entire drill string is not rotating. By pumping mud through the mud motor, the bit rotates though the drill string itself does not, allowing the bit alone to drill in the direction to which it points. When a particular wellbore direction is achieved, the new direction may be maintained by then rotating the entire drill string, including the bent section, so that the drill bit does not drill in a direction away from the intended wellbore axis, but instead sweeps around, bringing its direction in line with the existing wellbore. As it is well known by those skilled in the art, a drill bit has a tendency to stray from its intended drilling direction, a phenomenon known as “drill bit walk”. A device for addressing drill bit walk is shown in U.S. Pat. No. 7,610,970 to Sihler et al. issued Nov. 3, 2009, which is incorporated herein by reference.
[0007] The use of coiled tubing with downhole mud motors to turn the drill bit to deepen a wellbore is another form of drilling, one which proceeds quickly compared to using a jointed pipe drilling rig. By using coiled tubing, the connection time required with rotary drilling is eliminated. Coiled tube drilling is economical in several applications, such as drilling narrow wells, working in areas where a small rig footprint is essential, or when reentering wells for work-over operations.
[0008] In coiled tubing drilling, a BHA with a mud motor is attached to the end of a coiled tubing string. Typically, the mud motor has a fixed or adjustable bend housing in order to drill deviated holes. Because the coiled tubing is unable to rotate from surface, a so called orienter tool is used as part of the BHA to “orient” the bend of the mud motor into the desired direction. There exists a multitude of different designs for the drive systems of such tools. Some designs support continuous rotation such as electric motor and gearbox drives, while others only permit rotation by a certain limited angle. The orienter tool is typically a high-torque, low-speed device, wherein the design of the drive system provides a torque output which can at least match the reactive torque exerted by the drilling mud motor.
[0009] For example, some orienter tools have utilized planetary gears in an effort to drive the output shaft. Basically, creating a torque on an output shaft means that a tangential force has to be exerted. By way of example, an output torque of 1,000 ft-lbs from a 2-inch diameter shaft means a tangential force of 12,000 lbs. This amount of force will quickly yield any material unless the tangential force is evenly distributed over a sufficient area to reduce the stress levels. In a conventional planetary stage with a size constraint on the order of 3 inches in diameter, the limits of how much bending force the gear teeth can take, and how much stress the planet carrier is capable of supporting will be much below 1000 ft-lbs of torque.
SUMMARY OF THE INVENTION
[0010] A system and methodology are designed to facilitate control over the orientation of a bottom hole assembly. A planetary gear box assembly incorporates a sun wheel which cooperates with planet wheels at a plurality of levels along the planetary gear box assembly. The sun wheel and the planet wheels cooperate to convert rotational input to rotational output through an output carrier. Torsional rigidity characteristics of the sun wheel and the output carrier are selected to distribute torque load across the plurality of levels of the planetary gear box assembly. The distributed forces reduce the potential for component failure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings.
[0012] FIG. 1 is a cross-sectional view of a multi-level planetary gear box assembly for an orienter tool of a bottom hole assembly in accordance with the subject technology.
[0013] FIG. 2 is a schematic cross-sectional view of the multi-level planetary gear box assembly of FIG. 1 taken along lines A-A, B-B and C-C.
[0014] FIG. 3 is a qualitative plot of a twisting angle of the components of the planetary gear box assembly of FIG. 1 .
[0015] FIG. 4 is a schematic illustration of a drilling system having a bottom hole assembly utilizing the planetary gear box assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] The present disclosure overcomes many of the prior art problems associated with providing torque in bottom hole assemblies. The advantages, and other features of the planetary gear box assembly disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements.
[0017] All relative descriptions herein such as left, right, up, and down are with reference to the Figures, and not meant in a limiting sense. Unless otherwise specified, the illustrated embodiments can be understood as providing exemplary features of varying detail of certain embodiments, and therefore, unless otherwise specified, features, components, modules, elements, and/or aspects of the illustrations can be otherwise combined, interconnected, sequenced, separated, interchanged, positioned, and/or rearranged without materially departing from the disclosed systems or methods. Additionally, the shapes and sizes of components are also exemplary and unless otherwise specified, can be altered without materially affecting or limiting the disclosed technology.
[0018] The subject technology generally is directed to a high torque planetary gear system for a bottom hole assembly. The planetary gear system includes a geometry where the torque load, resulting in a tangential force, is better distributed inside the structure and hence the stress levels are reduced throughout the planetary stage compared to conventional systems. In one embodiment, the planetary gear system stacks several planes of planetary gears in several levels. By matching the torsional rigidity of a sun gear with that of a carrier body, taking into account the transmission ratio, even engagement of all planetary wheels can be ensured by a principle of elastic averaging, which allows the design of a very high output torque planetary gear stage. It is envisioned that a gear box design for a downhole orienter tool in accordance with the subject technology has extremely high output torque. According to one embodiment, the gear output torque at least matches the stall torque of the mud motor which is driven/oriented by the orienter.
[0019] The present technology also is directed to a high torque planetary gear box assembly for a bottom hole assembly (BHA) used in drilling. The gear box assembly comprises a housing having at least one stage with a plurality of levels, a sun wheel for connecting to an input shaft and having a gear portion within each level, at least one planet wheel coupled to the respective gear portion in each level, and a common carrier connected to the at least one planet wheel in each level. During operation, an external torque is transmitted by the sun wheel through the plurality of levels whereby tangential forces are transmitted from the gear portions to the respective at least one planet wheel, and, in turn, from the at least one planet wheel to the common carrier. The sun wheel is designed to match torsional rigidity characteristics of the common carrier to balance the tangential forces on each level.
[0020] By way of example, the plurality of levels may be three levels and the at least one planet wheel may be two planet wheels in each level, although other numbers of levels and planet wheels may be employed. Torsionally flexible elements may be incorporated into the sun wheel, and the gear box assembly may include a housing gear for engaging the gear portions. According to one embodiment, the common carrier twists by an angle α as a result of torque applied thereto and the gear box assembly has a transmission ratio i such that a twisting angle β of the sun wheel is characterized by β=i*α, and a torsional rigidity of the sun wheel is about i 2 times less than a torsional rigidity of the common carrier to accomplish even engagement in all levels of the gear box assembly.
[0021] The subject technology also may include a method for using a high torque planetary gear box in a bottom hole assembly (BHA). The method comprises providing a housing having at least one stage with a plurality of levels; and applying torque to a sun wheel, the sun wheel having a gear portion within each level that, in turn, applies torque to at least one planet wheel coupled to the respective gear portion in each level. The method also may comprise coupling a common carrier to the at least one planet wheel in each level whereby torque is transmitted from the planet wheels thereto; and matching torsional rigidity characteristics of the sun wheel to the common carrier such that tangential forces on each level are balanced.
[0022] It should be appreciated that the present technology can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, a method for applications now known and later developed. These and other unique features of the system disclosed herein will become more readily apparent from the following description and the accompanying drawings.
[0023] In brief overview, the subject technology includes a gear box design for a downhole orienter tool having an extremely high output torque. In some embodiments, the gear output torque at least matches the stall torque of the mud motor which is driven/oriented by the orienter. For example, the output torque for a 3-inch size orienter tool can be on the order of 1,000 ft-lbs and above. Conventional planetary gear boxes are normally not capable of such a high torque in the desirable small sizes. Limiting factors include the strength of the gear teeth as well as the planet carrier. For multi-stage designs, the last planetary stage at the high-torque side typically endures the highest loads and will normally break first.
[0024] To evenly distribute the stress over a sufficient area, one embodiment of the subject technology uses a principle of elastic averaging to spread the torque imposed onto the output shaft over several levels of planet wheels. Preferably, fewer planets per level are used rather than the maximum number that could normally be fitted before the planets start overlapping. By using relatively fewer wheels per level, the number of windows cut into the carrier is reduced, and the carrier will be much stronger against twisting deformation.
[0025] Referring generally to FIG. 1 , a multi-level stage 102 of a planetary gear box assembly 100 in accordance with the present technology is shown. The planetary gear box assembly 100 may include a plurality of stages or simply be a single stage as shown within a housing 104 . The multi-level stage 102 has an input shaft 106 . The input shaft 106 may be part of a motor or even the output of a previous stage. A sun wheel 108 is connected to or an extension of the input shaft 106 and has a gear portion 110 a - c within each level 112 a - c , respectively. One or more torsionally flexible elements 114 may be incorporated in the sun wheel 108 intermediate each sun gear portion 110 a - c.
[0026] In the example illustrated, the multi-level stage 102 includes two planet wheels 116 a - c in each of the three levels 112 a - c , respectively. There could be more or less planet wheels per level, perhaps even up to as many planet wheels as can be fitted in each gear box level without overlapping, depending on the design. Further, there could be more or less levels. Each planet wheel 116 a - c connects to and is supported by a respective planet axle 118 a - c . The planet wheels 116 a - c of all levels 112 a - c are all connected to a common carrier 120 . The common carrier 120 may be an output carrier, such as an output shaft or an input shaft connected to another stage (not shown). The planet wheels 116 a - c also engage a housing gear 122 mounted within the housing 104 . As would be known to those of ordinary skill in the art, each of the sun gear portions 110 a - c , planet wheels 116 a - c , housing gear 122 , and common carrier 120 include force transfer members, e.g. teeth (not explicitly shown) that engage and interact to transmit forces therebetween.
[0027] During operation, an external torque being transmitted by the input shaft 106 through the multi-level stage 102 results in a series of tangential forces occurring between the surfaces of the gear teeth that are interacting with each other. Tangential forces are transmitted from the sun gear portions 110 a - c to the planet wheels 116 a - c , and, in turn, from the planet wheels 116 a - c to the common carrier 120 . Tangential forces are also being transmitted to the housing gear 122 .
[0028] Because the pairs of planet wheels 116 a - c are divided into several levels 112 a - c rather than all being in one level, the total torque exerted onto the common carrier 120 (e.g., output shaft) is the result of all the tangential forces acting in the different levels. The resulting tangential forces will cause the common carrier 120 to twist by a certain amount.
[0029] Referring generally to FIG. 2 , a somewhat schematic cross-sectional view of the multi-level planetary gear box assembly 100 of FIG. 1 taken along lines A-A, B-B and C-C is shown to representatively indicate operational effects in each level 112 a - c . In each level, the common carrier 120 will twist by a certain angle α as a result of the torque applied. Due to the inherent gear ratio of the planetary gear box assembly 100 , the angle α of the common carrier 120 will require a twisting angle β=i*α of the sun wheel 108 in order to satisfy geometric compatibility, where i is the transmission ratio of the planetary stage 102 . On the other hand, the torque seen by the sun wheel 108 is reduced by a factor of the transmission ratio i as compared to the torque seen by the common carrier 120 . The torque applied to the sun wheel 108 is represented by the arrow “T sun ” and is equal to T Carrier /i. These calculations assume that the housing gear 122 is substantially infinitely stiff with no appreciable twisting. In practice, the housing gear 122 may twist and such twisting should be taken into account, but to simplify for illustrative purposes, this assumption may be utilized.
[0030] Referring again to FIG. 1 , the twisting angle of the common carrier 120 with respect to itself in cross section along line A-A will be larger than in cross section along line C-C because if the sun wheel 108 was infinitely stiff in torsion, most of the output torque would be taken by the components of level 112 c only. As a result, the components of level 112 c would wear out quickly. However, in the present approach the sun wheel 108 is designed to match or otherwise address the torsional rigidity characteristics of the common carrier 120 so the principle of elastic averaging will ensure that the tangential forces on all planet levels 112 a - c are distributed, e.g. balanced. When the load distribution is balanced, the loading is taken by all planet levels 112 a - c approximately evenly. If the sun wheel 108 is inherently too stiff to support the desired flexibility, torsionally flexible elements 114 can be used to increase the flexibility.
[0031] Referring again to FIG. 2 , it is possible to quantify the required balance of torsional rigidities to ensure elastic averaging. Preferably, the sun wheel 108 twists by an angle i times larger with a torque which is i times less than that of the common carrier 120 . Hence, the torsional rigidity of the sun wheel 108 should be about i 2 times less than that of the common carrier 120 to ensure even engagement in all levels 112 a - c of the gear box assembly 100 .
[0032] Referring generally to FIG. 3 , a qualitative plot 124 of a twisting angle of the components of the planetary gear box assembly 100 is shown. The plot 124 shows the torsional displacement situation inside the gear box assembly 100 . For illustrative purposes, it is assumed that the planet carrier or common carrier 120 is fixed to ground and a torque is applied to the input shaft 106 to create the internal twisting deformations. The twist angle is then measured with respect to ground. In each section, the twisting angle of the sun wheel 108 is approximately i times that of the common carrier 120 for geometric compatibility.
[0033] It should be noted that the lines in FIG. 3 are purely qualitative. In reality, the twisting angle as a function of position of the common carrier 120 and sun wheel 108 may be more complex, and in addition, such factors as the twisting of the housing 104 can be taken into account. However, the plot 124 well illustrates that by matching the torsional rigidities of the components involved, taking into account the gear ratio, elastic averaging is accomplished which enables the design of a planetary gear stage capable of much greater torque than conventional 1-level-per-stage designs.
[0034] Referring generally to FIG. 4 , an example of a well system 126 is illustrated as deployed in a well 128 defined by at least one wellbore 130 having at least one deviated wellbore section 132 being formed. Although the planetary gear box assembly 100 may be utilized in a variety of downhole systems to provide improved control over the orienting of a variety of components, the drilling example is illustrated in FIG. 4 . In this example, the well system 126 comprises a drilling system having a bottom hole assembly 134 delivered downhole by a suitable conveyance 136 , such as coiled tubing.
[0035] In the embodiment illustrated, bottom hole assembly 134 comprises an orienting tool 138 containing the planetary gear box assembly 100 . The orienting tool 138 and its planetary gear box assembly 100 may be used to ultimately control the drilling orientation of a drill bit 140 . In some drilling operations, the drill bit 140 is powered by a motor 142 , such as a mud motor. Depending on the application, the motor 142 may work in cooperation with a bent housing 144 and the orienting tool 138 to control the desired direction of drilling. As known to those of ordinary skill in the art, bottom hole assembly 134 may comprise a variety of other components, including steering components, valve components, sensor components, measurement components, drill collars, crossovers, and/or other components. The actual selection of components depends on, for example, the specifics of the drilling application and/or the characteristics of the environment.
[0036] As would be appreciated by those of ordinary skill in the pertinent art, the subject technology is applicable to use in a variety of applications with significant advantages for bottom hole assembly applications. The functions of several elements may, in alternative embodiments, be carried out by fewer elements, or a single element. Similarly, in some embodiments, any functional element may perform fewer, or different, operations than those described with respect to the illustrated embodiment. Also, functional elements shown as distinct for purposes of illustration may be incorporated within other functional elements, separated in different hardware or distributed in various ways in a particular implementation. Further, relative size and location are merely somewhat schematic and it is understood that not only the same but many other embodiments could have varying depictions.
[0037] Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Such modifications are intended to be included within the scope of this invention as defined in the claims. | A technique facilitates control over the orientation of a bottom hole assembly. A planetary gearbox assembly incorporates a sun wheel which cooperates with planet wheels at a plurality of levels along the planetary gear box assembly. The sun wheel and the planet wheels cooperate to convert rotational input to rotational output through an output carrier. Torsional rigidity characteristics of the sun wheel and the output carrier are selected to distribute torque loading across the plurality of levels of the planetary gear box assembly. The distributed forces reduce the potential for component failure. |
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TECHNICAL FIELD OF THE INVENTION
This invention relates generally to crematory urns for pets and particularly to customized crematory urns for pets.
BACKGROUND OF THE INVENTION
Cremation is a means of disposing of the remains of the deceased. From time immemorial, various vessels such as vases, jars and urns have been used as a repository for the cremated remains of humans. Many of these retainers pay tribute to a deceased individual through various means. Some urns are made with ornate decorations and fitted with jewelry, while others are formed in the likeness of cherished objects.
Although the prior art teaches many improvements to cremation urns for human remains, there are scant few disclosures of cremation urns for pets. For example, the art of human cremation urns, as previously disclosed, includes, U.S. Pat. No. 2,562,726, teaching an urn for ashes with a screw in stopper; U.S. Pat. Nos. 2,385,520, 2,235,617, and 2,075,859 teaching cremation urns with a screw-in stoppers; U.S. Pat. No. 4,324,026 teaching an urn with compartment for memorabilia of the deceased; and U.S. Pat. Des. No. 232,782 teaching an urn formed as a statue or bust. All of the above referenced art is with respect to vessels for human remains and not animals and specifically pets.
As this indicates, pet owners have had very few choices in electing to preserve the ashes of a beloved pet. Given the means, however, pet owners would choose to preserve their pet's cremated remains in an urn that evokes the likeness and the particular physical attributes and memories of a cherished pet. An urn bearing a close or nearly exact likeness of a family or personal pet would be a preferred means to keep alive the memories of one's pet. Presently, there are very few devices designed for storing and preserving the ashes of a beloved pet. In this regard, there are even fewer choices for pet urns that also memorialize the pet in a three-dimensional representation of the pet's likeness. The present invention provides a final resting place for the remains of a cherished pet in an urn customized in the form of the pet's likeness and that provides an improved means for accessing the repository chamber in which the ashes are stored.
History teaches that human beings have a tendency to form strong emotional attachments to specially chosen pets. Only recently, however, have pet owners had the freedom of resources to treat their pets to many of perquisites usually reserved for humans. Pet owners now provide for their pets in lavish and sometimes exorbitant ways, including custom-built air-conditioned doghouses, treatments by animal psychologists, luxurious grooming, hairstyling and polishing of nails, etc. Accordingly, the industry catering to specialty pet products and services has seen tremendous growth in recent years.
This trend of treating one's pet in every respect as family member has produced a need for providing pet owners with a means for memorializing the life of a cherished pet after its death. The emotional bond between owner and pet creates the need for bereavement services and funerary products for pets. This is evidenced by the increasingly popular practice of selling burial plots for pets and conducting formal internment ceremonies for the pets. The sale of pet burial plots in pet cemeteries has become a formidable business enterprise, catering to all the needs of bereaved pet owners. These practices may involve, for example, memorial services, caskets and the like in an attempt to replicate human burial ceremonies. Crematoriums have also started to cater specifically to bereaved pet owners, sometimes arranging for a fitting ceremony during which a pet's ashes may be dispersed.
Sometimes the ashes are retained in a crematory urn, typically displayed in a special place in the home of the pet owner. However, many such urns are expensive and yet do not fittingly memorialize the life of the pet. Many pet owners would find it desirable, given the means, to keep their pet's ashes in an urn that allows them to evocatively reflect upon and recollect the life of their pet. Toward that goal, the present invention provides a final resting place for the cremated remains of the pet formed in a replica of the animal whose remains are contained therein.
Among the prior art, one pet urn comprises a cremation receptacle with a decorative housing bearing a stylized likeness of a pet such as a dog or cat as disclosed in U.S. Pat. No. 6,023,822. Although this urn generally discloses a storage receptacle in the stylized likeness of the deceased pet, many of its features as a storage receptacle warrant improvement. For instance, the prior art shows a chamber for holding the ashes with an opening located, preferably on the bottom of the urn where it is difficult to access, particularly where the urn is made of a heavy material. In this case, it is necessary to turn the urn over on its side or its head in order to access the chamber opening, with the unfortunate consequence of increasing the risk of dropping and breaking the urn, particularly a heavy ceramic urn. Even more particularly, the prior art discloses a complicated threaded receptacle system wherein one chamber is threaded into a receptacle, which in turn, is then sealed by a threaded screw cap or screw plug. The above-described system, with its restricted access to the storage chamber and its difficult-to-operate sealing system provides an impediment to the use and enjoyment, as well as to the functionality of the pet urn. In so far as it is likely that many of the bereaved pet urn users are elderly and/or frail, the need for an easy to use pet urn becomes all the more important.
Moreover, the pet urns of the prior art comprise molded, sculpted, cast, or extruded material forming the decorative shell of the urn. These stylized urns of the prior art bear only a distant resemblance to the deceased pets because they lack realistic general features such as fur, whiskers as well as the individual markings that characterize the true likeness of the deceased pet. The prior art decorative housings may perform a decorative function, but they fall well short of a true likeness of the deceased pet.
It would be preferable to pet owners to have an urn that is a very close likeness of their deceased pet as opposed to a generic version of a pet breed. It would also be preferable to have a pet urn that provides ease of use and ease of access to the repository chamber. It is also preferable to develop a pet urn with the above characteristics that also has a supporting base for the urn, providing stability and an even more easily accessible chamber for the storage of ashes without the need for a separate sealable container.
SUMMARY OF THE INVENTION
This invention provides an improved devise comprising a decorative urn for the convenient reception and storage of ashes of deceased pets such that the ashes may be easily, securely and conveniently stored and displayed in the customized likeness of the deceased pet. The pet crematory urn of the present invention comprises a customized figurine or statue designed and crafted in the likeness of the deceased pet and, further, provides easy access to a repository chamber for the preservation and storage of the ashes of the pet. The present invention also provides a figurine or statue customizable to substantially the exact likeness of the deceased pet, including, at the customer's optional request, fur, whiskers, and color markings that match those of the deceased pet. Finally, the present invention also provides a process for the automation of the customization of the figurine of the present invention.
The urn of the instant invention is provided with an easily accessed repository chamber for the storage of the cremation ashes to be contained therein. The repository chamber of the present invention is the inside of the decorative likeness of the deceased pet without the need for any additional securing or holding means such as the tube described in U.S. Patent No. 6,023,822. The repository chamber, optionally, may also be contained within the decorative base/pedestal upon which the pet's statue rests, again without the need for any additional securing or holding means that encumber and complicate access to the chamber.
The chamber is conveniently accessed through a removable access means or opening formed in the pet statue, such as the head, neck, body, tail, leg or paw, for example. An inconspicuous hinged door flush with the body of the figurine may also be used to conceal access means located in the body of the pet statue. Where the cremated remains are to be deposited in the base upon which the statue rests, the access means may comprise a hinged compartment behind which is located a slidable compartment or drawer comprising the repository chamber. In any case, the opening may be securely sealed and, when closed, remains inconspicuous within the display.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 are profile views of various embodiments of the pet urn showing access means and cutaway views of the sealable repository chamber.
FIGS. 5-8 show the pet urn and supporting base member with views of sealable repository chambers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
In one preferred embodiment the present invention comprises a pet urn ma nufactured in the general likeness of a particular animal species and breed in various states of repose which is subsequently further customized upon request by the customer to the specific likeness of the animal whose ashes are to be contained therein. In one practical example of this embodiment, the urn may be manufactured in the likeness of the Labrador breed of dog, whereupon the urn maybe further customized, to bear the exact likeness of the deceased pet. The more particularized customization can be accomplished by matching the markings and coloration of the urn to the deceased pet, using photographs of the deceased or other written or verbal descriptions of the features.
Recent advances in technology allow production processes to be both highly automatic and at the same time customized. For instance, computer graphical representations of the urn to be produced can be created based on photographs, verbal descriptions, or scanned images digitally superimposed on an image of an urn in the general likeness of the pet's species and breed. Those images then can be previewed by the customer and further modified to depict features that the customer requests. Finally, the graphical representation is downloaded to the production facility that produces an individualized customized urn in that exact likeness. This entire process may take place over the Internet; through email, phone calls and U.S. mail; or by in-person consultation with the customer. Moreover, pre-need urns may be produced based on the physical representation of the live pet. Alternatively, veterinarian services may conveniently provide the equipment necessary for 3D graphical imaging used in production of the present invention. One such system, the Image Data Matrix system,is described by Mechatronics PTY LTC 51 Westchester Rd. Malaga (Perth) Western Australia, P.O. Box 2294, Malaga WA 6994.
As shown in FIG. 1, the cremated remains in this embodiment are contained within the figurine representing the deceased pet 1 . In this regard, the figurine serves both as the chamber 3 for the reception of the cremated remains and as a decorative housings 1 a . In this embodiment, the opening 2 for the repository chamber 3 is formed approximately at the base of the neck of the statute. Access to the chamber is gained by removing the head portion 4 of the pet statue as shown in FIG. 2 . The head portion is securely fitted by known means 5 , such as threaded female and male adaptations, friction plug, cork, decanter, or the like. Thus, the purchaser of the present urn may gain access to the repository chamber via the access means 2 , 4 , 5 without having to lift or move the urn. Moreover, the head portion 4 of the figurine is of sufficient size so that it is not difficult for elderly or frail users to grasp, manipulate and remove it.
Example 2
This embodiment is substantially the same as the previous example, except that the access means for the repository chamber 3 is located on the body 6 of the customized figurine, for example on its back 7 , in an inconspicuous manner. As shown in FIG. 3, the cover 9 may be hinged 8 and provide easy access to the repository chamber 3 without having to lift the urn. In this example as in the previous example, the cover 9 is of sufficient size and appropriate design to provide easy and convenient access. In this regard, the hinged covering 9 need only be provided with a slight lifting force to reveal the repository opening 2 to the chamber 3 contained there under. The hinged covering 9 is fitted with sealing means 15 , such as a rubber stopper, on the underside of the covering and adapted to fit into the opening such that closing the cover automatically engages the sealing means 15 into opening 2 thereby sealing the sealable chamber 3 . As in the previous example, the access means 2 , 9 , 15 of the present invention provides convenient access to the repository chamber 3 .
Example 3
This embodiment is substantially the same as Example 2 except that the opening 2 for the repository chamber 3 is located at the shoulder 10 of the pet figurine. Removal of one of the legs 11 of the pet figurine provides access to the opening 2 . As in Example 1, the leg 11 , shown in FIG. 4 a , is securely fitted by known means 5 , such as threaded female and male adaptations, friction plug, cork, stopper, or the like. Thus, the purchaser of the present urn may gain access to the repository chamber via the access means 2 , 5 , 11 without having to lift or move the urn.
Example 4
In a third preferable embodiment, shown in the FIGS. 5-8, the cremated remains are housed in a sealable repository chamber 3 located in a base portion 12 of the urn. FIG. 5 shows the customized figurine portion 16 resting on a pedestal-like base 12 , that itself may be of any shape or size, and which houses a slideable drawer 13 comprising the repository chamber 3 . In this regard, the slideable drawer 13 provides a convenient means for accessing the repository chamber 3 that is independent of having to lift, move or disassemble the urn, particularly a heavy urn. The base drawer 13 in this embodiment has a sealable cover 14 for secure closure and keeping of the ashes. The sealable cover may be secured in a closed position by means 17 known in the arts, such as a single ball bearing and a bearing support mounted to the drawer wall with a concave bearing surface for receiving the ball bearing and a coil spring for urging the bearing support and ball bearing against the concave bearing. FIG. 6 shows one embodiment with a drawer 13 , in the shape of a tube, comprising a sealable repository chamber 3 that slides angularly into the base portion 12 of the urn. The side circumference of the sealable cover 14 frictionally engages the top of drawer housing in the base portion 12 thereby forming the seal of the sealable repository chamber 3 . FIG. 6 also shows a closeable decorative cover 15 that renders the repository chamber inconspicuous within the urn. FIG. 6 a shows the drawer of this embodiment removed from the base, making apparent the ease of access to the opening 2 of the repository chamber 3 by slideably removing the drawer 13 . FIG. 7 shows a conventional type drawer 13 with a top 14 that sealably closes the repository chamber 13 . FIG. 8 shows the drawer inserted into a bottom portion of the base and a closeable decorative cover 15 to render the repository chamber inconspicuous within the urn.
In any of the above examples, the repository chamber of the present invention may be designed to sealably accept the ashes of the cremated pet directly or, as they may also be found, in a flexible container. In addition, the present invention may also be fitted with a durable removable rigid container such that the container with ashes may be securely transported.
The receptacle or urn may be made of cast material or the usual alloys for casting statues, such as bronze, ceramic material, curable resins, marble, or extrudable and thermoformed plastics and the like; but is preferably of marble, or most preferably of extrudable plastic. In all instances, the figuring portion of the urn may also be covered with a natural or synthetic fur, including whiskers, that may also be customized in length, color, and pattern representing the approximate exact likeness of the deceased animal contained therein.
Although for purposes of illustration certain material and sizes have been defined herein, those skilled in the art will recognize that various modifications to the same can be accomplished without departing from the spirit of the present invention and such modifications are clearly contemplated herein. | A pet crematory urn for storing the cremated remains of a deceased pet where a decorative figure in the nearly exact likeness of the deceased pet provides a sealable repository chamber for receiving cremated remains of a deceased pet. The pet urn, optionally, may rest upon a supporting base, where the sealable repository chamber is a drawer in the supporting base that is adapted to receive said cremated remains. |
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FIELD OF THE INVENTION
Induction heating of a steel susceptor is utilized to melt industry standard 100-pound cylinders of asphalt at the point of application. A face of the solid asphalt cylinder contacts a hot perforated steel susceptor and gravity flows to the roof surface. A wheeled supporting carriage is motor driven at a speed consistent with the surface distribution specification.
BACKGROUND OF THE INVENTION
Asphalt built up layer roofing (BUR) is primarily applied by moping 450° F. to 475° F. asphalt (petroleum distillate) or bitumen (naturally occurring coal tar) to a substrate and covering with felt paper in multiple layers. One hundred pound cylinders of material are broken with a sledge and shoveled into an under-fired gas or electric melting kettle. The surface of the vessel necessarily exceeds the target melt temperature of the thermally slow conducting material. This results in the liberation of odiferous and potentially carcinogenic smoke. The molten material is transported to the rooftop by heated pump and tubing to the application site and distributed with rag mops.
The current execution of this process is essentially the same as previously practiced for over 100 years. In recent years advances have been made in added smoke abatement equipment and material additives to coat the surface of the kettle melt.
The purpose of this invention is to replace the current apparatus and method of melting and distributing asphalt. The primary embodiment of the invention melts industry standard 100-pound cylinders of asphalt in a vertical orientation at the moving site of application. The asphalt is placed on a perforated metal disc that is magnetic induction heated to the target temperature. The material melts at this interface and is distributed to the substrate at a controlled rate, as the felt paper is unrolled to form a layer of the BUR roofing system. A wheeled carriage with a balancing pressure roller, of felt paper width, rides on the unrolling felt paper and disperses the asphalt melt flow. Continuously melting asphalt, high frequency induction heating power supply, rolled felt paper, and an electric motor to power the wheels are positioned on this carriage. The volume of asphalt melted is controlled to match the traverse speed of the unit. The hot asphalt flow can be stopped and restarted in seconds. An operator guides the unit and replenishes the felt paper and asphalt cylinder as required. The appliance is powered by flexible cable from a portable electric generator placed on the rooftop or at ground level as required by size.
This system provides the advantages of minimum exposure of melted material, controlled distribution, simultaneous application of the felt paper, avoids the smoke producing over heating, minimizes labor required and enhances job-site safety and energy efficiency.
A second embodiment of the invention is intended to address applications of rubberized asphalt and polymer asphalt blends that are placed to fill concrete highway expansion cracks and asphalt highway cracks, depressions for traffic control loops, and adhere highway reflective markers. Many of these compounds are currently distributed as briquettes to melt in hot oil heated tanks utilized to avoid local overheating. There would not be any economic disadvantage for material suppliers to package in cylinders to accommodate this superior method of melting. The same advantages of melt on demand, energy efficiency, safety and melt temperature control are present here.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross section illustrating the major items included on the moving carriage.
FIG. 2 is a cross section of the susceptors and inductor coil at the melt face.
FIG. 3 is a top view of an apparatus styled for crack filling.
FIG. 4 is a partial cross section of an elevation of a unit styled for crack filling.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a partial vertical cross section of an embodiment of the invention that illustrates a unit designed to distribute a 1/16″ thick layer of 450° F. asphalt, as 39″ wide felt paper is rolled out at 4 ft/min. Asphalt cylinders 1 are placed on carriage 2 with felt paper roll 3 . All items on carriage 2 are contained within the width of the felt paper 3 plus the thickness of steel plate frame of carriage 2 . Asphalt cylinders 1 rest on vee shaped slide 4 that is attached to carriage 2 at 15° from vertical to present the bottom face of asphalt cylinder 1 to heat susceptor assembly 5 . In operation, the unit rests on pneumatic tire 6 and a leveling roll 7 that is slightly shorter than the felt paper 3 width. An air-cooled high frequency power supply 8 is powered by flexible cable 9 that enters through the carriage guide handle 10 . Handle 10 also includes a grip switch 11 to assure that the unit is attended when the melt power and drive system are in operation. Electric motor 12 drives wheel 6 through a reduction sprocket and chain drive train 13 . Melted hot asphalt 14 drops to the roof 15 at the center of roll 7 that is distributing roof felt 16 .
Carriage 2 is rocked back to rest only on idle wheels 17 placed at the outer edges of carriage 2 to provide a rolling pivot of 180° for the laying of the succeeding layer. Lifting bail 18 at the top of the load support column is provided as a hoist attachment point to place the unit on a roof.
The apparatus can be constructed to be powered by a carriage 2 contained propane fuel cell delivering DC power to the high frequency power supply 8 . The size and weight of fuel cells produced for forklifts are suitable for this application at an added cost. Enhanced portability and the availability of propane fuel make this option attractive.
FIG. 2 illustrates in vertical cross section the items that make up heat susceptor assembly 5 . A rolled ring of aluminum angle 19 is attached to carriage 2 at the centerline of asphalt cylinder 1 . The ring has radial edge tabs 20 to position secondary susceptor 21 , inductor coil 22 , radial coil positioning spacers 23 , and primary susceptor 24 . Heat susceptor assembly 5 can support two 100# cylinders of asphalt 1 .
When high frequency power is applied to inductor coil 22 , magnetic field 25 intercepts both primary susceptor 24 and secondary susceptor 21 in proportion consistent with the proximity and turns placement of inductor coil 22 . The induced energy is evenly distributed by the fore mentioned means well known to those familiar with induction heating practice. Asphalt material in contact with susceptor face 26 melts and flows through perforations 27 as individual streams indicated by arrow 28 . Melted asphalt gravity flows below the application target temperature specified by the roofing material producers. Hot asphalt material flows through inductor coil 22 absorbing electrical losses as described in Lasko U.S. Pat. No. 5,584,419. Additional heat is added to the flowing asphalt by secondary susceptor 21 to attain the commonly specified 450° application temperature. Primary susceptor 24 is constructed of 18 gage perforated steel sheet. Secondary susceptor 21 is Metpore FeCrAlY metal foam that is 0.500″ thick. Thermocouple 29 provides the control signal to high frequency power supply 8 to modulate the power applied to hold the exit temperature at the specified application temperature. Power supply 8 provides power to inductor coil 22 at a frequency of 40 KHz to 100 KHz. Inductor coil 22 is constructed of 0.150″×0.050″ bare rectangular motor winding copper.
A second embodiment of the invention is illustrated in top view FIG. 3 and partial cross section FIG. 4 of a melting apparatus for crack filling. The same powered wheel 6 , drive motor 12 , high frequency power supply 8 , and heat susceptor assembly 5 are assembled on a tri-wheeled tubular frame carriage 30 to melt the same size asphalt cylinder 1 . Wheel 6 driven by motor 12 propels the unit at operator controlled variable speed. Trailing wheels 31 swivel for operator visual tracking of the crack.
Four Teflon guide blocks 32 position asphalt cylinder 1 , for melting in assembly 5 . The hot liquid is gathered in cone 33 formed of Teflon sheet to exit as stream 34 over a crack. Distribution roll 35 is added to level excess material. Handle 10 can be swiveled in pocket 36 and locked in place to guide the apparatus from various positions.
This apparatus attended by a pickup truck carrying a portable power generator, a cable boom, and supply of material can match the placement capacity of a propane fired, oil jacketed, crack filling melt trailer. Replacement of wheel 6 with a urethane tire face profiled to drop partially into a concrete expansion crack and locking the trailing swivel wheels can convert the apparatus into a dedicated expansion crack filler.
Both embodiments of the invention presented here can be sized to accommodate different diameter cylinders, material specific heat, and application temperature. Both embodiments of the invention can also process polymer modified asphalt or thermoplastic material particulate forms. Pelletized polymer materials or Trinidad Lake coated asphalt pellets can be processed in the same system with the addition of a Teflon cylinder sleeve acting as a pellet reservoir in the position of asphalt cylinder 1 . Where duel component materials are to be applied the apparatus can be equipped with an inductor coil/susceptor arrangement as described in Lasko U.S. Pat. No. 7,755,009 for melting and mixing. | Asphalt cylinders or thermoplastic polymer modified asphalt cylinders or particulate forms are induction melted by magnetic field susceptor for a controlled distribution with felt paper to accomplish the construction of an industry standard BUR roofing system. These forms are similarly melted for highway crack sealing in an additional embodiment of the invention. |
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TECHNICAL FIELD
This invention relates to the field of safety devices, and more particularly, to safety devices for preventing the operation of water faucet handles by unsophisticated individuals, including young children.
BACKGROUND
On occasions, unsophisticated children have unsupervised access to water faucets. Too often these children attempt to play with the water faucets and are injured by scalding hot water or from jerking away from cold water. These injuries can be minimized by the use of a faucet safety device that covers the faucet handle and prevents operation of the faucet by those too immature to understand the consequences. At the same time, the device should be easy to install and remove to facilitate and encourage use by supervising adults.
SUMMARY OF THE INVENTION
The present invention provides a simple, inexpensive handle cover that prevents operation of the faucet handle when installed. With respect to one aspect of the present invention, the safety device includes a restraining bar removably attachable to a fixed structure and an expandable faucet handle cover, fixed relative to the restraining bar. The cover presents a handle-receiving cavity that varies in size as the cover is expanded and contracted. It also includes a pair of elongated, opposed, separable toothed surfaces that move lengthwise relative to one another as the cover is expanded and contracted, with the teeth of the surfaces being interlockable to prevent expansion of the cover. The cover encloses the faucet handle to restrict operation of the handle independent of the cover, which is fixed by the restraining bar. Thus, an adult can easily install and remove the mechanism, but it prevents an endangered child from operating the faucet handle. The inventive features of the device are useful for both dual handle faucets and single handle faucets.
The present invention also concerns a faucet safety device for selectively restricting operation of a pair of faucet handles, where operation of either faucet handle involves movement of the handle relative to the other faucet handle. The device includes a restraining bar and a pair of independently expandable faucet handle covers that are fixed relative to the restraining bar. Each cover also presents a handle-receiving cavity that varies in size as the cover is expanded and contracted. The dual faucet safety device provides an independent locking mechanism for each of the faucet handle covers, with each mechanism being operable to selectively prevent expansion of each of said covers. The independent locking mechanisms facilitate use on various size faucet handles, particularly on handles that are larger than average. The restraining bar between the two covers prevents movement of the covers and therefore operation of either handle.
The present invention also concerns a faucet safety device where the faucet handle cover is operable be fixed to the faucet handle and the projecting, rigid restraining bar is dimensioned and configured to extend at least partly around a fixed structure. The cover and the bar thereby cooperate to prevent operational movement of the handle. The device is easily installed in a multitude of environments to prevent movement or rotation of the cover and therefore operation of the handle.
The present invention further concerns a simplified method of preventing rotation of the hot water and the cold water handles of a faucet. The first faucet handle cover is fixed to the hot water handle in such a manner that rotation of the hot water handle would require rotation of the first cover. The second faucet handle cover is independently fixed to the cold water handle in such a manner that rotation of the cold water handle would require rotation of the second cover. Wherein the first and second handle covers are fixed relative to one another, neither cover or the associated handle can be rotated and operation of the faucet is prevented. This method allows for improved installation on handles of various sizes.
A method particularly adapted to use with the single faucet safety device directs the positioning of an elongated, substantially rigid restraining bar around structure that is fixed relative to the handle during handle operation. Typically this might be the faucet spigot or another handle. The user then fixes the projecting handle cover to the handle in such a maimer that rotation of the handle would require rotation of the cover. The restraining bar prevents rotation of the cover, thus preventing operation of the handle.
Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is an isometric view of a dual faucet safety device incorporating the principles of the present invention;
FIG. 2 is a front view illustrating the dual faucet safety device installed on the hot water faucet handle and receiving but not yet fixing the cold water handle;
FIG. 3 is a top view of the dual faucet safety device installed on the faucet;
FIG. 4 is a side view of the dual faucet safety device installed on the faucet;
FIG. 5 a is a partial cross-sectional front view of a faucet handle cover installed on a large faucet handle;
FIG. 5 is a partial cross-sectional front view of a faucet handle cover installed on a faucet handle;
FIG. 6 is an enlarged, fragmentary, cross-sectional front view of a locking mechanism;
FIG. 7 is a cross-sectional side view of faucet handle cover installed on a faucet handle;
FIG. 8 is an isometric view of a single faucet safety device incorporating the principles of the present invention;
FIG. 9 is a front view of a single faucet safety device installed on a single handle faucet; and
FIG. 10 is a side view of a single faucet safety device installed on a single handle faucet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a dual faucet safety device 10 in a position for installation on a hot water handle 12 and a cold water handle 14 of a water faucet 16 . Naturally, the size, shape and composition of water faucet 16 may vary, but generally it will include structures positionally fixed in relative location, such as one or two handles 12 , 14 and a spigot 18 . Water faucets may be found in many areas of the home, typically including the kitchen,the laundry room and the bathroom. In the bathroom tub or shower, a water faucet 16 may include a shower head and a shower selector handle 20 . The water faucet handles 12 , 14 generally project out from a wall 22 , counter or other flat surface. While the faucet handles 12 , 14 in this description are depicted as having four radially projecting knobs 24 , it is recognized and within the spirit of this invention that faucet handles have many different shapes, such as squat cylindrical disks, tulip-shaped or knurled knobs. Typically, the user operates the faucet 16 by rotating the handle 12 , 14 relative to the wall 22 .
The faucet safety device 10 , illustrated in FIG. 1, includes a restraining bar 26 and first and second expandable faucet handle covers 28 , 30 . Since the cover 30 is structurally identical to and a mirror image of the cover 28 , detailed discussion of the cover 30 will be omitted in the sake of brevity. While other shapes are within the spirit and scope of the invention (e.g. spheroid, football-shaped, or rectangular with generally flat sides), the cover 28 is illustrated as cylindrically shaped with an outer cylindrical face 32 . The cover 28 also comprises a first portion 36 and a second portion 40 pivotly connected by a hinge 44 for allowing expansion and contraction of cover 28 . A tab 50 projects from the outer cylindrical face 32 . A pair of elongated, opposed toothed surfaces provide a locking mechanism 54 , with a first toothed surface 58 existing on the outer cylindrical face 32 and the tab 50 presenting an opposed toothed surface 62 . The tab 50 is depicted as projecting from the first portion 36 with the first toothed surface 58 on the second portion 40 , but it should be clear that the tab 50 may originate from a multitude of locations, including locations on the second portion 40 , with a length sufficient to allow the locking mechanism 54 to engage.
The cover 28 forms a handle-receiving cavity 66 partially filled by compressible material 70 (preferably extruded closed cell foam rubber). The compressible material 70 grips the handle 12 as depicted in FIG. 5, and is retained in the cover 28 . The material 70 will deform to accommodate various shape and sizes of handles.
The hinge 44 is a standard design with hollow tubes in line and a central rod around which the tubes rotate. Other pivoting connections are also included in the spirit of the invention including rotating pins in retaining cavities or rings on a central shaft.
The hinged relationship between the first portion 36 and the second portion 40 contributes to the expandibility of the cover 28 to improve the ability of the cavity 66 to accommodate an oversized handle 74 as illustrated in FIG. 5 a. Additionally, the cover 28 itself may be pliable, allowing substantial expansion of size. In an envisioned embodiment, the cover would be constructed of polyethylene terephthalate (PET) with sufficient malleability to form a cylinder with overlapping cylindrical sides and a cylindrical diameter varying from less than 2 inches to more than 5 inches. In some embodiments, with a highly flexible material, the hinge 44 is not required, and the first portion 36 and the second portion 40 become a unitary construction (not shown). The device 10 could be constructed from a variety of material including PET, molded plastic, brass or stainless steel.
The locking mechanism 54 also enhances the expandibility of the cover 28 . The interlockable first toothed surface 58 engages the opposed toothed surface 62 when the user presses the tab 50 onto the outer cylindrical face 32 while contracting the cover 28 about the handle 12 . The locking mechanism 54 thus fixes the cover 28 to the handle 12 . To remove the cover 28 , the user further compresses the cover 28 , or at least the second portion 40 , and lifts the tab 50 , disengaging the locking mechanism 54 (see FIG. 6 ).
Within the spirit of the invention, the locking mechanism 54 can be embodied in forms other than interlockable toothed surfaces. The mechanism would, for example, include a pin and sockets arrangement, where a plethora of sockets are presented on the outer cylindrical face. A further example of a suitable mechanism is a series of hook and eye latching arrangements.
The cover 28 also includes an end wall 76 near the wall 22 . The end wall 76 has an opening 80 which allows passage of a handle stem 84 from the handle 28 to the wall 22 . The end wall 72 further improves the ability of the cover 28 to grip the handle 12 and prevent undesired removal of the cover 28 by an unsophisticated individual. A front wall 88 may be provided on the cover 28 opposite the end wall 76 , with the same or a different sized opening 90 , to improve installation flexibility and fit.
In FIG. 1, the restraining bar 26 is shown as a pair of rigid, arcuate strips 96 , 98 with an open center area therebetween. The arcuate shape avoids the potentially obstructing shower selector handle 20 which may be present. The restraining bar 26 is of sufficient rigidity to prevent substantial rotation of the cover 28 relative to the bar 26 . As should be obvious to those skilled in the art, the restraining bar 26 can present a variety of different shapes within the spirit of this invention (e. g. single or multiple rods in a V-shaped configuration; a solid rigid arm, or an I-beam element). The restraining bar 26 need not be constructed of the same material as the cover. A suitable bar could be formed from a wide variety of material including PET, hard plastic or stainless steel, or a combination of components, where a stiff reenforcing element is encased in a more esthetic soft plastic jacket. Fabrication of the device is also adaptable, and might include one piece injection molding of the cover and the restraining bar. Alternatively, production of individual portions and subsequent assembly might be preferred.
In use, the faucet safety device 10 allows for simple, easy operation to promote effective use. With the faucet safety device 10 in an expanded configuration (see FIG. 1 ), the user positions the faucet safety device 10 such that the faucet handle 12 is received in the cavity 66 of the cover 28 , while the faucet handle 14 is similarly received in the cover 30 . The handle stem 84 is located within the semicircular portion of the opening 80 defined in either half of the end wall 76 . The cover 30 is similarly oriented relative to handle 14 . The user then closes the first portion 36 and contracts the cover 28 about the handle 12 to substantially enclose the handle 12 (see FIG. 2 ). Pressing the tab 50 onto the toothed surface 58 of the outer face 32 , the user interlocks the locking mechanism 54 thus fixing the cover 28 to the handle 12 , preventing operation of the handle 12 independent of the cover 28 (see FIG. 4 ). The cover 30 is fixed about the handle 14 in an identical fashion, such that operation of the handle 14 independent of the cover 30 is prevented (see FIG. 3 ). Joined by the restraining bar 26 , neither cover 28 , 30 can be rotated and operation of either handle 12 , 14 is thus prevented. The device 10 cannot be inappropriately pulled off the handle 12 by a child or unsophisticated user because the end wall 76 encases the handle 12 , as shown in FIG. 7 . Additionally, the compressible material 70 grips the handle to prevent forcible removal when the cover 28 is clamped in place (see FIG. 5 ).
As should be obvious to those with skill in the art, it is not essential that the cover 28 , 30 be completely closed when fixed to the handle 12 , 14 . If an oversized handle 74 is encountered, the device 10 can be installed and will function even if the cover 28 presents a gap or open section 100 , as shown in FIG. 5 a.
FIG. 8 illustrates a single faucet safety device 200 , which presents many of the same features as the dual faucet safety device 10 described above. Similar to the dual faucet, a single faucet 204 typically projects from a wall 222 and operates by rotation of a single faucet handle 206 relative to the wall 224 . The single faucet handle 206 is used primarily in showers and sinks, but can be found in other applications as well. It should be understood that the single faucet safety device 200 could be used on a dual handle faucet 16 to prevent the operation of a single handle, such as hot water faucet handle 12 .
The single faucet safety device 200 includes a restraining bar 226 and an expandable faucet handle cover 228 , depicted in FIGS. 9 and 10. The cover 228 is cylindrical in shape and consequently presents an outer cylindrical face 232 . The cover 228 presents a first portion 236 and a second portion 240 pivotly connected by a hinge 244 for allowing expansion and contraction of the cover 228 . Projecting from the outer cylindrical face 232 is a tab 250 .
A locking mechanism 254 exists, with a first toothed surface 258 on the outer cylindrical face 232 and a opposed toothed surface 262 on the tab 250 . The hinged relationship between the first portion 236 and the second portion 240 contribute to the expandibility of the cover 228 . The cover 228 forms a handle-receiving cavity 266 partially filled with a compressible material 270 (preferably extruded closed cell foam rubber). The material 270 will deform to accommodate various shapes and sizes of handles and to improve the ability of the cavity 266 to accommodate an oversized handle 74 .
The locking mechanism 254 also enhances the ability to accommodate oversized handles. The interlockable first toothed surface 258 engages the opposed toothed surface 262 when the user presses the tab 250 onto the outer cylindrical face 232 while contracting the cover 228 about the handle 206 . The locking mechanism 254 thus fixes the cover 228 to the handle 206 . To remove the cover 228 , the user further compresses the cover 228 , or at least the second portion 240 , and lifts the tab 250 , disengaging the locking mechanism 254 .
In a preferred embodiment, a rear end wall 276 is provided, with an opening 280 being defined centrally in the end wall 276 to simplify placement around handle stem 284 while improving retention of the handle 206 within the cover 228 . A front wall 288 with an opening 292 may also be present.
In the single faucet safety device 200 , the restraining bar 226 forms an open continuous loop 294 that can be easily placed around a nearby fixed structure, such as the faucet spigot 218 , as shown in FIG. 9 . Other fixed structures displaced perpendicular to the wall 222 , such as the shower selector handle 20 illustrated in FIG. 1 could also be used to fix restraining bar 226 .
In a preferred embodiment, the restraining bar 226 is generally triangular in shape to facilitate installation while still preventing movement when installed. Other restraining bar configurations within the scope of the invention are possible, including a bar with an adjustable loop strap, for example. The loop 294 is dimensioned to fit standard bath fixtures, and different sized loops might be manufactured for different faucets. The device is preferentially manufactured in a process where a substantial portion of the cover and the restraining bar are formed as an integral unit. The restraining bar projects from a central location on the outer surface of the cover to improve strength and stability. Alternatively, the cover and the restraining bar can be assembled from individually formed components to form a rigid faucet safety device in accordance with the present invention.
The use of the single faucet safety device 200 is simple. The loop 294 of the restraining bar 226 is placed over a structure that is positionally fixed relative to the handle 206 , such as the water spigot 218 . The expandable faucet handle cover 228 is then positioned such that the handle 206 is in the handle-receiving cavity 266 and the handle stem 284 rests in the opening 280 . The cover 228 is contracted by pivoting the first portion 236 to enclose the handle 206 and by further compressing the outer cylindrical face 232 . The user then presses the tab 250 onto the toothed surface 258 on the outer cylindrical face 232 , engaging the locking mechanism 254 (see FIG. 10 ). Thus, since rotation of the cover 228 is prohibited by the restraining bar 226 , and movement of the handle 206 independent of the cover 228 is constrained, operation of the handle 206 is prevented. To remove the cover 228 , the second portion 240 is compressed and the locking mechanism 254 is disengaged. The user then expands the cover 228 and removes the handle 206 from the cavity 266 .
While it should be obvious that the dual faucet safety device 10 is most conveniently used when both a hot water handle 12 and a cold water handle 14 are present, a single faucet safety device 200 could also be used if the user desired only to prevent the operation the hot water handle. Further, while not optimal, the dual faucet safety device 10 could be used to prevent operation of a single faucet handle 206 by enclosing any positionally fixed structure, such as the water spigot 218 , in the second expandable faucet handle cover 30 .
The preferred forms of the invention described above are to be used as illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as herein above set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventor(s) hereby states their intent to rely on the doctrine of equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims: | A safety device and method to selectively prevent the operation of a faucet handle by unsophisticated individuals are disclosed. More specifically, a water faucet safety device including a faucet handle cover which expands and contracts to enclose the handle, wherein the handle includes a locking mechanism that selectively fixes the cover to the handle and prevents cover expansion, and a restraining bar that cooperates with the cover to prevent rotation of the faucet handle. The restraining bar may be anchored to the faucet spigot or other nearby fixed structures. The device may be configured for use with a single handle or a dual handle faucet. With respect to the dual handle configuration, the device includes a pair of independently operable faucet handle covers sharing a common restraining bar. Thus, when both covers have been separately fixed to the respective faucet handles using the independent locking mechanisms, operation of both handles is prevented. |
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FIELD OF THE INVENTION
[0001] This invention relates in general to installation of electrical submersible pumps (ESPs), and in particular the installation of ESP equipment inside an inverted shroud.
BACKGROUND OF THE INVENTION
[0002] A typical subsea installation can use an Electric Submersible Pump (ESP) within an inverted shroud. An ESP unit consists of a motor section, a seal section, and a pump section having an inlet and a discharge connected to production tubing and is used to provide artificial lift to liquid from a formation.
[0003] An inverted shroud can be used in combination with an ESP for use in gassy wells to divert the gas past the entrance of the ESP to reduce the possibility of gas locking. The shroud is a cylindrical steel tube that encompasses the ESP and is sized to allow clearance for fluid to pass both inside past the ESP and outside between the well casing and the shroud.
[0004] In gassy oil wells, gas and liquid enter the casing from the formation then both travel up the casing past the ESP unit to the top of the shroud. Due to gravity, the liquid can fall back down inside the shroud, which has an open top, and into the entrance of the pump. Gas slugs, however, effectively continue moving past the ESP. This reduces the chances for the ESP to experience gas locking due to gas slugs.
[0005] The assembly and installation of an inverted shroud with an ESP is very time consuming and difficult because the shroud, the pump, and lengths of production tubing must be assembled in unison as it is lowered into the hole. Parts for the assembly must be manufactured to strict tolerances in order to allow for proper assembly. Further, the diameter of the shroud limits the size of the motor that can be used for the ESP, which in turn affects the capability of the ESP to produce artificial lift.
[0006] A need exists for a technique that addresses the limitations and shortcomings described above. In particular a need exists for a technique to allow for an inverted shroud to be installed with an ESP in a timely manner and in a manner that does not limit the size of the motor that can be used. The following technique may solve these problems.
SUMMARY OF THE INVENTION
[0007] In an embodiment of the present technique, a shroud assembly is provided with a bottom that can be fixed to the top of a seal section connected to the top of a motor. Additional lengths of shroud can be added as the shroud assembly is lowered into the well. This allows for a relatively less time consuming and less difficult assembly process as the shroud can be assembled independently from the electrical submersible pump (ESP) and the production tubing, which in the past have been assembled in unison with the shroud. Further, assembly of the shroud in this manner makes the motor size independent from the inner diameter of the shroud because the motor is not located within the shroud.
[0008] In the illustrated embodiment, a motor is located at the base of an assembly with a seal section through which the motor shaft passes. A power cable descends from the surface and runs along between the casing and the shroud to serve the motor. The shaft protrudes into a special section of shroud about a foot in length that is bolted onto the seal section. The pump is connected to the protruding shaft and can have multiple stages. The pump can also have a pump positioner or guide at the base to aid in positioning the pump. Additional sections of shroud extend upwards from the special section of shroud and house the ESP within. The shroud sections can be sections of pipe connected end to end and can extend up to 300 feet or more above the ESP. Inlet holes are located approximately at the top end of the shroud to allow formation liquid to enter the shroud and fall down to the entrance of the ESP.
[0009] The discharge of the ESP located inside the shroud connects to production tubing that extends past the top of the shroud and to the surface. A shroud hanger located at the top of the shroud supports the weight of shroud assembly comprising the shroud, motor, and seal section, and transfers the weight to the production tubing via the hanger.
[0010] During installation of the shroud assembly and ESP, a clamp at the wellhead holds the assembled components, and a lifting clamp lifts the next component over the wellhead to be assembled. For example, the clamp at the wellhead initially holds the assembled seal section to support the seal section and the motor connected below. The special shroud section, about a foot in length and housing a protruding shaft spline from the motor, is lifted with a second clamp and placed over the seal section located at the wellhead. The special shroud section can then be bolted onto the seal section. Once the special section of the shroud is bolted onto the seal section, the clamp holding the seal section can be released and then replaced by the clamp used to lift and hold the special shroud section so that it sits on the wellhead. This alternating use of the lifting clamp and the clamp at the wellhead is used to add additional sections of shroud.
[0011] Once the shroud sections are assembled, the ESP can be lifted and lowered down inside the shroud until it engages the shaft spline of the motor protruding into the special shroud section. At this point the top of the shroud is still supported by a clamp at the wellhead. Once the ESP is positioned within the shroud, a section of production tubing is lifted with a clamp and lowered down inside the shroud to connect with the discharge end of the ESP. As with the shroud sections, additional production tubing sections are lifted and connected end to end by releasing the clamp holding the assembled production tubing at the wellhead and replacing it with the clamp holding the last added section of production tubing. A hanger is then installed at the top of the shroud at the point where the length of production tubing is sufficient to extend to or above the top of the shroud. The hanger engages the production tubing to thereby transfer the weight of the shroud assembly to the production tubing, allowing the clamp holding the shroud assembly to be released. The production tubing along with the shroud assembly and the ESP within are then lowered to the desired depth in the well for operation, with additional sections of production tubing added to extend the production tubing up to the wellhead.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a seal section and a motor section clamped to the wellhead, in accordance with the invention.
[0013] FIG. 2 shows a shroud section with a pump positioner attached to the seal section, in accordance with the invention.
[0014] FIG. 3 shows the top of the completed shroud clamped at the wellhead and the motor and seal attached to the bottom, in preparation to receive a pump, in accordance with the invention.
[0015] FIG. 4 shows the pump lowered by production tubing into the shroud and mated with the pump positioner, the shroud being hung off the production tubing in accordance with the invention.
[0016] FIG. 5 shows the pump, seal section, motor, and shroud assembly lowered by production tubing to the desired location in the well, in accordance with the invention.
[0017] FIG. 6 shows an additional embodiment of the assembly varying in the type of hanger used to support the shroud off of the production tubing in accordance with the invention.
[0018] FIG. 7 shows another additional embodiment of the assembly varying in the type of hanger used to support the shroud off of the production tubing in accordance with the invention.
[0019] FIG. 8 shows a sectional top view of the shroud offset from the center of the well to provide clearance for a power cable guard, in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to FIGS. 1 through 5 , an embodiment of the installation of a shroud 24 with a pump 26 is illustrated. Pump 26 is a rotary pump such as a centrifugal pump or progressing cavity pump. Referring initially to FIG. 1 , a motor 14 connected to the lower end of a seal section 16 is shown suspended inside a well casing 12 . A power cable 17 is connected to the motor 14 and runs up to the surface of the well. A clamp 18 supports the assembled motor 14 and seal section at the wellhead 10 by holding the seal section 16 . Clamp 18 can be slips or a spider type of supporting system. Clamp 18 may be located on a rig floor of a workover rig.
[0021] A second clamp (not shown), of the workover rig, typically a pipe elevator, can then lift the next component to be assembled as shown in FIG. 2 . For example, in this embodiment a special shroud section 20 is lifted with the second clamp (not shown) and can be bolted to the top of the seal section 16 held by the clamp 18 at the wellhead 10 . The clamp 18 at the wellhead 10 is released and replaced by the lifting clamp, thereby moving the assembled components downward into the well. The special shroud section 20 can be approximately a foot in length and houses a spline shaft 22 to mate with and align the pump 26 ( FIG. 4 ). The special shroud section also has an anti-rotational slot or key (not shown) to prevent the pump 26 from rotating.
[0022] As shown in FIG. 3 , the shroud 24 can be comprised of sections of pipe, such as casing, connected end to end. The sections of shroud 24 can be lifted by the lifting clamp (not shown) and connected to the previous section of shroud 24 supported at the wellhead 10 by the clamp 18 . The clamp 18 at the wellhead can then be released and replaced by the lifting clamp in the same manner described for the special shroud section 20 above. This procedure of replacing the clamp 18 at the wellhead 10 with the lifting clamp is repeated until the desired shroud length is reached. The uppermost section of shroud 24 has an intake, such as inlet holes 30 in the side wall near the top. The lower end of shroud 24 is closed.
[0023] Referring to FIG. 4 , once the shroud 24 sections are assembled, the pump 26 can be lifted and lowered down inside the shroud until it engages a spline shaft 22 and also engages the anti-rotation slot or key (not shown). At this point the top of the shroud 24 is still supported by clamp 18 at the wellhead 10 . Once the pump 26 is positioned within the shroud, a section of production tubing 28 is lifted with a clamp (not shown) and lowered down inside the shroud 24 to connect with the discharge end of the pump 26 . As with the shroud 24 sections, additional production tubing 28 sections are lifted and connected end to end by releasing the clamp 18 holding the assembled production tubing 28 at the wellhead 10 and replacing it with the clamp holding the last added section of production tubing 28 . The tubing inside shroud 24 may be considered to be a lower production tubing string 28 . Shroud 24 remains suspended at wellhead 10 during this process.
[0024] A hanger 32 is then installed at the top of the shroud 24 at the point where the length of lower production tubing 28 is sufficient to extend to or above the section of shroud 24 having inlet holes 30 . The inlet holes 30 allow formation liquid to enter the shroud 24 and flow down to the entrance of the pump 26 during operation. The hanger 32 engages the upper production tubing 29 to thereby transfer the weight of the shroud 26 , motor 14 , and seal section 16 , to the upper production tubing 29 via the hanger 32 . Once the hanger 32 is installed, the clamp 18 holding the shroud 24 can be released. The lower production tubing 28 , pump 26 , along with the shroud assembly comprising the shroud 24 , motor 14 , and seal section 16 , are then lowered to the desired depth in the well for operation, as shown in FIG. 5 , with additional sections of upper production tubing 29 added to extend the production tubing up to the wellhead.
[0025] Hanger 32 has external threads that engage internal threads formed in the upper section of shroud 24 . Hanger 32 has internal upper and lower threads for securing upper tubing string 29 and lower tubing string 28 .
[0026] In other embodiments illustrated in FIGS. 6 and 7 , different types of hangers can be utilized. The hangers 34 , 36 shown are also used to hang the shroud assembly from the production tubing 28 . FIG. 6 shows a hanger 34 having a lower slip with a lower tapered bowl. The lower tapered bowl has external threads that engage internal threads formed in the upper section of shroud 24 . To prevent upward movement of the production tubing due to thermal growth, the hanger 34 additionally comprises an upper slip with an upper tapered bowl. A set of internal threads on the upper tapered bowl engages external threads on the lower tapered bowl.
[0027] FIG. 7 shows a hanger 36 having a lower slip with a lower tapered bowl. The lower tapered bowl has external threads that engage internal threads formed in the upper section of shroud 24 . A retainer secures the slip to prevent upward movement of the slip.
[0028] FIG. 8 shows a sectional top view of the shroud 24 offset from the center of the well to provide clearance for a power cable guard 40 attached to the exterior of the shroud 24 . The electrical power cable 17 is routed inside the guard 40 to protect it from damage. The guard 40 can comprise a continuous channel or can be comprised of a plurality of spaced apart channels.
[0029] In an additional embodiment (not shown), the power cable 17 can run inside the shroud 24 . The power cable 17 could stab into an electrical connector assembled as part of the special shroud section 20 at the base of the pump 26 .
[0030] Assembling the shroud assembly comprising the shroud 24 , motor 14 , and seal section 16 prior to the installation of the pump 26 and production tubing 28 can reduce installation time and difficulty by eliminating the need for strict tolerances required when the shroud assembly, ESP, and production tubing are assembled in unison. Further, the size of the motor is not limited by the shroud diameter because the motor is installed prior to and outside the shroud, allowing for a larger motor size. In the example shown in the figures, the outer diameter of motor 14 is greater than the inner diameter of shroud 24 .
[0031] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. These embodiments are not intended to limit the scope of the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. For example, a rotary gas separator could be located in shroud below pump as part of the pump assembly. If so, however, a gas outlet diverter would be connected between a exterior port of the shroud and the cross over of the gas separator. | The pump can be utilized in gassy oil wells to prevent gas slugs from locking the electrical submersible pump. A shroud assembly is provided with a bottom that can be fixed to the top of a seal section connected to the top of a motor. Additional lengths of shroud can be added as the shroud assembly is lowered into the well. The electrical submersible pump can then lowered into the shroud and supported from a production tubing string. A hanger can then be attached to the production tubing string to carry the weight of the shroud assembly, motor, and seal section. |
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RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of co-pending U.S. Provisional Application Ser. No. 61/422,396, filed Dec. 13 th , 2010, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The disclosure herein relates generally to the field of subterranean hydrocarbon production. More specifically the present invention relates to a system for facilitating desired orientation of a downhole string.
[0004] 2. Description of Related Art
[0005] Many downhole tools, including perforating guns, comprise multiple elongated bodies joined end to end. If the elongated bodies are to be rotated or axially positioned, the elongated bodies must be able to rotate freely with respect to the adjacent body or bodies they are connected to. When a downhole tool is inserted within a deviated wellbore, gravity and other forces causes friction. Free rotation of the elongated bodies of a downhole tool is then hindered. If free rotation of the elongated bodies is hindered, they will not be able to be positioned into the desired orientation. Therefore, when the downhole tool consists of multiple perforating guns, perforations cannot be produced at the desired orientation along the wellbore.
[0006] When perforating guns, are used in slanted or deviated wellbores it is often important that the tool be in a specific radial orientation. For example, orienting perforating guns in deviated wells enables the well operator to aim the shaped charges of the perforating gun at specific radial locations along the circumference of the wellbore. This is desired because the potential oil and gas producing zones of each specific well could exist at any radial position or region along the wellbore circumference. Based on the presence and location of these potential producing zones adjacent a deviated well, a well operator can discern a perforating gun orientation whose resulting perforations result in a maximum hydrocarbon production. Not only could a perforation aimed at the wrong angle not result in a preferred hydrocarbon production, but instead could produce unwanted sand production from the surrounding formation into the wellbore.
SUMMARY OF THE INVENTION
[0007] Disclosed herein is an example of a device for attachment to a downhole string. In one example the device is a roller system for use in a wellbore downhole that is made of a body having a substantially cylindrical outer surface and that is selectively engaged by a couple to the downhole tool. A bore is formed axially through the body that is adapted to receive a portion of a downhole string. Also include is a swivel in the couple so that the body rotates with respect to the downhole string. Rollers are mounted on opposing lateral sides of the body that are rotatable about an axis that intersects the housing and that have diameters greater than a height of the body, so that when the downhole string is disposed in the wellbore, the rollers are rotatable with respect to an axis of the downhole string. The body can include lateral sections that bolt together. The portion of the downhole string that extends through the bore can be a mandrel having opposing ends adapted for coupling within the downhole string. In this example, the mandrel is retained in substantially the same azimuthal position as the downhole string. The swivel can include bearings between the housing and mandrel and that are adjacent shoulders on the mandrel defined where the outer surface of the mandrel projects radially outward at location that are spaced axially apart and wherein a spindle is defined on the mandrel between the shoulders. The portion of the downhole string that extends through the bore can be a downhole tool. In an example, the rollers have a hemispherically shaped convex outer surface and a concave inner surface that is partially hollow and receives a portion of the body therein. Indentations may be included on an outer surface of the rollers for promoting traction between the rollers and an inner surface of a tubular in the wellbore. A portion of the convex outer surface of the rollers can have a contour approximate to a contour of an inner surface of a tubular in the wellbore to thereby define a contact length between the rollers and the tubular. In one example, the portion of the downhole string that extends through the bore is a perforating gun.
[0008] Also included herein is a downhole string that is selectively deployed in a tubular that is disposed in a wellbore. The downhole string is made up of a series of elongate members connected end to end with a swivel on an outer surface of a portion of one of the members. A housing is releasably coupled onto the swivel and is rotatable about an axis of the one of the members. Rollers are mounted onto lateral sides of the housing that have a diameter greater than a height of the housing, so that an outer circumference of the rollers is in contact with an inner surface of the tubular. One of the members can be a roller sub having opposing ends configured for coupling to other elongate members. In one example, the roller sub includes a mandrel having axially spaced apart shoulders defined where an outer surface of the mandrel extends radially outward and a spindle provided between the shoulders. Optionally, the swivel includes bearings between the housing and the spindle so the housing and rollers can rotate with respect to an axis of the roller sub. Optionally, the lateral sides of the housing are substantially planar and wherein the shoulders project past the lateral sides to define a recess in which the rollers are disposed. In an example embodiment, the one of the members is a downhole tool. Optionally, the rollers can have a hemispherically shaped convex outer surface and a concave inner surface that is partially hollow and receives a portion of the body therein. Indentations may be included on an outer surface of the rollers for promoting traction between the rollers and an inner surface of a tubular in the wellbore, and wherein a portion of the convex outer surface of the rollers has a contour approximate to a contour of an inner surface of a tubular in the wellbore to thereby define a contact length between the rollers and the tubular.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0009] 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:
[0010] FIG. 1 is a side perspective view of an example embodiment of a roller assembly sub.
[0011] FIG. 2 is another side perspective view of the roller assembly sub of FIG. 1 .
[0012] FIG. 3 is a side perspective partial sectional view of the roller assembly sub of FIG. 1 .
[0013] FIG. 4 is a side sectional view of the roller assembly sub of FIG. 3 .
[0014] FIG. 5 is a side perspective view of a roller assembly in a tubular.
[0015] FIG. 6A is an end view of the roller assembly FIG. 5 .
[0016] FIG. 6B is an end view of an alternate embodiment of the roller assembly of FIG. 6A .
[0017] FIG. 6C is an end view of an alternate embodiment of the roller assembly of FIG. 6A .
[0018] FIG. 7 is a side partial sectional view of a downhole string having a roller assembly.
[0019] 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 THE INVENTION
[0020] 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.
[0021] 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.
[0022] Referring now to FIG. 1 , one example embodiment of a roller sub 20 is shown in a side perspective view. The roller sub 20 is made up of a body 22 and an elongate annular mandrel 23 . The body 22 is mounted in a mid portion of the mandrel 23 , which is a reduced diameter portion of the mandrel 23 . Opposing ends 24 , 25 of the mandrel 23 are shown having profiles for coupling within a downhole string (not shown). Wherein in an example the profiles are threaded fittings, that can be male or female. The outer radius of the mandrel 23 projects radially outward adjacent opposing ends of the body 22 to define shoulders 26 on the mandrel 23 . A channel 27 is formed substantially along an entire circumference of one of the shoulders 26 . A channel 28 in the other shoulder 26 is shown formed along a portion of its circumference. An axial bore 29 in the roller sub 20 extends the length of the mandrel 23 . Recesses 30 are shown on lateral sides of the body 22 disposed at about a mid-portion of the body 22 and configured to receive rollers 32 therein. The recesses 30 have a substantially planar surface on the outer surface of the body 22 and terminate adjacent the shoulders 26 . The outer surface of the body 22 between the recesses 30 is generally curved. The rollers 32 rotate about an axis A X shown intersecting the body 22 .
[0023] Referring now to FIG. 2 , another side perspective view of the roller sub 20 is provided that illustrate fasteners 34 set in counter bores formed through the outer wall of the housing 22 that depend downward from an upper surface of the housing 22 . In an example, the fasteners 34 are used for coupling together sections of the body 22 for mounting around the mandrel 23 . In the embodiments of FIGS. 1 and 2 , the rollers 32 are rotatingly mounted onto the body 22 for facilitating movement of the roller sub 20 within a tubular. The rollers 32 are disklike members having a generally planar surface facing the body 22 and a hemispherically shaped surface facing away from the body 22 . The diameter of the rollers 32 of FIGS. 1 and 2 exceeds the height of the body 22 , so that by positioning the axis of the rollers 32 at about the mid point of the height of the body 22 , the outer radius of the rollers 32 extends past both the upper end lower surfaces of the body 22 . In this example embodiment, the body 22 can be in more than a single orientation that allows the rollers 32 to engage an inner surface of a tubular in which the roller sub 20 is disposed.
[0024] Shown in FIG. 3 is a side perspective and partially exploded view of the roller sub 20 of FIGS. 1 and 2 . In this example, the body 22 of FIGS. 1 and 2 is removed from the assembly 20 so the mid portion of the mandrel 23 is visible. As noted above, the mandrel 23 has a reduced diameter portion to define a spindle 35 over which the body 22 mounts. In the embodiment of FIG. 3 a multiplicity of spherical bearings 36 are shown set within a groove 37 that circumscribes the outer circumference of the spindle 35 . The groove 37 and bearings 36 are shown at an end of the spindle 35 . Although not shown in FIG. 3 , another set of groove 37 and bearings 36 may be included at the opposite end of the spindle 35 . Other embodiments exist wherein the groove 37 and bearings are formed at any axial distance along the length of the spindle 35 .
[0025] Referring now to FIG. 4 , a side sectional view of the assembly 20 from FIG. 3 is provided. In the embodiment of FIG. 4 , a pair of bearing assemblies made up of the bearings 36 set in grooves 37 are illustrated at distal locations on the spindle 35 . The body segments 22 are shown set over the spindle 35 and in contact with the bearings 36 . As will be described in more detail below, the roller sub 20 can be used in conjunction with any thing or device that is insertable within a subterranean well. The things used with the roller sub 20 can be passive or active; examples include a downhole string, downhole tools, completion strings, and any device used in wellbore operations. Also, a component of a tool or string can be used with the roller sub 20 , such as a valve, a packer, a whipstock, a sleeve, and the like. An axle (not shown) couples the rollers 32 to the housing 22 and is rotatable with respect to the housing 22 so that the rollers 32 are freely rotatable as well with respect to the housing 22 . Thus, when set within a tubular within a well, or in an open hole configuration, the rolling action of the rollers 32 introduces less drag than does a downhole string sliding through the well. In an example embodiment, the body segments 22 are positioned on the mandrel 23 , then the bearings 36 are fed into grooves via a slot at each end. A cover 39 is provided for retaining the bearings 36 within the body segments 22 after the bearings 36 are inserted therein. The cover 39 is a substantially solid L shaped member with an elongate portion that inserts into the slot. A lower end of the cover 39 is curved to accommodate the shape of the bearings 36 .
[0026] Moreover, addition of the groove 37 and bearings in the sub 20 enables the housing 22 to axially rotate with respect to the mandrel 23 . As such, orientation of the mandrel 23 along with any associated or attached downhole string or string members experiences a substantially reduced resistance to turning. Thus when a downhole string is to be oriented, such as from an eccentric weight, the likelihood that the desired or selected orientation occurs is substantially increased.
[0027] FIG. 5 illustrates an example of a roller assembly 40 that can be coupled with a downhole string or element of a downhole string. In the embodiment of FIG. 5 , the roller assembly 40 includes a housing 42 made up of a pair of lateral segments 44 , 46 that can be coupled to one another in a clam shell fashion for defining the housing 42 . The lateral segments 44 , 46 of FIG. 5 are bowl shaped members having a convex outer surface on one side and is concave and hollowed out on an opposite side. The concave sides of the lateral segments 44 , 46 are facing one another with the convex sides facing radially outward. Each of the lateral segments 44 , 46 is equipped with a hemispherical roller 48 on the convex outer surface of the lateral segments 44 , 46 , wherein the roller 48 is adapted to freely rotate with respect to either of the lateral segments 44 , 46 . The roller assembly 40 of FIG. 5 is shown set on a cut away of a tubular 50 , wherein the tubular 50 can be a wellbore casing or a section of tubing. As discussed above, the addition of the rollers 48 enables movement of the roller assembly 40 along the axial length of the tubular 50 and substantially parallel with the direction of an axis A L of the tubular 50 . The hollowed out concave sides of the lateral segments 44 , 46 defines a bore 52 when the lateral segments 44 , 46 are coupled as shown in FIG. 5 . An example downhole device 54 (shown in dashed outline) projects through the bore 52 , the downhole device 54 can rotate about axis A L of the tubular 50 as illustrated by arrow A R . An optional opening 56 is shown extending through the housing 42 .
[0028] FIG. 6A provides a partial sectional end view of the roller assembly 40 of FIG. 5 . In this embodiment, a multiplicity of bearings 58 are shown packed in a circumferential assembly within the housing 42 and across an inner periphery of each of the lateral segments 44 , 46 . The bearings 58 provide a frictional reduction for relative motion between the housing 42 and downhole string 54 coaxially set within the housing 42 . Referring back to FIG. 5 , the bearings 58 enhance movement along curved arrow A R . The bearings 58 can be spherical as well as cylindrical roller bearings and can either be individually set within a recess provided on an inner circumference of the housing 42 or within respective inner and outer races (not shown).
[0029] Still referring to FIG. 6A , a side of the rollers 48 facing the lateral segments 44 , 46 can be recessed in order to receive therein outer radial portions of the lateral segments 44 , 46 . The hemispherical outer surface of the rollers 48 is shown having a contour similar to the contour of the tubular 50 so that a larger contact length L and area can be realized between the rollers 48 and inner surface of the tubular 50 . Moreover, spacing the rollers 48 apart a designated distance provides stability of the roller assembly 40 and reduces chances of tipping over in the tubular 50 . Indentations 59 are optionally provided on the hemispherical surface of the rollers 48 that in one example can increase traction between the rollers 48 and tubular 50 and promote rotation of the rollers 48 when the roller assembly 40 moves through the tubular 50 .
[0030] FIG. 6B illustrates an alternate embodiment of a roller assembly 40 B in an end partial sectional view. The tubular 508 of FIG. 6B has a diameter that is less than the diameter of the tubular 50 of FIG. 6A . As such, the width W and diameter D of the rollers 48 B of FIG. 6B are respectively reduced over that of the width W and diameter D of the rollers 48 of FIG. 6A . Whereas the housing 42 of both roller assemblies 40 , 40 B may have substantially the same dimensions. Referring now to FIG. 6C , an example of a roller assembly 40 C is shown in an end partial sectional view, where the roller assembly 40 C is coupled with a downhole tool T and disposed within a tubular 50 C. Here the tool T has an outer diameter of about 85% the inner diameter of the tubular SOC. In this example, the rollers 48 C are dimensioned so that clearance is provided between the lower surface of the tool T and inner surface of the tubular 50 C.
[0031] FIG. 7 provides a partial side sectional view an example of a downhole string 60 set within a subterranean wellbore 62 . In the example of FIG. 7 , the downhole string 60 is made up of a number of individual string members 64 attached in series. Example members include perforating guns, sensors, acoustic devices, submersible pumps, and the like. A wireline 66 is shown suspending the string 60 within the well 62 . A surface truck 68 is provided for manipulating and controlling the string 60 via the wireline 66 . Alternatively, coiled tubing, drill pipe, or other elongate tubulars could be used for deploying the string 60 in the well 62 . In the example of FIG. 7 , roller subs 20 as well as roller assemblies 40 are shown either combined within the string 60 or coupled on an outer surface of the string 60 for facilitating movement throughout the well 62 . In the embodiment of FIG. 7 , the string 60 is optionally equipped with eccentric weights for strategically orienting one or more of the string members 64 within the string. Optionally, springs or motors (not shown) could be used for the step of orienting the string elements. An advantage of the device described herein is that because the reduced friction of axial movement of the string in a wellbore, longer perforating strings can be deployed and properly oriented that in the past. Moreover, as embodiments exist wherein the rollers 32 , 48 respectively project past the outer surface of the body 22 and housing 42 , bodies 22 and/or housings 42 in the string 60 can be azimuthally rotated with respect to other bodies 22 and/or housings 42 in the string 60 so that rolling engagement between the string 60 and tubular (not shown) in the well 62 can occur at any angular position about an axis of the string 60 .
[0032] The improvements described herein, therefore, are well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While presently preferred embodiments have 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 disclosure and the scope of the appended claims. | A downhole system includes a downhole string insertable within a subterranean wellbore and a roller assembly coupled with the string. The roller assembly includes rollers mounted on lateral sides of the downhole string for reducing the resistance of deploying the string within the wellbore. The string is rotatable about its axis with respect to the roller assembly; bearing surfaces, or low torque surfaces, are included in the roller assembly to further reduce rotational friction so the string precisely positions itself to a designated orientation. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims the benefit of U.S. patent application Ser. No. 10/396,619, filed Mar. 25, 2003, entitled “PLOW BLADE WITH WATER PASSAGEWAY.”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] Many types of services are delivered to homes through conduits installed in relatively shallow underground trenches. These include telephone, television, natural gas, electricity, and drainage. These utilities are often installed with a plow. FIG. 1 illustrates an example installation of a utility 20 with a prior art plowing process. A plow 30 is attached to a prime mover, typically a tractor 10 . The tractor 10 propels the plow through the ground. The plow 10 is relatively narrow and will split the ground open with a sharpened steel blade. The utility line 20 is introduced into the ground through a chute 40 that is attached to and directly behind the blade. The chute 40 holds the ground open as the utility line 20 is being fed into the desired vertical position and places the utility line 20 into a horizontal position at the desired depth under ground.
[0004] An alternate configuration is illustrated in FIG. 2 where the utility line 20 is laid out on the ground behind its intended position and then the plow 30 is connected to one end. The plow is then pulled through the ground in order to pull the utility line 20 into the correct position. In this configuration there is no chute.
[0005] Depending on the desired depth, size of utility line, and the ground (soil) conditions (clay, sand, loam, etc.). This process may be slow and require a large amount of power from the tractor 10 to pull the blade/chute through the ground. To reduce this loading various efforts have been made to inject liquid to the plow and to the utility being installed to wet the ground.
[0006] In some past designs the liquid was water, ejected in the direction of travel of the plow blade, and at the edge of the plow blade, utilizing the water to assist in the cutting action required to slice the ground.
[0007] In other designs, useful for applications as illustrated in FIG. 2 , the liquid has been water directed to the area around the utility line being pulled through the ground to lubricate and reduce the frictional drag.
[0008] In still other designs water has been directed through long holes 36 drilled into the blade 34 of the plow 30 . Additional cross-drilled holes threaded to accept cooperating nozzles 38 are drilled near front edge 32 , as illustrated in FIGS. 3 and 4 . Water was then pumped into inlet fitting 37 to route water to the sides of the plow. This design has proven successful as the lubrication provided by the water significantly reduces the power necessary to pull the plow. However this requires complicated manufacturing processes, with the result that a wear item, the blade, becomes a relatively expensive component. There exists a need for a blade to provide this water distribution in a manner, that is less expensive to initially manufacture and to maintain.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention relates to a novel design for a plow blade which provides a fluid passage and points of fluid ejection which is produced with basic manufacturing processes allowing efficient production.
[0010] Another aspect of the present invention is a blade construction including a multiple component assembly. This provides the ability to rebuild a blade, replacing a portion of the blade that may be worn.
[0011] In another aspect of the present invention a process of ejecting a specific fluid at specific points along a plow blade the desirable characteristics are maximized, while the volume of ejected fluid is minimized. This method is adaptable in static plowing and vibratory plowing utilities. Lubricating the sides of the blade/chute that come into contact with the ground with fluid has been found to greatly reduce the amount of drag (friction).
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a side view of a prior art tractor propelling a plow through the ground and installing a utility line that is being ejected through a chute attached to the plow;
[0013] FIG. 2 is a side view of a prior art tractor propelling a plow through the ground and installing a utility that is being pulled through the ground and attached to the plow;
[0014] FIG. 3 is side view of a prior art plow;
[0015] FIG. 4 is cross section of the prior art plow taken along line 4 - 4 as illustrated in FIG. 3 ;
[0016] FIG. 5 is a side view of one embodiment of a plow constructed in a manner of the present invention;
[0017] FIG. 6 is an isometric view of a portion of another embodiment of the plow of the present invention;
[0018] FIG. 7 is a cross-section taken along plane 7 - 7 as illustrated in FIG. 6 ;
[0019] FIG. 8 is an isometric view of a front edge section;
[0020] FIG. 9 is an isometric view of a portion of still another embodiment of the plow of the present invention;
[0021] FIG. 10 is a cross-section taken along plane 10 - 10 as illustrated in FIG. 9 ;
[0022] FIG. 11 is a side view of another preferred embodiment of a plow constructed in a manner of the present invention;
[0023] FIG. 11A is an enlarged view of the part marked 11 A in FIG. 11 ;
[0024] FIG. 12 is a cross-section taken along plane 12 - 12 as illustrated in FIG. 11 ;
[0025] FIG. 13 is cross-section taken along plane 13 - 13 as illustrated in FIG. 11 ;
[0026] FIG. 14 is a partial cross-section taken along plane 13 - 13 as illustrated in FIG. 11 : and
[0027] FIG. 15 is a view like FIG. 7 but showing an alternate embodiment with the void or channel formed in the blade instead of in the back of the front edge section.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring now to the drawings, like reference numerals designate identical or corresponding parts throughout the several views. The included drawings reflect the current preferred and alternate embodiments. There are many additional embodiments that may utilize the present invention. The drawings are not meant to include all such possible embodiments.
[0029] FIG. 5 illustrates a plow 100 constructed according to the principles of the present invention. Plow 100 consists of blade 110 , leading edge sections 120 , point 130 and a fluid tube 140 . Chute 40 is attached to the rear edge 114 of blade 110 , and is constructed to receive and guide utility line 20 from above the ground to the desired depth where it is oriented generally parallel to the ground surface. In other embodiments, the chute may be replaced by a puller adapted to hold a utility line that is being pulled through the ground, similar to the arrangement shown in FIG. 2 .
[0030] The blade 110 further includes a front edge 112 , a top end 116 and a bottom end 118 . The top end 116 includes apertures 117 which will serve as attachment points, to adapt to a power unit. Many different types of power units can be used in conjunction with the preset invention.
[0031] The bottom end 118 is adapted to support a variety of points 130 . The type of point to be installed may be dependent upon the soil conditions of a particular job.
[0032] A component of the present invention is the manner in which the components are assembled to form flow paths for fluid to exit the blade at controlled locations and with a controlled flow rate. The flow paths of this first embodiment illustrated in FIG. 1 are defined when the front edge 120 is attached to the blade 110 . FIG. 8 illustrates a void 124 in surface 122 of leading edge section 120 . Fluid tube 140 is adapted to travel in void 124 to transfer pressurized fluid from the top of plow 100 into the void 124 , and may be sealed with weld 152 illustrated in FIG. 6 . Other forms of sealing the connection between the tube 140 and the front edge sections 120 are possible, but are not illustrated herein as they are not a critical element of the present invention. Tube 140 has a top end 144 and a bottom end 146 and may extend into void 124 for any desired distance, as will be explained later.
[0033] As illustrated in FIGS. 6 and 7 the leading edge sections are attached to blade 110 with stitch welds 150 . Flow paths are defined by providing a small gap 154 between the front surface 112 of the blade and the rear surface 122 . The spaces between the stitch welds 150 results a flow path for the pressurized fluid, allowing fluid to pass from the void 124 , through the gap 154 between surfaces 122 and 112 , and out between the stitch welds 150 . In this manner, the location and length of the stitch welds 150 defines the location at which the fluid will exit the blade 110 . The gap 154 ( FIG. 7 ) between the surfaces 112 and 122 combined with the total amount of weld gap will define the volume at which the fluid will be ejected from the blade 110 at a certain fluid pressure.
[0034] FIG. 15 shows an alternate arrangement of the FIG. 7 structure, having the void or groove 224 formed in the front of the blade instead of having the void or groove 124 formed in the back of the leading edge section as shown in FIG. 7 .
[0035] The fluid pressure at a certain point along the blade's length will vary. If the tube 140 terminates at the top of blade 110 , the fluid pressure will be highest at that point and will decrease at points closer to the bottom. This is not ideal as there tends to be more resistance from the soils near the bottom of the blade, which requires the highest fluid pressure near that area. This is due to the types of soils typically encountered at lower depths. The surface soils typically include some percentage of organic matter, and higher percentage of air pockets: it is typically less dense. The soils encountered at points deeper can include the more difficult soils including clay. Thus there is an area, illustrated in FIG. 5 , as a critical high friction area. This is the area in which the fluid is most critical. In order to assure that the fluid is ejected most aggressively in this area tube 140 can be extended so that it terminates at a position towards the bottom of this critical high friction area, the tube end 146 is located near the bottom end 118 of the blade 110 . The fluid pressure in void 124 will be highest at the point the tube terminates. In this manner the volume of fluid at this point can be maximized.
[0036] In addition to varying the length of tube 140 , the number of leading edge sections 120 that are welded onto blade 110 can be varied to match the requirements of a specific job, including specific installation depths. The number of and location of the stitch welds can also be adjusted to tailor a plow 100 for a specific application. In this manner it is possible to provide a nearly infinite variety of configurations in an economic manner.
[0037] Another embodiment is illustrated in FIGS. 9 and 10 . In this configuration a manifold 160 is installed in between the blade 110 and the leading edge sections 120 . The manifold includes drilled holes 166 extending from a front side 164 to a rear side 162 , as illustrated in FIG. 10 . The drilled holes 166 intersect at the middle, and when the leading edges 120 are installed onto the front side 164 the drilled holes 166 will terminate at the void 124 in the leading edge 120 . In this manner a flow path is defined by the void 124 and the holes 166 which will allow fluid to be routed from tube 140 to nozzles 168 that are installed at the rear side 162 of the manifold 160 .
[0038] In this embodiment varying the nozzles 168 utilized in the assembly allows control of the flow rates and location of the fluid injection. The nozzles 168 can be replaced by plugs (not shown) if there are areas where fluid is not required, and the size of the nozzles 168 can be varied if the there are areas where extra flow is required. It provides a plow that can be modified using hand tools, without welding.
[0039] Still another preferred embodiment is illustrated in FIGS. 11 , 11 A, 12 and 13 . In this embodiment the fluid tube 140 has been located on the opposite side of blade 110 , the rear side 114 . As can be seen in FIG. 12 the fluid tube is located between the blade 110 and the chute 40 . In this configuration it is protected by plates 42 . The fluid tube includes an inlet fitting 142 at the top and travels to the bottom end 118 of blade 110 where it terminates at tube end 146 . The cross hatched portion shown in FIG. 11A represents a weld.
[0040] Tube end 146 is adapted to attach to a bottom end section 126 , as illustrated in FIG. 13 . Bottom end section 126 includes void 128 in the top side 127 as illustrated in FIG. 14 . Tube 140 includes a bend that allows it to enter into void. The tube 140 is then sealed by welding it to the bottom end section 126 and the blade 110 with weld 156 such that the fluid is forced into void 128 . The bottom end section 126 is also welded to the blade 110 at the locations where it contacts the blade 110 , thus sealing the void 128 .
[0041] Void 128 intersects void 124 at the bottom-front corner of blade 110 . At this point the fluid is transferred to void 124 and will flow along the front edge 112 of blade 110 . As described for the previous two embodiments, the fluid can then be allowed to travel to the edge of the blade and out to the soil either through a gap and spaces between stitch welds 150 , or through a manifold 160 between the front edge sections 120 and the blade 110 . FIGS. 11 and 12 illustrate the use of the stitch welds 150 and gaps 151 between stitch welds 150 . However, the manifold 160 would work equally well.
[0042] All the previously described embodiments provide a plow that can be tailored to provide fluid injection characteristics to match specific job requirements. The components are all manufactured with traditional manufacturing processes. The flow paths are defined by stacking together leading edge sections with flow voids, and welding or otherwise attaching them to a blade. This configuration provides appropriate function and provides an easily tailored configuration.
[0043] Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A plow blade having a fluid passageway and points of fluid ejection is produced with basic manufacturing processes allowing for efficient production. The blade construction has a multiple component assembly for providing the ability to rebuild a blade and replacing a portion of the blade that may be worn. In another aspect of the invention a process of ejecting a specific fluid at specific points along a plow blade the desirable characteristics are maximized, while the volume of ejected fluid is minimized. This method is adaptable in static plowing and vibratory plowing utilities since lubricating the sides of the blade/chute that come into contact with the ground with fluid has been found to greatly reduce the amount of drag (friction). |
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a U.S. National Stage Application of International Application No. PCT/US2013/057702 filed Aug. 30, 2013, which is incorporated herein by reference in its entirety for all purposes.
BACKGROUND
This disclosure generally relates to monitoring of hydrocarbon wellbores. In particular, this disclosure relates to systems and methods for monitoring a wellbore using Distributed Acoustic Sensing (DAS).
When performing subterranean operations, acoustic sensing may be used to measure many important properties and conditions of a wellbore, pipeline, other conduit/tube, or fluids used. For example, when performing subterranean operations, it may be desirable to monitor a number of properties related to the subterranean formation and/or conduits used downhole, including, but not limited to, pressure, temperature, porosity, permeability, density, mineral content, electrical conductivity, and bed thickness. Further, certain properties of fluids used in conjunction with performance of subterranean operations, such as pressure, temperature, density, viscosity, chemical elements, and the content of oil, water, and/or gas, may also be important measurements. In addition, downhole-logging tools based on sonic well logging systems may be used to measure downhole properties such as formation porosity, location of bed boundaries and fluid interfaces, well casing condition, and behind casing cement location and bonding quality. Monitoring properties and conditions over time may have significant value during exploration and production activities.
A DAS system may be capable of producing the functional equivalent of 10s, 100s, or even 1000s of acoustic sensors. Properties of downhole formations surrounding or otherwise adjacent to a wellbore may be monitored over time based on the acoustic sensing. Further, hydrocarbon production may be controlled, or reservoirs may be managed based on the downhole formation properties sensed by in-well acoustic measurement methods using a DAS system.
Acoustic sensing based on DAS may use the Rayleigh backscatter property of a fiber's optical core and may spatially detect disturbances that are distributed along the fiber length. Such systems may rely on detecting phase changes brought about by changes in strain along the fiber's core. Externally-generated acoustic disturbances may create very small strain changes to optical fibers. The acoustic disturbance may also be reduced or masked by a cable in which the fiber is deployed.
BRIEF DESCRIPTION OF THE DRAWINGS
These drawings illustrate certain aspects of certain embodiments of the present disclosure. They should not be used to limit or define the disclosure.
FIG. 1 depicts a hydrocarbon drilling site in accordance with one embodiment of the present disclosure.
FIG. 2 depicts a distributed acoustic sensing system.
FIG. 3 depicts a distributed acoustic sensing system in accordance with one embodiment of the present disclosure.
FIG. 4 depicts a distributed acoustic sensing system in accordance with an alternative embodiment of the present disclosure.
FIG. 5 depicts a distributed acoustic sensing system in accordance with an alternative embodiment of the present disclosure.
FIG. 6 depicts a distributed acoustic sensing system in accordance with an alternative embodiment of the present disclosure.
FIG. 7 depicts a distributed acoustic sensing system in accordance with an alternative embodiment of the present disclosure.
While embodiments of this disclosure have been depicted and described and are defined by reference to example embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only, and not exhaustive of the scope of the disclosure.
DETAILED DESCRIPTION
Illustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions may be made to achieve the specific implementation goals, which may vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.
The terms “couple” or “couples” as used herein are intended to mean either an indirect or a direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect electrical or mechanical connection via other devices and connections. The term “upstream” as used herein means along a flow path towards the source of the flow, and the term “downstream” as used herein means along a flow path away from the source of the flow. The term “uphole” as used herein means along the drillstring or the hole from the distal end towards the surface, and “downhole” as used herein means along the drillstring or the hole from the surface towards the distal end.
It will be understood that the term “oil well drilling equipment” or “oil well drilling system” is not intended to limit the use of the equipment and processes described with those terms to drilling an oil well. The terms also encompass drilling natural gas wells or hydrocarbon wells in general. Further, such wells can be used for production, monitoring, or injection in relation to the recovery of hydrocarbons or other materials from the subsurface. This could also include geothermal wells intended to provide a source of heat energy instead of hydrocarbons.
For purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include random access memory (“RAM”), one or more processing resources such as a central processing unit (“CPU”) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of the information handling system may include one or more disk drives, one or more network ports for communication with external devices as well as various input and output (“I/O”) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communications between the various hardware components.
For the purposes of this disclosure, computer-readable media may include any instrumentality or aggregation of instrumentalities that may retain data and/or instructions for a period of time. Computer-readable media may include, for example, without limitation, storage media such as a direct access storage device (e.g., a hard disk drive or floppy disk drive), a sequential access storage device (e.g., a tape disk drive), compact disk, CD-ROM, DVD, RAM, ROM, electrically erasable programmable read-only memory (“EEPROM”), and/or flash memory; as well as communications media such as wires.
To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the disclosure. Embodiments of the present disclosure may be applicable to horizontal, vertical, deviated, multilateral, u-tube connection, intersection, bypass (drill around a mid-depth stuck fish and back into the wellbore below), or otherwise nonlinear wellbores in any type of subterranean formation. Certain embodiments may be applicable, for example, to logging data acquired with wireline, slickline, and logging-while-drilling/measurement-while-drilling (LWD/MWD). Certain embodiments may be applicable to subsea and/or deep sea wellbores. Embodiments described below with respect to one implementation are not intended to be limiting.
FIG. 1 illustrates an example drilling system 100 according to aspects of the present disclosure. The drilling system 100 includes a rig 101 located at a surface 111 and positioned above a wellbore 103 within a subterranean formation 102 . In certain embodiments, a drilling assembly 104 may be coupled to the rig 101 using a drill string 105 . In other embodiments, the drilling assembly 104 may be coupled to the rig 101 using a wireline or a slickline, for example. The drilling assembly 104 may include a bottom hole assembly (BHA) 106 . The BHA 106 may include a drill bit 109 , a steering assembly 108 , and a LWD/MWD apparatus 107 . A control unit 110 located at the surface 111 may include a processor and memory device, and may communicate with elements of the BHA 106 , in the LWD/MWD apparatus 107 and the steering assembly 108 . In certain implementations, the control unit 110 may be an information handling system. The control unit 110 may receive data from and send control signals to the BHA 106 . Additionally, at least one processor and memory device may be located downhole within the BHA 106 for the same purposes. The LWD/MWD apparatus 107 may log the formation 102 both while the wellbore 103 is being drilled, and after the wellbore is drilled to provide information regarding ongoing subterranean operations. The steering assembly 108 may include a mud motor that provides power to the drill bit 109 , and that is rotated along with the drill bit 109 during drilling operations. The mud motor may be a positive displacement drilling motor that uses the hydraulic power of the drilling fluid to drive the drill bit 109 . In accordance with an exemplary embodiment of the present disclosure, the BHA 106 may include an optionally non-rotatable portion. The optionally non-rotatable portion of the BHA 106 may include any of the components of the BHA 106 excluding the mud motor and the drill bit 109 . For instance, the optionally non-rotatable portion may include a drill collar, the LWD/MWD apparatus 107 , bit sub, stabilizers, jarring devices and crossovers. In certain embodiments, the steering assembly 108 may angle the drill bit 109 to drill at an angle from the wellbore 103 . Maintaining the axial position of the drill bit 109 relative to the wellbore 103 may require knowledge of the rotational position of the drill bit 109 relative to the wellbore 103 .
Referring now to FIG. 2 , a system for performing Distributed Acoustic Sensing (DAS) is referenced generally by reference numeral 200 . The system 200 may be incorporated into the drilling assembly 104 and lowered downhole using a drill string, by wireline, slickline, coiled tubing, or by any other means known to those in the art having the benefit of this disclosure. Alternatively, the system 200 or a portion of the system 200 may be positioned downhole for permanent monitoring and coupled to the casing or tubing. The system 200 may be a single pulse coherent Rayleigh scattering system with a compensating inferometer but is not intended to be limited to such.
Still referring to FIG. 2 , a pulse generator 214 may be coupled to a first coupler 210 using the optical fiber 212 . The pulse generator 214 may be located at any suitable location when performing subterranean operations. For instance, in some embodiments, the pulse generator 214 may be located at the surface of the wellbore 103 . The pulse generator 214 may include associated opto-electronics and laser. The first coupler 210 may be a traditional fused-type fiber optic splitter, a circulator, a PLC fiber optic splitter, or any other type of splitter known to those with ordinary skill in the art having the benefit of this disclosure. In other embodiments, the first coupler 210 may be a circulator. Optical pulses from the pulse generator 214 may be amplified using optical gain elements, such as any suitable amplification mechanisms including, but not limited to, Erbium Doped Fiber Amplifiers (EDFAs) or Semiconductor Optical Amplifiers (SOAs).
Still referring to FIG. 2 , a second coupler 208 may be coupled to an interferometer 202 . The second coupler 208 may split light from the optical fiber 232 into two paths along a top interferometer arm 224 and a bottom interferometer arm 222 . In other words, the second coupler 208 may split the backscattered light (e.g., backscattered light 228 ) from the optical fiber 232 into a first backscattered pulse and a second backscattered pulse. The first backscattered pulse may be sent into the top interferometer arm 222 . The second backscattered pulse may be sent into the bottom interferometer arm 224 . The first and second backscattered pulses from the top and bottom interferometer arms 222 , 224 are then re-combined at a third coupler 234 to form an interferometric signal. The first, second, and third couplers 210 , 208 , and 232 may be a traditional fused-type fiber optic splitter, a PLC fiber optic splitter, or any other type of splitter known to those with ordinary skill in the art having the benefit of this disclosure.
The interferometer 202 may be used to determine the relative phase shift variations between the light in the top interferometer arm 224 and the bottom interferometer arm 222 as they recombine. The interferometric signal, i.e., the relative phase shift, will vary over the distance of the distributed optical fiber 226 , and the location of the interferometric signal can be determined using time of flight for the optical pulse 216 . In the illustrative embodiment of FIG. 2 , the interferometer is a Mach-Zehnder interferometer, but it is not intended to be limited to such. For instance, in certain implementations, a Michelson interferometer or any other type of interferometer known to those of skill in the art having the benefit of this disclosure may also be used without departing from the scope of the present disclosure.
The interferometer 202 may be coupled to a photodetector assembly 220 . The photodetector assembly 220 may include associated optics and signal processing electronics (not shown). The photodetector assembly 220 may be a semiconductor electronic device that uses the photoelectric effect to convert light to electricity. The photodetector assembly 220 may be an avalanche photodiode or a pin photodiode but is not intended to be limited to such. As the light from the top interferometer arm 224 and the bottom interferometer arm 222 reach the third coupler 234 , the photodetector assembly 220 may convert the optical signal (i.e., the interferometric signal) to an electronic signal proportional to the acoustic signal along the distributed optical fiber 226 . The photodetector assembly 220 may be coupled to an information handling system 230 . The photodetector assembly 220 and information handling system 230 may be communicatively and/or mechanically coupled. A first device may be communicatively coupled to a second device if it is connected to the second device through a wired or wireless communication network which permits the transmission of information. Thus, the information handling system 230 may be located uphole, downhole, or at a remote location. The information handling system 230 may also be communicatively or mechanically coupled to the pulse generator 214 .
In operation of the system 200 , the pulse generator 214 may generate a first optical pulse 216 which is transmitted through the optical fiber 212 to the first coupler 210 . In certain implementations, the pulse generator 214 may be a laser. The first coupler 210 may direct the first optical pulse 216 through the optical fiber 226 . At least a portion of the optical fiber 226 may be arranged in coils 218 . As the first optical pulse 216 travels through the optical fiber 226 , imperfections in the optical fiber 226 may cause a portion of the light to be backscattered along the optical fiber 226 due to Rayleigh scattering. Scattered light according to Rayleigh scattering is returned from every point along the optical fiber 226 along the length of the optical fiber 226 and is shown as backscattered light 228 in FIG. 2 . This backscatter effect may be referred to as Rayleigh backscatter. Density fluctuations in the optical fiber 226 may give rise to energy loss due to the scattered light, with the following coefficient:
α scat = 8 π 3 3 λ 4 n 8 p 2 kT f β
where n is the refraction index, p is the photoelastic coefficient of the optical fiber 226 , k is the Boltzmann constant, and β is the isothermal compressibility. T f is a fictive temperature, representing the temperature at which the density fluctuations are “frozen” in the material. The optical fiber 226 may be terminated with a low reflection device (not shown). In certain implementations, the low reflection device (not shown) may be a fiber coiled and tightly bent to violate Snell's law of total internal reflection such that all the remaining energy is sent out of the fiber. In other implementations, the low reflection device (not shown) may be an angle cleaved fiber. In still other implementations, the low reflection device (not shown) may be a coreless optical fiber with high optical attenuation. In still other implementations, the low reflection device (not shown) may be a termination, such as the AFL Endlight.
The backscattered light 228 may travel back through the optical fiber 226 , until it reaches the second coupler 208 . The first coupler 210 may be mechanically coupled to the second coupler 208 on one side by the optical fiber 232 such that the backscattered light 228 may pass from the first coupler 210 to the second coupler 208 through the optical fiber 232 . The second coupler 208 may split the backscattered light 228 based on the number of interferometer arms so that one portion of any backscattered light 228 passing through the interferometer 202 travels through the top interferometer arm 224 and another portion travels through the bottom interferometer arm 222 . In other words, the second coupler 208 may split the backscattered light from the optical fiber 232 into a first backscattered pulse and a second backscattered pulse. The first backscattered pulse may be sent into the top interferometer arm 222 . The second backscattered pulse may be sent into the bottom interferometer arm 224 . These two portions may be re-combined at the third coupler 234 , and at that point, they may generate an interferometric signal. In an interferometric signal, two signals are superimposed from points separated by a distance of L, where L is the difference in length between the top interferometer arm 224 and bottom interferometer arm 222 . The output from the compensating interferometer 202 , or the interferometric signal, includes backscattered interfered light from two positions. This interferometric signal may reach the photodetector assembly 220 , where it may be converted to an electrical signal. The photodetector assembly 220 may integrate or add up the number of photons received in a given time period. The photodetector assembly 220 may provide output relating to the backscattered light 228 to the information handling system 230 , which may convey the data to a display and/or store it in computer-readable media.
Referring now to FIG. 3 , an exemplary system for performing Distributed Acoustic Sensing (DAS) is referenced generally by reference numeral 300 . A DAS interrogation unit 310 includes the information handling system 230 , the pulse generator 214 coupled to the information handling system 230 , the photodetector assembly 220 coupled to the information handling system 230 , and an interferometer 302 coupled to the photodetector assembly 220 . As shown in FIG. 3 , the optical fiber 226 may be disposed between the interferometer 302 and the pulse generator 214 but other configurations are possible. The optical fiber 226 may be lowered downhole but the DAS interrogation unit 310 may be located at the surface. Specifically, the optical fiber 226 may be coupled to a casing or tubing.
Still referring to FIG. 3 , the system 300 may include the interferometer 302 . The interferometer 302 may include three or more interferometer arms 304 a -N that may be selectively engaged. Each interferometer arm 304 a -N may be coupled to an optical gain element 306 a -N, and each optical gain element 306 a -N may be coupled to the information handling system 230 . The interferometer arms 304 a -N may each be of a different length. The interferometer arms 304 a -N may be arranged in coils. However, the disclosure is not intended to be limited to any number or combination of coils. An optical gain element 306 a -N may include any amplifier of optical transmissions that uses any suitable means to achieve desired gains and/or any desired attenuation element that may prohibit light from passing through the selected interferometer arms. An example of an attenuation element is a Variable Optical Attenuator (VOA). For instance, in certain implementations, a semiconductor optical amplifier or rare earth doped fiber or any other optical amplification medium known to those with skill in the art may be used to achieve gains. In some embodiments, the optical amplification medium may be replaced with VOAs that may be used to attenuate selected interferometer arms while allowing light to pass through other interferometer arms with minimum attenuation.
Still referring to FIG. 3 , the interferometer 302 may be communicatively and/or mechanically coupled to a photodetector assembly 220 . The photodetector assembly 220 may include associated optics and signal processing electronics. The photodetector assembly 220 may be coupled to an information handling system 230 . The information handling system 230 may be located downhole, uphole, or at a remote location. A second coupler 208 may be part of the interferometer 302 . A first coupler 210 may be coupled at one side to the second coupler 208 and at the other side, to an optical fiber 212 . A pulse generator 214 may be coupled to the first coupler 210 using the optical fiber 212 . The pulse generator 214 may include associated opto-electronics and a laser but is not intended to be limited to such. The pulse generator 214 may be located at any suitable location when performing subterranean operations. For instance, in some embodiments, the pulse generator 214 may be located at the surface of the wellbore 103 .
In operation of the system 300 , the pulse generator 214 may generate a first optical pulse 216 which is transmitted through the optical fiber 212 to the first coupler 210 . The optical pulse may be optically amplified using optical gain elements, for example, Erbium Doped Fiber Amplifiers (EDFAs) or Semiconductor Optical Amplifiers (SOAs). The first coupler 210 may direct the first optical pulse 216 through the optical fiber 226 . At least a portion of the optical fiber 226 may be arranged in coils 218 . As the pulse 216 travels through the optical fiber 226 , imperfections in the optical fiber 226 may cause light to be reflected back along the optical fiber 226 . Backscattered light 228 according to Rayleigh scattering may be returned from every point along the optical fiber 226 along the length of the optical fiber 226 . This backscatter effect may be referred to as Rayleigh backscatter. The optical fiber 226 may be terminated with a low reflection device (not shown). In certain implementations, the low reflection device (not shown) may be a fiber coiled and tightly bent to violate Snell's law of total internal reflection such that all the remaining energy is sent out of the fiber. In other implementations, the low reflection device (not shown) may be an angle cleaved fiber. In still other implementations, the low reflection device (not shown) may be a coreless optical fiber with high optical attenuation. In still other implementations, the low reflection device (not shown) may be a termination, such as the AFL Endlight.
Still referring to FIG. 3 , the backscattered light 228 may travel back through the optical fiber 226 until it reaches the second coupler 208 . The second coupler 208 may be coupled to an interferometer 302 . The second coupler 208 may split the backscattered light 228 from the optical fiber 232 into various paths along the interferometer arms 304 a -N. Two of the optical gain elements 306 a -N may be active and turned on to allow light to pass through, and they may provide gain on two selected interferometer arms (for example, 304 a and 304 b ) while all the other optical gain elements may be turned off to provide high attenuation. Thus, there may be high optical attenuation in the remaining interferometer arms (for example, 304 c -N). The two active optical paths will form an interferometer, and the difference in path length will be dependent on which optical gain elements 306 a -N are active and which optical gain elements 306 a -N are turned off. Thus, the second coupler 208 may split the backscattered light from the optical fiber 232 into a number of backscattered pulses, based on the number of interferometer arms in the interferometer 302 . A first backscattered pulse may be sent into a top interferometer arm. A second backscattered pulse may be sent into a bottom interferometer arm. The interferometer arms 304 a -N may then be re-combined at a third coupler 234 , and the first and second backscattered pulses from the selected active interferometer arms may be re-combined to form an interferometric signal. The interferometric signal is comprised of backscattered interfered light. In an interferometric signal, two signals are superimposed from points separated by a distance of L, where L is the difference in length between the top interferometer arm and bottom interferometer arm. The interferometric signal (i.e., the backscattered interfered light) may be representative of a downhole condition. For example, the downhole condition may include, but is not limited to: perforating, operating downhole hardware, monitoring downhole pumps, sensing acoustic signals during fracturing and in-flow stimulation, water injection, production monitoring, flow regimes, reflection seismic, micro-seismic, and acoustic events related to wellbore integrity (e.g., leaks, cross-flow, and formation compaction). The interferometric signal may also be representative of a condition on pipelines, flow-lines and risers related to flow, leaks, integrity, pigging and maintenance. Further, the interferometric signal may also be representative of conditions on subsea equipment where rotating equipment may cause vibration and/or acoustic noise. Similarly, the interferometric signal may be representative of a condition on infrastructure and security monitoring where it may be beneficial to dynamically vary the optical path length in the system 300 .
Still referring to FIG. 3 , the photodetector assembly 220 may convert the interferometric signal (i.e., an optical signal) to an electrical signal proportional to the acoustic signal along the distributed optical fiber 226 . The photodetector assembly 220 may be an avalanche photodiode or a pin photodiode but is not intended to be limited to such. The photodetector assembly 220 may include associated optics and signal processing electronics that may be used to measure the voltage of the light incoming from the interferometer 202 . The photodetector assembly 220 may be coupled to an information handling system 230 . The photodetector assembly 220 and information handling system 230 may be communicatively and/or mechanically coupled. Thus, the information handling system 230 may be located uphole, downhole, or at a remote location. The information handling system 230 may also be communicatively and/or mechanically coupled to the pulse generator 214 . The photodetector assembly 220 may integrate or add up the number of photons received in a given time period. The photodetector assembly 220 may provide output relating to the back reflected light to the information handling system 230 , which may convey the data to a display and/or store it in computer-readable media.
The optical pulse 216 may travel down the length of the optical fiber 226 while generating backscattered light 228 from various positions along the length of the optical fiber 226 . The time at which the optical pulse 216 is sent from the pulse generator 214 , and the time it takes for the backscattered light 228 to travel to the photodetector assembly 220 may be measured accurately. The velocity of the optical pulse 216 as it travels down the optical fiber 226 may be well-known. The location of any backscattered light 228 may then simply be calculated by measuring the time at which it reaches the photodetector assembly 220 , i.e., a time of flight measurement. Using contiguous readings over the time it takes for the backscattered light 228 to traverse the optical fiber 218 , a measurement may be collected at the photodetector assembly 220 relating to how the back reflected light varies over the length of the optical fiber 226 .
The interferometer arms 304 a -N may each be of a different length. Thus, various combinations of optical gain element 306 a -N may be selectively activated such that the backscattered light 228 may travel through them and the interferometer arm 304 a -N coupled to them, thereby varying the distance over which the reflected optical pulse 228 may travel. Each optical gain element 306 a -N may be communicatively coupled to a control unit (not shown) such that a user may select which optical gain elements 306 a -N may be engaged at any given time. In certain implementations, the control unit may be an information handling system. Alternatively, the optical gain elements 306 a -N may be engaged according to an automated program. Thus, the sensitivity and spatial resolution of the system 300 may be changed in-situ depending on the needs of the system 300 . Applications where active sources are used may generate strong acoustic signals, and users may prefer to have the system settings selected to provide higher spatial resolution with good signal-to-noise ratios. The well depth as well as the associated signal paths may vary. Thus, shallow applications may have a stronger signal, whereas signals in deep wells may experience higher signal attenuation due to the longer travel path for acoustic signals. It may therefore be beneficial to change the difference in path length to optimize the signal-to-noise ratio dependent on the attenuation of the acoustic signals or on the application. Other applications may include micro-seismic sensing and/or passive sensing where small micro-seismic events in the formation may generate noise, and it may be beneficial to record these events and use them for reservoir characterization and optimization.
The term “spatial resolution” as used herein refers to the ability to discriminate between two adjacent acoustic events along an optical fiber. It is generally desirable to have a fine spatial resolution in a system to allow for detection of events that are spatially near each other, like perforations in a hydrocarbon well, for example. The spatial resolution of the system 300 is a function of the width of the first optical pulse 216 and the difference in length between the top interferometer arm, which may be any of 304 a - 304 (N−1) and the bottom interferometer arm, which may be any of 304 b - 304 N, depending on which of the arms in the system have activated optical gain elements 306 a -N. The sensitivity of the system 300 is a function of the difference in length between the top interferometer arm and the bottom interferometer arm, and a greater difference in length between these two fibers improves the system's sensitivity to acoustic and/or vibrational energy. In other words, greater sensitivity allows the system 300 to detect acoustic and/or vibrational events with smaller signal amplitude.
Additional optical pulses may be sent into the optical fiber 226 from the pulse generator 214 in close succession and at a fixed rate. By measuring the backscattered interfered light from each of these optical pulses at the photodetector assembly 220 , a discrete representation of the change in acoustic energy in the wellbore may be measured as a function of time. The changes in acoustic energy may then be correlated with sub-surface events. For example, a change in acoustic energy may be related to a change in flow, a change in solids in a fluid, or a change in the oil/water/gas ratio present in the wellbore 103 . The pulse generator 214 may be operable to vary the pulse width of optical pulses it generates. Further, the differential path length difference between two selected interferometer arms may be varied. In this way, the spatial resolution of the system 300 may be varied.
Referring now to FIG. 4 , an exemplary system for performing Distributed Acoustic Sensing (DAS) according to an alternative embodiment of the present disclosure is referenced generally by reference numeral 400 . As shown in FIG. 4 , the interferometer 402 may be disposed between the pulse generator 214 and the optical fiber 226 , although other configurations are possible. The pulse generator 214 may generate a single pulse that may be split in the first coupler 420 into N paths according to the number of active arms in the interferometer 402 (i.e., those arms of interferometer 402 that allow light transmission). For example, two of the N paths may be active. In this example, a first optical pulse may be split into a number of portions, according to the number of arms in the interferometer 402 . A first portion of the first optical pulse may be sent into a first active arm of the interferometer 402 . A second portion of the first optical pulse may be sent into a second active arm of the interferometer 402 . The first portion and the second portion may then both reenter the optical fiber 408 at the second coupler 422 . The two portions may be separated in time by a delay proportional to the difference in path length between the selected interferometer arms. Both portions may generate backscattered light as they travel down the optical fiber 226 . The backscattered light from the first portion may then interfere with the backscattered light from the second portion. The two portions of backscattered light may interfere in the optical fiber 226 , and they may travel in the optical fiber 226 to the photodetector assembly 220 , where the backscattered interfered light may be converted to an electrical signal. As discussed with respect to FIG. 3 , the backscattered interfered light may be representative of a downhole condition. The downhole condition may include, for example, perforating, operating downhole hardware, monitoring downhole pumps, sensing acoustic signals during fracturing and in-flow stimulation, water injection, production monitoring, flow regimes, reflection seismic, micro-seismic, and acoustic events related to wellbore integrity, like, e.g., leaks, cross-flow, formation compaction. The interferometric signal may also be representative of a condition on pipelines, flow-lines and risers related to flow, leaks, integrity, pigging and maintenance. The interferometric signal may also be representative of conditions on subsea equipment where rotating equipment cause vibration and/or acoustic noise. Similarly, the interferometric system signal may be representative of a condition on infrastructure and security monitoring where it may be beneficial to dynamically vary the optical path length in the system 400 . The spatial resolution and sensitivity of the system 400 may be tuned by changing which optical gain elements 406 a -N are active. As discussed with respect to FIG. 3 , the pulse generator 214 may be operable to vary the optical pulse width. Further, the differential path length difference between two selected interferometer arms may be varied. In this way, the spatial resolution of the system 400 may be varied.
Referring now to FIG. 5 , an exemplary system for performing Distributed Acoustic Sensing (DAS) according to an alternative embodiment of the present disclosure is referenced generally by reference numeral 500 . A DAS interrogation unit 310 , such as that shown in FIG. 3 , includes the information handling system 230 , the pulse generator 214 coupled to the information handling system 230 , the photodetector assembly 220 coupled to the information handling system 230 , and an interferometer 302 coupled to the photodetector assembly 220 . As shown in FIG. 5 , the optical fibers 226 may be disposed between the interferometer 302 and the pulse generator 214 , but other configurations are possible. The optical fibers 226 may be lowered downhole but the DAS interrogation unit 310 may be located at the surface. Specifically, the optical fibers 226 may be coupled to a casing or tubing.
Like system 300 of FIG. 3 , system 500 may include the interferometer 302 . The interferometer 302 may include three or more interferometer arms 304 a -N that may be selectively engaged. Each interferometer arm 304 a -N may be coupled to an optical gain element 306 a -N, and each optical gain element 306 a -N may be coupled to the information handling system 230 . The interferometer arms 304 a -N may each be of a different length. The interferometer arms 304 a -N may be arranged in coils. However, the disclosure is not intended to be limited to any number or combination of coils. An optical gain element 306 a -N may include any amplifier of optical transmissions that uses any suitable means to achieve desired gains and/or any desired attenuation element that may prohibit light from passing through the selected interferometer arms. An example of an attenuation element is a Variable Optical Attenuator (VOA). For instance, in certain implementations, a semiconductor optical amplifier or rare earth doped fiber or any other optical amplification medium known to those with skill in the art may be used to achieve gains. In some embodiments, the optical amplification medium may be replaced with VOAs that may be used to attenuate selected interferometer arms while allowing light to pass through other interferometer arms with minimum attenuation.
Referring to FIG. 5 , the interferometer 302 may be communicatively and/or mechanically coupled to a photodetector assembly 220 . The photodetector assembly 220 may include associated optics and signal processing electronics. The photodetector assembly 220 may be coupled to an information handling system 230 . The information handling system 230 may be located downhole, uphole, or at a remote location. A second coupler 208 may be part of the interferometer 302 . A first coupler 210 may be coupled at one side to the second coupler 208 and at the other side, to an optical fiber 212 . A pulse generator 214 may be coupled to the first coupler 210 using the optical fiber 212 . The pulse generator 214 may include associated opto-electronics and a laser but is not intended to be limited to such. The pulse generator 214 may be located at any suitable location when performing subterranean operations. For instance, in some embodiments, the pulse generator 214 may be located at the surface of the wellbore 103 .
In operation of the system 500 , the pulse generator 214 may generate a first optical pulse 216 which is transmitted through the optical fiber 212 to the first coupler 210 . The optical pulse may be optically amplified using optical gain elements, for example, Erbium Doped Fiber Amplifiers (EDFAs) or Semiconductor Optical Amplifiers (SOAs). The first coupler 210 may direct the first optical pulse 216 through the optical fibers 226 a and 226 b . Before traveling through optical fibers 226 a and 226 b , the light from the first optical pulse 216 may be directed through attenuator or gain elements such as VOAs 510 a and 510 b (corresponding to optical fibers 226 a and 226 b , respectively). VOAs 510 may each be coupled to and controlled by information handling system 230 such that only one of VOAs 510 is activated. In other words, through activation of a particular VOA 510 , information handling system 230 may determine and select which of optical fibers 226 a and 226 b that the light from the first optical pulse 216 may travel through. As the pulse 216 travels through the selected optical fiber 226 , imperfections in the optical fiber may cause light to be reflected back along the optical fiber. Backscattered light according to Rayleigh scattering may be returned from every point along the optical fiber 226 along the length of the optical fiber 226 . This backscatter effect may be referred to as Rayleigh backscatter. Optical fibers 226 a and 226 b may be terminated with a low reflection device (not shown). In certain implementations, the low reflection device (not shown) may be a fiber coiled and tightly bent to violate Snell's law of total internal reflection such that all the remaining energy is sent out of the fiber. In other implementations, the low reflection device (not shown) may be an angle cleaved fiber. In still other implementations, the low reflection device (not shown) may be a coreless optical fiber with high optical attenuation. In still other implementations, the low reflection device (not shown) may be a termination, such as the AFL Endlight.
In particular implementations, one or both of optical fibers 226 may comprise a coating that, when exposed to an electromagnetic signal (e.g., electromagnetic signal 560 from electromagnetic source 550 ), causes the fiber to expand or contract. The electromagnetic signal 560 may come from any electromagnetic source 550 , which may be located adjacent to system 500 . For example, one or more electromagnetic sources may be deployed in adjacent wells to system 500 , on the surface of a well in which system 500 is deployed, or on the ocean floor near a well in which system 500 is deployed. Electromagnetic sources 550 may operate at a range of 0.1 Hz to 30 kHz in particular implementations. In some implementations, the coating may include a magnetostrictive material that may surround the optical fiber(s) 226 or may be bonded to the optical fiber(s) 226 . Some examples of magnetostrictive materials include Cobalt, Iron, Nickel, alloys of the preceding, METGLAS, and Terfenol-D. Examples of magnetostrictive materials that may expand when exposed to an electromagnetic signal (i.e., negative magnetostriction) include METGLAS, Iron, Permalloy, and Terfenol-D. Examples of magnetostrictive materials that may contract when exposed to an electromagnetic signal (i.e., negative magnetostriction) include Nickel, Cobalt, ferrites, Nickel ferrites, and Cobalt-doped Nickel ferrites.
In some implementations, only one fiber of optical fibers 226 may comprise a coating that causes it to expand when exposed to an electromagnetic signal (e.g., electromagnetic signal 560 ). For example, as shown in FIG. 5 , optical fiber 226 a may comprise a coating that causes it to expand when exposed to electromagnetic signal 560 (as shown by the dotted line extending the length of optical fiber 226 a in FIG. 5 ), while optical fiber 226 b may not comprise any coating and may not expand or contract when exposed to the same electromagnetic signal 560 as optical fiber 226 a . In other implementations, one fiber of optical fibers 226 may comprise a coating that causes it to expand when exposed to electromagnetic signal 560 , while the other fiber of optical fibers 226 may comprise a coating that causes it to contract when exposed to the same electromagnetic signal 560 . For example, although not shown in FIG. 7 , optical fiber 226 a may comprise a coating that causes it to expand when exposed to an electromagnetic signal, while optical fiber 226 b may comprise a coating that causes it to contract when exposed to the same electromagnetic signal as optical fiber 226 a.
In operation of system 500 , an electromagnetic signal 560 from electromagnetic source 550 may be applied to or received at each of optical fibers 226 simultaneously, causing optical fibers 226 a and 226 b to have different lengths (due to one or both of optical fibers 226 having a magnetostrictive coating as described above). For example, as shown in FIG. 5 , optical fiber 226 a may be coated with a magnetostrictive coating causing it to expand and lengthen when exposed to electromagnetic signal 560 (as shown by the dotted line in FIG. 5 ), while optical fiber 226 b may have no magnetostrictive coating and may not expand or contract in the presence of the electromagnetic signal 560 . Backscattered light from the first optical pulse 216 may then return back through the selected optical fiber 226 and through a second coupler 208 . The second coupler 208 may be coupled to an interferometer 302 . The second coupler 208 may split the backscattered light from the optical fiber 232 into various paths along the interferometer arms 304 a -N. As described above with respect to FIG. 3 , two of the optical gain elements 306 a -N may be active and turned on to allow light to pass through, and they may provide gain on two selected interferometer arms (for example, 304 a and 304 b ) while all the other optical gain elements may be turned off to provide high attenuation. Thus, there may be high optical attenuation in the remaining interferometer arms (for example, 304 c -N). The two active optical paths will form an interferometer, and the difference in path length will be dependent on which optical gain elements 306 a -N are active and which optical gain elements 306 a -N are turned off. Thus, the second coupler 208 may split the backscattered light from the optical fiber 232 into a number of backscattered pulses, based on the number of interferometer arms in the interferometer 302 . A first backscattered pulse may be sent into a top interferometer arm. A second backscattered pulse may be sent into a bottom interferometer arm. The interferometer arms 304 a -N may then be re-combined at a third coupler 234 , and the first and second backscattered pulses from the selected active interferometer arms may be re-combined to form an interferometric signal comprised of backscattered interfered light.
After the interferometric signal has passed through the third coupler 234 , the photodetector assembly 220 may convert the interferometric signal (i.e., an optical signal) to an electrical signal proportional to the acoustic signal along the distributed optical fibers 226 a and 226 b . The photodetector assembly 220 may be an avalanche photodiode or a pin photodiode but is not intended to be limited to such. The photodetector assembly 220 may include associated optics and signal processing electronics that may be used to measure the voltage of the light incoming from the interferometer 202 . The photodetector assembly 220 may be coupled to an information handling system 230 . The photodetector assembly 220 and information handling system 230 may be communicatively and/or mechanically coupled. Thus, the information handling system 230 may be located uphole, downhole, or at a remote location. The information handling system 230 may also be communicatively and/or mechanically coupled to the pulse generator 214 . The photodetector assembly 220 may integrate or add up the number of photons received in a given time period. The photodetector assembly 220 may provide output relating to the back reflected light to the information handling system 230 , which may convey the data to a display and/or store it in computer-readable media.
The backscattered interfered light may be representative of a downhole condition. The downhole condition may include, for example, perforating, operating downhole hardware, monitoring downhole pumps, sensing acoustic signals during fracturing and in-flow stimulation, water injection, production monitoring, flow regimes, reflection seismic, micro-seismic, and acoustic events related to wellbore integrity, like, e.g., leaks, cross-flow, formation compaction. The interferometric signal may also be representative of a condition on pipelines, flow-lines and risers related to flow, leaks, integrity, pigging and maintenance. The interferometric signal may also be representative of conditions on subsea equipment where rotating equipment cause vibration and/or acoustic noise. Similarly, the interferometric system signal may be representative of a condition on infrastructure and security monitoring where it may be beneficial to dynamically vary the optical path length in the system 500 . The spatial resolution and sensitivity of the system 500 may be tuned by changing which optical gain elements 306 a -N are active. The pulse generator 214 may be operable to vary the optical pulse width. Further, the differential path length difference between two selected interferometer arms may be varied. In this way, the spatial resolution of the system 500 may be varied.
As described above with respect to FIG. 3 , measuring the backscattered interfered light at the photodetector assembly 220 may allow a user to determine a discrete representation of the change in acoustic or vibrational energy in the wellbore as a function of time. Using system 500 as described above, a user may be able to measure backscattered interfered light coming from each of optical fibers 226 a and 226 b when each is exposed to an electromagnetic signal such as electromagnetic signal 560 , with each path being selected at different times (but still substantially close in time to each other such that acoustic or vibrational energy measurements are not substantially different from one another). For instance, a first path through one of the optical fibers 226 may be selected first with backscatter light measured from that path first, and a second path through the other optical fiber 226 may be selected second with backscatter light measured from that path second. Because of the difference in length of these paths when exposed to an electromagnetic signal, the backscattered light measured from the first path (e.g., through optical fiber 226 a of FIG. 5 ) and the backscattered light measured from the second path (e.g., through optical fiber 226 b of FIG. 5 ). The measurements from each path may comprise the same measure of acoustic and/or vibrational energy, but may comprise differing measures of the electromagnetic energy due to one or both fibers expanding or contracting due to the applied electromagnetic signal.
By varying the spatial resolution of system 500 as described above, a user may be able to measure resistivity of a formation at different distances along the optical fibers 226 and thus may be able to detect flooding of a well. In addition, by varying the spatial resolution as described above, a user may be able to vary the sensitivity of measurements and may thus measure resistivity of signals with varying strength. This is especially true if there are multiple electromagnetic sources adjacent to system 500 having varying distances between the positive and negative poles.
Referring now to FIG. 6 , an exemplary system for performing Distributed Acoustic Sensing (DAS) according to an alternative embodiment of the present disclosure is referenced generally by reference numeral 600 . As shown in FIG. 6 , the interferometer 402 may be disposed between the pulse generator 214 and the optical fibers 226 a and 226 b , although other configurations are possible. The pulse generator 214 may generate a single pulse that may be split in the first coupler 420 into N paths according to the number of active arms in the interferometer 402 (i.e., those arms of interferometer 402 that allow light transmission). For example, two of the N paths may be active. In this example, a first optical pulse may be split into a number of portions, according to the number of arms in the interferometer 402 . A first portion of the first optical pulse may be sent into a first active arm of the interferometer 402 . A second portion of the first optical pulse may be sent into a second active arm of the interferometer 402 . The first portion and the second portion may then both reenter the optical fiber 408 at the second coupler 422 . The two portions may be separated in time by a delay proportional to the difference in path length between the selected interferometer arms.
As described with respect to FIG. 5 , the light from the two portions of the first optical pulse 216 may be directed through attenuator or gain elements such as VOAs 510 a and 510 b (corresponding to optical fibers 226 a and 226 b , respectively) before traveling through optical fibers 226 a and 226 b . VOAs 610 may each be coupled to and controlled by information handling system 230 such that only one of VOAs 610 is activated. Thus, through activation of a particular VOA 610 , information handling system 230 may determine and select which of optical fibers 226 a and 226 b that the portions of the first optical pulse 216 may travel through. Similar to optical fibers 226 in FIG. 5 , one or both of optical fibers 226 of system 600 may comprise a coating that, when exposed to an electromagnetic signal (e.g., electromagnetic signal 660 from electromagnetic source 650 ), causes the fiber to expand or contract. The electromagnetic signal 660 may come from any electromagnetic source 650 , which may be located adjacent to system 600 . In some implementations, the coating may include a magnetostrictive material that may surround the optical fiber(s) 226 or may be bonded to the optical fiber(s) 226 . In some implementations, only one fiber of optical fibers 226 may comprise a coating that causes it to expand when exposed to an electromagnetic signal (e.g., electromagnetic signal 660 ). In other implementations, one fiber of optical fibers 226 may comprise a coating that causes it to expand when exposed to electromagnetic signal 660 , while the other fiber of optical fibers 226 may comprise a coating that causes it to contract when exposed to the same electromagnetic signal 660 .
In operation of system 600 , an electromagnetic signal 660 from electromagnetic source 650 may be applied to or received at each of optical fibers 226 simultaneously, causing optical fibers 226 a and 226 b to have different lengths (due to one or both of optical fibers 226 having a magnetostrictive coating as described above). For example, as shown in FIG. 6 , optical fiber 226 a may be coated with a magnetostrictive coating causing it to expand and lengthen when exposed to electromagnetic signal 660 (as shown by the dotted line in FIG. 6 ), while optical fiber 226 b may have no magnetostrictive coating and may not expand or contract in the presence of the electromagnetic signal 660 . As the portions of the optical pulse travel down the selected optical fiber 226 , they may generate backscattered light. The backscattered light from the first portion may then interfere with the backscattered light from the second portion. The two portions of backscattered light may interfere in the selected optical fiber 226 and may travel toward the photodetector assembly 220 , where the backscattered interfered light may be converted to an electrical signal.
As discussed with respect to FIG. 5 , the backscattered interfered light may be representative of a downhole condition, such as, for example, perforating, operating downhole hardware, monitoring downhole pumps, sensing acoustic signals during fracturing and in-flow stimulation, water injection, production monitoring, flow regimes, reflection seismic, micro-seismic, and acoustic events related to wellbore integrity, like, e.g., leaks, cross-flow, formation compaction. The interferometric signal may also be representative of a condition on pipelines, flow-lines and risers related to flow, leaks, integrity, pigging and maintenance. The interferometric signal may also be representative of conditions on subsea equipment where rotating equipment cause vibration and/or acoustic noise. Similarly, the interferometric system signal may be representative of a condition on infrastructure and security monitoring where it may be beneficial to dynamically vary the optical path length in the system 600 . The spatial resolution and sensitivity of the system 600 may be tuned by changing which optical gain elements 406 a -N are active. In addition, the pulse generator 214 may be operable to vary the optical pulse width. Further, the differential path length difference between two selected interferometer arms may be varied. In this way, the spatial resolution of the system 400 may be varied.
Using system 600 as described above, a user may be able to measure backscattered interfered light coming from each of optical fibers 226 a and 226 b when each is exposed to an electromagnetic signal such as electromagnetic signal 660 , with each path being selected at different times (but still substantially close in time to each other such that acoustic or vibrational energy measurements are not substantially different from one another). For instance, a first path through one of the optical fibers 226 may be selected first with backscattered light measured from that path first, and a second path through the other optical fiber 226 may be selected second with backscattered light measured from that path second. Because of the difference in length of these paths when exposed to an electromagnetic signal, the backscattered light measured from the first path (e.g., through optical fiber 226 a of FIG. 6 ) and the backscattered light measured from the second path (e.g., through optical fiber 226 b of FIG. 6 ). The measurements from each path may comprise the same measure of acoustic and/or vibrational energy, but may comprise differing measures of the electromagnetic energy due to one or both fibers expanding or contracting due to the applied electromagnetic signal.
By varying the spatial resolution of system 600 as described above, a user may be able to measure resistivity of a formation at different distances along the optical fibers 226 , and thus may be able to detect flooding of a well. In addition, by varying the spatial resolution as described above, a user may be able to vary the sensitivity of measurements and may thus measure resistivity of signals with varying strength. This is especially true if there are multiple electromagnetic sources adjacent to system 600 having varying distances between the positive and negative poles.
Referring now to FIG. 7 , an exemplary system for performing Distributed Acoustic Sensing (DAS) according to an alternative embodiment of the present disclosure is referenced generally by reference numeral 700 . A DAS interrogation unit 710 includes the information handling system 230 , the pulse generator 214 coupled to the information handling system 230 , and the photodetector assembly 220 coupled to the information handling system 230 . DAS interrogation unit 710 may be coupled to optical fibers 726 as shown in FIG. 7 . The optical fibers 726 may be lowered downhole but the DAS interrogation unit 710 may be located at the surface. Specifically, the optical fibers 726 may be coupled to a casing or tubing.
In particular implementations, pulse generator 214 may generate a pulse that travels through coupler 708 , creating pulses 716 a and 716 b . Pulses 716 a and 716 b may then travel down optical fibers 726 a and 726 b , respectively, and may each have the same pulse width. As pulses 716 travel through the optical fibers 726 , imperfections in the optical fibers 726 may cause a portion of the light to be backscattered along the optical fibers 726 due to Rayleigh scattering. Scattered light according to Rayleigh scattering is returned from every point along the optical fibers 726 along the length of the optical fibers 726 . This backscatter effect may be referred to as Rayleigh backscatter. The optical fibers 726 may be terminated with a low reflection device (not shown). In certain implementations, the low reflection device (not shown) may be a fiber coiled and tightly bent to violate Snell's law of total internal reflection such that all the remaining energy is sent out of the fiber. In other implementations, the low reflection device (not shown) may be an angle cleaved fiber. In still other implementations, the low reflection device (not shown) may be a coreless optical fiber with high optical attenuation. In still other implementations, the low reflection device (not shown) may be a termination, such as the AFL Endlight.
In particular implementations, one or both of optical fibers 726 may comprise a coating that, when exposed to an electromagnetic signal (e.g., electromagnetic signal 760 from electromagnetic source 750 ), causes the fiber to expand or contract. The electromagnetic signal 760 may come from any electromagnetic source 750 , which may be located adjacent to system 700 . For example, one or more electromagnetic sources may be deployed in adjacent wells to system 500 , on the surface of a well in which system 500 is deployed, or on the ocean floor near a well in which system 500 is deployed. In some implementations, the coating may include a magnetostrictive material that may surround the optical fiber(s) 726 or may be bonded to the optical fiber(s) 726 . Some examples of magnetostrictive materials include Cobalt, Iron, Nickel, alloys of the preceding, METGLAS, and Terfenol-D. Examples of magnetostrictive materials that may expand when exposed to an electromagnetic signal (i.e., negative magnetostriction) include METGLAS, Iron, Permalloy, and Terfenol-D. Examples of magnetostrictive materials that may contract when exposed to an electromagnetic signal (i.e., negative magnetostriction) include Nickel, Cobalt, ferrites, Nickel ferrites, and Cobalt-doped Nickel ferrites.
In some implementations, only one fiber of optical fibers 726 may comprise a coating that causes it to expand when exposed to an electromagnetic signal (e.g., electromagnetic signal 760 ). For example, as shown in FIG. 7 , optical fiber 726 a may comprise a coating that causes it to expand when exposed to electromagnetic signal 760 (as shown by the dotted line extending the length of optical fiber 726 a in FIG. 7 ), while optical fiber 726 b may not comprise any coating and may not expand or contract when exposed to the same electromagnetic signal 760 as optical fiber 726 a . In other implementations, one fiber of optical fibers 726 may comprise a coating that causes it to expand when exposed to electromagnetic signal 760 , while the other fiber of optical fibers 726 may comprise a coating that causes it to contract when exposed to the same electromagnetic signal 760 . For example, although not shown in FIG. 7 , optical fiber 726 a may comprise a coating that causes it to expand when exposed to an electromagnetic signal, while optical fiber 726 b may comprise a coating that causes it to contract when exposed to the same electromagnetic signal as optical fiber 726 a.
In particular implementations of system 700 , such as the one shown in FIG. 7 , an electromagnetic signal 760 from electromagnetic source 750 may be applied to or received at each of optical fibers 726 simultaneously, causing optical fibers 726 a and 726 b to have different lengths (due to one or both of optical fibers 726 having a magnetostrictive coating as described above; as shown in FIG. 7 , optical fiber 726 a may be coated with a magnetostrictive coating while optical fiber 726 b may have no magnetostrictive coating). Pulses 716 a and 716 b may be sent down optical fibers 726 a and 726 b , respectively, through couplers 720 a and 720 b , respectively. Backscattered light from pulses 716 a and 716 b may then return back through optical fibers 726 a and 726 b , respectively, and through couplers 720 a and 720 b , respectively, on its way toward coupler 730 . Coupler 730 may then combine the backscattered light from pulses 716 a and 716 b , generating an interferometric signal that is then sent to photodetector 220 . The interferometric signal therefore includes backscattered, interfered light from two positions along the length of optical fibers 726 . The photodetector assembly 220 may then convert the interferometric signal to an electrical signal, which may be done in certain implementations by integrating or adding up the number of photons received in a given time period. The photodetector assembly 220 may then provide output relating to the interferometric signal to the information handling system 230 , which may convey the data output to a display and/or store it in computer-readable media.
In operation of system 700 , the information handling system 230 may compare the interferometric signal to determine a phase difference between the backscattered light coming from optical fiber 726 a and the backscattered light coming from optical fiber 726 b . Because of the difference in distance caused by the electromagnetic signal, the phase difference between the backscattered light coming from optical fiber 726 a and the backscattered light coming from optical fiber 726 b may be proportional to the electromagnetic signal. This is because the backscattered light coming from optical fiber 726 a and the backscattered light coming from optical fiber 726 b may each comprise information about acoustic energy and/or vibrational energy in the near the optical fibers 726 , but may be out of phase because of the difference in length between the optical fibers 726 a and 726 b . Thus, information handling system 230 may be able to determine a magnitude of the electromagnetic signal 760 applied to or received at the optical fibers 726 by determining the phase difference between the backscattered light coming from optical fiber 726 a and the backscattered light coming from optical fiber 726 b.
In particular implementations of system 700 , spatial resolution of system 700 may be varied by varying the pulse width of optical pulses 716 a and 716 b . For example, using lower pulse widths in pulses 716 a and 716 b may allow for shorter spatial resolution. However, lower pulse widths may cause a lower signal level in the backscattered light from optical fibers 726 . This may not be an issue at higher wellbore depths, but may be an issue at lower wellbore depths. Accordingly, information handling system 230 may increase the pulse width in order to have higher spatial resolution and better visibility into the lower wellbore depths.
Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. | Systems and methods for distributed acoustic sensing based on coherent Rayleigh scattering are disclosed herein. A system comprises a pulse generator, optical fibers coupled to the pulse generator, an interferometer coupled to the optical fibers, a photodetector assembly coupled to the interferometer, and an information handling system configured to detect a difference in backscattered light from the optical fibers. A method comprises sending an optical pulses down optical fibers, receiving backscattered light from the optical pulses, combining the backscattered light from the optical pulses to form an interferometric signal, receiving the interferometric signal at a photodetector assembly, and determining a difference in the interferometric signal at an information handling system. |
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TECHNICAL FIELD
[0001] This invention relates generally to a foldable blade and, more particularly, to a foldable blade having folding wing portions.
BACKGROUND
[0002] Blade assemblies are widely used in earth working machinery as well as other similar machines in order to push, scrape or otherwise transport earth between two remote locations. These same blade assemblies may also be used to clear snow from highways, streets and parking lots, as well as perform a host of other tasks.
[0003] Typically, blade assemblies include a replaceable cutting edge at the bottom portion of the blade and a stiffener plate at the opposing top portion of the blade. Also, conventional blade assemblies are of a fixed length typically greater than three (3) meters. This fixed length enables the blade to scrape or push a large amount of earth during each pass of the machine.
[0004] However, some blades are of such a large length that transporting the machine is of great difficulty. This is due mainly to the limited width of many highways, streets and the like. In fact, there are even many regulations, both domestically and internationally, that regulate or limit the entire width of the machine during transport. In one such known regulation, the width of the entire machine during transport is limited to no more than approximately three (3) meters. Thus, with blades over three (3) meters in length, for example, the entire blade assembly must be removed from the machine prior to transporting the machine.
[0005] The removal of the blade assembly from the machine is a very time consuming and tedious task. This can also be a very cost prohibitive procedure, especially when the machine must be transported several times depending on the location of the next work site. In any event, in order to remove the blade from the machine, several hydraulic systems, wiring harnesses and other mechanics must be disassembled, removed and stored prior to the transporting of the machine. To reattach the blade assembly to the machine, the reverse operation must be performed. After the blade is reassembled, the hydraulics as well as other components must be tested for reliability.
[0006] U.S. Pat. No. 5,638,618 to Niemela et al., issued on Jun. 17, 1997, discloses a plow with plow wings which are individually adjustable for both extension and forward angling. A hydraulic cylinder is pivotally attached to the plow wings and, when actuated, extends and forward angles the plow wings. However, during use of the plow a large load is placed upon the wings, and hence the hydraulic cylinder. This large load placed on the hydraulic cylinder may damage or even result in total failure of the hydraulic cylinder thus leading to collapse of the plow wings. This will render the plow useless and will require valuable time to repair.
[0007] The present invention is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
[0008] In one aspect of the present invention, a foldable blade has a main body portion and at least one side foldable wing portion rotatably mounted to a side of the main body portion between a first position and a second position. A first locking assembly is positioned between the main body portion and the at least one side foldable wing portion and locks the at least one side foldable wing in the first position and the second position. A second locking assembly is positioned between the main body portion and the at least one side foldable wing portion and locks the at least one side foldable wing portion in the first position.
[0009] In another aspect of the present invention, a foldable blade has a main body portion and a foldable wing portion rotatably mounted, between a first position and a second position, to the main body portion. A locking mechanism is positioned between the main body portion and the foldable wing portion, and includes a first locking assembly and a second locking assembly. The foldable wing portion is rotated about the first locking assembly and locked in the first and second positions by the first locking assembly and further locked in the second position by the second locking assembly.
[0010] In still another aspect of the present invention, a method of folding and locking a foldable blade into a retracted position is provided. The method has the steps of removing a first pin from apertures of a first locking assembly and removing a second pin from apertures of a second locking assembly. A side wing of the foldable blade is then extended outward and rotated rearwardly about a pivot pin of the first locking assembly. A second set of apertures of the first locking assembly are then aligned and a pin is inserted therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 shows a front view of the foldable blade of the present invention;
[0012] [0012]FIG. 2 shows a rear view of the foldable blade of the present invention;
[0013] [0013]FIG. 3 shows a locking mechanism of the foldable blade in a locked first position;
[0014] [0014]FIG. 4 shows a foldable wing of the foldable blade in an extended position;
[0015] [0015]FIG. 5 shows the locking mechanism in a locked second position;
[0016] [0016]FIG. 6 shows a second embodiment of the locking mechanism of the foldable blade in a locked first position;
[0017] [0017]FIG. 7 shows the foldable wing in an extended position; and
[0018] [0018]FIG. 8 shows the locking mechanism of the second embodiment in a locked second position.
DETAILED DESCRIPTION
[0019] [0019]FIG. 1 shows a foldable blade of the present invention. The foldable blade is generally depicted as reference numeral 2 and includes a main body portion 4 and opposing side foldable wing portions 6 in substantial alignment with the main body portion 4 . The foldable blade 2 also includes a main cutting edge or scraper 8 at a bottom portion of the main body portion 4 and the opposing side foldable wing portions 6 . A stiffener bar 10 is provided at an opposing top portion of the main blade portion 4 . A face 12 of the foldable blade 2 is preferably a concave shape.
[0020] [0020]FIG. 2 shows a rear view of the foldable blade 2 . In this view, a side plate 18 is shown fixed to the foldable wing portions 6 and a hitch mechanism 20 is shown mounted on the rear portion of the main body portion 4 . A locking mechanism is also shown on the rear side of the foldable blade 2 between each of the foldable wing portions 6 and the main body portion 4 . The locking mechanism includes a first locking assembly generally depicted as reference numeral 14 and a second locking assembly generally depicted as reference numeral 16 . The first locking assembly 14 is located near a top portion of the foldable blade 2 between the foldable wing portion 6 and the main body portion 4 . The second locking assembly 16 is located near a bottom portion of the foldable blade 2 also between the foldable wing portion 6 and the main body portion 4 .
[0021] It should be recognized by those of ordinary skill in the art that the first locking assembly 14 and the second locking assembly 16 may also be located at other positions between the main body portion 4 and the foldable wing portion 6 . For example, the first locking assembly 14 may be located at the bottom portion of the main body portion 4 and the foldable wing portion 6 . Also, the use of a single foldable wing portion 6 on either side of the main body portion 4 is contemplated by the present invention. In such case, it is only necessary to provide one locking mechanism, i.e., one each of the first and second locking assemblies.
[0022] [0022]FIG. 3 shows a first embodiment of the locking mechanism of the foldable blade 2 . In FIG. 3, the first locking assembly 14 of the locking mechanism is shown to include a top plate 22 and a bottom plate 24 fixed to the main body portion 4 of the foldable blade 2 . Both the top plate 22 and the bottom plate 24 include extended portions (ears) 22 a and 24 a , respectively. The first locking assembly 14 also includes an intermediate plate 26 fixed to the foldable wing portion 6 between the top plate 22 and the bottom plate 24 . The top plate 22 and the bottom plate 24 each have respectively aligned apertures 28 a , 28 b and 28 c , where the aligned apertures 28 c preferably extend through the ears 22 a and 24 a . The intermediate plate 26 also includes apertures 30 a , 30 b and 30 c which will align with the apertures 28 a , 28 b and 28 c . (Aperture 30 b of the intermediate plate 26 is shown more clearly in FIG. 5.)
[0023] A plate guide 32 having an elongated slot 34 is fixed to the foldable wing portion 6 . The shape of the plate guide 32 is preferably curved such that the elongated slot 34 is aligned with the apertures 28 a of the top plate 22 and the bottom plate 24 and the aperture 30 a of the intermediate plate 26 . A first pin 36 is positioned within the aligned apertures 28 a and 30 a and extends through the top plate 22 , the bottom plate 24 and the intermediate plate 26 . The first pin 36 also extends into the elongated slot 34 of the plate guide 32 . A bearing 38 may be positioned about the aperture 30 a of the intermediate plate 26 . In the first locked position, a second pin 40 is inserted through the apertures 28 b and 30 b thus extending through the top plate 22 , the bottom plate 24 and the intermediate plate 26 .
[0024] Still referring to FIG. 3, the second locking assembly 16 of the locking mechanism includes a recess portion 42 mounted at a bottom portion of the main body portion 4 . The recess portion 42 includes an aperture 44 located therethrough. A lock bar 46 is mounted to a bottom portion of the foldable wing portion 6 and is aligned with and engages the recess portion 42 when in a locked position. The lock bar 46 also includes an aperture 48 (FIG. 4) which is in alignment with the aperture 44 of the recess portion 42 . A third pin 50 is inserted through the apertures 44 and 48 .
[0025] [0025]FIG. 4 shows the foldable wing portion 6 in an extended position and the locking assemblies 14 and 16 in an unlocked state. In the unlocked state, the second pin 40 is disengaged from the aligned apertures 28 b and 30 b , and the third pin 50 is disengaged from the apertures 44 and 48 . The lock bar 46 is also removed from the recess 42 . The elongated slot 34 of the plate guide 32 is translated to a second position with respect to the first pin 36 .
[0026] [0026]FIG. 5 shows the first locking assembly 14 and the second locking assembly 16 in a locked second position. In this locked second position, the foldable wing portion 6 is in a retracted or folded position behind the face 12 of the foldable blade 2 . Also, the apertures 28 c located in the respective ears 22 a and 24 a of the top plate 22 and the bottom plate 24 are aligned with the aperture 30 c of the intermediate plate 26 . A locking pin 52 is inserted through the apertures 28 c and 30 c . The second pin 40 may be placed through the aligned apertures 28 b of the top plate 22 and the bottom plate 24 , while the entire foldable wing portion 6 is rotatable about the first pin 36 . The third pin 50 may be placed through the aperture 44 and extended through the recess portion 42 .
[0027] [0027]FIG. 6 shows a second embodiment of the locking mechanism of the present invention. In this embodiment, the first locking assembly 14 is the same as the first locking assembly 14 of FIGS. 3 - 5 and a discussion herein is thus omitted. The second locking assembly 16 includes the recess portion 42 and the lock bar 46 . A bolt hole 54 extends longitudinally through the lock bar 46 and is aligned with a bolt hole 56 located at a remote end of the recess portion 42 . In the locked position of FIG. 6, the lock bar 46 extends into the recess and a bolt (or pin) 58 extends through the bolt hole 54 of the lock bar 46 and into the bolt hole 56 of the recess portion 42 .
[0028] [0028]FIG. 7 shows the foldable wing portion 6 in an extended position. Much like the extended position shown in FIG. 4, the second pin 40 is disengaged from the apertures 28 b and 30 b of the first locking assembly 14 , and the elongated slot 34 of the plate guide 32 is translated to a second position with respect to the first pin 36 . In this embodiment, the bolt 58 is disengaged from the bolt hole 56 and the lock bar 46 is also removed from the recess portion 42 .
[0029] [0029]FIG. 8 shows the locking mechanism of the second embodiment in a locked second position. In this locked second position, the foldable wing portion 6 is in a retracted or folded position behind the face 12 of the foldable blade 2 . The apertures 28 c located on the respective ears 22 a and 24 a are aligned with the aperture 30 c of the intermediate plate 26 . The locking pin 52 is inserted through the apertures 28 c and 30 c . The second pin 40 may be placed through the aligned apertures 28 b of the top plate 22 and the bottom plate 24 . Also, the bolt 58 remains within the bolt hole 54 of the lock bar 46 .
[0030] Industrial Applicability
[0031] In operation, the foldable blade 2 includes foldable wing portions 6 which are capable of being retracted to a folded position for transportation of the machine and unfolded for use in scraping, pushing and transporting earth. In the unfolded position, the locking assemblies 14 and 16 are locked into a first position.
[0032] Specifically, apertures 28 b of the top plate 22 and the bottom plate 24 as well as the aperture 30 b of the intermediate plate 26 are aligned with one another. Also, a portion of the lock bar 46 is inserted within the recess portion 42 such that the aperture 44 of the recess portion 42 and the aperture 48 of the lock bar 46 are aligned with one another. To lock the foldable wing portions 6 in the unfolded position, the second pin 40 is inserted through the apertures 28 b and 30 b and the third pin 50 is inserted through the apertures 44 and 48 . In another embodiment, the bolt 58 may be bolted between the recess portion 42 and the lock bar 46 .
[0033] To unlock and fold the foldable wing portions 6 , the second pin 40 is removed from the apertures 28 b and 30 b and the third pin 50 is removed from the apertures 44 and 48 . The wing portions 6 are then extended outward such that the elongated slot 32 is translated with respect to the first pin 36 . In this manner, a portion of the lock bar 46 is removed from the recess portion 42 . The foldable wing portions 6 are then rotated about the first pin 36 until the aperture 30 c of the intermediate plate 26 is aligned with the apertures 28 c of the top plate 22 and the bottom plate 24 (located on the respective ears 22 a and 24 a ). The locking pin 52 is then inserted through the apertures 28 c and 30 c in order to lock the foldable wing portions 6 behind the main body portion 4 of the foldable blade 2 . The second pin 40 may be placed within the apertures 28 b and the third pin 50 may be placed in aperture 44 for storage.
[0034] Other aspects and features of the present invention can be obtained from a study of the drawings, the disclosure, and the appended claims. | A foldable blade having foldable wing portions for use in earth moving machinery. The foldable wing portions include a locking mechanism which enables the foldable wing portions to be locked in a folded position or an extended position. The locking mechanism is robust thus ensuring that the wing portions will be able to withstand considerable forces without collapsing during the pushing, scraping or transporting processes. The locking mechanism includes a locking pin assembly which is easy to lock and unlock, and also allows the foldable wing portions to be rotatable. |
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REFERENCE TO RELATED APPLICATION
Application Ser. No. 203,407 filed in the U.S. Patent Office Nov. 11, 1980 by applicant and entitled "Geothermal Well Head".
DESCRIPTION OF THE PRIOR ART
In the production of fluid from a geothermal well certain operational difficulties are encountered that are not present in producing oil and gas from a well. Due to variations in temperature, the casing in a geothermal well tends to expand and contract longitudinally, and if the casing is rigidly secured to the valved assembly at the well head substantial damage may be done to the assembly due to this variation in length of the casing.
In my prior application, Ser. No. 203,407 above identified, a well head assembly is disclosed and claimed that allows such variation in length to the casing without damaging the assembly.
Also, in the production of fluid from a geothermal well, the well head assembly and valves supported therefrom have hard mineral layers deposited on the interior thereof that not only restricts the flow of fluid therethrough but may render the valves inoperative.
A major object of the present invention is to provide a valve supporting assembly for mounting on a geothermal well head in which solid mineral deposits that accumulate in the interior thereof may be removed therefrom without shutting down the well, and also permitting the valves supported from the assembly to be removed therefrom, or maintenance work performed on the valves while they remain in place on the assembly without shutting down the well.
Another object of the invention is to supply a vertically disposed tubular valve supporting assembly for mounting on a geothermal well head, with the assembly including a longitudinally movable plug that may be removably locked in a first sealing position above the outlets for the valves, may be moved downwardly in the assembly for teeth on the plug to scrape hard deposited material from the interior surface thereof, may be moved downwardly in the interior of the assembly to a second position below the outlets to the valves where it packs off the interior of the assembly to permit maintenance work to be performed on the valves, with all of the above described functions capable of being performed without shutting down the well. A further object of the invention is to supply a tubular valve supporting assembly in which the plug therein includes means to equalize the pressure above and below the plug to permit the plug and components thereabove to be removed from the assembly.
Another object of the present invention is to provide a valve supporting assembly that is particularly adapted for use with the well head of my previous application Ser. No. 203,407 that allows longitudinal expansion and contraction of the casing extending to the geothermal zone relative to the well head without damage to the latter.
A still further object of the invention is to supply a valve supporting assembly that includes a normally open gate valve that supports a hydraulic cylinder that powers an actuator to move the plug longitudinally in the assembly, with the plug capable of being moved above the valve member when the latter is closed, and the plug, actuator and hydraulic cylinder then capable of being removed from the assembly for maintenance purposes without shutting down the geothermal well.
SUMMARY OF THE INVENTION
The valve supporting assembly of the present invention, as may best be seen in FIGS. 1 and 2, is illustrated as mounted on a spool assembly secured to the upper end portion of a casing assembly, which spool assembly and casing assembly are disclosed and claimed in my prior application Ser. No. 203,407. The casing assembly includes a surface string of casing. The valve supporting assembly is defined by a vertically disposed tubular body that has tubular valve supporting bosses projecting outwardly therefrom intermediate the upper and lower ends thereof.
A plug is longitudinally movable within the tubular body, with the plug having packers on the upper end portion, and teeth on the lower portion for removing scale from the interior of the tubular body when it is moved downwardly therein. Two sets of longitudinally spaced pins are mounted for lateral movement in the tubular body, and when both sets are moved inwardly the plug is removably locked therebetween in a first position above the valve supporting bosses, and the plug sealing the upper interior of the tubular body.
A pressurized fluid actuator assembly is removably secured to the upper end of a gate valve. The lower end of the gate valve is secured to the upper end of the tubular body. The valve member of the gate valve is normally in an open position, with the actuator extending downwardly through the gate valve to move the plug. When the lowermost set of pins is moved outwardly, the actuator assembly may move the plug downwardly in the tubular body to remove scale therefrom. When the plug is moved downwardly to a second position below the tubular valve supporting bosses, the interior of the tubular body below the bosses is packed off, and the valves may be removed therefrom or maintenance work performed on the valves without shutting down the well. The actuator is of such structure that it visually indicates the position of the plug in the tubular member.
After the valve maintenance work and scraping has been completed the actuator is moved upwardly to raise the plug to a position where the upper ends of slots in the lower exterior side portion thereof are above the lowermost set of pins. The lowermost set of pins are now moved inwardly to engage the slots. The actuator now applies pressure to the packing on the upper end of the plug to compress the same with a pressure ring, and to the extent that the upper set of pins may be moved inwardly to engage the pressure ring. The plug is now removably locked in the first sealing position in the tubular body, and the actuator may be removed therefrom.
The plug includes valve means that are normally closed but may be opened by downward movement of the actuator to permit equalization of gas pressure below and above the plug in the tubular assembly. After such equalization the plug and actuator may be moved upwardly in the gate valve above the valve member.
The transversely movable valve member of the gate valve is now moved to a closed position, and the plug, actuator and hydraulic cylinder may be removed from the invention to have maintenance work performed thereon, and without shutting down the well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the geothermal valve supporting assembly with a gate valve, visible portion of the actuator, and pressurized fluid cylinder supported there above;
FIG. 2 is a longitudinal cross sectional view of the invention taken on the line 2--2 of FIG. 1, with the plug in a first position that allows fluid from the geothermal well to discharge through the valve supporting tubular bosses;
FIG. 3 is the same view as shown in FIG. 2 but with the threaded pins that maintain the plug in a first position having been retracted to permit the plug to be forced downwardly in the tubular valve supporting assembly to remove caked mineral deposits from the interior surface thereof;
FIG. 4 is a fragmentary vertical cross sectional view of one of the uppermost threaded pins in engagement with a recess in the packer engaging ring that forms a part of the plug assembly and taken on the line 4--4 of FIG. 2;
FIG. 5 is a fragmentary vertical cross sectional view of one end of a transverse engageable member of the actuator in engagement with the lowermost portion of one of a pair of vertical slots in the plug assembly and taken on the line 5--5 of FIG. 2;
FIG. 6 is a fragmentary vertical cross sectional view of one end of a transverse engageable member on the actuator in engagement with an intermediate horizontal leg that forms a part of one of the pair of vertical slots in the plug assembly and taken on the line 6--6 of FIG. 3;
FIG. 7 is an enlarged longitudinal cross sectional view of one of the threaded pins taken on the line 7--7 of FIG. 8;
FIG. 8 is a vertical cross sectional view of the plug assembly that includes a normally closed valve, but a valve that may be opened by manipulation of the actuator to permit gas pressure to equalize in the tubular valve supporting assembly above and below the plug prior to the plug actuator, and air cylinder being removed from the tubular valve supporting assembly;
FIG. 9 is a fragmentary side elevational view of one of a number of tapered upwardly extending recesses in the plug assembly that is oriented to have one of the lower most threaded pins moved into engagement therewith and taken on the line 9--9 of FIG. 8;
FIG. 10 is a fragmentary side elevational view of the position one end of the engageable member of the actuator will occupy when the valve on the plug is moved to the open position and taken on the line 10--10 of FIG. 8;
FIG. 11 is a side elevational view of the position one end of the engageable member on the actuator will occupy in one of a pair of slots on the plug assembly when the latter is to be moved upwardly in the valve supporting assembly and removed therefrom;
FIG. 12 is a fragmentary longitudinal cross sectional view of the valve supporting assembly the plug assembly, actuator and pressurized air cylinder is removed therefrom;
FIG. 13 is a vertical cross sectional view of a portion of the hydraulic cylinder, piston, actuator, and visible portion of the actuator that inidicates not only the depth of the plug assembly in the tubular valve supporting assembly but the rotational position thereof;
FIG. 14 is a fragmentary top plan view of the piston taken on the line 14--14 of FIG. 13;
FIG. 15 is a longitudinal cross sectional view of the valve supporting assembly and gate valve in the open position, with the plug removably locked in a first position by the upper and lower pins, and the actuator extending upwardly through the open gate valve; and
FIG. 16 is the same view as shown in FIG. 15 but with the upper and lower pins disengaged from the plug, with the plug disposed above the gate valve member which is in a closed position, and the plug, actuator and hydraulic cylinder now capable of being removed from the tubular valve supporting body for maintenance purposes without shutting down the well.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The geothermal well head and actuator assembly invention A as best seen in FIGS. 1, 3, 15 and 16 is illustrated as mounted on a spool B that is secured to a casing assembly C. The casing assembly C extends to a geothermal zone. The invention A is capable of having caked foreign material removed from the interior thereof without shutting down the well. A toothed scraping and sealing plug may be so disposed in the invention A that fluid control valves may be removed from the invention A for repair or replacement without shutting down the well. Also, the toothed scraping and sealing plug, actuator and hydraulic cylinder may be removed from the invention without shutting down the well.
The spool assembly B includes a cylindrical shell 24 that has a first flange 26 mounted on the upper end thereof and extending outwardly therefrom. The first flange 26 has a number of circumferentially spaced bolt holes 28 therein, and a circular groove 30 is formed in the upper face 32 of the first flange 26 as shown in FIG. 2. A second flange 34 is in abutting contact with the first flange 26 as shown in FIG. 2, with the second flange having a groove 36 and bolt holes 38 therein that are aligned with the groove and bolt holes in the first flange. A resilient ring 40 is disposed within the grooves 30 and 36. Bolts 42 extend downwardly through the bolt holes 28 and 38, and with the lower ends of the bolts being engaged by nuts 44.
The cylindrical shell 24 has an interior surface 46, with an upper portion 46a thereof tapering downwardly and inwardly as shown in FIG. 2. A tubular member 50 is provided that has an external diameter substantially less than the diameter of the interior surface 46 of the shell 24, with the tubular member 50 having an upper end 50a that is adjacently disposed to the second flange 34. The tubular member 50 and the interior surface 46 of the shell 24 cooperate to define an annulus space 52 therebetween. The tubular member 50 is in communication with a string of production casing (not shown) that extends to the geothermal zone from which fluid is being produced. A seal assembly L is shown in FIG. 2, which assembly effects a seal between the interior surface of the spool B and the exterior surface of tubular member 50. The seal combination L includes a first rigid ring 68 that has an outer tapered face 68a that is substantially the same angulation as that of the tapered surface 46a of spool B. The tapered face 68a has a number of spaced recesses 68b extending inwardly therefrom in which first sealing rings 70 are disposed, with the first sealing rings extending outwardly from the recesses 68b a sufficient distance as to be compressed when in contact with the surface 46a.
The first ring 68 includes a flat upper surface 68c, and interior cylindrical surface 68d that is radially spaced from the exterior surface of the tubular member 50, and a circular abutment 68e that extends inwardly. Second sealing rings 72 encircle the tubular member 50 as shown in FIG. 2, and are disposed in an annulus space defined by the lower circular abutment 68e and the cylindrical first surface 68d.
A second rigid ring 74 is mounted in the annulus space 52 above the first ring 68 as shown in FIG. 2. The second ring 74 is defined by a first vertically extending leg 74a, which leg has a lower end thereof in engagement with the uppermost one of the sealing rings 72. The first vertical leg 74a has a second horizontal leg 74b extending outwardly from the upper portion thereof as shown in FIG. 2, which second leg is situated within the annulus space 52.
The second flange 34 threadedly supports a number of externally threaded first elongate members 76 in tapped bores 76a and second elongate threaded members 78 in tapped bores 78a that are circumferentially spaced from one another, with the first members extending downwardly through bores 80 formed in the second leg 74b as shown in FIG. 2. By rotating the first member 76 they may be moved downwardly relative to the second flange 34, with the lower ends of the members being in contact with the upper surface 68c of the first ring 68, and moving the latter downwardly to force the first sealing ring 70 into pressure sealing contact with the surface 46a.
By rotating the second member 78 in an appropriate direction, lower ends thereof exert a downward force on the second horizontal leg 74b, to force the member 74 downwardly, and compress the second sealing rings 72 into sealing engagement with the exterior surface of the tubular member 50. From the above description, it will be seen that the first and second sealing rings 70 and 72 may be periodically subjected to increased force to maintain them in sealing contact with the tapered surface 46a and the external surface of the tubular member 50. The upper end portions of the first and second members 76 and 78 are of cylindrical shape and sealingly disposed in bushings 82 mounted in the upper portions of the tapped bores 76a and 78a. The upper extremities 76b and 78b of the first and second members 76 and 78 are of non-circular transverse cross section to permit the members to be rotated by a suitable hand tool (not shown).
In detail, it will be seen that the valves supporting geothermal well head assembly A includes a tubular member 100 that extends upwardly from the second flange 34 to terminate on the upper end in a third flange 102. The tubular member 100 as best seen in FIG. 2 includes an upwardly extending confined space 104 through which geothermal fluid G from the well on which the assembly A is mounted may flow upwardly when the plug assembly P is disposed as shown in FIG. 2. The tubular member 100 is illustrated in FIG. 2 as having a pair of oppositely disposed tubular bosses 106 extending outwardly therefrom that are in communication with the space 104.
The bosses 106 terminate on their outer ends in flanges 108 that are in abutting contact with flanges 110 that form a part of conventional valves 112 that are but partially shown in FIG. 2. Each pair of flanges 108 and 110 are removably secured to one another by bolts 114 and nuts 116 in a conventional manner. The valves 112 serve to control the flow of the geothermal fluid G from the assembly A.
In FIG. 2 it will be seen that the tubular member 100 has a lower set of circumferentially spaced, internally threaded, tubular bosses 118 projecting outwardly therefrom. Each of the lower tubular bosses 118 has a seal defining bushing 120 in threaded engagement therewith. Each one of the bushings 120 sealingly engages one of a lower set of elongate pins 122. Each of the pins 122 includes a wrench engageable outer end 122a, and inner end portion 122b, and an externally threaded intermediate portion 122c that threadedly engages the interior of one of the bosses 118 as shown in FIG. 2.
An upper set of circumferentially spaced internally threaded tubular bosses 124 also extends outwardly from the tubular member 100 as best seen in FIG. 2, with each of these bosses also including an upper seal defining bushing 126 that has threads formed on the interior thereof. An upper set of elongate pins 128 is provided, with each of these pins including a wrench engageable outer end 128a and inner end portion 128b, and an intermediately disposed externally threaded portion 128c that engages the interior of one of the upper bosses 124. In FIG. 2 it will be seen that the pins have been screwed inwardly in the upper and lower bosses 118 and 124 and are in removable engagement with the plug assembly P to removably support the same in a fixed position in the tubular member 100 above the pair of bosses 106 through which the geothermal fluid G may discharge.
The third flange 102 as may be seen in FIG. 2 is in abutting contact with the lower flange 129 on an elongate tubular body 131 of a gate valve V which body has an upper flange 133. The purpose of valve V will later be explained.
The details of the plug assembly P are best seen in FIG. 2, with the plug assembly including a rigid cylindrical body 132 that has a lower end surface 133 from which a tapered centered valve seat 134 extends upwardly. The valve seat 134 is normally sealingly engaged by a tapered valve member 136. The cylindrical body 132 includes a cylindrical sidewall 138 that snuggly and slidably engages the interior 104a of the tubular member 100 that defines the confined space 104. The plug body 132 below the sidewall 138 defines a number of circumferentially extending, longitudinally spaced teeth 140 of decreasing diameter that may be seen in FIG. 2. Each of the teeth 140 has a sharp circumferential edge that is adapted to scrape hard deposited mineral layers M from the interior surface 104a of the tubular member as the plug assembly is moved downwardly therein as will later be explained.
The cylindrical body 132 as best seen in FIGS. 2 and 9 has a number of circumferentially spaced slots 142 formed in the lower sidewall portion thereof. The slots 142 may be removably engaged by the inner portions 122b of the lower set of pins 122 as shown in FIG. 2. One of the slots 142 is provided for each of the lower pins 122.
Each of the slots 142 as shown in FIG. 9 includes a lower outwardly flared end portion 142a, and an upper portion 142b of uniformed width that terminates on the upper end in a top 142c. When the pin portions 122b are in engagement with the slots 142 as shown in FIG. 9, the plug assembly P cannot move downwardly in the confined space 104.
The plug body 132 has a tubular collar 144 extending upwardly therefrom which has a diametrically opposed pair of slots 146 defined therein which in detail are best seen in FIGS. 5, 6, 10 and 11. Each of the slots 146 includes a horizontal leg 146a and a vertical leg 146b, and the lower leg 146d terminating in a bottom 146c as shown in FIG. 10. A rigid ring 148 is mounted in a downwardly extending cavity 144 formed in the body 132 directly below the interior of the collar 144 which ring is identified by the numeral 148. A circumferentially extending recess 150 is formed in the upper portion of the plug 132 and terminated on the lower end in a circumferentially extending body shoulder 152. The recess 150 serves to support a number of resilient packers 154 that are stacked one above the other and encircle the plug body 132 as shown in FIG. 2.
In FIG. 2 it will be seen that a rigid pressure exerting ring 156 is provided that has an inverted L transverse cross section, which ring is defined by a horizontal leg 156a and a vertical leg 156b. The leg 156b terminates in a lower surface 156c that is in abutting contact with the uppermost one of the packers 154. The horizontal leg 156a has an upper surface 156d in which a number of circumferentially spaced semi-circular recesses 158 are defined as best seen in FIGS. 2 and 4, that may be removably engaged by the inner end portions 128b of the upper pins 128 when the pins 128 are screwed inwardly as shown in FIG. 2.
The plug body 132 and the ring 156 are removably secured in non-rotatable engagement relative to one another by a key 160 that engages slots (not shown) in the body and ring. The valve seat 134 as best seen in FIG. 3 developed into a first upwardly extending bore 162 that developed into a second bore 164 of greater diameter that communicates with the cavity 149. The valve member 136 is secured to a valve stem 166 that is slidably mounted in bore 162. Valve stem 166 develops into an enlarged upper end portion 168. A first compressed helical spring 170 encircles the valve stem 168, with the upper end of the spring being in abutting contact with the enlarged upper end 168 and the lower end of the spring being in abutting contact with a body shoulder 164a defined at a junction of first and second bores 162 and 164.
A second helical spring 172 is also mounted in the second bore 164 and has the lower end in abutting contact with the body shoulder 164a, and the upper end being in pressure contact with the circular plate 174. Plate 174 on the upper surface thereof has a groove 176 defined therein in which a number of ball bearings 178 are disposed.
The actuator J of the present invention includes a hydraulic cylinder 180 that extends upwardly from a fourth flange 181 that rests on the upper valve flange 133 as best seen in FIG. 1 and is removably secured thereto by bolts 42 and nuts 44 in a conventional manner. Cylinder 180 has a top 182 secured thereto in which a centered transverse bore 184 is defined. Bore 184 has one or more recesses 186 extending outwardly therefrom that serve to support resilient rings 188. A plug depth indicating rod 190 is slidably mounted in the bore 184 and extends upwardly above the top 182. The rod 190 as shown in FIG. 1 has graduations 192 thereon that indicate the depth at which the plug assembly P is disposed within the tubular member 100 when one of the graduations is horizontally aligned with the upper surface of top 182.
The actuator assembly J as may best be seen in FIG. 13 includes a piston 194 in cylinder 180 that has grooves 192 on the exterior surface thereof that support resilient sealing rings 198 that are in slidable contact with the interior surface of the hydraulic cylinder 180. The piston 194 has a top 194a in which a cavity 195 extends downwardly and develops into a tapped bore 195b, which bore on the lower portion thereof develops into a body shoulder 195c.
An actuator rod 196 extends upwardly through valve body 131 when valve V is open to engage the piston 194, which actuator rod has a body shoulder 195c, and also the actuator rod having threads 196b on the upper portion thereof that engage the threads 195b as best seen in FIG. 13. The piston 194 has a tapped bore 199 in the lower portion thereof in which a set screw 200 is disposed that bears against the actuator rod 196 to prevent the actuator rod rotating relative to the piston 194. The lower end of the position indicating rod 190 has external threads 190a formed thereon that engage a tapped bore 201a in a locking plate 201 that is disposed in the cavity 195, as well as the threads on the rod engaging a tapped cavity 202 that extends downwardly in the actuator rod 196.
In FIG. 1 it will be seen that a hydraulic fluid inlet tube 204 is provided in the upper portion of the cylinder 180 and a similar hydraulic fluid inlet 206 is in communication with the lower interior of the cylinder 180. When pressurized hydraulic fluid from a source (not shown) is discharged through one of the inlets and hydraulic fluid allowed to discharge through the other, the piston 194 is moved upwardly and downwardly in the air cylinder to longitudinally move the actuator rod 196 of the actuator assembly J for reasons that will later be explained.
The interior of fourth flange 181 has threads 210 formed on the interior thereof that are engaged by threads 212 formed on a hydraulic cylinder end plate 214 that has a centered transverse bore 216 therein in which the actuator rod 196 is slidably movable. Bore 216 has recesses 218 extending outwardly therefrom in which resilient sealing rings 220 are disposed that sealingly engage actuator rod 196.
Actuator rod 196 has a flat lower end 222 best seen in FIG. 3 from which a semi-circular groove 224 extends upwardly and engages ball bearings 178. A tapped recess 226 extends upwardly from end 222 and is engaged by an externally threaded end 228 of a cylindrical rigid member 230 that extends through a transverse bore 232 in plate 174. Member has an enlarged head 234 on the lower end thereof that maintains plate 174 in rotatable engagement with actuator rod 196. A tapped bore 236 extends upwardly in member 230 that may be removably engaged by the upper threaded valve actuator pin 241 as shown in FIG. 8.
In FIGS. 2 and 3 it will be seen that the actuator rod 196 supports a transverse actuator pin 240 that has outwardly projecting portions 240a that are movable in the slots 146 shown in FIGS. 5, 6, 10 and 11. Actuator rod 196 above pin 240 has a circular member 242 extending outwardly therefrom that has a circular force exerting member 244 extending downwardly therefrom.
The visible portion of depth indicating rod 190 has a first mark 246 thereon as shown in FIG. 1 that when vertically aligned with a second mark 248 on the upper end of hydraulic cylinder 180 visually dicates that the plug P is so oriented in tubular member 100 that upper and lower pins 122 and 128 are radially aligned with recesses 158 and slots 142 shown in FIGS. 4 and 9. The upper end portion of rod 190 is formed with a non-circular end portion 250 to permit it to be rotated by a suitable power source (not shown).
When it is desired to remove foreign material M from the interior of the cylindrical member 100, which material is shown in FIG. 1, the pins 122 are rotated in a direction to move outwardly from disengagement with slots 142. Plug P is now free to move downwardly in tubular member 100. Pressurized fluid is now discharged into air cylinder J above piston 194 and the actuator rod 196 is moved downwardly together with plug P. The actuator pin portions 240a will be disposed in horizontal slot portions 146a as shown in FIG. 11 to prevent the packers 154 being radially expanded into pressure sealing contact with the interior surface of tubular member 100. As plug P is moved downwardly in tubular member 100 the teeth 140 scrape the foreign material M therefrom. End 250 may be rotated to rotate plug P if desired during the scraping operation.
When it is desired to remove the valves 112 for repair or replacement plug P is moved downwardly below the bosses 106 as shown in FIG. 3, with the plug sealing the interior of the tubular member 100 without killing the well.
When it is desired to return the plug C to the sealing position shown in FIG. 2 hydraulic fluid is discharged in and out of cylinder 180. The actuator end portions 240a are in engagement with horizontal slot portions 146a as shown in FIG. 6. The piston 194 is moved upwardly until the depth indicating rod 190 shows that the slots 140 in the plug P are above the lower pins 122. Depth indicating rod 190 has a non-circular upper portion that permits rotation of the rod. The rod 190 is now rotated to concurrent rotate piston 194, actuator rod 196, and plug P to radially align lower pins 122 with slots 140 and upper pins 128 with recesses 158. Lower pin portions 240a are rotated out of horizontal slot portions 146a into slots 146. Actuator rod 196 is now caused to move downwardly for member 244 to pressure contact rigid ring 156. Rigid ring 156 moves downwardly and compresses packers 154 into sealing contact with the interior surface of tubular member 100. Upper pins 128 are now rotated to move inwardly to engage recesses 158 in ring 156 as shown in FIGS. 2 and 4.
When the plug P is disposed as shown in FIG. 8 and it is desired to equalize the gas pressure above and below the plug P, the actuator rod is rotated to dispose actuator pin end portions in slots 146 and then moved downwardly therein. Member 240 shown in FIG. 8 will pressure contact the upper end of member 166 and move the latter downwardly to separate valve member 136 from seat 134 with pressurized gas and fluid flowing upwardly through the interior portion of plug P to the space thereabove.
The above precedure is desirable when the plug P and actuator assembly are to be separated from the tubular member 100 without shutting down the well.
The gate valve V has a transversely movable valve member 300 which in FIG. 15 is shown in the open position. A space 302 is defined in valve body 131 to accomodate the plug P. To remove the plug P for maintenance without shutting down the well, the plug is moved upwardly into the space 302, and valve member 300 moved to the left to the closed position shown in FIG. 16. The actuator assembly and hydraulic cylinder 180 may now be separated from gate valve V for maintenance or repair. The hydraulic cylinder 180 and actuator assembly are returned to the position shown in FIG. 1 by reversing the above procedure. Movement of the gate valve member 300 may be achieved by rotating a wheel 304 shown in FIG. 1.
The use and operation of the invention has been explained previously in detail and need not be repeated. | A valve supporting tubular assembly capable of being mounted on a geothermal well head, with the tubular assembly of such structure that an internal plug that supports resilient packers and has circumferentially extending teeth defined thereon may be removably locked in a first position to seal the interior of the tubular assembly above the outlets to the valves, the plug may also be moved longitudinally in the tubular assembly to scrape solids deposited on the interior surface thereof by geothermal fluids, and the plug may also be moved to a second position to pack off the interior of the tubular assembly below the valve outlets to permit the valves to be moved or maintenance work performed thereon without shutting down the geothermal well. In addition, the plug is provided with means to equalize the pressure above and below the plug in the tubular assembly to permit the plug and components situated thereabove to be removed from the tubular assembly.
A gate valve is situated above the valve supporting assembly and is normally open, with the gate valve supporting a hydraulic cylinder that serves to longitudinally move an actuator connected to the plug. Visual means are provided to indicate the position of the plug in the valve supporting assembly. The gate valve defines a confined space above the valve member when the latter is in a closed position in which the plug may be disposed. With the gate valve member in a closed position, the plug, actuator and hydraulic cylinder may be removed from the valve supporting tubular assembly for maintenance purposes without shutting down the well. |
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This application is a continuation of application Ser. No. 642,747 filed Jan. 18, 1991, now abandoned.
TECHNICAL FIELD
The present invention relates to a vibration-proofing device and particularly it relates to a vibration-proofing device wherein an upper structure, such as a building, a machine or a floor on which such machine is mounted, is swingably supported on a lower structure, such as a foundation, thereby isolating vibrations, such as earthquakes, traffic vibrations produced around buildings, and vibrations produced from the equipment installed in another room of the building to protect said upper structure from such vibrations. The present invention is also applicable to a dynamic damper designed to reduce resonance, a damper utilizing rolling and/or frictional resistance on rollers, etc.
Various vibration-proofing devices have been developed to protect buildings and machines from vibrations, such as earthquakes and traffic vibrations, by horizontally swingably supporting an upper structure, such as said building, computers and other machines, and a floor on which such machines are mounted, on a lower structure, such as a foundation, so as to reduce the input acceleration to the upper structure as when an earthquake occurs, thereby protecting said upper structure
Such vibration-proofing devices include various types: (a) a first type in which a laminate of a soft rubber-like elastic plate, such as natural rubber or synthetic rubber, and a steel plate is used as a support for upper structures, (b) a second type in which a slide member, such as of Teflon, installed between upper and lower structures, is used as a support, and (c) a third type in which a rolling body assembly, such as a ball bearing or roll bearing, is used as a support.
Such bearing type of vibration-proofing device is disclosed in Japanese Patent Application Laid-Open No. 17945/1989. This vibration-proofing device comprises a plurality of ball bearings installed between upper and lower structures so as to support the upper bearing structure for horizontal swing movement, and a stud which allows the upper structure to return to its original position when it is horizontally displaced.
Another bearing type of vibration-proofing device is disclosed in Japanese Patent Application Laid-Open No. 140453/1982. This vibration-proofing device comprises a plurality of roll bearings with eccentric rolls of small and large diameters are installed in two rows in orthogonal relation between upper and lower structures, the arrangement being such that when the upper structure is horizontally displaced on the roll bearings, it is lifted by the eccentric rolls of small and large diameters of the roll bearings. The lifted upper structure lowers to its original position; thus, the potential energy is utilized.
A further bearing type of vibration-proofing device is disclosed in Japanese Patent Application Laid-Open No. 45303/1979. This vibration-proofing device comprises a plurality of roll bearings disposed in two vertically spaced rows, side by side and orthogonal to each other, the arrangement being such that the rolling of the roll bearings absorb horizontal vibrations.
In the conventional vibration-proofing devices, particularly the one described in (a) above, a load of about 50 kg is required per cm 2 of the area of the mount, but the amount of movement of the upper structure relative to the lower structure caused as by an earthquake is about 25 cm. To provide for this amount of displacement with safety, it has been required that the outer diameter of the laminated rubber support be not less than 50 cm. Therefore, the total load required for every one laminated rubber support is about 100-300 t or more. In this connection, since a small-sized building, such as a dwelling house, weights about 100-300 t, it has been regarded as difficult to provide a vibration-proofing design using a laminated rubber support. Therefore, each vibration-proofing device for small-sized buildings is desired to have a load support capacity of several tons to tens of tons. The vibration-proofing device described in (b) above is not suitable for structures which should avoid vibration.
Further, in the conventional bearing type of vibration-proofing devices described above, since the ball and roll bearings which support an upper structure are rigid bodies of metal and since the upper and lower structures disposed above and below and in contact with the ball and roll bearings are rigid bodies of concrete or steel plate, there have been the following problems.
First, upon occurrence of an earthquake or traffic accident, not only horizontal but also vertical vibrations take place and the latter vibrations are transmitted directly to the upper structure without being absorbed, resulting in a decrease in dwelling comfortability and damage to machines.
Second, since the areas of contact between the ball and roll bearings and the upper and lower structures are very small, the pressures on the areas are very high, with the result that when strong vertical vibrations are produced during an earthquake, the ball and roll bearings or the upper and lower structures can be easily damaged; this danger is high particularly for ball bearings. If damage has once started in this manner, strong vibrations and loud noises are produced and damage become enlarged during the rolling of the ball and roll bearings, leading to failure in vibration-proofing function.
Third, since it is technically difficult to machine the outer diameters of ball and roll bearings with high precision or to provide accurate spacing between upper and lower structures and maintain accurate parallelism of upper and lower structures, some of the ball and roll bearings fail to function, thus making it impossible to develop the proper vibration-proofing function.
Fourth, if foreign matter in the form of small solids enters the rolling surfaces of ball and roll bearings, it interferes with the rolling of the ball and roll bearings, thus degrading the vibration-proofing function to a great extent.
Last, in the vibration-proofing device disclosed in Japanese Patent Application Laid-Open No. 140453/1982, since a plurality of roll bearings having eccentric small and large diameter rolls are used, if there is a difference in the amount of relative displacment of the roll bearings upon horizontal displacement of the upper structure, the timing with which the upper structure lifted is lowered as it returns to its original position is disturbed for the respective roll bearings, thus producing the so-called rocking phenomenon in the upper structure, which means an increase in the amount of sway of the upper portion of the upper structure. Further, a force greater than the weight of the upper structure acts on the roll bearings, thus damaging the latter.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been proposed with the above in mind and has for its object the provision of a bearing type of vibration-proofing device which is simple in construction and is capable of reliably absorbing not only the horizontal but also vertical components of an earthquake or traffic vibration and which properly functions even under low load and produces little vibration during operation.
The technical means for achieving the above object of the invention lies in an arrangement wherein rolling bodies for supporting an upper structure for horizontal swing are held between the upper and lower structures, said arrangement being characterized in that said rolling bodies are cylindrical rollers, with elastomeric bodies disposed between said cylindrical rollers and the upper and lower structures.
Further, in the present invention, it is desirable that the cylindrical rollers be stacked in n rows and that the rows of cylindrical rollers form an angle of 180°/n.
Further, it is also desirable that an air spring or coil spring means be disposed vertically of the cylindrical rollers or that a plurality of taper rollers be disposed vertically of the cylindrical rollers and radially connected together.
In a vibration-proofing device according to the invention, since the rolling bodies are made in the form of cylindrical rollers, their areas of contact with the upper and lower structures are very large, providing an increased pressure resistance. And the elastomeric bodies disposed between the cylindrical rollers and the upper and lower structures will be elastically deformed under the vertical load of the upper structure to increase the load support areas of the cylindrical rollers, dispersing the vertical load of the upper structure. Further, the elastic deformation of the elastomeric bodies accommodates variations in the outer diameter of the cylindrical rollers and in the parallelism of the upper and lower structures. Further, even if foreign matter in the form of solids adheres to the rolling surfaces of the cylindrical rollers, the elastomeric bodies elastically deform to accommodate them, thereby maintaining the rolling performance of the cylindrical rollers.
Further, said cylindrical rollers are stacked in n rows and the cylindrical rollers between the rows form an angle of 180°/n. With this arrangement, the property of absorbing vibrations in the vertical direction is improved. In addition, when n=1, the device acts in one direction only, but when n≧2, it acts in all horizontal vibration directions. As this n increases, the difference in the rolling resistance in the horizontal vibration directions decreases. Further, when n=2, the angle between the cylindrical rollers in the upper and lower rows must be accurately set at 90°, but when n≧3, there will be no problem even if the angle formed by the cylindrical rollers in adjacent rows is not accurately set.
Further, in the vibration-proofing device of the invention, an air spring or coil spring means is disposed vertically of a plurality of rollers interposed between the upper and lower structures, so that not only a weak vibration such as a traffic vibration or a vibration from the equipment in another room but also the vertical component of strong vibration such as an earthquake can be reliably absorbed by the air spring or coil spring means. In the case where an air spring is used, the adjustment of the horizontal level of the upper structure can be adjusted by adjusting the internal air pressure in the air spring.
A plurality of taper rollers are disposed vertically of the rollers interposed between the upper and lower structures and a radially connected together in a horizontal plane. In this arrangement, even if a torsional movement including a rotational component is inputted, the taper rollers are rolled in a horizontal plane in the direction of rotation, whereby the rotational component of the torsional vibration can be reliably absorbed.
Vibration-proofing devices according to embodiments of the invention will now be described with the reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a first embodiment of the invention having cylindrical rollers stacked in two rows;
FIG. 2 is a plan view including parts omitted in FIG. 1;
FIG. 3 is an enlarged front view of the principal portion of FIG. 1;
FIGS. 4 and 5 are front views of vibration-proofing devices showing modifications of the first embodiment;
FIG. 6 is a schematic plan view for explaining drawbacks caused by positional shift of the upper rollers in FIG. 2;
FIG. 7 is a front view showing a second embodiment having cylindrical rollers stacked in three rows;
FIG. 8 is a plan view including parts omitted in FIG. 1;
FIG. 9 is a front view of a connecting plate supporting rollers;
FIG. 10 is a plan view showing rollers arranged with different pitches;
FIG. 11 is a plan view showing rollers in slanted arrangement;
FIG. 12 is an enlarged plan view showing a pair of rollers taken from FIG. 11;
FIG. 13 is a front view showing a restoring elastic body and a damper installed between the upper and lower structures;
FIG. 14 is a front view showing a third embodiment having an air spring added to the vibration-proofing device of the first embodiment;
FIG. 15 is a sectional view showing the vibration-proofing device of FIG. 1 applied for proofing floors against vibrations;
FIG. 16 is a plan view of FIG. 15;
FIG. 17 is a front view showing a fourth embodiment having coil spring means added to the vibration-proofing device of the first embodiment;
FIG. 18 is a front view showing a fifth embodiment having means added to the vibration-proofing device of the first embodiment, said means being capable of absorbing vibrations including rotational components;
FIG. 19 is a plan view of FIG. 18;
FIG. 20 is a fragmentary enlarged sectional view of FIG. 18;
FIG. 21 is a front view showing a sixth embodiment having an air spring added to the vibration-proofing device of the fifth embodiment; and
FIG. 22 is a front view showing a seventh embodiment having coil spring means added to the vibration-proofing device of the fifth embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment shown in FIGS. 1 and 2 is a vibration-proofing device A having rolling bodies to be later described which are arranged in two rows. This device is installed between an upper structure 11, such as a building, and a lower structure 12, such as a foundation, or, within a building, said device is installed between an upper structure 11 which is the floor on which machines, such as computers and precision measuring instruments, are mounted, and a lower structure 12 which is a slab of the building.
In the vibration-proofing device A of this first embodiment, the numeral 13 denotes an upper pressure resisting plate in the form of a steel plate fixed to the lower surface of the upper structure 11, with an elastomeric body 14 in the form of a sheet bonded to the lower surface thereof as by vulcanization adhesion. The numeral 15 denotes a lower pressure resisting plate in the form of a steel plate fixed to the upper surface of the lower structure 12 in opposed relation to the upper pressure resisting plate 13, with an elastomeric body 15 in the form of a sheet bonded to the upper surface thereof as by vulcanization adhesion. The material of the elastomeric bodies 14 and 16 may be anything that has elasticity, for example, rubber or plastic material. The numerals 17 and 18 each denote a plurality of rolling bodies disposed between the upper and lower pressure resisting plates 13 and 15, which are cylindrical rollers (hereinafter referred to as the upper and lower rollers, respectively). The upper and lower rollers 17 and 18 are stacked in two rows forming an angle of 90°. In addition, the material of the upper and lower rollers 17 and 18 may be anything that can withstand vertical loads, for example, metal, concrete, ceramics, rigid plastics, or FRP. The numeral 19 denotes an intermediate pressure resisting plate in the form of a steel plate or the like interposed between the upper and lower rollers 17 and 18, with elastomeric bodies 20 and 21 in the form of sheets bonded to the upper and lower surfaces thereof as by vulcanization adhesion. With this arrangement, the upper and lower rollers 17 and 18 are held between the upper and intermediate pressure resisting plates 13 and 19 and between the intermediate and lower pressure resisting plates 19 and 15, respectively, through the elastomeric bodies 14, 20 and 21, 16. The surfaces of the elastomeric bodies 14, 20, and 21, 16 against which the upper and lower rollers abut serve as the rolling surfaces for the upper and lower rollers. In addition, instead of applying the elastomeric bodies 14, 16, 20, 21 in the form of sheets to the upper, lower and intermediate pressure resisting plates 13, 15 and 19, the upper and lower rollers 17 and 18 themselves or their surfaces may be formed of elastomer.
In the vibration-proofing device A of the first embodiment, the upper structure 11 is supported for horizontal swing movement by the upper and lower rollers, so that upon occurrence of an earthquake or traffic vibrations, the input acceleration to the upper structure 11 is reduced to protect the upper structure 11. In this connection, in an actual earthquake, not only horizontal vibrations but also vertical vibrations are produced. In this vibration-proofing device A, since the upper and lower rollers 17 and 18 are cylindrical, their areas of contact with the upper and lower structures 11 and 12 are much larger than when balls are used, thus exhibiting greater pressure resisting performance. Further, since the elastomeric bodies 14, 16, 20 and 21 are disposed on and under the upper and lower rollers, the elastomeric bodies 14, 16, 20 and 21 are elastically deformed, as shown in FIG. 3, thereby increasing the load carrying areas of the upper and lower rollers 17 and 18 and dispersing the vertical load of the upper structure 11. Further, even in the case where the outer dimensions of the upper and lower rollers 17 and 18 vary or where the parallelism of the upper and lower structures is not accurate, this can be accommodated by the elastic deformation of the elastomeric bodies 14, 16, 20 and 21. Further, even if foreign matter in the form of small solids adhere to the rolling surfaces for the upper and lower rollers 17 and 18, the elastic deformation of the elastomeric bodies 14, 16, 20 and 21 accommodate them, thereby maintaining the rolling performance of the upper and lower rollers 17 and 18. In this manner, vertical vibrations can be reliably absorbed by the upper and lower rollers 17 and 18 and the elastomeric bodies 14, 16, 20 and 21.
In the first embodiment described above, a description has been given of the vibration-proofing device A wherein the intermediate pressure resisting plate 19 having elastomeric bodies 20 and 21 in the form of sheets bonded to the upper and lower surfaces thereof is interposed between the upper and lower rollers 17 and 18. However, the invention is not limited thereto. For example, as shown in FIG. 4, instead of using the intermediate pressure resisting plate, an elastomeric body 22 in the form of a sheet alone may be interposed between the upper and lower rollers 17 and 18. Alternatively, an intermediate pressure resisting plate having no elastomeric bodies applied thereto may be interposed or, as shown in FIG. 5, the upper rollers 17 may be placed directly on the lower rollers 18.
In the first embodiment and the modifications described above, the vibration-proofing devices A, A' and A" have been described wherein the upper and lower rollers 17 and 18 are stacked in two rows at an angle of 90°. In this case, this angle 90° formed between the upper and lower rollers 17 and 18 must be accurately set.
This reason will now be described. Usually, such vibration-proofing devices will be installed at a plurality of places for a single upper structure. Then, as shown in FIG. 6, if the upper rollers 17 in one vibration-proofing device A 1 are somewhat shifted counterclockwise relative to the lower rollers 18 while the upper rollers 17 in another vibration-proofing device A 2 are somewhat shifted clockwise relative to the lower rollers 18, then when a horizontal force F acts axially of the lower rollers 18 owing to an earthquake, forces f 1 and f 2 act on the upper rollers 17 in the two vibration-proofing devices A 1 and A 2 , said forces being orthogonal to the axes of the upper rollers. However, since the upper rollers 17 in the vibration-proofing devices A 1 and A 2 are positionally shifted as described above, the directions of forces f 1 and f 2 acting on the upper rollers 17 differ from each other. If the rolling directions of the upper rollers 17 in the two vibration-proofing devices A1 and A2 disposed between the upper and lower structures differ in this manner, the upper structure 11 will sometimes become unable to swing horizontally, failing to develop its vibration-proofing function.
Thus, in the case where it is difficult to set the angle between the upper and lower rollers 17 and 18 accurately at 90°, a vibration-proofing device having cylindrical rollers stacked in three or more rows is preferred.
A second embodiment having cylindrical rollers stacked in three rows will now be described with reference to FIGS. 7 and 8. In addition, parts which are identical or correspond to those of the vibration-proofing device A in FIGS. 1 and 2 are marked with the same reference characters.
This vibration-proofing device B has cylindrical rollers 17, 23 and 18 (hereinafter referred to as the upper, intermediate and lower rollers, respectively) stacked in three rows between the upper and lower structures 11 and 12. The angles formed between the upper, intermediate and lower lowers 17, 23 and 18 are set at 60°. Further, interposed between the upper and lower structures are upper and lower pressure resisting plates 13 and 15 having elastomeric bodies 14 and 16 in the form of sheets bonded thereto to form rolling surfaces for the upper and lower rollers 17 and 18. Further, interposed between the upper and lower rollers are first and second pressure resisting plates 19a and 19b having elastomeric bodies 20a, 21a, 20b and 21b in the form of sheets bonded thereto to form rolling surfaces for the upper, intermediate and lower rollers 17, 23 and 18.
In the vibration-proofing device B of this second embodiment, like the vibration-proofing device A of the first embodiment, upon occurrence of an earthquake, not only horizontal but also vertical vibrations are reliably absorbed to reduce the input acceleration to the upper structure to protect the upper structure 11 from earthquakes. In this connection, in the case of the vibration-proofing device A having two rows of cylindrical rollers, the angle formed between the upper and lower rollers 17 and 18 must be set accurately at 90°, as described with reference to FIG. 6. However, in the case of the vibration-proofing device B having three rows of cylindrical rollers, even if the angles formed between the upper, intermediate and lower rollers 17, 23 and 18 are not set accurately at 60°, since the rollers 17, 23 and 18 compensate each other there is no danger of the upper structure 11 becoming unable to swing horizontally to exert the vibration-proofing function.
In addition, in the vibration-proofing device B of this second embodiment, the first and second intermediate pressure resisting plates 19a and 19b having elastomeric bodies 20a, 21a, 20b and 21b bonded thereto have been used. However, they are not absolutely necessary; as in the case of the vibration-proofing devices A' and A" in FIGS. 4 and 5, elastomeric bodies alone with no intermediate pressure resisting plates combined therewith may be interposed or intermediate pressure resisting plates with no elastomeric bodies bonded thereto may be interposed or the rollers 17, 23 and 18 may be directly stacked using neither intermediate pressure resisting plates nor elastomeric bodies.
As for the elastomeric bodies used in the first and second embodiments described above, those which have a poor damping property may be used. However, since the rolling surfaces of the elastomeric bodies locally moved up and down as the rollers 17, 18 and 23 roll, the performance of the vibration-proofing device can be further improved by using elastomeric bodies of high damping property which are capable of absorbing greater energy as they are deformed.
Further, if the rollers 17, 18 or 23 in each row in the first and second embodiments are supported for rotation by a connector plate 24 as shown in FIG. 9, the positional relation of the rollers 17, 18 and 23 can be desirably maintained. If the connector plates 24 are connected to the associated pressure resisting plates 13, 15, 19a and 19b so that they are slidable in the rolling direction, the positional relation of the rollers 17, 18 and 23 can be correctly maintained for a long period of use and their durability is desirably improved.
If the elastomeric bodies are subjected to the vertical load of the upper structure 11, the affected areas thereof creep to thereby form recesses. This phenomenon serves as a trigger when they are subjected to a vibration input. However, if they are subjected to a high vibration input, the rollers 17, 18 and 23 fall into the recesses resulting from the creep and vertical vibrations will thus be produced. This can be prevented, as shown in FIG. 10, by setting the pitches a, b, c, d, e of the rollers 17, 18 and 23 so that they all differ (a≠b≠c≠d≠e). With this arrangement, it is possible to prevent all rollers 17, 18 and 23 from simultaneously falling into the recesses resulting from creep.
As shown in FIG. 11, it is also possible to prevent falling into the recesses by inclining the direction of arrangement of the rollers 17, 18 and 23 with respect to the rolling direction. In this case, two rollers which are inclined with respect to the rolling direction by the same angle in opposite directions (17a and 17b are shown in the figure) must be paired. More preferably, two pairs of rollers (17a, 17b and 17c, 17d in the figure) are grouped in one set, whereby satisfactory linear motion and damping property (high reaction) can obtained. The reason will now be described. Referring to FIG. 12 showing two rollers 17a and 17b inclined with respect to the rolling direction by the same angle α in opposite directions, if a displacement E takes place in the rolling direction, slip takes place between the the rollers 17a, 17b and the elastomeric bodies by an amount corresponding to a displacement Da or Db corresponding to the angle of inclination α, acting as a damping force. In addition, the angle of inclination α is allowed to be about 45°, but since this results in too high resistance or unstability, angles of 30° or less are suitable.
To actually utilize the vibration-proofing devices A, A', A" and B, it is necessary to restore the upper structure 11 to its original position after its horizontal displacement when an earthquake takes place. To this end, as shown in FIG. 13, restoring elastic bodies 25 and 26 in the form of rubber-like elastic bodies or metal springs are installed between the upper and lower structures 11 and 12. In addition, the restoring elastic body 26 in the form of a metal spring may be installed horizontally. Since this restoring elastic body is not subjected to any load, springs of various spring constants ranging from high to low may be used. Generally, when the upper structure is light, springs of low spring constant are used, while when it is heavy, springs of high spring constant are used. Thereby, even if the upper structure weighs only several tens of kg, they can operate well. Further, to exert the damping performance, a damper 27, such as an oil damper, viscosity damper, lead damper, steel rod damper, friction damper or viscoelastic damper, may be installed between the upper and lower structures 11 and 12 to absorb vibration energy, or highly damping rubber may be used as said restoring elastic body 25 of rubber-like elastic material. Further, though not shown, the vibration-proofing devices A, A', A" and B may be provided with a stop for limiting the distance to be traveled by the rollers or a cover for preventing foreign matter from adhering to the rolling surfaces. Said stop may be opposed to the rolling direction of the rollers on the pressure resisting plate, while the cover may be disposed around the entire periphery of the pressure resisting plate so as to surround the clearances storing the rollers, or it may be disposed to close the spaces of the upper and lower structures along the outer wall.
A third embodiment of the invention will now be described with reference to FIGS. 14 through 16. In addition, the parts which are identical or correspond to those used in the first embodiment shown in FIG. 1 are marked with the same reference characters.
The vibration-proofing device C of the third embodiment has an air spring 28 added to the first embodiment shown in FIG. 1. More particularly, as described in the first embodiment, the upper rollers 17 are interposed between the upper and intermediate pressure resisting plates 13 and 19 through elastomeric bodies 14 and 20 and the lower rollers 18 are interposed between the intermediate and lower pressure resisting plates 19 and 15 through elastomeric bodies 21 and 16, said upper and lower rollers 17 and 18 being stacked in two rows, forming an angle of 90°. The upper and lower rollers 17 and 18 are respectively rotatably supported in parallel arrangement by their respective connector plates 24. In this third embodiment, the air spring 28 is disposed above the upper and lower rollers 17 and 18. The air spring 28 is fixed at its upper end to the lower surface of the upper structure 11 and at its lower end to the upper surface of the upper pressure resisting plate 13, with air at desired pressure being sealed therein. In addition, restoring elastic bodies 25 or 26 made of rubber or in the form of coil springs are provided between the peripheral edges of the upper and lower pressure resisting plates 13 and 15. Though not shown, as in the case of the first embodiment, various dampers may be provided or highly damping rubber may be used for said restoring elastic bodies 25 or stops and covers may be provided, of course.
In the vibration-proofing device C of this third embodiment, the vertical component of a weak vibration, such as a traffic vibration or a vibration from the equipment installed in another room, is absorbed by the elastic deformation of the elastomeric bodies 14, 16, 20 and 21 forming the rolling surfaces for the upper and lower rollers 17 and 18, while the vertical component of a strong vibration, such as an earthquake, is absorbed by the air spring 28. Further, the horizontal components of a weak vibration, such as a traffic vibration, and of a strong vibration, such as an earthquake, are absorbed in that the upper and lower rollers 17 and 18 roll on the rolling surfaces defined by the elastomeric bodies 14, 16, 20 and 21. In addition, during the rolling of the upper and lower rollers 17 and 18, the elastomeric bodies 14, 16, 20 and 21 elastically deform to thereby exert the damping performance In this manner, three-dimensional vibrations of vertical and horizontal directions of the lower structure due to traffic vibrations or earthquakes are blocked to maintain the upper structure stationary.
FIGS. 15 and 16 show a floor vibration-proofing arrangement wherein vibration-proofing devices C are applied to part of a building. The planar pattern of a plurality of vibration-proofing devices C disposed between a vibration-proofing floor which is an upper structure 11 and a slab which is a lower structure 12 is designed by vertical load distribution based on the disposition of machines mounted on the upper structure (positions of center of gravity). In this floor vibration-proofing arrangement, in order to supply the air springs 28 of the vibration-proofing devices C with compressed air, there are provided a compressed air supply source 29 and pipes 31 extending from the compressed air supply source 29 to the respective vibration-proofing devices C via pressure reducing valves 30.
Thereby, when the vertical load distribution changes owing to a shift of the disposition (positions of center of gravity) of the machines or when the vertical load distribution somewhat differs from its estimate made before the machines are installed, the level of the vibration-proofing floor which is the upper structure 11 can be adjusted. More particularly, the pressure reducing valves 30 are adjusted to adjust the compressed air pressure supplied to the vibration-proofing devices C from the compressed air supply source 29 via the pipes 31. In the vibration-proofing devices C, the compressed air pressures in the internal spaces of the air springs 28 are increased or decreased to control the respective heights of the air springs, thereby adjusting the level of the vibration-proofing floor.
In the vibration-proofing device C of this third embodiment, air springs 28 have been used to absorb the vertical component of a strong vibration, such as an earthquake; however, such air springs 28 may be replaced by coil spring means 32 as in the vibration-proofing device D of a fourth embodiment shown in FIG. 17. In addition, the parts which are identical or correspond to those of the vibration-proofing device C of the third embodiment shown in FIG. 14 are marked with the same reference characters to avoid a repetitive description.
The vibration-proofing device D of this fourth embodiment shown in FIG. 17 has coil spring means 32 disposed above the upper and lower rollers 17 and 18. Stated concretely, a plurality of vertical springs 33 are installed between the lower surface of the upper structure 11 and the upper pressure resisting plate 13. A pair of links 35 each comprising two levers 34 are installed between the end edges of the upper structure 11 and the upper pressure resisting plate 13, and a horizontal coil spring 37 is taut between the pivots 36 of the levers 34 of the links 35. In the figure, only one horizontal coil spring 37 is shown, but two or more horizontal coil springs may be provided. Further, it is not absolutely necessary to use both the vertical coil springs 33 and the horizontal coil spring 37 simultaneously; either of them alone may be used.
In the vibration-proofing device D of this fourth embodiment, if a strong vibration, such as an earthquake, is inputted in the direction Y, the vertical coil springs 33 are contracted to produce restoring forces acting in the direction opposite to the direction of contraction, folding the links 35 to stretch the horizontal coil spring 37 while stretching the horizontal spring 37 to produce a restoring force acting in the direction opposite to the direction of stretch. If a strong vibration, such as an earthquake, is inputted in the direction-Y, the vertical coil springs 33 are stretched while the horizontal spring 37 is contracted with restoring forces produced in the vertical and horizontal springs 33 and 37. In this manner, the vertical component of a strong vibration, such as an earthquake, is absorbed by the elastic deformation of the vertical and horizontal springs 33 and 37. The horizontal component of a strong vibration, such as an earthquake, and the vertical and horizontal components of a weak vibration, such as a traffic vibration, are absorbed in the same manner as in the embodiment shown in FIG. 14; therefore, a repetitive description thereof is omitted.
A fifth embodiment of the invention will now be described with reference to FIGS. 18 through 20. In addition, the parts which are identical or correspond to those of the first embodiment shown in FIG. 1, the third embodiment shown in FIG. 14 or the fourth embodiment shown in FIG. 14 are marked with the same reference characters to avoid a repetitive description.
The vibration-proofing device E of this fifth embodiment has means added to the first embodiment for absorbing rotational components. Stated concretely, the vibration-proofing device E has a plurality of taper rollers 38 radially disposed in horizontal plane, this taper roller assembly being located above the upper rollers 17, i.e., between the upper pressure resisting plate 13 and the upper structure 11. In this case, there is no need to provide an elastomeric body on the upper surface of the upper pressure resisting plate 13. Disposed on the lower surface of the upper structure 11 and the upper surface of the upper pressure resisting plate 13 are an inverted conical pressure resisting plate 39 and a conical pressure resisting plate 40, respectively, the lower and upper surfaces thereof having elastomeric bodies 41 and 42 bonded thereto as by vulcanization to form rolling surfaces for the rollers 38. The rollers 38 are rotatably held in radial arrangement by concentric large and small annular connector plates 43 and 44.
In the vibration-proofing device E of this fifth embodiment, when a torsional vibration having horizontal, vertical and rotational components, such as an earthquake, is inputted, the rollers 38 roll around the center O, and the rolling of the rollers in the rotational direction absorbs the torsional vibration including the rotational component. Thus, the invention exerts the superior vibration-proofing function, absorbing all vibrations having horizontal, vertical and rotational components, including weak vibrations, such as traffic vibrations, strong vibrations, such as earthquakes.
Lastly, sixth and seventh embodiments comprising the third embodiment of FIG. 14 and the fourth embodiment of FIG. 17 added to the fifth embodiment of FIG. 15 will now be described with reference to FIGS. 21 and 22.
In the vibration-proofing device E of the fifth embodiment shown in FIGS. 18 through 20, the rolling surfaces for the rollers 17, 18 and 38 are defined by elastomeric bodies 14, 16, 20, 21, 41 and 42 to absorb the vertical components of vibrations. When weak vibrations, such as traffic vibrations or vibrations from the equipment in another room are inputted, the elastic deformation of the elastomeric bodies 14, 16, 20, 21, 41 and 42 exerts satisfactory vibration-proofing function, but when a strong vibration, such as an earthquake, is inputted, there is a danger of it becoming difficult to cope with the situation.
Accordingly, the vibration-proofing device shown in FIGS. 21 and 22 has means added to the fifth embodiment shown in FIGS. 18 through 20 for reliably absorbing strong vibrations such as earthquakes. In addition, the parts which are identical to those of FIGS. 18 through 20 are marked with the same reference characters to avoid a repetitive description.
The vibration-proofing device F of the sixth embodiment shown in FIG. 21 has an air spring disposed above the rollers 38 of the fifth embodiment, while the vibration-proofing device G of the seventh embodiment shown in FIG. 22 has coil spring means 32, instead of an air spring 28, disposed above the rollers 38 of the fifth embodiment. The air spring 28 and the coil spring means 32 in the vibration-proofing devices F and G of the sixth and seventh embodiments are the same as those used in the third embodiment shown in FIG. 13 and the fourth embodiment shown in FIG. 17 and a detailed description thereof is omitted.
The vibration-proofing devices F and G of the sixth and seventh embodiments shown in FIGS. 21 and 22 exert superior vibration-proofing function, absorbing all vibrations having horizontal, vertical and rotational components, including weak vibrations, such as traffic vibrations, and strong vibrations, such as earthquakes.
In addition, the horizontal component of a strong vibration, such as an earthquake, and the horizontal component of a weak vibration, such as a traffic vibration, are absorbed in the same manner as in the fifth embodiment shown in FIGS. 18 through 20, and a description thereof is omitted.
According to the vibration-proofing device of the present invention, since the rolling bodies are in the form of cylindrical rollers, the vibration-proofing effect is attained for lightweight buildings such as small buildings for which vibration-proofing designs have been considered to be difficult. Further, when vibrations are inputted into the lower structure or when vibrations stop, the cylindrical rollers roll to exert the vibration-proofing effect without producing strong vibrations. Further, since elastomeric bodies are disposed between the cylindrical rollers and the upper and lower structures, the device is superior in pressure resistance, and since no accuracy is required for the outer diameter of the cylindrical rollers and the parallelism of the upper and lower structures, manufacture and installation are easy and the appropriate vibration-proofing function is continuously exhibited; thus, the present vibration-proofing device is highly practical.
If an air spring or coil spring means is disposed vertically of the rollers, the vertical and horizontal components of not only weak vibrations, such as traffic vibrations and vibrations from the equipment housed in another room, but also strong vibrations, such as earthquakes, can be rapidly absorbed. And a vibration-proofing device having a superior vibration-proofing function can be constructed with a simple arrangement. In the case where said air spring is used, the level adjustment of the upper structure can be easily made by adjusting the internal air pressure of the air spring.
Further, if a plurality of taper rollers are radially arranged in a horizontal plane, then upon occurrence of traffic vibrations or earthquakes, the device can absorb torsional vibrations having rotational components as well as horizontal and vertical components. | The present invention relates to a vibration-proofing device which supports an upper structure, such as a building, computers and other machines or a floor having such machines mounted thereon, on a lower structure, as a foundation, to allow the upper structure to swing, thereby isolating earthquakes, traffic vibrations and vibrations from the equipment installed in another room so as to protect the upper structure from vibrations. The invention is to provide a bearing type of vibration-proofing device which is simple in construction and capable of reliably absorbing not only horizontal but also vertical components of earthquakes, traffic vibrations and other vibrations, whether they are weak or strong, and which properly operates under low load and produces little vibration during operation. The invention provides an arrangement wherein interposed between upper and lower structures are rolling bodies for horizontally supporting the upper structure for swing movement. The rolling bodies are in the form of cylindrical rollers, elastomeric bodies are interposed between the cylindrical rollers and the upper and lower structures. It is desirable that the cylindrical rollers be stacked in n rows and that these rows of cylindrical rollers form an angle of 180° /n. An air spring or coil spring device is disposed vertically of the cylindrical rollers and a plurality of taper rollers is radially arranged in a horizonial plane vertically of the cylindrical rollers. |
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention pertains to a rail arrangement for rail vehicles furnished with flanged wheels.
Description of the Related Art
Rail arrangements for rail vehicles furnished with flanged wheels such as, e.g., streetcars are generally known. Corresponding examples are described in DE 100 11 468 B4, DE 103 02 521 A1, DE 44 11 833 A1, DE 198 01 583 A1 and WO 92/05313 A1. Rail arrangements of this type frequently comprise grooved rails, in which a groove that accommodates the wheel flange is formed in the rail head. Grooved rails are also known, for example, from DE 10 2004 018 914 A1, DE 10 2004 054 794 B3, DE 20 2004 017 132 U1, DE 20 2005 004 107 U1, DE 479 362, DE 499 056, DE 608 258, DE 812 674, DE 564 508 and EP 1 462 570 A1.
However, this groove represents a potential safety hazard for outside traffic participants such as, e.g., cyclists, whose tires can get caught in the groove, wherein this regularly leads to sometimes serious accidents. Pedestrians such as, e.g., women wearing shoes with tapered heels or older persons also encounter problems when crossing roads with such rails. In EP 2 298 991 A1, it is therefore proposed to bond a protective insert that preferably consists of plastic, e.g. foamed polyurethane, into the groove. DE 87 07 445 U1 furthermore proposes to fix a filler profile of rubber or rubber-like material in the groove by means of retaining lips and bonding. However, it has become apparent that such solutions are inadequate for largely precluding the risk of accidents for users of two-wheeled vehicles and pedestrians, particularly for reliably and sufficiently closing the groove for the longer term in the unstressed state despite the constantly recurring loads applied by the flanged wheels. Filler profiles of this type particularly are subject to significant wear and/or do not adequately prevent, e.g., bicycle tires from getting caught in the groove.
It is therefore the objective of the present invention to reduce the risk of accidents associated with grooved rails, particularly for users of two-wheeled vehicles and pedestrians, in a more reliable fashion than previous solutions.
BRIEF SUMMARY OF THE INVENTION
This objective is attained with the subject-matter of claim 1 . Advantageous embodiments of the invention are disclosed in the dependent claims.
The invention proposes a rail arrangement for rail vehicles furnished with flanged wheels that comprises
a. a rail ( 2 ) comprising a running rail ( 6 ) with a running rail head ( 16 ), a guide rail ( 7 ) with a guide rail head ( 17 ), a rail foot ( 5 ), and a rail web ( 4 ) connecting the running rail ( 6 ) and the guide rail ( 7 ) with the rail foot ( 5 ), wherein the guide rail ( 7 ) is provided on one side of the running rail ( 6 ) defining a flange groove ( 8 ) between the running rail ( 6 ) and the guide rail ( 7 ), the flange groove ( 8 ) having an upper end with a groove opening ( 23 ) and a lower end with a groove bottom ( 24 ), and wherein the rail ( 2 ) has a rail height H S , the flange groove ( 8 ) has a groove depth T R and the groove depth T R amounts to at least 35% of the rail height H S , and
b. a filler profile ( 9 ) arranged in the flange groove ( 8 ), wherein the filler profile ( 9 ) features an upper part A and a lower part B, and wherein the lower part B can be elastically deformed and the upper part A has a greater hardness and/or rigidity than the lower part B.
The rail arrangement according to the invention solves the above-described problem with a combination of a comparatively deep groove and a filler profile that is arranged in the groove and divided into an elastically deformable lower part B and a comparatively hard or rigid upper part A. When the wheel flange passes over the filler profile, the thusly generated pressure essentially only causes an elastic deformation of the lower part B of the filler profile whereas the rigid/hard upper part A of the filler profile essentially is merely displaced in the vertical direction. After the wheel flange has passed over the filler profile, its upper part A is once again pushed upward by the restoring forces of the elastically deformable lower part B such that the groove is reliably closed. The elastic properties of the elastically deformable lower part B naturally are adapted to the typical pressures or weights exerted by wheel flanges of rail vehicles and, for example, two-wheeled vehicles such that a deformation of the elastically deformable lower part B is in essence only caused by a rail vehicle, but not by a two-wheeled vehicle such as, for example, a bicycle and/or a pedestrian. Accordingly, the hardness/rigidity of the upper part A is also adapted to the occurring alternating pressures or forces.
The flank of the running rail on the groove side and the flank of the guide rail on the groove side may form an angle that slightly opens upward, i.e. toward the groove opening, such as, e.g., an angle of no more than 1-5°, preferably no more than 1-3° or no more than 1-2°. The flanks may also extend essentially parallel to one another. According to the invention, it is particularly preferred that the flank of the running rail on the groove side and the flank of the guide rail on the groove side form an angle α that opens toward the rail foot. In contrast to conventional groove designs, in which the groove flanks extend apart from one another in the direction of the rail head and form a cup-shaped groove with a comparatively wide opening, the inventive design results in a groove that widens toward the rail foot. In this way, the filler profile is reliably held in the groove and does not have to be bonded, for example, to the groove bottom, although this naturally is still possible. A minimal widening toward the rail foot suffices. The angle alpha amounts to at least 0.5°, preferably 1°, particularly 1-5°, especially 1-3°, e.g. 1°, 1.5°, 2°, 2.5° or 3°.
In order to additionally anchor the filler profile in the groove, the groove side of the running rail and/or the guide rail may be provided with one or more undercuts, recesses, projections or the like, into which the filler profile can engage with corresponding complementary projecting retaining lips or recesses.
In a preferred embodiment of the rail arrangement of the invention, the groove depth T R amounts to at least 40%, preferably at least 45%, particularly at least 50%, of the rail height H S . The rail height H S is the dimension between the bottom of the rail foot and the surface of the running rail or the horizontal tangent on the running rail surface and the groove depth T R is the dimension between the surface of the running rail or the horizontal tangent on the running rail surface and the groove bottom at the height midway between the flanks of the running rail and the guide rail on the groove side.
The upper part A of the filler profile pointing toward the rail head may consist of the same material as the lower part B pointing toward the rail foot or of a different material. For example, both upper and lower parts A and B may consist of elastomeric material. Suitable elastomeric materials are, for example, materials on the basis of styrene-butadiene rubber (SBR), natural rubber (NR), a natural rubber/butyl rubber mixture (NR/BR) or ethylene-propylene-diene rubber (EPDM).
For example, one suitable material for the filler profile is SBR with the properties specified below in Table 1.
TABLE 1
Material properties of a suitable filler profile material (SBR-polymer,
measured on plates, d = days, RT = room temperature):
Property
Measuring method
Value
Unit
Shore hardness A
DIN 53505
62 ± 5
SHE
ISO 7619
Tearing resistance
DIN 53504
>10.0
N/mm 2
ISO 37
Elongation at tear
DIN 53504
>380
%
ISO 37
Ageing 7 d/70° C.
ISO 53508
(relative change)
ISO 88
Shore hardness A
DIN 53505
8
SHE
ISO 7619
Tearing resistance
DIN 53504
±15
%
ISO 37
Elongation at tear
DIN 53504
±25
%
ISO 37
Tear propagation resistance
DIN 53507
≧8
N/mm
(method A)
ISO 34
Rebound resilience
DIN 53512
≧25
%
(at RT)
ISO 815
Compression set
DIN 53517
ISO 815
72 h/RT
≦30
%
24 h/70° C.
≦35
%
Ozone 0.5 ppm/48 h/RT
DIN 53509
0
stage
ISO 1431 A
Abrasion
DIN 53516
≦200
mm 2
ISO 4649 A
Volume resistivity
DIN IEC 93
>1 * 10 9
Ohm * cm
Temperature range
−30 to 80
° C.
The upper part A of the filler profile pointing toward the rail head may consist of a harder elastomer than the lower part B pointing toward the rail foot, for example have a greater Shore hardness A. Alternatively or additionally, both parts A and B may consist of an elastomer with the same degree of hardness, but the upper part A is realized solid whereas the lower part B is realized with gas-filled, e.g. air-filled, cavities or in a foamlike fashion. Gas-filled microspheres may also be incorporated into the lower part B. The upper part A of the filler profile also may at least partially consist of a thermoplastic elastomer, a thermosetting polymer, metal or the like whereas the lower part B of the filler profile consists of an elastomer. For example, the upper part A may also feature an additional coating of a thermoplastic elastomer such as, e.g., a polyethylene layer, namely even if it consists of an elastomer. Although it is preferred that the lower part B consists of an elastomer, it would also be possible, in principle, to realize the lower part B in the form of a metal spring.
The upper part A of the filler profile is preferably realized as wear-resistant as possible such that it can withstand the loads applied by the wheel flanges as long as possible without having to be replaced or without being subjected to excessive abrasion that would cause the surface of the filler profile to be recessed deeper within the groove and therefore expose the groove. For this purpose, it would also be possible to incorporate hard particles such as, for example, metal or plastic particles into the upper part A.
The upper and lower parts A and B preferably are rigidly connected to one another or realized in one piece. If different elastomeric materials are used, the upper and lower parts A and B may be integrally connected to one another, for example, by means of coextrusion. It would naturally also be possible to produce the connection by means of bonding, threaded joints, vulcanizing, etc.
The elastically deformable lower part B of the filler profile pointing toward the rail foot preferably constitutes the majority of the filler profile. For example, the height H FB of the lower part B of the filler profile amounts to at least 60%, preferably at least 65%, for example 70%, 75%, 80% or 85%, of the overall height H F of the filler profile. The upper part A preferably has a minimum height, i.e. a minimum layer thickness. It is preferred that the height H FA of the upper part A of the filler profile pointing toward the rail head amounts to at least 15%, particularly at least 20%, especially 25%, 30% or 45%, of the overall height H F of the filler profile. Examples for suitable percental ratios between the heights of the parts A and B are 60/40, 65/35, 70/30, 75/25, 80/20 and 85/15. For example, the overall height H F of the filler profile, as well as the height ratios between the parts A and B, can be determined based on the height of the wheel flange.
The upper surface, i.e. the surface of the filler profile, over which the wheel flange passes, is preferably realized in a non-skid fashion, for example profiled or roughened. For this purpose, it would also be possible to incorporate hard particles into the surface of the filler profile.
The guide rail may be realized in one piece with the running rail or preferably in the form of a separate component. In the latter instance, the guide rail preferably is suitably connected to the running rail, for example bolted or welded to the rail web. For example, the running rail may consist of a conventional Vignol rail or crane rail, on the rail web of which a guide rail is mounted. The running rail and the guide rail preferably consist of conventional rail materials, typically of metal.
In a particularly preferred embodiment of the rail arrangement of the invention, the sides of the filler profile, i.e. the surfaces that face the flanks of the miming rail and the guide rail, particularly those of the upper part A, are coated with an easily sliding material such as, for example, a smooth plastic material. The sides are preferably coated with polytetrafluoroethylene (PTFE). In this way, the filler profile can slide along the flanks of the running rail and the guide rail more easily when it is pushed down by the wheel flange, as well as during the restoration of the filler profile, such that the filler profile quickly reassumes its original position after the wheel flange has passed over it and the wear due to abrasion is minimized.
The filler profile preferably has a cross section that widens toward the rail foot, i.e. the filler profile widens toward the groove bottom. This makes it possible to achieve an improved seat of the filler profile, particularly in an embodiment, in which the flanks of the mining rail and the guide rail on the groove side also extend apart from one another toward the rail foot such that the groove cross section widens toward the rail foot.
The filler profile may be realized in the form of a one-piece, two-piece or multipiece filler profile. In an embodiment, in which a combination of a Vignol rail and a guide rail bolted or welded to the rail web thereof is provided, for example, it may be advantageous to arrange a separate profiled part such as, e.g., a profiled part with a circular cross section in the hollow space formed on the groove side between the rail web, the guide rail and the underside of the running rail head. In this way, the installation of the filler profile is also simplified, for example, if the guide rail is welded to the miming rail. In this case, a restiform profiled part can initially be placed into the aforementioned hollow space and the remainder of the filler profile can subsequently be installed. The separate profiled part may consist of the same material as the upper part A and/or the lower part B of the filler profile or of a different material or a different material combination.
In the unstressed state, the upper surface of the filler profile preferably lies essentially at the level of the guide rail head. In this way, an essentially plane surface is formed in the groove region such that cyclists and pedestrians can respectively ride or walk across the rails without increased risk of falling.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention is described in greater detail below with reference to the attached figures that show preferred embodiments of the invention purely for elucidative purposes. In these figures:
FIG. 1 shows a preferred embodiment of the rail arrangement according to the invention in the form of a cross section.
FIG. 2 shows a detail of the rail arrangement according to FIG. 1 under a load.
FIG. 3 shows another embodiment of the rail arrangement according to the invention in the form of a cross section.
FIG. 4 shows another embodiment of the rail arrangement according to the invention in the form of a cross section.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 schematically shows a cross section through a rail arrangement 1 according to the invention. The rail arrangement 1 comprises a rail 2 with a rail head 3 , a rail web 4 and a rail foot 5 . The running rail 6 has a running rail head 16 and a guide rail 7 has a guide rail head 17 . In this case, the rail 2 consists of a Vignol rail that is essentially realized symmetrical referred to its central longitudinal axis 29 , wherein the rail web 4 of said rail is connected to a guide rail 7 by means of a flange 18 and a bolt connection 19 . In FIG. 1 , broken lines 21 , 22 are drawn along the flank 10 of the running rail 6 or the running rail head 16 on the groove side and the flank 11 of the guide rail 7 on the groove side. The broken line 22 a extending parallel to the line 22 was drawn as an aid for elucidating the angle α foil red between the flanks 10 , 11 on the groove side. The flanks 10 , 11 extend apart from one another toward the rail foot 5 such that an angle α is formed between the flanks 10 , 11 . The cross section of the flange groove 8 therefore widens from its opening 23 toward its bottom 24 . In this case, the groove depth T R , i.e. the dimension between the horizontal tangent 27 on the surface 28 of the running rail head 16 and the groove bottom 24 at the height midway between the two flanks 10 , 11 , amounts to approximately 40% of the rail height H S , i.e. the dimension between the horizontal tangent 27 on the surface 28 of the running rail head 16 and the base 26 , i.e. the underside, of the rail foot 5 .
A groove 8 is formed between the running rail 6 and the guide rail 7 and a filler profile 9 consisting of two components 9 a , 9 b is inserted into said groove. The filler profile 9 consists of an upper upper part A that points toward the rail head 3 or the groove opening 23 and a lower lower part B that points toward the rail foot 5 or the groove bottom 24 . In this figure, the boundary between the upper part A and the lower part B is merely indicated in the form of the broken line 20 for illustrative purposes because both parts are integrally connected to one another. The upper part A of the filler profile 9 a consisting of elastomeric material is realized solid in this case whereas the lower part B of the filler profile 9 a consisting of elastomeric material respectively features gas-filled or air-filled channels 25 . The surface 12 of the upper part A is profiled. The surface 12 of the upper part A essentially lies at the level 15 of the guide rail head 17 . The filler profile 9 engages behind the running rail head 16 with a retaining lip 31 .
FIG. 2 schematically shows the rail arrangement 1 of the invention according to FIG. 1 under a load. A merely indicated flanged wheel 32 rolling along the running rail head 16 presses the filler profile 9 a into the groove with its wheel flange 33 . The upper part A of the filler profile 9 a slides in the direction of the groove bottom 24 along the flanks 10 , 11 of the running rail 6 and the guide rail 7 with its PTFE-coated sides 13 , 14 . The upper part A essentially maintains its shape whereas the lower part B is elastically deformed. The air-filled channels 25 are compressed during this elastic deformation. The restiform filler profile component 9 b arranged in the hollow space 30 underneath the underside of the running rail head 16 on the groove side is also deformed in this case such that it essentially fills out the hollow space 30 . However, it may also be realized such that it essentially maintains its shape. As soon as the flanged wheel 32 with its wheel flange 33 has rolled over the filler profile 9 such that it is no longer subjected to a load, the filler profile 9 reassumes its original shape. The upper part A essentially slides in the direction of the flange groove opening 23 due to the restoring forces of the lower part B and in this way closes the flange groove 8 . The filler profile 9 is held in the flange groove without requiring bonding or the like. In this case, a reliable retention is ensured due to the cross-sectional widening of the filler profile 9 and the flange groove 8 toward the groove bottom 23 , as well as the retaining lip 31 .
FIG. 3 shows a detail of another embodiment of the inventive rail arrangement 1 . The rail arrangement 1 can merely be distinguished from the rail arrangement illustrated in FIG. 1 or 2 in that the upper part A of the filler profile 9 consists of metal. The upper part A is rigidly connected to the elastically deformable lower part B of the filler profile 9 by means of bonding. A coating such as, e.g., a PTFE-coating may also be provided on the sides of the filler profile 9 in this case, particularly in the region of the upper part A. In other respects, the rail arrangement 1 according to FIG. 3 corresponds to the rail arrangement illustrated in FIGS. 1 and 2 such that we refer to the preceding description thereof.
FIG. 4 shows a cross section through another embodiment of an rail arrangement 1 according to the invention, wherein characteristics corresponding to the embodiment illustrated in FIG. 1 are identified by the same reference symbols. In this embodiment, the running rail 6 and the separate guide rail 7 are arranged on a common base 36 that consists of a suitable metal in this case, but may also be made of plastic or an elastomer. The facing sides of the running rail 6 and the guide rail 7 respectively abut on a projection 37 formed by the base 36 whereas their outer sides are welded to the base 36 and thusly fixed in position. The running rail 6 and the guide rail 7 are connected to one another by means of a bolt connection 19 in this case, wherein a metallic sleeve 34 acts as a spacer. The groove bottom 24 is formed by a supporting plate 35 arranged on the sleeve 34 in this case, wherein said supporting plate extends between the running rail 6 and the guide rail 7 parallel to the rail 2 and is bonded to the underside of the filler profile 9 arranged on the supporting plate 35 . In this embodiment, the longitudinal axis 29 of the running rail 6 is slightly inclined, e.g. 1:40, relative to the horizontal line in the direction of the flange groove 8 or the running rail 7 , respectively. The flanks 10 , 11 of the running rail 6 and the guide rail 7 on the groove side extend nearly parallel in this case and form a slight opening toward the groove opening 23 . However, an angle that opens toward the rail foot 5 may also be realized, if applicable, with a corresponding design of the guide rail 7 . The filler profile 9 features a retaining lip 31 , by means of which the filler profile 9 engages behind the running rail head 16 . The retaining lip 31 ensures that the filler profile 9 is additionally fixed in the flange groove 8 . It is neither absolutely imperative to provide the retaining lip 31 nor to bond the filler profile 9 to the supporting plate 35 in order to hold the filler profile 9 in the intended position, but both are suitable for complicating an unforeseen or willful removal of the filler profile 9 . The upper and lower parts A and B of the filler profile 9 are realized in one piece by means of coextrusion. The groove depth T R amounts to approximately 48% of the rail height H S in this case. When a rail vehicle such as, e.g., a streetcar passes over the upper part A of the filler profile 9 consisting of wear-resistant material, the filler profile 9 is elastically deformed, namely compressed in the vertical direction, and yields into the hollow space 30 . Correspondingly designed restoring forces subsequently ensure that the filler profile 9 returns into its initial position. The elastic properties of the filler profile 9 are realized in such a way that the weight of a rail vehicle passing over the filler profile 9 leads to a compression thereof whereas the weight of a bicycle or a pedestrian causes no compression or only an insignificant compression of the filler profile 9 . | A rail arrangement for rail vehicles furnished with flanged wheels. To reduce the risk of accident existing in connection with grooved rails, particularly for cyclists and pedestrians, a rail arrangement is provided including a. a rail ( 2 ) having a rail head ( 3 ), a rail web ( 4 ) and a rail base ( 5 ), the rail head ( 3 ) having a drive rail ( 6 ), a guide rail ( 7 ) and a rail groove ( 8 ) lying therebetween; and b. a filler profile ( 9 ) arranged in the rail groove ( 8 ). |
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority in U.S. Provisional Application No. 61/406,005, filed Oct. 22, 2010, and is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosed technology relates generally to an apparatus for raising and aligning the structural towers of a collapsible performance stage, and more specifically to a rolling shuttle which receives the ends of the structural towers of a collapsible performance stage and facilitates positioning the towers in their upright positions supporting a roof over the stage.
[0004] 2. Description of the Related Art
[0005] Mobile performance stages are commonly used for temporary venues, performances, or rallies. Typical mobile performance stages must be assembled on site. Modern mobile stages may come in the form of a trailer, wherein the mobile stage is collapsible to a compact and mobile unit. The APEX 3224 Mobile Stage, manufactured by APEX Stages of Pittsburg, Kans., is an example of such a mobile stage.
[0006] Mobile stages generally include a stage deck and can include a stage roof. In order to support the stage roof, columns or towers are often used as structural elements. A mobile stage can be a large structure, and its components are manufactured from steel or other structural, heavy metals. In a typical stage setup situation it may take four laborers to raise the stage roof from the stage deck. In doing so, the laborers may have to drag the base of the stage towers across the stage deck, which may damage the deck or the tower itself. Because these stages are typically rented out for limited use, resiliency and long-term reliability are important features.
[0007] Mobile stages are often an economical alternative to erecting a permanent stage at a site. The typical reasons for electing to use a mobile stage include temporary use, cost, and reliability. Cutting the costs of using a mobile stage provides additional incentive for using a mobile stage. The simplest way to cut costs would be to reduce the number of persons required to setup and operate the stage. Costs are also saved when the owner of a mobile stage knows the stage will last. These cost savings can be passed on to customers, increasing the incentive to use one mobile stage over another.
[0008] What is needed is a system of erecting a mobile stage featuring minimal labor, minimal time, and minimal wear on the mobile components. Heretofore there has not been a mobile stage tower-erecting apparatus with the capabilities of the invention presented herein.
SUMMARY OF THE INVENTION
[0009] The preferred embodiment of the present invention includes a connection post, including a socket joint, connected to a shuttle cart on casters. The socket joint is capable of receiving a ball connection at the base of a structural tower. This connection allows a single operator to fully assemble a mobile performance stage with ease and with no damage to the stage deck. The tower shuttle allows the towers to be moved into position no matter the required direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The drawings constitute a part of this specification and include exemplary embodiments of the disclosed subject matter illustrating various objects and features thereof, wherein like references are generally numbered alike in the several views.
[0011] FIG. 1 is an isometric view of a tower shuttle embodying an aspect of the present invention.
[0012] FIG. 2 is an elevation view thereof.
[0013] FIG. 3 is a top plan view thereof.
[0014] FIG. 4 is a sectional view thereof taken generally along line 4 - 4 in FIG. 3 and showing a ball-and-socket interconnection.
[0015] FIG. 5 is an exploded, isometric view thereof.
[0016] FIG. 6 is an isometric view of an initial step of erecting a mobile stage assembly comprising an aspect of the present invention.
[0017] FIG. 7 is an isometric view of an intermediate step of erecting the mobile stage assembly.
[0018] FIG. 8 is an isometric view of a final step of erecting the mobile stage assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction and Environment
[0019] As required, detailed aspects of the disclosed subject matter are disclosed herein;
[0020] however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.
[0021] Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, base, front, back, right and left refer to the invention as oriented in the view being referred to. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.
[0022] A preferred embodiment of the present invention relies on the construction of a tower shuttle 17 using a connection post 1 mounted onto a shuttle base 2 The shuttle 17 is used in conjunction with a mobile stage 19 for erection and deconstruction of the stage.
II. Tower Shuttle 17
[0023] Referring to the drawings in more detail, reference numeral 17 generally refers to a tower shuttle. FIGS. 1-5 demonstrate the assembly of the tower shuttle 17 . The shuttle 17 is comprised of a connection post 1 and a shuttle cart 2 . The connection post 1 may be manufactured from a section of plastic pipe or plastic rod. Ideally, the material must hold a significant amount of weight and be nearly wear-resistant. The preferred embodiment comprises a connection post 1 formed from a plastic rod coated in ceramic, such as the Ceram-Back® line of products manufactured by Progressive Products Inc. of Pittsburg, Kans.
[0024] In the preferred embodiment, the shuttle cart 2 is a square plastic cart including four plastic casters 4 attached to the cart 2 with plastic caster brackets 6 . As shown in FIGS. 2 , 4 , and 5 , the casters 4 are located on a ball bearing wheel base 9 , which allows the casters 4 to freely rotate 360°, permitting the cart 2 to travel in any desired direction. The connection post 1 is attached to the cart 2 using a securing bolt 7 and washer 8 .
[0025] FIG. 3 demonstrates the tower shuttle 17 in further detail. The connection post 1 includes a base 5 which may be of a larger diameter than the main body of the post 1 . The base 5 physically contacts the shuttle 2 to disburse the force of a supported tower downward, and includes a chamfered bottom edge 11 . The connection post 1 further includes a chamfered top face 10 and houses a socket joint 3 at the apex of the post 1 . The socket joint 3 is adapted for receiving a ball joint connected to an appropriate tower.
[0026] FIG. 4 is a sectional view of the tower shuttle 17 showing how the socket joint 3 accepts the ball joint 20 of a stage tower 18 or other structural element. The connection forms a ball-and-socket joint that allows the tower 18 to raise no matter which direction the shuttle 17 is pushed.
[0027] FIG. 5 shows the complete assembly of the tower shuttle 17 in an exploded view. The bolt 7 threads through the washer 8 , the bolt-hole 12 located in the shuttle cart 2 , and into the connection post 1 . This forms a rigid connection between the post 1 and the cart 2 .
III. Mobile Stage 19
[0028] As shown in FIGS. 6-8 , in an embodiment of the present invention a mobile stage 19 is hauled to a performance site and is erected thereon. In the preferred embodiment, the mobile stage 19 will transform from a trailer hauled by a truck or other vehicle into a fully functional temporary performance stage.
[0029] The mobile stage 19 includes a roof section 13 , roof wing 14 , side walls 25 , a rear wall 26 , a stage deck 15 suspended upon a number of retractable stage jacks 27 , and at least two towers 18 . As shown in the progression demonstrated by FIGS. 6-8 , the roof wing 14 includes two attached towers 18 . As the towers 18 are moved from a starting, folded position in FIG. 6 to a final, standing position in FIG. 8 , the roof wing 14 fully extends over the stage deck 15 . This forms a complete stage with a roof covering for protecting performers and allowing lights and other equipment to be mounted above the performers.
[0030] The roof section 13 is also held suspended above the stage deck 15 via expanding pillars 23 . The pillars may expand using hydraulics, or other mechanical means; or they may expand as the towers 18 are moved into place. Once the roof section 13 is at an apex, and the towers 18 are in a final position, the expanding pillars 23 lock to maintain a final roof height.
[0031] Side walls 25 and a rear wall 26 are affixed to the roof section 13 . As the roof section 13 raises, the side walls 25 and rear wall 26 are also raised. These walls act to enclose the performance space of the mobile stage 19 .
[0032] Each tower 18 includes proximal and distal ends 22 , 24 . The proximal end is attached to the roof wing 14 via a hinged connection. The distal end 24 includes a ball joint 20 capable of being seated into the socket joint 3 of the tower shuttle 17 . Once the tower ball joint 20 is connected to the tower shuttle 17 , the shuttle aids in moving the tower 18 from a folded position as shown in FIG. 6 to a standing position as shown in FIG. 8 .
[0033] Upon the towers 18 and tower shuttles 17 reaching their final positions as indicated in FIG. 8 , the tower 18 is disconnected from the tower shuttle 17 , and the tower ball joint 20 is attached to a socket joint 16 affixed to the stage deck 15 . This secures the tower 18 in a final standing position that will ensure the stage 19 remains structurally supported during the duration of the performance.
[0034] Once the performance has been completed, the mobile stage 19 must be deconstructed and returned to its mobile form. The tower 18 is disconnected from the stage mounted socket joint 16 and reseated into the tower shuttle 17 . The shuttle 17 will guide the towers 18 from the standing position indicated in FIG. 8 back to a folded position indicated in FIG. 6 . The roof section 13 and stage deck 15 may then be folded up and the mobile stage 19 transported to a new location. A standard trailer hitch 28 is affixed to the mobile stage 19 at an end, and allows the stage to be hauled by a standard truck or transport tractor. A number of wheels, not shown, may be affixed to the mobile stage 19 to accommodate transportation of the stage.
[0035] Because the mobile stage 19 may include hydraulic power for moving the towers into place, the person operating the stage simply ensures that the tower ball joints 20 are firmly seated into the shuttle socket joints 3 , and then activates the stage's hydraulics. The towers will move into position, where the operator can then transfer the tower 18 from the shuttle socket 3 to the stage mounted socket 16 . This allows a single operator to setup and deconstruct the entire mobile stage 19 without additional labor.
[0036] It will be appreciated that tower shuttle 17 can be used for various other applications. For example, the transforming structural element does not need to be a mobile performance stage 19 . The structural element could be a store-front which transforms from a closed position to an open position by erecting towers to support said store front. Moreover, the tower shuttle 17 can be compiled of additional elements or alternative elements to those mentioned herein, while returning similar results.
[0037] It is to be understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects. | A transportable, transformable structure utilizing a tower shuttle apparatus for converting the structure from a closed, transportable unit to an open, stationary unit. The tower shuttle includes a connection post, including a socket joint, connected to a shuttle cart on casters. The socket joint is capable of receiving a ball connection at the base of a structural tower affixed to the transformable structure. This connection allows a single operator to fully assemble a mobile performance stage or other transportable, transformable structure with ease and with no damage to the stage deck. The tower shuttle allows the towers to be moved into position no matter the required direction. |
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BACKGROUND OF THE INVENTION
The present invention relates generally to fluid circuits, and more particularly to an apparatus and method for controlling multiple fluid cylinders.
Fluid circuits, such as hydraulic circuits, are commonly used on heavy tractors such as excavators and front loaders. Such heavy tractors typically have a boom pivotally attached at a first end thereto. Pivotally attached to a second end of the boom is a beam member. An example of known beam members may include a stick or a telescoping arm. In addition, the beam member has an attachment coupled thereto to perform a number of operations. For example, a stick may have a bucket pivotally coupled thereto in order to perform an excavating operation, or a telescoping arm may have a scraping tool attached thereto for removing slag or other debris from a ladle used in a steel mill's operation.
A number of known cylinders or rams are attached to the boom and beam member in order to move the boom and beam member relative one another and the heavy tractor. In a known manner, fluid pressure is used to extend and retract the cylinders in order to generate the desired movement.
Heavy tractors are equipped with a number of control devices coupled to a plurality of fluid circuits, thereby allowing the operator of the heavy tractor to control the movement of the boom, the beam member, and the attachment. Each of these components, i.e. the boom, the beam member, and the attachment, may require a separate fluid circuit for the control thereof. For example, in the case of an excavator, a first fluid circuit controls the raising and lowering of the boom, a second fluid circuit controls the tilt of the stick, and a third fluid circuit controls the movement of the bucket.
It may be desirable to alternatively control the movement of two components. That is, it may be desirable to prevent the extension or retraction of the cylinder or cylinders that control the movement of one or more components, i.e. the boom, the beam member, or attachment, while the cylinder or cylinders that control the movement of another component are being extended or retracted. For example, in the case of a heavy tractor equipped with a telescoping arm and a scraping tool, the tractor may be rendered unstable if the operator is allowed to simultaneously raise or lower the boom while changing the attitude of, i.e. tilting, the telescoping arm. Therefore, the controls of the tractor must be configured so as to allow the operator to alternatively, as opposed to simultaneously, control the raising or lowering of the boom and the tilting of the telescoping arm.
Moreover, a given heavy tractor may include only a limited number of fluid circuits therein. Therefore, if the heavy tractor is to be fitted with a beam member and attachment assembly that requires more fluid circuits than are present on the tractor, additional fluid circuits must be added. In addition to the cost of the of the additional fluid circuits themselves, additional costs may be incurred if the tractor must be redesigned or otherwise retrofitted to physically accommodate the additional fluid circuits.
What is needed therefore is an apparatus and method for alternatively controlling multiple cylinders with the same fluid circuit.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention there is provided an apparatus for controlling a first fluid cylinder and a second fluid cylinder including an operational pressure source and a fluid control circuit. The fluid control circuit includes a pilot valve assembly having a first valve position and a second valve position. Moreover, the fluid control circuit (1) delivers pressure from the operational pressure source to the first fluid cylinder when the pilot valve assembly is positioned in the first valve position, (2) isolates the second fluid cylinder from the operational pressure source when the pilot valve assembly is positioned in the first valve position, (3) delivers pressure from the operational pressure source to the second fluid cylinder when the pilot valve assembly is positioned in the second valve position, and (4) isolates the first fluid cylinder from the operational pressure source when the pilot valve assembly is positioned in the second valve position.
In accordance with another embodiment of the present invention, there is provided a method for controlling a first fluid cylinder and a second fluid cylinder with a fluid control circuit including an operational pressure source and a pilot valve assembly having a first valve position and a second valve position. The method includes the steps of (1) delivering pressure from the operational pressure source to the first fluid cylinder when the pilot valve assembly is positioned in the first valve position, (2) isolating the second fluid cylinder from the operational pressure source when the pilot valve assembly is positioned in the first valve position, (3) delivering pressure from the operational pressure source to the second fluid cylinder when the pilot valve assembly is positioned in the second valve position, and (4) isolating the first fluid cylinder from the operational pressure source when the pilot valve assembly is positioned in the second valve position.
It is therefore an object of the present invention to provide a new and useful apparatus for controlling a plurality of fluid cylinders.
It is another object of the present invention to provide an improved apparatus for controlling a plurality of fluid cylinders.
It is yet another object the present invention to provide a new and useful method for controlling multiple fluid cylinders.
It is moreover an object of the present invention to provide an improved method for controlling multiple fluid cylinders.
It is further an object of the present invention to provide an apparatus which alternatively controls multiple fluid cylinders from a single main control valve.
It is yet another object of the present invention to provide and apparatus for alternatively controlling multiple fluid cylinders.
It is another object of the present invention to provide an apparatus for controlling multiple fluid cylinders which enhances the stability of a heavy tractor.
The above and other objects, features, and advantages of the present invention will become apparent from the following description and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a heavy tractor which incorporates the features of the present invention therein; and
FIG. 2 is a schematic view of a fluid control circuit of the heavy tractor of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular form disclosed, but 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.
Referring now to FIG. 1, there is shown a heavy tractor 10 which includes a body 12, a boom 14, a telescoping arm 16, a scraping device 18, a fluid control circuit 20, a boom cylinder 22, and a tilt cylinder 24. The body 12 includes a boom brace 26 attached thereto. A first end of the boom 14 is pivotally attached to the boom brace 26, thereby allowing the boom 14 to move relative the body 12. Moreover, the telescoping arm 16 includes a flange 28 attached thereto which is pivotally mounted to a second end of the boom 14, thereby allowing the telescoping arm 16 to move relative the boom 14.
The boom cylinder 22 includes a housing 21 and a rod 23. The housing 21 is pivotally connected to a brace 30 which is coupled to the body 12, whereas the rod 23 is pivotally connected to a brace 32 which is coupled to the boom 14. In a known manner, the rod 23 is urged into or out of the housing 21 upon the application of a fluid pressure in the respective direction thereon. Hence, the boom cylinder 22 provides the motive power for raising or lowering the boom 14. That is, if the boom cylinder 22 is extended, i.e. the rod 23 is urged out of the housing 21, the boom 14 is raised relative to the body 12. Alternatively, if the boom cylinder 22 is retracted, i.e. the rod 23 is urged into the housing 21, the boom 14 is lowered relative to the body 12.
The tilt cylinder 24 includes a housing 25 and a rod 27. The housing 25 is pivotally connected to a brace 34 which is coupled to the boom 14, whereas the rod 27 is pivotally connected to the flange 28 of the telescoping arm 16. In a known manner, the rod 27 is urged into or out of the housing 25 upon the application of a fluid pressure in the respective direction thereon. Hence, the tilt cylinder 24 provides the motive power for altering the attitude, i.e. tilting, of the telescoping arm 16 and hence the scraping device 18. That is, if the tilt cylinder 24 is extended, i.e. the rod 27 is urged out of the housing 25, the telescoping arm 16 is tilted in a downward direction. Alternatively, if the tilt cylinder 24 is retracted, i.e. the rod 27 is urged into the housing 25, the telescoping arm 16 is tilted in an upward direction.
The boom cylinder 22 and the tilt cylinder 24 are controlled by the fluid control circuit 20. In particular, the boom cylinder 22 and the tilt cylinder 24 are extended and/or retracted by a fluid pressure within the fluid control circuit 20. Moreover, the fluid circuit is coupled to a lever 106 (not shown in FIG. 1, but see FIG. 2), thereby allowing an operator of the heavy tractor 10 to control the movement of the boom cylinder 22 and the tilt cylinder 24.
If the boom 14 is raised or lowered simultaneously as the telescoping arm 16 is tilted upwardly or downwardly, the heavy tractor 10 may be rendered unstable, thereby creating a potentially dangerous situation wherein the heavy tractor 10 may tip or overturn. Therefore, the boom cylinder 22 and the tilt cylinder 24 must be alternatively controlled. What is meant herein by the term "alternative control" is that the simultaneous movement of the boom cylinder 22 and the tilt cylinder 24 is prohibited. That is, during the time in which the boom cylinder 22 is being extended or retracted, the tilt cylinder is rendered motionless, and vice versa. As shall be discussed in more detail below, the fluid logic of the fluid control circuit 20 allows for the alternative control of the boom cylinder 22 and the tilt cylinder 24.
Referring now to FIG. 2, the fluid control circuit 20 of the heavy tractor 10 is shown in fluid communication with the boom cylinder 22 and the tilt cylinder 24. The fluid control circuit 20 includes an operation circuit 36 and a pilot circuit 38. The operation circuit 36 includes a source of pressurized operational fluid such as an operation fluid pump 40, an operation fluid reservoir or drain 42, a main control valve 44, and a pair of diverter valves 46 and 48.
The main control valve 44 is a pilot-controlled three-position, four-way valve with an inlet port 44a, an exhaust port 44b, a first control port 44c, and a second control port 44d. Collectively, the control ports 44c and 44d are commonly referred to as the "stem" of the fluid control circuit 20. An operation fluid, such as oil, is supplied from the operation fluid pump 40 to the inlet port 44a via a fluid line 54, whereas operation fluid is transmitted from the exhaust port 44b to the operation fluid reservoir 42 via a drain line 56.
The main control valve 44 transmits operation fluid to the diverter valves 46 and 48. Each of the diverter valves 46 and 48 is a pilot-actuated, two-position valve. The diverter valves 46 and 48 are identical, except that the diverter valve 46 includes an inlet port 46a, whereas the diverter valve 48 includes an inlet/outlet port 48a. Each of the diverter valves 46 and 48 further includes a first diverter port 46b and 48b, respectively, and a second diverter port 46c and 48c, respectively. In particular, the control port 44c of the main control valve 44 is coupled to the inlet port 46a of the diverter valve 46 via a fluid line 58. Similarly, the control port 44d of the main control valve 44 is coupled to the inlet/outlet port 48a of the diverter valve 48 via a fluid line 60.
The diverter valve 46 transmits operation fluid to either a check valve 62 or a check valve 64. More specifically, the diverter port 46b is coupled to an inlet of the check valve 62 via a fluid line 66. Moreover, the diverter port 46c is coupled to an inlet of the check valve 64 via a fluid line 68. Each of the check valves 62 and 64 is coupled to a head end port 22a and 24a of the boom cylinder 22 and the tilt cylinder 24, respectively. In particular, an outlet of the check valve 62 is coupled to the head end port 22a of the boom cylinder 22 via a fluid line 70, whereas an outlet of the check valve 64 is coupled to the head end port 24a of the tilt cylinder 24 via a fluid line 72.
Similarly, the diverter valve 48 transmits operation fluid to either a rod end port 22b of the boom cylinder 22a or a check valve 74. That is, the diverter port 48b is coupled to the rod end port 22b of the boom cylinder 22 via a fluid line 78. Moreover, the diverter port 48c is coupled to an inlet of the check valve 74 via a fluid line 76. An outlet of the check valve 74 is coupled to a rod end port 24b of the tilt cylinder 24 via a fluid line 80.
Each of the check valves 62, 64, and 74 may be bypassed by a number of relief valves 82, 84, and 86, respectively. The relief valves 82, 84, and 86 are pilot-actuated, two-way valves with an operation fluid inlet port and an operation fluid outlet port. As shown in FIG. 2, the relief valves 82, 84, and 86 are arranged in parallel flow relationship with the check valves 62, 64, and 74, respectively. More specifically, the inlet ports of each of the relief valves 82, 84, and 86 are respectively coupled to the fluid lines 70, 72, and 80 by a number of bypass fluid lines 88, 90, and 92, respectively. Moreover, the outlet ports of each of the relief valves 82, 84, and 86 are coupled to an operation fluid reservoir or drain 94 via a drain line 96.
In order to control the position of the various valves within the operation circuit 36, i.e. the main control valve 44, the diverter valves 46 and 48, and the relief valves 82, 84, and 86, the fluid control circuit 20 includes the pilot circuit 38. The pilot circuit 38 includes a pilot fluid pump 98, a pilot fluid reservoir or drain 100, a pair of directional valves 102 and 104 coupled to a lever 106, a pilot valve assembly 109, and a number of ball resolvers 114, 116, and 118. Moreover, the pilot valve assembly 109 includes a pair of electrically actuated pilot valve units 108 and 110 which are electrically coupled a voltage potential B+ via an electrical signal line 111 with a normally-open switch 112 therein.
Each of the directional valves 102 and 104 is an operator-controlled, two-position, three-way valve which respectively includes an inlet port 102a and 104a, an exhaust port 102b and 104b, and a directional port 102c and 104c. A pressurized pilot fluid, such as oil, is supplied from the pilot fluid pump 98 to the inlet ports 102a and 104a via a pilot line 120, whereas pilot fluid is transmitted from the exhaust ports 102b and 104b to the pilot fluid reservoir 100 via a pilot drain line 122.
The directional valves 102 and 104 direct pilot fluid to the pilot valve assembly 109. More specifically, the directional valve 102 is coupled to the pilot valve unit 108, whereas the directional valve 104 is coupled to the pilot valve unit 110. Each of the pilot valve units 108 and 110 is an electrically-actuated, two-position, four-way valve which respectively includes an inlet port 108a and 110a, an outlet port 108b and 110b, a first pilot port 108c and 110c, and a second pilot port 108d and 110d. In particular, the directional port 102c of the directional valve 102 is coupled to the inlet port 108a of the pilot valve unit 108 via a pilot line 124. Similarly, the directional port 104c of the directional valve 104 is coupled to the inlet port 110a of the pilot valve unit 110 via a pilot line 126. Moreover, the exhaust ports 108b and 110b are coupled to a pilot reservoir or drain 128 via a pilot drain line 130.
The pilot port 108c of the pilot valve unit 108 is coupled to a pilot line 132, which is in turn coupled to (1) a port 114a of the ball resolver 114 via a pilot line 134, (2) a pilot inlet of the relief valve 86, and (3) a port 118b of the ball resolver 118. Moreover, the pilot port 108d is coupled to a port 114b of the ball resolver 114 via a pilot line 136.
Similarly, the pilot port 110c of the pilot valve unit 110 is coupled to a pilot line 138, which is in turn coupled to (1) a port 118a of the ball resolver 118 via a pilot line 140, (2) a port 116b of the ball resolver 116 via a pilot line 142, and (3) a pilot inlet of the relief valve 84 via a pilot line 144. Moreover, the pilot port 110d of the pilot valve unit 110 is coupled to a port 116a of the ball resolver 116 and a pilot inlet of the relief valve 82 via a pilot line 146.
A pair of actuation ports 114c and 116c of the ball resolvers 114 and 116, respectively, are coupled to the main control valve 44 by a pair of pilot lines 148 and 150, respectively, as shown in FIG. 2. Moreover, an actuation port 118c of the ball resolver 118 is coupled to a pilot inlet port of the diverter valves 46 and 48 via a pilot line 152.
Each of the relief valves 82, 84, and 86 includes a pilot outlet port which is coupled to the pilot reservoir 128 via a pilot drain line 154. Similarly, a pilot outlet port included on each of the diverter valves 46 and 48 is coupled to the pilot drain line 154, and hence the pilot reservoir 128, via a pilot drain line 156.
In order to raise the boom 14 (see FIG. 1), i.e. extend the boom cylinder 22, the lever 106 is moved upwardly (relative to the view in the fluid schematic of FIG. 2) such that the directional valve 102 is moved from a neutral position (as shown) to an active position, thereby placing the directional port 102c in fluid communication with the pilot line 120 and hence the fluid pump 98. After which, pilot fluid is directed to the inlet port 108a of the pilot valve unit 108 via the pilot line 124. When isolated from the voltage potential B+, the pilot valve assembly 109 remains in a first valve position. More specifically, the pilot valve unit 108 remains in a first pilot position (as shown) as long as the switch 112 is in an open or first switch position (as shown). Hence, pilot fluid entering the inlet port 108a is exited through the pilot port 108d.
Thereafter, pilot fluid is advanced via the pilot line 136 to the port 114b of the ball resolver 114 which transmits an actuation signal on the pilot line 148. The actuation signal on the pilot line 148 causes the main control valve 44 to be shifted downwardly (relative to the view in the fluid schematic of FIG. 2) from a neutral or fluid obstructing position (as shown) to a first fluid transmitting position.
Once the main control valve 44 is switched from the neutral or fluid obstructing position, pressurized operation fluid is directed from the operation fluid pump 40 to the inlet port 44a of the main control valve 44 via fluid line 54. Since the main control valve 44 is in a first fluid transmitting position, operation fluid is exited therefrom via the control port 44c. Thereafter, operation fluid is advanced via the fluid line 58 to the inlet port 46a of the diverter valve 46.
Since the diverter valve 46 is in a first or boom-control position (as shown), operation fluid is exited therefrom via the diverter port 46b. Operation fluid is then advanced to the head end port 22a of the boom cylinder 22 via a fluid path which includes the fluid line 66, the check valve 62, and the fluid line 70, thereby urging or extending the rod 23 out of the housing 21.
Operation fluid is exhausted from the rod end port 22b of the boom cylinder 22 via the fluid line 78. Exhausted operation fluid is advanced through the fluid line 78 to the diverter port 48b of the diverter valve 48. Since the diverter valve 48 is in a first or boom-control position (as shown), exhausted operation fluid is advanced into the diverter port 48b and exited through the inlet/outlet port 48a. After which, exhausted operation fluid is advanced to the operation fluid reservoir 42 via a fluid path which includes the fluid line 60, the main control valve 44, and the drain line 56.
In order to lower the boom 14 (see FIG. 1), i.e. retract the boom cylinder 22, the lever 106 is moved downwardly (relative to the view in the fluid schematic of FIG. 2) such that the directional valve 104 is moved from a neutral position (as shown) to an active position, thereby placing the directional port 104c in fluid communication with the pilot line 120 and hence the fluid pump 98. After which, pilot fluid is directed to the inlet port 110a of the pilot valve unit 110 via the pilot line 126. When isolated from the voltage potential B+, the pilot valve assembly 109 remains in the first valve position. More specifically, the pilot valve unit 110 remains in a third pilot position (as shown) as long as the switch 112 is in an open or first switch position (as shown). Hence, pilot fluid entering the inlet port 110a is exited through the pilot port 110d.
Thereafter, pilot fluid is advanced via pilot line 146 to the port 116a of the ball resolver 116 which transmits an actuation signal on the pilot line 150. The actuation signal on the pilot line 150 causes the main control valve 44 to be shifted upwardly (relative to the view in the fluid schematic of FIG. 2) from a neutral or fluid obstructing position (as shown) to a second fluid transmitting position. Simultaneously, pilot fluid is advanced via the pilot line 146 to the pilot inlet of the relief valve 82 causing the relief valve 82 to be switched from a first or fluid obstructing position (as shown) to a second or fluid transmitting position.
Once the main control valve 44 is switched from the neutral or fluid obstructing position, pressurized operation fluid is directed from the operation fluid pump 40 to the inlet port 44a of the main control valve 44 via the fluid line 54. Since the main control valve 44 is in a second fluid transmitting position, operation fluid is exited therefrom via the control port 44d. Thereafter, operation fluid is advanced via the fluid line 60 to the inlet/outlet port 48a of the diverter valve 48.
Since the diverter valve 48 is in the first or boom-control position (as shown), operation fluid is exited therefrom via diverter port 48b. Operation fluid is then advanced to the rod end port 22b of the boom cylinder 22 via the fluid line 78, thereby urging or retracting the rod 23 into the housing 21.
Operation fluid is exhausted from the head end port 22a of the boom cylinder 22 via the fluid line 70. Exhausted operation fluid is not permitted to advance from the outlet to the inlet of the check valve 62, but rather is advanced to the operation fluid reservoir 94 via a fluid path which includes the fluid line 88, the relief valve 82, and the drain line 96. Note that the pilot signal which actuates the relief valve 82 is exhausted to the pilot reservoir 128 via the pilot drain line 154.
In order to tilt the telescoping arm 16 (see FIG. 1) downwardly, i.e. extend the tilt cylinder 24, the switch 112 is depressed, thereby positioning the switch 112 in a closed or second switch position, and the lever 106 is moved upwardly (relative to the view in the fluid schematic of FIG. 2). Hence, the pilot valve assembly 109 is placed in electrical contact with the voltage potential B+ and is therefore moved from the first valve position (as shown) to a second valve position. More specifically, the pilot valve unit 108 is moved from the first pilot position (as shown) to a second pilot position. Moreover, the upward movement of the lever 106 causes the directional valve 102 to be moved from the neutral position (as shown) to the active position, thereby placing the directional port 102c in fluid communication with the pilot line 120 and hence the pilot fluid pump 98. After which, pilot fluid is directed to the inlet port 108a of the pilot valve unit 108 via the pilot line 124. Since the pilot valve unit 108 is in the second pilot position, pilot fluid entering the inlet port 108a is exited through the pilot port 108c.
Thereafter, pilot fluid is advanced via pilot line 132 to (1) the port 114a of the ball resolver 114 via pilot line 134 which in turn transmits an actuation signal on the pilot line 148, (2) the port 118b of the ball resolver 118 which in turn transmits an actuation signal on the pilot line 152, and (3) the pilot inlet port of the relief valve 86 which causes the relief valve 86 to change from a first or fluid obstruction position to a second or fluid transmitting position. The actuation signal on the pilot line 148 causes the main control valve 44 to be shifted downwardly (relative to the view in the fluid schematic of FIG. 2) from the neutral or fluid obstructing position (as shown) to the first fluid transmitting position. Moreover, the actuation signal on the pilot line 152 causes the diverter valve 46 to change from the first or boom-control position (as shown) to a second or tilt-control position.
Once the main control valve 44 is switched from the neutral or fluid obstructing position, pressurized operation fluid is directed from the operation fluid pump 40 to the inlet port 44a of the main control valve 44 via the fluid line 54. Since the main control valve 44 is in the first fluid transmitting position, operation fluid is exited therefrom via the control port 44c. Thereafter, operation fluid is advanced via the fluid line 58 to the inlet port 46a of the diverter valve 46.
Since the diverter valve 46 is in the second or tilt-control position, operation fluid is exited therefrom via diverter port 46c. Operation fluid is then advanced to the head end port 24a of the tilt cylinder 24 via a fluid path which includes the fluid line 68, the check valve 64, and the fluid line 72, thereby urging or extending the rod 27 out of the housing 25.
Operation fluid is exhausted from the rod end port 24b of the tilt cylinder 24 via the fluid line 80. The exhausted operation fluid is not permitted to advance from the outlet to the inlet of the check valve 74, but rather is advanced to the operation fluid reservoir 94 via a fluid path which includes the fluid line 92, the relief valve 86, and the drain line 96. Note that the pilot signal which actuates the relief valve 86 is exhausted to the pilot reservoir 128 via the pilot drain line 154. Moreover, the pilot signal which actuates the directional valve 46 is exhausted to the pilot drain line 154 and hence the pilot reservoir 128 via the pilot drain line 156.
In order to tilt the telescoping arm 16 (see FIG. 1) upwardly, i.e. retract the tilt cylinder 24, the switch 112 is depressed, thereby positioning the switch 112 in the closed or second switch position, and the lever 106 is moved downwardly (relative to the view in the fluid schematic of FIG. 2). Hence, the pilot valve assembly 109 is placed in electrical contact with the voltage potential B+ and is therefore moved from the first valve position (as shown) to the second valve position. More specifically, the pilot valve unit 110 is moved from the third pilot position (as shown) to a fourth pilot position. Moreover, the downward movement of the lever 106 causes the directional valve 104 to be moved from the neutral position (as shown) to the active position, thereby placing the directional port 104c in fluid communication with the fluid line 120 and hence the pilot fluid pump 98. After which, pilot fluid is directed to the inlet port 110a of the pilot valve unit 110 via pilot line 126. Since the pilot valve unit 110 is in the fourth pilot position, pilot fluid entering the inlet port 110a is exited through the pilot port 110c.
Thereafter, pilot fluid is advanced via pilot line 138 to (1) the port 116b of the ball resolver 116 via pilot line 142 which in turn transmits an actuation signal on the pilot line 150, (2) the port 118a of the ball resolver 118 which in turn transmits an actuation signal on the pilot line 152, and (3) the pilot inlet port of the relief valve 84 via the pilot line 144 which causes the relief valve 84 to change from a first or fluid obstruction position to a second or fluid transmitting position. The actuation signal on the pilot line 150 causes the main control valve 44 to be shifted upwardly (relative to the view in the fluid schematic of FIG. 2) from the neutral or fluid obstructing position (as shown) to the second fluid transmitting position. Moreover, the actuation signal on the pilot line 152 causes the diverter valve 48 to change from the first or boom-control position (as shown) to a second or tilt-control position.
Once the main control valve 44 is switched from the neutral or fluid obstructing position, pressurized operation fluid is directed from the operation fluid pump 40 to the inlet port 44a of the main control valve 44 via the fluid line 54. Since the main control valve 44 is in the second fluid transmitting position, operation fluid is exited therefrom via the control port 44d. Thereafter, operation fluid is advanced via the fluid line 60 to the inlet/outlet port 48a of the diverter valve 48.
Since the diverter valve 48 is in the second or tilt-control position, operation fluid is exited therefrom via diverter port 48c. Operation fluid is then advanced to the rod end port 24b of the tilt cylinder 24 via a fluid path which includes the fluid line 76, the check valve 74, and the fluid line 80, thereby urging or retracting the rod 27 into the housing 25.
Operation fluid is exhausted from the head end port 24a of the tilt cylinder 24 via the fluid line 72. Exhausted operation fluid is not permitted to advance from the outlet to the inlet of the check valve 64, but rather is advanced to the operation fluid reservoir 94 via a fluid path which includes the fluid line 90, the relief valve 84, and the drain line 96. Note that the pilot signal which actuates the relief valve 84 is exhausted to the pilot reservoir 128 via the pilot drain line 154. Moreover, the pilot signal which actuates the directional valve 48 is exhausted to the pilot drain line 154 and hence the pilot reservoir 128 via the pilot drain line 156.
From the above discussion, it should be appreciated that the control of the boom cylinder 22 is isolated from the control of tilt cylinder 24. That is, the position, i.e. open or closed, of the switch 112 and hence the position of the pilot valve units 108 and 110, i.e. the boom-control position or the tilt-control position, determines whether the lever 106 controls the movement, i.e. extension or retraction, of either the boom cylinder 22 or the tilt cylinder 24. Therefore, it should be appreciated that the lever 106 may not move, i.e. extend or retract, the boom cylinder 22 and the tilt cylinder 24 simultaneously. Hence, the boom cylinder 22 and the tilt cylinder 24 may be alternatively controlled by the same set of controls, i.e. the lever 106 and the switch 112.
Moreover, it should be further appreciated that the boom cylinder 22 and the tilt cylinder 24 are both controlled from the same stem. That is, the same control ports 44c and 44d of the main control valve 44 may be used to control the movement, i.e. the extension and contraction, of both the boom cylinder 22 and the tilt cylinder 24.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
For example, although the fluid control circuit 20 in FIG. 2 is shown having a separate operation fluid pump 40 and pilot fluid pump 98, it should be appreciated that a single operational pressure source, i.e. a single pump, may be used to supply the fluid pressure for both the operation circuit 36 and the pilot circuit 38.
Moreover, the magnitude of the voltage potential B+ in the demonstrated embodiment of FIG. 2 is +24 VDC. However, it should be appreciated that the magnitude of the voltage potential may be altered to any value which may be readily available in the electrical system of a given heavy tractor 10, so long as the value of the voltage potential selected can actuate the pilot valve units 108 and 110.
In addition, although the lever 106 and switch 112 are shown as separate, discrete devices in FIG. 2, it should be appreciated that the two may be integrated. More specifically, the switch 112 may be integrated into a handle of the lever 106, thereby allowing the operator of the heavy tractor 10 to operate the lever 106 and the switch 112 with the same hand.
Further, although the boom cylinder 22 and the tilt cylinder 24 are each described as a single cylinder, it should be appreciated that the boom cylinder 22 or the tilt cylinder 24 may be a plurality, e.g. a pair, of boom cylinders 22 or tilt cylinders 24, respectively, working in unison. | An apparatus for controlling a first fluid cylinder and a second fluid cylinder includes an operational pressure source and a fluid control circuit. The fluid control circuit includes a pilot valve assembly having a first valve position and a second valve position. Moreover, the fluid control circuit (1) delivers pressure from the operational pressure source to the first fluid cylinder when the pilot valve assembly is positioned in the first valve position, (2) isolates the second fluid cylinder from the operational pressure source when the pilot valve assembly is positioned in the first valve position, (3) delivers pressure from the operational pressure source to the second fluid cylinder when the pilot valve assembly is positioned in the second valve position, and (4) isolates the first fluid cylinder from the operational pressure source when the pilot valve assembly is positioned in the second valve position. A method for controlling a first fluid cylinder and a second fluid cylinder is also disclosed. |
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CROSS REFERENCE TO RELATED APPLICATION
The present application relates to copending application Ser. No. 249,596 filed on Sept. 26, 1988 and entitled SEGMENTED RAIL ASSEMBLY FOR CLOSED WORKPIECE CONVEYOR SYSTEM which application is commonly assigned with the present application.
BACKGROUND OF THE INVENTION
The present invention relates to a device for engaging a movable object at one position and advancing it to another position and more particularly relates to a transfer slide assembly employed in a rail conveyor system for transferring a trolley from a rail in a subsidiary system onto an elevator for movement upwardly to a main rail system.
U.S. Pat. No. 4,615,273 discloses a conveyorized transport system of the type embodying the transfer slide assembly of the present invention having a main rail upon which trolleys ride, subsidiary loops located along the main rail leading to and from a work station, and switching means for transferring a trolley between the main rail and each subsidiary loop. It is known to utilize an elevator having a slotted track section which receives a trolley crown portion to lift the trolley from a position adjacent the lower free end of an inclined subsidiary loop rail upwardly toward the switching means for transfer onto the main rail of the conveyor. While the elevator car is sized and shaped to receive the crown portion of the troley, the trolley must be actively and positively pushed or pulled into the elevator car because a trolley travelling down the inclined subsidiary loop rail towards the elevator usually cannot consistently travel from the rail into and through the narrow confines of the elevator car slotted track under the force of its own momentum. In addition, the forward movement of a trolley rolling down off of the inclined subsidiary loop rail end may often be arrested or be significantly reduced by the trolley crown portion entering into the elevator slotted track. Moreover, trolley side sway occurring as the trolley rolls down the rail may further prohibit the crown portion of the trolley from aligning with the elevator car slotted track and thus hinder the trolley from the entering the elevator car.
One type of device previously used to advance a trolley with positive force employs a piston and cylinder assembly such as the one suggested in U.S. Pat. No. 4,615,273 utilizing a hinged claw fixed to a piston rod for gripping a single trolley and pulling it into the slotted track of the elevator. One problem experienced in these previously known advancing mechanisms is the relatively complex mechanical structure of the hinged claw. Since the claw must operate to consistently engage and move successive numbers of trolleys into the slotted track of the elevator, the hinge and the other cooperating mechanical components may become worn and eventually breakdown. In addition, such hinged claw devices tend not to be self-contained compact mechanisms but instead usually involve awkwardly oriented grasping means such as the hinged claw depending from the laterally extending piston rod.
As previously mentioned, a trolley may tend to swing laterally relative to the longitudinal extent of the rail as it approaches the elevator car. This lateral swinging movement may at times prevent an advancing assembly such as the hinged claw from contacting and gripping th trolley crown portion and moving it into the elevator. Moreover, a trolley advancing device such as suggested in U.S. Pat. No. 4,615,273 engages the trolley crown which is positioned on the top portion of a trolley and thereby advances the trolley into the elevator by pulling the trolley from the top. As a result, a yet further problem of tilting about the trolley roller axes occurs when the trolley carries a substantially heavy garment piece and is pulled from its top crown portion by an advancing device. Tilting motion of this type may cause the crown portion of the trolley to become dislodged from the advancing device and in turn may subsequently cause the trolley not to be advanced into the slotted track of the elevator car.
Accordingly, it is the object of the present invention to provide a transfer slide assembly supported at the end of the subsidiary loop rail and positioned adjacent an elevator in a conveyorized transport system having means for positively engaging with a trolley and moving successive ones of such trolleys consistently into the elevator for movement upwardly to a main conveyor rail system.
It is yet another object of the present invention to provide a compact and mechanically simplified transfer slide assembly usable in a conveyorized transport system having generally a two-piece construction such that one piece is fixed to the rail while second piece slides relative to the first to positively push the trolley onto an elevator.
A further object of the present invention is to provide a transfer slide assembly having a dual action stroke capable of advancing a trolley into registry within a slotted track serving as an elevator car.
SUMMARY OF THE INVENTION
A transfer slide assembly is used to advance a trolley from one position to another position and includes an elongate body having a longitudinal axis extending along the longitudinal extent of the body and has a cavity formed throughout the length of the body along the longitudinal axis and the body has at least two surfaces extending parallel with the body longitudinal axis and has an opening extending substantially with said cavity and communicating between the surfaces and the cavity, which surfaces being positioned along either side of the opening for providing a rolling surface upon which the trolley may move along the body. A slide is received within the cavity and is movable relative to the body along the longitudinal axis and has pusher means extending from the slide and is engagable with a trolley to push it from the one position to another position using actuator means for moving the slide relative to said body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a conveyorized transport system employing the transfer slide assembly of the present invention.
FIG. 2 is a perspective view of a section of the conveyorized transport system of FIG. 1 and includes a stretch of the main rail and propulsion track plus two oppositely disposed subsidiary loops each employing the transfer slide assembly of the present invention.
FIG. 3 is a side view of the transfer slide assembly as it is employed with the elevator assembly in the conveyorized transport system of FIG. 1 and 2 and shows the slide in its extended position.
FIG. 4 is a sectional view of the transfer slide assembly embodying the present invention shown separately from the elevator and shows the slide in its retracted position.
FIG. 5 is an enlarged view taken along line 5--5 in FIG. 4 showing a transverse cross section, the transfer slide body as it is fixed to the rail absent the slide normally received within the slide body.
FIG. 6 shows in side elevation view one embodiment of the slide used in the present invention.
FIG. 6a is an end view taken of the slide shown in FIG. 6 looking to the right.
FIG. 7a is a view taken in transverse section along line 7--7 of FIG. 3 and shows a trolley riding downwardly along a subsidiary loop rail prior to engaging the body of the transfer slide assembly.
FIG. 7b is a view taken in transverse section along line 7--7 of FIG. 3 and shows a trolley engaging the body of the transfer slide assembly after having rolled off the subsidiary loop rail.
FIG. 7c is an end view taken along line 7c--7c of FIG. 3 and shows a trolley positioned on the body of the transfer slide assembly and in line with the elevator car prior to being advanced into it by the slide.
FIG. 8 is a side elevation view of an alternative embodiment of a slide used in the present invention.
FIG. 8a is an end elevation view taken of the slide shown in FIG. 8 looking to the left.
FIG. 9 is a view taken in transverse cross section through a transfer slide assembly employing the slide shown in FIG. 8 and shows a trolley travelling down along the subsidiary loop rail prior to passing over the spring pusher.
FIG. 9a is a view taken in transverse cross section through a transfer slide assembly employing the slide shown in FIG. 8 and shows a trolley resting on the body of the transfer slide assembly after having travelled over the spring pusher.
FIG. 10 is a sectional view of another embodiment of the transfer slide assembly embodying the present invention shown separately from the elevator and shows the modified slide in its retracted position.
FIG. 11 is an enlarged view taken along line 11--11 in FIG. 10 showing in transverse cross section, the slide as it is received within the body of the transfer slide assembly.
FIG. 12 is an elevation view of the modified slide shown in FIG. 10 looking to the left on FIG. 11.
FIG. 13 is a top fragmented view of the slide shown in FIG. 12 showing in detail the pusher structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, a conveyorized transport system embodying the present invention includes a master computer 8, a propulsion track 10 having pushers 15 extending from it, a drive unit 3 for the propulsion track 10, a main rail 12 situated beneath the propulsion track 10, trolleys 14 riding on the rail 12 held by the pushers 15 and subsidiary loops 16 and 32 located along the main rail. Each subsidiary loop usually services a work station and includes a three position switch 25 for routing the trolleys between the main rail and each pair of subsidiary loops or directly between subsidiary loops of a given pair and two position switches 27 for routing the trolleys between the main rail and an unpaired subsidiary loop or a diversion rail 31.
FIG. 2 illustrates an isolated section of the conveyorized transport system shown in FIG. 1 and more particularly shows in detail the cooperation between the main rail 12, the propulsion track 10 and the pair of subsidiary loops 16, 32 servicing a pair of work stations 33, 35 positioned adjacent each subsidiary loop. The trolleys 14 ride on the main rail 12 and are propelled by one of the pushers 15 toward the subsidiary loops 16, 32 in the direction of flow indicated by the arrow drawn on track 10. Each subsidiary loop 16, 32 includes a looping rail 28, a stop assembly 38 and an elevator 54. The stop assembly 38 is one such as described in U.S. Pat. No. 4,667,602 issued on May 26, 1987 to Vaida et al. and which is commonly assigned to the assignee of the present application. The stop 38 is used as a gate to index and advance a single one of a number of trolleys collecting at the stop 38 to advance it down the inclined rail 28 toward the elevator.
The three position switch 25 having an actuator apparatus 18 for moving a section of rail 24 between laterally aligned gaps 29 in each of the subsidiary loops 16, 32 and the main rail 12, routes individual trolleys between the loops 16, 32 and the main rail 12. The actuator apparatus 18 is controlled by the computer 8 and selectively energizes the actuator 18 to alternatively position the rail section 24 thereby bridging and bridge one of the gaps 29 and effecting trolley transfer to the main rail from one of the subsidiary loops or from the main rail to either of the subsidiary loops. For a more complete description of the actuator apparatus operation, reference made be had to U.S. Pat. No. 4,615,273. Once a trolley is transferred onto the looping rail 28, it travels downwardly on the rail toward one of the work stations 33, 35 under the force of gravity and is further aided in its travel down the rail 28 by forward movement imparted to the trolley by the pusher 15 as it is moved off of and away from the transfer rail segment 24. The trolley travels down the rail 28 and arrives at the stop 38 where a series of trolleys 14b-d may collect at a stop upper gate. A downstream gate located at the other end of the stop 38 allows a single trolley 14e to be isolated from the remaining trolleys 14b-d so that an operator 42 has easy access to work pieces 46 carried by hanger 48 on the isolated trolley and in turn performs a work operation on such work pieces.
After the work operation is performed on work pieces 46, the operator releases the isolated trolley from the downstream gate of the stop 38 by pushing a button on control box 50 to cause the downstream gate to open and allow isolated trolley 14e to roll under the force of gravity down looping rail 28 toward the elevator 54. The trolley is then loaded onto a slotted track car carried by the elevator 54, and when the master computer 8 senses a break in a parade of trolleys on the main rail 12 it directs the elevator 54 to raise the trolley 14 upwardly toward the main rail. When the elevator car reaches the top, a next pusher 15 arrives and engages a crown located on the top portion of the trolley 14 and pushes the trolley from the slotted track elevator car onto the transfer rail 24 positioned in the gap 29 of the subsidiary loop adjacent the elevator. From the transfer rail section, the trolley 14 can either be transferred back to the beginning of the subsidiary loop 16, to main rail 12, or to the opposite subsidiary loop 32.
In accordance with the invention, FIG. 3 shows a transfer slide assembly 70 fixed to the lower free end of the subsidiary rail 28 and functions to advance a single trolley 14 from the rail 28 into an elevator car 1 positioned adjacent the rail end. The transfer slide assembly of the present invention is comprised of a body 72 having a central longitudinal axis L and a slide 74 connected to a piston rod 78 of a double acting dual chamber pneumatic actuator 75 for moving a slide 74 in small strokes of approximately 3 to 4 inches away from and toward the body 72. The slide 74 is secured to the piston rod 78 through a slide depending portion 80 having an aperture for receiving the piston rod 78. The end of the piston rod is threaded at 82 and utilizes two adjusting nuts which may selectively position the depending portion 80 on the threaded portion 82 of the piston rod 78 to vary the stroke length is desired. The body 72 is fixed to the rail 28 by screws 86 threadably engaging the body 72 through openings formed in the rail 28 and has a body depending portion 76 rigidly mounting the dual acting actuator 75 such that the piston rod 82 slides relative to the stationary actuator secured to the body portion.
One feature of the invention is the particularly compact and multipurpose design of the body 72. As shown in FIG. 4, the body 72 forms a segment of the rail 28 and provides a housing for the slide 74 while a depending portion 84 of the body 72 fixes the actuator 75 to the transfer slide assembly 70. The body depending portion 84 has a through counterbore formed throughout its width and defines a first larger diameter opening D-1 receiving the housing of the actuator 75 and a second smaller diameter D-2 opening receiving a threaded neck portion 172 of the actuator 75. A portion of the threaded neck portion 172 protrudes beyond the depending portion 84 such that a nut 174 threadably engages the exposed neck portion and when tightened draws the actuator 75 within the opening diameter D-1 to clamp it against the shoulder formed by the differing diameters. In addition, the free end of the body 72 is bifurcated at 178 so that the depending portion 80 of the slide 74 extends through the slot formed by the bifurcated end portions of the body 72 thus allowing the aperture in the slide depending portion 80 to be positioned adjacent the actuator 75 and in line with the rod 82.
Referring now to FIGS. 4 and 5, the body 72 of the transfer slide assembly 70 is shown attached to the rail 28 at its lowermost free end. A cutout 90 is formed in the rail 28 extending longitudinally from its free end along a segment of the length of rail 28. As shown in FIG. 5, the rail 28 is preferably formed from a hollow steel pipe and the cutout 90 therefore defines a lower C-shaped portion 94 having an inner curved surface 92. The body 72 has two correspondingly curved support surfaces 96 and 98 bearing against portions of the surface 92 to vertically position the body 72 on the rail 28. In addition, the body 72 has two flat surfaces 100 and 102 each of which extends in planes parallel to the axis L and each of which underlies two, laterally extending body arm portions 104 and 106. Each of the surfaces 100 and 102 also support the body 72 on flat, longitudinally extending upper surfaces 93 and 95 of the C-shaped portion 94 of the rail 28 formed by the cutout 90 and which flat surfaces also extend in planes parallel to the axis L. The screws 86 engaging within threaded openings in the body 72 and which pass through apertures formed in the bottom of the C-shaped portion 94 of the rail 28, secure the body 72 on the rail 28 such that it is vertically supported on both the flat surfaces 93, 95 and by portions of the inner curved surface 92. Thus, when the screws 86 are tightened, the body surfaces 100, 102, 96 and 98 are drawn into simultaneously engagement with the respectively confronting surfaces of the rail 28 thereby securing the body 72 against rotational and longitudinal movement relative to the rail 28.
As shown in FIG. 5, each laterally extending arm portion 104 and 106 of the body 72 also has an upper surface respectively labelled 108 and 110 extending longitudinally along the body parallel to the axis L. The upper surfaces 108 and 110 are contiguous with two upstanding body portions 112 and 114 defining two spaced apart tracks. The outer surface of each of the upwardly extending portions 112 and 114 forms an angle A equal to approximately 135 degrees with each of the corresponding one of upper surfaces 108 and 110. The body upper surfaces 108 and 110 being disposed at such an angle relative to the upwardly extending body portions 112 and 114, provide a surface upon which the trolley 14 may be guided. In addition, the tracks 112 and 114 as shown in FIGS. 7a-c served to space and guide rollers 116 of the trolley 14 along the body 72 thereby preventing or ceasing trolley side sway once the trolley engages with the body 72.
The body 72 has an internal cavity 118 extending longitudinally along the central axis L and is defined by two, parallel spaced apart surfaces 120 and 122 transversely connected by a bottom surface 124 oppositely facing a cavity opening 125 to define a generally U-shaped cavity within the body 72. The cavity 118 is sized and shaped to receive the elongate slide 74 within its generally U-shaped confines. As shown in FIGS. 6 and 6a, the slide 74 carries two laterally and outwardly extending portions or guides 126 and 128 formed on opposite side faces of the slide 74. Each guide 126, 128 has in transverse cross section a truncated peak configuration engaging correspondingly shaped recesses 130 and 132 formed respectively in each of the confronting surfaces 120 and 122 defining the cavity 118 of the body 72. As is shown in FIG. 6a, the slide 74 has a width B which dimension is slightly smaller in size than the cavity width C shown in FIG. 5 by an amount equal to approximately six one thousandths of an inch. Similarly, a slight clearance equal to approximately two hundredths of an inch exists between the juxtaposed surfaces of the corresponding guides 126, 128 and recesses 130, 132 thus permitting relative movement therebetween. While the guides 126, 128 and recesses 130, 132 cooperate with one another to constrain the slide 74 from moving upwardly out of the cavity 118, it should be undertood that the slide 74 is preferably mounted within the cavity 118 such that slide bottom surface 134 contacts with and bears on the body transverse surface 124 as the slide 74 reciprocates along the axis L of the body 72. In addition, the body 72 and the slide 74 are formed from generally hard and rigid synthetic material such as, for example DELRIN, having a low frictional characteristic thus permitting slidable engagement between the slide 74 and the body 72.
When the slide 74 is fully extended as shown in FIG. 3, the slide depending portion 80 is supported by piston rod 78 while a portion of the slide 74 adjacent guides 126, 128 remains within and is supported by the body 72. Conversely, when the slide 74 is in the retracted position as shown in FIG. 4, the guides 126, 128 are received within the recesses 130, 132 extending into a rear portion 73 formed integrally with the body 72. The cavity 118 formed within the body 72 is continuous with the rear portion 73 such that the portion of the slide 74 extending into the rear portion 73 is supported by the lower cavity surface 124 and is laterally confined by the side walls 120 and 122 which likewise are coextensive with the surface 124.
The slide 74 shown in FIGS. 6 and 6a has a pusher 136 located at the end of the slide 74 adjacent the guides 126, 128 and has a vertically extending face 138 for contacting with a trolley. The support provided by the rear portion 73 is important because when the slide 74 is moved into the retracted position shown in FIG. 4, the pusher 136 is received within a slot 91 formed in the rail 28 and extending longitudinally beyond the edge of the cutout 90 such that the pusher 136 protrudes above the surface of the rail 28 along longitudinal length D of the slot 91. Thus, it should be appreciated that the stroke of the pusher 136 begins at a point along the distance D from the edge of the cutout 90 in the rail 28 and continues its advance along the body 72 until the slide 74 is extended to its outermost position.
As previously discussed, the transfer slide assembly 70 of the present invention loads a trolley 14 into the elevator car 1 for carriage upwardly to the mail rail 12 by advancing it from a position adjacent the free end of the rail 28 into the elevator car 1. The elevator 54 comprises a pneumatic lift (not shown) connected to the elevator car 1 riding on an inclined track between upper and lowermost positions. As is shown in FIG. 7c, the elevator car 1 consists generally of a split rail 148 having a slot 142 defining two laterally extending portions 151 and 153 of the elevator car 1. When the elevator car 1 is moved by the pneumatic lift to the lowermost elevator position by a command by the master computer 8, the slot 142 and the slide 74 become coaligned with one another in a plane which includes the longitudinal axis L of the body 72. Each trolley 14 carries an upwardly extending protrusion or crown 144 fixed to a transversely extending portion 115 of the trolley 14. The upwardly extending crown 144 is T-shaped and has a web thickness smaller in dimension than that of the width of the slot 142. A laterally extending flange 146 is connected to the top end of the web and defines a flange width of substantially greater dimension than that of the width of the slot 142. The web of the crown 144 is capable of being received within the slot 142 and a guide or an apron 150 having an outwardly tapered extension of the slot 142 is positioned at the open end of the elevator car 1 to facilitate the moving of the web into the slot 142.
In FIGS. 7a-c, the general operation of a transfer slide assembly is shown cooperating with a trolley 14 having been once it is released from the lower gate of the stop 38 in the subsidiary loop 16. The trolley typically travels down the rail 28 under the force of gravity toward the transfer slide assembly 70 on the angularly oriented rollers 116 which ride on the upper curved surface of the rail 28 such that an under surface 117 of the transversely extending portion 115 of the trolley 14 is spaced from the uppermost curved surface of the rail 28 by a distance represented as E in FIG. 7a. The pusher 136 extends upwardly beyond the upper curved surface of the rail 28 at a height represented by the dimension F being of a significantly smaller magnitude than that of the dimension E. Thus, it should be appreciated that the under surface 117 of the transverse portion 115 of the trolley 14 passes over the pusher 136 with a clearance equal to the difference between the dimensions E and F when the trolley travels along the surface of the rail portion labelled D as represented in FIG. 4.
Referring now to FIG. 7b, the trolley 14 is shown having travelled off of the upper surface of the rail 28 and onto the longitudinally extending surfaces 108 and 110 of the body 72. Since the longitudinally extending surfaces 108 and 110 are oriented below the curved upper surface of the rail 28 upon which trolley 14 rides, the trolley 14 when it rolls off of the curved surface of the rail 28 drops downwardly onto the spaced apart longitudinally extending surfaces 108 and 110 and therefore experiences a height differential. The dimension G generally represents the drop experienced by the rollers 116 from the upper surface of the rail 28 downwardly to the body surfaces 108 and 110. Since the rollers 116 are inclined relative to the vertical plane V at an angle A' equal to approximately 45 degrees, the rollers 116 and surfaces 108 and 110 are disposed orthogonally with one another thus providing corresponding flush surfaces upon which the rollers 116 engage. Once the rollers 116 drop onto the surfaces 108 and 110, the trolley under surface 117 is no longer elevated above the pusher 136 as it was previously when the rollers 116 were supported on the upper surface of the rail 28. Rather, the pusher 136 now positioned behind the transverse portion 115 of the trolley 14 extends upwardly beyond the under surface 117 such that a portion of the pusher face 138 is engagable with the transversely extending portion 115 of the trolley 14. It should be understood that the drop dimension G must be greater in magnitude than the difference between dimensions E and F to insure that the pusher is engagable with the portion 115 of the trolley 14.
As is shown in FIG. 7c, the apron or guide 150 which extends outwardly from the elevator car 1 is positioned symmetrically about the longitudinal axis L of the body 72 when the elevator car 1 is in the lowermost position. The apron 150 and the laterally extending portions 151, 153 of the split rail 148 are contiguous with one another and form a support surface engagable with the lower surface of the flange 146 of the trolley 14. When the trolley 14 is supported on the body surfaces 108 and 110, and the trolley car 1 is oriented in its lowermost position, the lower surface of the flange 146 is spaced slightly above the supporting surface formed by the apron 150 and the laterally extending portions 151, 153 such that the flange 146 passes above the supporting surface without interfering with it. Thus, a trolley 14 travelling along the rail 28 drops downwardly onto the surfaces 108 and 110 of the body 72 and continues moving forwardly to initially position the web of the crown 144 within the slot 142 of the apron 150.
At this point, however, the crown 144 does not advance into the elevator car 1 beyond the apron 150 because a thin, flexible, C-shaped metal leaf spring 160 extends downwardly from transverse portions 162 of the elevator car 1 and slightly interferes with the path of the flange 146 into the elevator car 1. However, the spring being flexible is capable of being deflected upwardly by the flange 146 when the slide 74 pushes the trolley 14 into the elevator car 1. Once the flange 146 is received within the car 1, however, the spring 160 provides a sufficient downward biasing force to hold the flange 146 of the trolley 14 in place against the portions 151, 153 while it is being moved upwardly thus eliminating the need to use stops or other fastening devices while the trolley is upwardly moved. It should thus be appreciated that the trolley travelling along the rail 128 and onto the body 72, positions the crown 144 only within the apron 150 and not within the remaining portion of the elevator car 1. It is only when the trolley is advanced against the bias of the spring 160 by the pusher 136 that the crown 144 is completely received within the elevator car 1.
The actuator 75 is energized when a switch 164 is activated by the insertion of a trolley within the car 1. As is shown in FIG. 3, the switch 164 is mounted within the car 1 such that when the flange 146 deflects the spring upwardly, it also pushes upwardly the normally downwardly biased arm 250 of the switch 164. The switch 164 is connected to the master computer 8 and indicates to the computer 8 that the trolley 14 is in place within the car 1 and ready for carriage upwardly to the main rail 12. The actuator 75 is then energized by a command from the computer 8 which activates an electrically controlled valve and prompts the piston rod 78 to advance toward the elevator car 1. The pusher 136 thus engages the back face of the transversely extending portion 115 of the trolley 14 and thus forces the flange 146 between the spring 160 and the portions 151, 153 of the elevator car 1. The engaging surface of the leaf spring 160 is curved upwardly toward the transverse portion 162 of the car 1 such that the leading upper edge of the flange 146, which preferably is tapered for camming engagement, gradually engages the lower surface of the spring 160 to bias it upwardly as the trolley is advanced into the elevator car 1 by the pusher 136.
The slide 74 is substantially longer in length than the body surfaces 108, 110. This feature enables the pusher 136 to extend outwardly beyond the outer end of the body 72 in order to advance the trolley 14 off of the body surface 108, 110 and move it into the elevator car 1. A stop plate 166 is fixed to the lower end of the inclined elevator track and provides an abutment face against which the trolley 14 may be advanced thus assuring complete registry of the trolley 14 within the car 1. It should be appreciated that once the trolley 14 is advanced off of the body 72 by the pusher 136, it becomes suspended by the portions 151, 153 of the split rail 148 and therefore the slide 74 does not support the trolley weight once the trolley 14 is advanced into the elevator car 1.
Referring now to FIGS. 8 and 8a, an alternate embodiment of a slide 74' is shown. The slide 74' in FIG. 8 has been modified to incorporate a stainless steel wire torsion spring 180 housed within a portion of the slide 74'. In addition, the face 138' of the pusher 136' is oriented at an angle I equal to approximately 20 degrees relative to the vertically extending plane V transversely intersecting the slide. A bore 182 is formed in the slide 74' and extends transversely through the slide along with a slot 184 also formed in the slide 74' coextensively with the bore 182 and provides a passage between the bore 182 and the outer surface of the slide 74'. Along each side wall 188 and 190 of the slide 74' are formed shallow indentations 192 and 194 having depth equal to approximately the thickness of the wire forming the spring 180. The indentations 192 and 194 recess the spring 180' inwardly from the surfaces 188 and 190 so that the slide 74' reciprocates within the cavity 118 without the spring interfering with the cavity walls 120 and 122 of the body 72.
The spring 180 is comprised of a coil portion 200, arm portions 206 extending upwardly from each end of the coil portion and a bent loop portion 204 extending between the other ends of each of the arm portions. The arm portions 206 are capable of pivoting about a transversely extending axis J from an upper position shown in solid line in FIG. 8 to a lowermost position shown by the phantom line. To limit this movement to the illustrated range, the indentations 192 and 194 each have at least one abutment face 196 for limiting the downward displacement of the spring arms 206 as they are pivoted about the axis J. The bent loop portion 204 of the spring 180 is normally biased against the face 138' by the resilient force of the spring coil portion 200 utilizing a tab 202 received within the slot 184 to prevent the coil 200 from freely rotating within the bore 182 and thereby generating torque within the coil.
The arms 206 and the tab 202 are generally coaligned with one another when the spring is in its relaxed state. Thus, the spring 180 is inserted within the slide 74' by sliding the coil portion 200 and the arms 206 coaligned with the and tab 202 laterally into the bore 182 and the slot 184. Once the spring 180 is so positioned within the slide 74' the loop portion 204 is pulled forwardly up beyond the peak of the pusher 136' and thereafter is released to engage with the face 138. Since the loop portion 204 is somewhat resilient, the inner U of the loop 204 is capable of being flexed forward over the peak of the pusher 136' and then returning into engagement with the face 138'.
As shown in FIG. 9, the loop portion 204 of the spring 180' extends above the under surface 117 of the trolley 14 when the trolley travels along the rail 28. However, the transverse body portion 115 of the trolley 14 will push the loop portion 204 of the spring 180 downwardly against the bias of the coil portion 200 as the trolley 14 rolls down the rail 28 and over the spring 180. As is shown in FIG. 9a once the trolley body portion 115 moves past the spring 180, the spring is no longer depressed by the under surface 117 of the trolley 14 and returns under the bias of the coil 200 back into its generally upright position against the face 138'. Since the trolley 14 now rests on the body surfaces 108 and 110, it now may be positively engaged by the loop portion 204 of the spring 180 to move it into the elevator car 1 as discussed previously. It should be appreciated that the portion of the spring 180 extending above the pusher 136' in FIG. 8 is supported against bending by four parallel spaced apart segments of the loop 204 which abut the face 138' as a trolley is pushed by the loop portion 204 thereby offering increased strength to the spring where it is otherwise unsupported by the surface 138'.
Referring now to FIGS. 10-13, another embodiment of the transfer slide assembly is shown. The operation of the transfer slide assembly 70' in this embodiment is identical to the operation previously discussed with reference to FIGS. 1-7. However, certain structural modifications have been made to the slide 74" and the body 72' in this embodiment.
As is shown in FIGS. 10 and 11, the body 72' of the transfer slide assembly 70' is attached to the rail 28 at its lower free end. The cutout 90 in the rail 28 allows the body 72' to be supported by the surfaces 93 and 95 of the lower C-shaped portion 94 of the rail 28 as has been previously discussed. The cavity 118' formed along the axis L of the body 72' and the rear portion 73' is modified in that the parallel spaced apart surfaces 120' and 122' do not have recesses extending parallel to the axis but rather have outwardly protruding angled portions 130' and 132' extending longitudinally throughout the length of the body 72'. Also, the lower end of the slide 74" has in transverse cross section a dovetail configuration extending along its length and defined essentially by two tail portions 126' and 128' correspondingly sized and shaped to cooperate with two angled portions 130' and 132' such that the dovetail may be received within the cavity 118' when it is slid longitudinally between the bottom surface 124' and the angled portions 130' and 132'.
The confronting surfaces of each of the angled and tail portions 130', 132', and 126', 128' are provided with a slight clearance therebetween thus allowing these interengaged portions to slide relative to each other without substantial interference resulting from frictional engagement. However, the slide bottom surface 134' does contact with and bear on the body transverse surface 124' as the slide 74" reciprocates along the axis L of the body 72'. In addition, since both the body 72' and the slide 74" are preferably formed from a generally rigid synthetic material, the engagement between the surfaces 124' and 134' has a low friction characteristic thereby assisting the slidable engagement of the surfaces 124' and 134'. It should thus be appreciated from FIG. 10 that because the dovetail on the slide 74" is coextensively supported along the length of the body 72', the rear portion 73' can be shorter since a substantial portion of the dovetail is still supported within the body 72'.
The laterally extending arm portions 104' and 106' of the body 72' in this embodiment are each defined by the intersection of one of the upper surfaces 108' and 110' with one of the underlying surfaces 100' and 102'. Angle A" in FIG. 11 represents the angle of intersection between these surfaces and is equal to approximately 45 degrees which angle corresponds to the vertical inclination of the trolley rollers 116 thus allowing the rollers 116 to engage correspondingly oriented support surfaces. Since the upper surfaces 108' and 110' directly intersect with the underlying surfaces 100' and 102' rather than being spaced from one another by an intermediate portion, the surfaces 108' and 110' can be spaced a greater distance below the upper surface of the rail 28. This feature is important because it allows the upwardly extending portions 112' and 114' to have greater lengths thereby creating a more effective track by which each trolley is guided on the body 72'.
Referring now to FIGS. 12 and 13, the slide 74" shown has a modified pusher 136" with side surfaces 270 and 280 tapering from the face 138" rearwardly toward the slide free end. Each of the surfaces 270 and 280 is disposed symmetrically about the body axis L and extends upwardly above the surface of the rail 28 to present the rollers 116 of an approaching trolley with the body axis L. Thus, it should be appreciated that the pusher 136", while in its retracted position shown in FIG. 10, serves also as a guide to align an otherwise swinging trolley in a parallel relationship with the upwardly extending portions 112' and 114' of the body 72' so that the rollers 116 of the trolley 14 seat evenly upon the surfaces 108' and 110' when the trolley drops from the rail 28 downwardly onto the body 72'.
By the foregoing transfer slides embodying the present invention have been disclosed. However, it should be understood that numerous modifications and substitutions may be made without departing from the spirit of the invention. For example, in a slight modification of the illustrated embodiments the inclined face 136' shown in FIG. 8 may be provided in the embodiment of the slide in FIG. 5 showing a face 136 without any inclination relative to the vertical plane intersecting it. Accordingly, the invention has been described by way of illustration rather than limitation. | A transfer slide is used in a conveyor system to advance a trolley from one position to another position and includes a body fixed to a free end of a rail and has a cavity formed substantially throughout its length. The body has longitudinally extending surfaces spaced apart from one another by an opening communicating with the cavity which surfaces provide a rolling surface upon which a trolley travels. A slide is received within the cavity of the body and reciprocates within the body in response to the reciprocating movements of an actuator means connected with the slide. The slide has a pusher device extending upwardly from the body and above the rail and which pusher device is engageable with the trolley to push it from the initial position to a final position. |
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RELATED APPLICATIONS
This application is a §371 application from PCT/EP2013/075792 filed Dec. 6, 2013, which claims priority from French Patent Application No. 12 61804 filed Dec. 7, 2012, each of which is herein incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention belongs to the field of well stimulation.
“Well stimulation” should be understood to mean the generation of a shockwave in a natural or drilling well. A well stimulation notably makes it possible to improve the production of a well for extracting an underground resource (oil, natural gas, water, etc.), to perform a seismological survey (for example by performing measurements by means of a sensor on the surface), to produce a fracturing of underground rock, etc.
STATE OF THE ART
In the field of well stimulation, it is known practice to use a tool of elongate form suitable for being inserted into a well obtained by drilling.
Such a tool comprises a first electrode and a second electrode, electrically insulated from one another, extending substantially from one end to the other of said tool. Said first and second electrodes of the tool form, at one end of said tool, a stimulation head. The stimulation head generally comprises a chamber intended to receive a fluid, into which said first and second electrodes emerge. Exemplary embodiments of such a tool are known:
from the U.S. Pat. No. 4,345,650, which describes a tool implemented to improve the production of an underground resource extraction well, from the international patent application WO9013830, which describes a tool implemented to perform a seismological survey, from the U.S. Pat. No. 4,479,680, which describes a tool implemented to produce a fracture in underground rock.
In well stimulation operations, the tool is inserted into said well with the stimulation head at the bottom, and is lowered to the point where the stimulation is to be performed. Once the stimulation point is reached, pulses of high intensity electrical current (possibly exceeding one hundred or so kilo-amps) are sent into the first electrode. A current arc is then formed, in the chamber of the stimulation head, between the first electrode and the second electrode (generally linked to the electrical ground). Said current arc makes it possible to form a shockwave which will stimulate the well. For example, such a shockwave can make it possible to unplug an extraction well.
Such a tool has a length that is generally between three and twenty meters, and is also very heavy, of the order of several hundreds of kilograms.
In order notably to facilitate the transport and handling thereof, such a tool generally takes the form of a plurality of sections intended to be joined end-to-end. Each section then comprises a first electrode and a second electrode electrically insulated from one another. The first electrode of the tool is thus formed by the connection of the first electrodes of said sections, and the second electrode of the tool is formed by the connection of the second electrodes of said sections.
The operations of joining said sections are, however, very difficult, notably because each section is very heavy.
OBJECT AND SUMMARY OF THE INVENTION
The main object of the present invention is to propose a solution which allows for a joining of the sections of a tool which is faster and simpler than the prior art solutions.
Furthermore, another objective of the present invention is to propose a solution which allows, in certain embodiments, a mechanical coupling between the sections which is both robust (resistant to a load of several hundreds of kilograms) and tight (resistant to a pressure of the order of several hundreds of bar at a temperature greater than one hundred or so degrees Celsius).
Furthermore, another objective of the present invention is to propose a solution which allows, in certain embodiments, an electrical coupling which is both robust (resistant to very high voltages—several tens of kilovolts—and very strong currents—several tens of kilo-amps) and effective in order to limit the electrical energy losses, the degradation of the electrical contacts and the electrical creeping by skin effect.
To this end, the invention relates to an electrical well stimulation device, said device comprising a plurality of sections, said sections being suitable for being joined end-to-end so as to form a tool comprising a first electrode formed by first electrodes of said sections and a second electrode formed by second electrodes of said sections, said second electrode being a peripheral electrode electrically insulated from said first electrode, and said first electrode and second electrode of the tool forming, at one of the ends of said tool, a stimulation head.
Furthermore, one end of a body of a first section comprises a peripheral ring which is rotationally mobile relative to said body of said first section and translationally immobile relative to said body of said first section, said peripheral ring comprising a threading suitable for cooperating with a threading of the second electrode of one end of a second section to join said second section to said first section.
Furthermore, if the threading of the peripheral ring is an external threading, then the second electrode of the first section comprises an extension between the peripheral ring and a termination of the end of said first section. If it is the threading of the second electrode of the second section which is an external threading, then the second electrode of the second section comprises an extension between the threading and a termination of the end of said second section. Finally, the first section and/or the second section comprise means, called “electrical contact means”, suitable for establishing an electrical contact between the second electrodes of the first section and the second section in a zone of contact of the extension, when the second section is joined onto the first section.
Because of the peripheral ring, it will be understood that it is possible to directly join the second section onto the first section, without requiring any intermediate part between said first and second sections.
The joining of the second section onto the first section will also be easier. In effect, once the threading of the second section is engaged with the threading of the peripheral ring, it will be sufficient, to produce the join, to rotate said peripheral ring while keeping the body of the second section rotationally immobile relative to the body of the first section.
Furthermore, the electrical contact means, arranged thus on the first section and/or the second section, make it possible to protect the faces, the seals and the threadings of the peripheral ring and of the second section. In effect, because of the electrical current levels considered, the circulation of the electrical current via the threadings could result in a seizing together, even a welding together of said threadings. It should be noted that the end of the section which bears the external threading must necessarily be engaged in the end of the other section, which then takes the form of a sleeve with an internal threading. Consequently, the extension of the second electrode of the section which bears the external threading is closer to the electrically insulating material, which separates said second electrode from the first electrode, than the second electrode of the other section. By skin effect, the electrical current has a tendency to circulate, in the second electrode of the tool, as close as possible to said electrically insulating material. It will therefore be understood that, by skin effect, the current will have a tendency to circulate mainly via the electrical contact means, such that the circulation of electrical current via the threadings will be limited.
In particular embodiments, the electrical well stimulation device comprises one or more of the following features, taken in isolation or in all technically possible combinations.
In a particular embodiment, the zone of contact is a peripheral zone of the extension.
Such arrangements make it possible to ensure a greater electrical contact surface area between the respective second electrodes of the first section and of the second section, while maximizing the distance between the electrical contact means and the first electrode.
In a particular embodiment, the extension comprises a peripheral seal arranged between the zone of contact of said extension and the external threading.
The use of a peripheral seal makes it possible to ensure the tightness of the mechanical coupling, and therefore to avoid the formation of current micro-arcs. Such an arrangement of the peripheral seal is also advantageous in that it makes it possible to protect said peripheral seal. In effect, as has been described for the threadings, the electrical current, by skin effect, will have a tendency to circulate mainly via the electrical contact means, such that the electrical current to which said peripheral seal could be subjected will be limited.
In a particular embodiment, the electrical contact means comprise an electrically conductive peripheral seal, a toroidal spring and/or an electrically conductive foil.
In a particular embodiment, the first section and the second section comprise respective means, called “rotation blocking means”, suitable for cooperating to rotationally immobilize a body of the second section relative to the body of the first section when said second section is joined onto said first section.
Such arrangements make it possible to further simplify the joining of the second section onto the first section. In effect, once the rotation blocking means of the second section have been engaged with the rotation blocking means of the first section, it will be sufficient, to produce the join, to rotate said peripheral ring.
In a particular embodiment, in which the device comprises at least three sections, the rotation blocking means of at least one section are not geometrically suited to cooperate with the rotation blocking means of at least one other section.
Such arrangements make it possible to avoid joining together sections which are not designed to be joined together. In other words, the rotation blocking means have, in this embodiment, an additional polarizing function.
In a particular embodiment, the peripheral ring and/or the body of the first section comprise an indentation forming a bearing surface suitable for cooperating with gripping means.
Such provisions make it possible to facilitate the handling of the peripheral ring and/or of the body of the first section, and therefore facilitate the joining of the second section onto the first section. For example, the indentation takes the form of a blind hole or of a flat.
In a particular embodiment, the first section comprises another peripheral ring that is rotationally mobile and translationally immobile relative to the body of said first section, said other peripheral ring comprising a threading suitable for cooperating with a threading of the second electrode of a third section to join said third section onto said first section.
DESCRIPTION OF THE FIGURES
The invention will be better understood on reading the following description, given as a nonlimiting example, and with reference to the figures which represent:
FIGS. 1, 2, and 3 : views before joining, after joining and in half-cross section after joining of an electrical well stimulation device,
FIGS. 4 and 5 : cross-sectional views of a first section and of a second section of an electrical well stimulation device according to a particular embodiment, before joining and after joining,
FIG. 6 : a perspective view of the first section of FIG. 4 ,
FIG. 7 : a cross-sectional view of a first section, of a second section and of a third section of an electrical stimulation device according to a particular embodiment, after joining, and
FIG. 8 : a cross-sectional view of a variant embodiment of the electrical stimulation device of FIG. 7 .
In these figures, identical references from one figure to another denote identical or analogous elements. For reasons of clarity, the elements represented are not to scale, unless stated otherwise.
DETAILED DESCRIPTION OF EMBODIMENTS
FIGS. 1, 2 and 3 schematically represent an electrical well stimulation device 10 .
Hereinafter in the description, the nonlimiting case of a stimulation device 10 for a well for extracting an underground resource, such as oil, natural gas, water, etc., will be assumed. However, as indicated previously, “well stimulation” should be understood generally to mean the generation of a shockwave in a natural or drilling well. Such a well stimulation can be implemented to improve the production of an underground resource extraction well, to perform a seismological survey, to produce a fracturing of underground rock, etc.
As illustrated by FIG. 1 , the electrical stimulation device 10 comprises a plurality of sections 11 adapted to be joined end-to-end.
FIG. 2 represents said electrical stimulation device 10 after said sections 11 have been joined so as to obtain a tool 10 a . FIG. 3 schematically represents a view in half-cross section of the tool 10 a of FIG. 2 .
It should be noted that “electrical stimulation device” denotes all of the sections 11 , whether joined or not, whereas “tool” denotes the object obtained by the joining of the sections 11 . Consequently, all the various sections 11 joined together will be able to be denoted hereinbelow in the description as “electrical stimulation device” or “tool”.
As illustrated by FIG. 3 , the tool 10 a comprises a first electrode 12 and a second electrode 13 . Said first electrode 12 and said second electrode 13 are electrically insulated from one another, throughout the body of the tool 10 a , by an electrically insulating layer 14 .
Said first and second electrodes 12 , 13 of the tool 10 a form, at one end of said tool 10 a , a stimulation head 15 , which is considered to be known to those skilled in the art.
Each section 11 comprises, for example, a part of the first electrode 12 , a part of the electrically insulating layer 14 and a part of the second electrode 13 of the tool 10 a.
Hereinafter in the description the nonlimiting case will be assumed in which the second electrode 13 is a peripheral electrode surrounding the electrically insulting layer 14 , said electrically insulating layer 14 surrounding the first electrode 12 which constitutes a central core of the tool 10 a.
It should be noted that the tool 10 a can comprise other elements not represented in FIGS. 1 to 3 . For example, one or more sections 11 of the tool 10 a may each comprise an electrical energy accumulator, an electrical protection device, etc.
The present invention relates to a refinement made to the joining means of at least two sections of the electrical stimulation device 10 , hereinafter respectively denoted first section 11 a and second section 11 b . It should be noted that this refinement is preferably implemented for the joining means of all the sections 11 of said electrical stimulation device 10 .
More particularly, one end of the body of the first section 11 a comprises a peripheral ring 16 . Said peripheral ring 16 is rotationally mobile relative to said body of said first section 11 a and is translationally immobile relative to said body of said first section 11 a . Furthermore, said peripheral ring 16 comprises a threading adapted to cooperate with a threading 133 of one end of a body of the second section 11 b to join said second section 11 b onto said first section 11 a.
FIGS. 4 and 5 schematically represent cross-sectional views of an exemplary embodiment of the first and second sections 11 a , 11 b , respectively before joining and after joining FIG. 6 schematically represents, in perspective, the first section 11 a of FIGS. 4 and 5 .
In the embodiment illustrated by FIGS. 4 and 5 , the threading of the peripheral ring 16 of the first section 11 a is an external threading, that is to say a threading arranged on the face of the peripheral ring 16 located on the side opposite the first electrode 12 forming the central core of said first section 11 a . Furthermore, the second electrode 13 of the first section 11 a comprises an extension 130 between the peripheral ring 16 and a termination 131 of the end of said first section 11 a.
As illustrated by FIG. 6 , the peripheral ring 16 is, for example, produced by means of two half-rings 16 a , 16 b joined between two peripheral abutments 132 a , 132 b of the second electrode 13 of the first section 11 a . The two half-rings 16 a , 16 b are joined together by any appropriate means, for example by means of screws 160 . Because the peripheral ring 16 is arranged between the two abutments 132 a , 132 b of the second electrode 13 of the first section 11 a , said peripheral ring 16 , while being rotationally mobile relative to said second electrode 13 of said first section 11 a , is translationally immobile relative to said second electrode 13 of said first section 11 a.
On the side of the second section 11 b , the second electrode 13 forms, at the end of said second section 11 b , a sleeve inside which the extension 130 of the second electrode 13 of the first section 11 a can penetrate. The threading 133 of the second section 11 b , produced on said sleeve, is an internal threading, that is to say a threading arranged on the face of said sleeve located on the side of the first electrode 12 forming the central core of the second section.
As illustrated by FIG. 5 , the internal threading 133 of the second electrode 13 of the second section 11 b is adapted to cooperate with the external threading of the peripheral ring 16 of the first section 11 a to join said second section 11 b onto said first section 11 a.
Because of the presence of the peripheral ring 16 , the joining of the second section 11 b onto the first section 11 a is simple to form. In effect, once the threading 133 of the second section 11 b has been engaged with the threading of the peripheral ring 16 , it will be sufficient, to produce the join, to rotate said peripheral ring 16 while keeping the body of the second section 11 b rotationally immobile relative to the body of the first section 11 a.
In order to further facilitate the joining of the second section 11 b onto the first section 11 a , the peripheral ring 16 and/or the body of the first section 11 a comprise an indentation forming a bearing surface suitable for cooperating with handling means.
In the example illustrated by FIG. 6 , the peripheral ring 16 and the body of the first section 11 a both comprise such indentations, in order to be able to immobilize the body of the first section 11 a when the peripheral ring 16 is rotated. More particularly, the peripheral ring 16 comprises, in the example illustrated by FIG. 6 , blind holes 161 suitable for cooperating with a pin wrench, and the body of the first section 11 a comprises flats 111 . According to other examples, there is nothing to preclude considering other forms of indentations.
In a preferred embodiment, the first section 11 a and the second section 11 b comprise respective means, called “rotation blocking means”, adapted to cooperate to rotationally immobilize the body of the second section 11 b relative to the body of the first section 11 a when joining said second section 11 b onto said first section 11 a.
The presence of such rotation blocking means makes it possible to further facilitate the joining of the second section 11 b onto the first section 11 a . In effect, once the rotation blocking means of the second section 11 b have been engaged with the rotation blocking means of the first section 11 a , it is sufficient, to produce the join, to rotate the peripheral ring 16 relative to the body of the first section 11 a.
In the example illustrated by FIG. 6 , the rotation blocking means are, for the first section 11 a , in the form of a key 110 . For the second section 11 b , said rotation blocking means are, for example, in the form of a groove (not represented in the figures) in which said key can slide while the second section 11 b is being joined onto the first section 11 a.
After joining, the end of the second electrode 13 of the second section 11 b surrounds the extension 130 of the second electrode 13 of the first section 11 a and a part of the peripheral ring 16 of said first section 11 a.
The electrical contact between the first electrode 12 of the first section 11 a and the first electrode 12 of the second section 11 b can be established by using any suitable means known to those skilled in the art. In the example illustrated by FIGS. 4 and 5 , the end of the first electrode 12 of the first section 11 a forms a sleeve 121 suitable for receiving an extension 120 of the first electrode 12 of the second section 11 b . The extension 120 of the first electrode 12 of the second section has no layer of electrically insulating material, and means are provided inside the sleeve 121 of the first electrode 12 of the first section 11 a for establishing the electrical contact between the first electrodes. In a preferred embodiment, illustrated by FIGS. 4 and 5 , the electrical contact means of the sleeve 121 are of multicontact type, for example a sleeve comprising blades with shape memory, a helical spring or even foils.
The electrical contact between the second electrode 13 of the first section 11 a and the second electrode 13 of the second section 11 b is, for example, established via the peripheral ring 16 , the latter being optionally made of an electrically conductive material.
In a preferred embodiment, illustrated by FIGS. 4 and 5 , the second electrode 13 of the first section 11 a comprises means called “electrical contact means”, suitable for establishing an electrical contact between the second electrode 13 of the second section in a contact zone of the extension 130 of the second electrode 13 of the first section 11 a.
In the example illustrated by FIGS. 4 and 5 , said electrical contact means are in the form of an electrically conductive peripheral seal 134 . There is nothing to preclude, according to other examples, considering other types of electrical contact means, for example an electrically conductive foil arranged at the periphery of the extension 130 of the second electrode 13 of the first section 11 a . Furthermore, it should be noted that the electrical contact means could be borne by the second electrode 13 of the second section 11 b , or even by both the first section 11 a and the second section 11 b.
By virtue of the electrical contact established at the extension 130 of the second electrode 13 , the electrical current, which by skin effect has a tendency to circulate in the second electrode 13 as close as possible to the electrically insulating layer 14 , will have a tendency to circumvent the peripheral ring 16 . In effect, by assuming that the electrical current circulates from the first electrode 12 of the first section 11 a to the first electrode 12 of the second section 11 b then returns by circulating from the second electrode 13 of the second section 11 b to the second electrode 13 of the first section 11 a , it can be seen that the shortest path allowing the electrical current to pass as close as possible to the electrically insulating layer 14 consists in passing through the contact zone of the extension 130 of the first section 11 a . That said, the electrical current will have a tendency to circumvent the peripheral ring 16 .
In the example illustrated by FIGS. 4 and 5 , the extension 130 of the second electrode 13 of the first section 11 a comprises two peripheral seals 135 . Advantageously, said peripheral seals 135 are arranged between the contact zone of said extension 130 and the peripheral ring 16 . In this way, as indicated previously, the electrical current will have a tendency to circumvent said peripheral seals 135 , and the risks of the latter being damaged by the circulation of the electrical current are reduced.
FIG. 7 schematically represents a variant embodiment of the first section 11 a illustrated by FIGS. 4 to 6 . In this variant embodiment, said first section 11 a , (represented with grey shading in FIG. 7 ) comprises two peripheral rings arranged at opposite ends of said first section 11 a.
Thus, the first section 11 a comprises, at an end opposite the end of the peripheral ring 16 described with reference to FIGS. 4 to 6 , another peripheral ring 17 . Said peripheral ring 17 is rotationally mobile and translationally immobile relative to the body of the first section 11 a . Furthermore, said peripheral ring 17 comprises a threading suitable for cooperating with a threading of one end of a body of a third section 11 c to join said third section 11 c onto said first section 11 a.
In the embodiment illustrated by FIG. 7 , the threading of the peripheral ring 17 of the first section 11 a is an external threading. Furthermore, the second electrode 13 of the first section 11 a comprises an extension 136 between the peripheral ring 17 and a termination 137 of the end of said first section 11 a.
On the side of the third section 11 c , the second electrode 13 forms, at the end of said third section 11 c , a sleeve into which the extension 136 of the second electrode 13 of the first section 11 a can penetrate. The threading of the third section 11 c , produced on the second electrode at said sleeve, is an internal threading, that is to say a threading arranged on the face of said sleeve located on the side of the first electrode 12 forming the central core of the third section 11 c.
As illustrated by FIG. 7 , the internal threading of the second electrode 13 of the third section 11 c is adapted to cooperate with the external threading of the peripheral ring 17 of the first section 11 a to join said third section 11 c onto said first section 11 a.
Everything that has been described above concerning the peripheral ring 16 and the extension 130 can also be applied to the peripheral ring 17 and to the extension 136 of the second electrode 13 of the first section 11 a.
In the nonlimiting example illustrated by FIG. 7 , the first section 11 a has no electrically insulating layer 14 and no first electrode 12 . In effect, the respective electrically insulating layers 14 and first electrodes 12 of the second section 11 b and of the third section 11 c extend inside the first section 11 a , and cooperate therein so as to ensure both the electrical continuity of the first electrode 12 and the electrical insulation between said first electrode 12 of the tool 10 a and the second electrode 13 of the first section 11 a.
There is nothing to preclude, according to other examples, having a first section 11 a comprising a part of the electrically insulating layer 14 and/or a part of the first electrode 12 .
FIG. 8 schematically represents a variant embodiment of the first section 11 a of FIG. 7 , in which said first section 11 a comprises a part of the electrically insulating layer 14 and a part of the first electrode 12 of the tool 10 a . Advantageously, the first electrode 12 of the first section 11 a forms two opposite sleeves, respectively 121 and 123 , adapted to receive respective extensions 120 and 122 of the first electrode of the second section 11 b and of the first electrode of the third section 11 c.
Such arrangements are advantageous in that they make it possible to have identical ends for the second section 11 b and the third section 11 c , which facilitates their production and their internal arrangement.
More generally, it should be noted that the embodiments considered above have been described as nonlimiting examples, and that other variants can consequently be envisaged.
Notably, the electrical stimulation device 10 has been described by considering a peripheral ring 16 comprising an external threading. There is nothing to preclude, according to other examples, considering a peripheral ring 16 comprising an internal threading adapted to cooperate with an external threading produced on the periphery of the body of the second section 11 b . The peripheral ring 16 then takes the form of a sleeve into which the end of the second section 11 b can penetrate. In the case, described with reference to FIGS. 7 and 8 , of a first section 11 a comprising two peripheral rings 16 , 17 , one and/or the other of said two peripheral rings can comprise an internal threading adapted to cooperate with an external threading produced on the periphery of the second electrode 13 of another section.
Furthermore, the electrical stimulation device 10 may comprise only two sections 11 , but it may also comprise more thereof. In a preferred embodiment, when said electrical stimulation device 10 comprises at least three sections, the rotation blocking means of at least one section are not geometrically adapted to cooperate with the rotation blocking means of at least one other section.
Such provisions make it possible to use said rotation blocking means as polarizers. Such a polarizing function can prove advantageous notably in the case where the sections comprise electrical energy accumulators and/or electrical protection devices. In such a case, the position of the sections relative to one another may prove essential, and will be able to be ensured by virtue of the rotation blocking means also offering a polarizing function.
In the case where said rotation blocking means are in the form of keys and associated grooves, the polarizing function will be able to be obtained by considering keys in different numbers, of different dimensions, of different positions, etc., from one section to another. | An electrical device for well stimulation comprising a plurality of sections configured to be assembled, end to end, to form a tool. The tool comprises first and second electrodes. The second electrode is an electrically insulated peripheral electrode of the first electrode. The first and second electrodes of the tool forming, at one of the ends of the tool, a stimulation head. Additionally, one end of a body of a first section comprises a peripheral ring that is rotatably movable and translatably immobile relative to the body of the first section. The peripheral ring comprises a thread configured to engage with a thread of the second electrode of one end of a second section. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to handling and lifting attachments for boom-type vehicles and more particularly to an attachment which is particularly adaptable for use with a panel assembly of the type having a purline and a panel, the purline securely attached to the panel and disposed at an angle thereto.
2. Description of the Related Art
Modern techniques for constructing tilt-up type buildings involves installing spaced, vertical columns. Roof panel assemblies are also generally constructed (or at least stored) at one location at the construction site and must be transported via a boom-type vehicle through the columns to their desired point of installation. Referring to FIG. 5 of the drawings, which illustrates the environment in which the present invention operates, it can be readily seen how a navigational dilemma exists while transporting panel assemblies.
In this figure, the construction site is designated generally as 10. The vertical spaced columns 12 provide difficult obstacles for the boom-type vehicle 14 carrying a load as it navigates from the panel assembly storage area (not shown) at one area of the construction site to the area of installation shown in FIG. 5. It can be seen in this figure, as well as by reference to FIG. 2, that the typical roof panel assembly, designated generally as 16, includes a purline 18 attached to a panel 20. The panel 20 includes, typically, a relatively thin sheet of plywood 22 and a plurality of parallel spaced 2×4's, labeled 24. The panel assembly is typically about 50 feet wide. The panel assembly 16 typically further includes first metal clips 26 at the purline ends and second metal clips 28 at the ends of the members 24, as shown in FIG. 3.
Referring again to FIG. 5, the panel assembly 16 is transported to the point of installation, and the panel assembly 16 positioned so that the 2×4 clips 28 (not shown in this figure) fit over a purline 16 of a previously attached panel assembly 16 and the purline clips 26 engage structural beams 30, the panel assembly 16 then being securable in its position. The resulting roof structure is illustrated in FIG. 1.
Referring again to FIG. 5, it is noted that an attachment 32 to a boom 34, is illustrated. Attachment 32 is, in fact, the attachment of the present invention. (The discussion of this drawing, in this section of the patent application, should not be, by any means, construed as an acknowledgment that the attachment is prior art. Its inclusion in this section of the patent application has been made to assist the reader in attaining a better understanding of the environment in which the attachment operates and the problems faced by the present inventors in their endeavors.)
In a typical prior art forklift, a wooden cross member is fixedly attached to the fork tips to support the panel of the panel assembly. The heel portion of the fork supports the purline. The cross member typically has a height which is lower than the height of the purline and, as a result, the panel sits sloping downward and no adjustment can be made to hold it at a level attitude. When the panel assembly is reaching its point of installation, the ends of the 2×4's first come to rest on the existing purline. The forklift must than be lowered so that the presently installed purline comes to rest on the main structural beams. This presents compound navigational dilemmas and may even sacrifice the structural integrity of the panel assemblies. (The panel assemblies are generally quite flimsy and achieve a good portion of their structural integrity upon being connected to adjacent panels and structural beams.)
As can be seen by the environment illustrated in FIG. 5, maneuvering the tractor through the columns is very difficult. In prior art methods, the crane must be turned 180 degrees in order to pass between the columns. Furthermore, the panel assembly must be raised sufficiently to clear the panel above the structural beams. Navigation is very difficult without the ability of forward reach swing movements and fine adjustments thereof.
U.S. Pat. No. 4,280,785, entitled MULTI-DIRECTIONAL LIFTING AND HANDLING ATTACHMENT FOR A CRANE BOOM, issued to R. G. Albrecht, discloses a multi-directional lifting and handling device mounted on the end of a standard telescoping crane boom. The elongated generally fore and aft main frame of the device includes a hydraulic rotary actuator which selectively rotates a pivotally connected sub-frame about a transverse, substantially horizontal axis. A cradle-like framework, in turn, is rotatably connected to the sub-frame and is selectively rotated by a second hydraulic actuator, the cradle-like framework being rotatable about a longitudinal generally fore and aft axis. Work pieces, such as pipes, beams, or the like are detachably secured in the cradle-like framework by flexible chain straps which form a U-shaped clamp about the workpiece, the chain straps being easily attached to and detached from the load, facilitating quick loading and unloading of the object to be moved.
U.S. Pat. No. 4,553,899, entitled HIGH LIFT TRUCK WITH TELESCOPING BOOM ASSEMBLIES, issued to R. Magni, discloses a high lift truck with a first telescopic boom. Its essential feature, basically, is that of providing a second telescopic boom fixed immovably to the top end of the first raise-and-lower boom which is likewise telescopic, and hinges at the bottom with a mounting on the truck axis; the two booms thus associated, creating an obtuse angle such that the second boom will project forward along the line of the truck axis when the first boom is fully raised.
U.S. Pat. No. 4,382,743, entitled LOADING APPARATUS WITH A TILTABLE AND EXTENDABLE FORK CARRIAGE MOUNTED THEREON, issued to L. H. Newell discloses an apparatus including a mobile chassis having a turntable on which is supported a boom assembly. At the free end of the boom assembly, a forklift carriage is tiltably mounted which can be extended and retracted relative to the boom assembly.
U.S. Pat. No. 4,650,389, entitled MECHANISM AND METHOD FOR POSITIONING A FENDER ON A DOCK VERTICAL WALL, issued to P. J. Mulqueen, discloses a mechanism for positioning on a dock vertical wall a fender including spaced openings, the mechanism comprising a movable support, a first arm pivotally attached to the movable support, a first hydraulic cylinder piston rod assembly for pivoting the first arm, a second arm pivotally attached to the first arm, means for pivoting said second arm, a plurality of spaced projections attached to and extending from the second arm, and pins for releasably securing the projections in the spaced openings in the fender.
U.S. Pat. No. 4,082,197, entitled ARTICULATED HIGH LIFT VEHICLE, issued to R. N. Stedman discloses a vehicle comprising first and second frame assemblies pivotally connected together and actuating means, preferably extensible and retractable steering cylinders, interconnected between the frame assemblies to selectively pivot them relative to each other.
U.S. Pat. No. 4,583,907, entitled EXTENSIBLE APPARATUS, issued to R. J. Wimberley, discloses a flexible extensible apparatus for employing an end-use work tool for one of multiple purposes characterized by combinations of a pivotal base; main support structure; pivotally mounted support structure; extensible base unit having first and last respective pairs of booms and levers; attachments for the work tool; and a plurality of extension units each comprising respective pairs of booms and levers.
Thus, from the above recital of the problem to be faced and the above descriptions of references revealed in a patent search, it can be seen that prior art methods of attempting to solve the problems associated with present Applicant's endeavors is lacking. As will be disclosed below, the present invention provides an improved attachment for a boom-type vehicle which provides extremely versatile multi-directional lifting and handling capabilities. The present invention is particularly adaptable for use with a panel assembly of the type having a panel and a purline, the purline securely attached to the panel and disposed at an angle thereto.
SUMMARY OF THE INVENTION
An attachment to the boom of a boom-type vehicle is disclosed for lifting and supporting a panel assembly of the type having a panel and a purline. The purline is securely attached to the panel and disposed at an angle thereto. The attachment comprises attachment means connectable to a forward end of the boom of the vehicle for supporting at least a portion of the purline and at least a portion of the panel. The attachment means provides selective movement between the purline, the panel, and the boom for permitting the panel assembly to be maneuvered in the desired manner at the construction site.
The attachment preferrably includes a mast assembly connectable to the forward end of the boom of the vehicle. The mast assembly includes means for providing selective vertical translation of a forward portion of the mast assembly relative to the boom, along a Y-axis defined by an X-Y-Z rectangular coordinate system, the Y-axis being substantially perpendicular to the surface upon which the vehicle is operating. The mast assembly also includes means for providing selective rotation of the forward portion of the mast assembly relative to the boom, about the Y-axis. Furthermore, means are included for providing selective horizontal translation of the forward portion of the mast assembly relative to the boom, along an X-axis orthogonal to a Y-Z plane defining the orientation of the boom.
A panel handler assembly is connectable to the forward portion of the mast assembly. The panel handler assembly includes a rearwardly disposed purline supporting portion securably connectable to the mast assembly; a forwardly disposed panel supporting portion rotatably attached to the purline supporting portion; and, means for providing selective rotation of the panel supporting portion relative to the purline supporting portion along an offset axis, X', parallel to a plane supporting the forward portion of the mast assembly.
The attachment provides versatile multi-directional lifting and handling capabilities which have been unachievable in prior art attachments to boom-type forklifts. It is understood that use of the term purline herein is not limited to a panel assembly such as those only used on roofs and may apply to any panel assembly having one portion disposed at a relative angle to a second portion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a plurality of attached roof panel assemblies connected to a structural beam, the roof panel assemblies being of the type particularly adapted for use with the present invention.
FIG. 2 is an exploded perspective view of a panel assembly of FIG. 1.
FIG. 3 is an enlarged perspective view of a portion of the panel assembly, taken along curved line 3 of FIG. 2.
FIG. 4 is a side perspective view of a boom-type vehicle supporting the attachment of the present invention.
FIG. 5 is a view of the construction site, illustrating a panel assembly being installed.
FIG. 6 is a side perspective view of the attachment of the present invention in a lowered position.
FIG. 7 is a top view of the panel handler assembly of the present invention, partially in cross-section.
FIG. 8 is a side perspective view of the attachment of the present invention with the adjustable support arm assembly shown in a raised position.
FIG. 9 is a side view of the panel handler assembly of the present invention, in partial cross-section, illustrating the ability of the adjustable support arm assembly to be raised, this figure being taken along line 9--9 of FIG. 7.
FIG. 10 is a front perspective view of the mast assembly of the present invention, the panel handler assembly removed.
FIG. 11 is a rear perspective view of the mast assembly in the direction of the arrow shown in FIG. 10.
FIG. 12 is a side elevational view of the mast assembly and a portion of the panel handler assembly, partly in cross-section.
FIG. 13 is a top plan view of the mast assembly, in partial cross-section.
FIG. 14 is a top view of the tractor supporting the attachment of the present invention, illustrating the ability of the invention to swivel approximately 50 degrees on either side of the longitudinal axis of the vehicle.
The same elements or parts throughout the figures of the drawings are designated by the same reference characters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring again to the figures of the drawings and the characters of reference marked thereon, FIG. 4 illustrates the attachment 32 attached to a forward end of the boom 34 of a boomtype vehicle 14. The attachment 32 comprises means for supporting at least a portion of the purline 18 and at least a portion of the panel 20 of a panel assembly 16. The attachment provides selective movement between the purline 18, the panel 20, and the boom 34 for permitting the panel assembly 16 to be maneuvered in the desired manner at the construction site. The attachment comprises a mast assembly 36 and a panel handler assembly 38.
Referring now to FIG. 6, it can be seen that the mast assembly 36 is connectable to the forward end of the boom 34 of the vehicle. For the purposes of explanation, the relative movement of a forward portion 40 of the mast assembly 36 relative to the boom 34 may be viewed in reference to the rectangular coordinate system X, Y, Z. In this regard, movement can be viewed as translation along one or more of the three rectangular coordinate axes and/or rotation about those three axes. As will be described below, in detail, the mast assembly 36 provides the following three functions:
(a) selective vertical translation of the forward portion 40 of the mast assembly 36 relative to the boom 34, along the Y-axis, the Y-axis being perpendicular to the surface upon which the vehicle is operating;
(b) selective rotation of the forward portion 40 of the mast assembly 36 relative to the boom 34, about the Y-axis (i.e. φ y ); and,
(c) selective horizontal translation of the forward portion 40 of the mast assembly 36 relative to the boom 34 along the X-axis which is orthogonal to the Y-Z plane defining the position of the boom 34.
The panel handler assembly, as viewed in a broad context, includes a rearwardly disposed purline supporting portion 42 securely connected to the forward portion 40 of the mast assembly 36; a forwardly disposed panel supporting portion 44 rotatably attached to the purline supporting portion 42; and, hydraulic actuation means 46 for providing selective rotation of the panel supporting portion 44 relative to the purline supporting portion 42 along an offset axis, X', parallel to the forward portion 40 of the mast assembly 36, the X', Y', Z' axes representing an offset rectangular coordinate system.
Referring now to FIG. 6, in conjunction with FIG. 7, it can be seen that the purline supporting portion 42 includes a rigid purline backrest assembly comprising a pair of elongate, parallel, substantially vertical spaced rigid members 48; an elongate, rigid horizontal member 50 integrally connected to the bottoms of the vertical rigid members 48; and a lifting support sub-assembly 52 integrally connected to the vertical rigid members 48 and the horizontal member 50.
As may best be seen in FIG. 9, the lifting support sub-assembly 52 includes two vertically disposed extensions 54, each extension 54 being integral with its associated vertical rigid member 48. Each vertical extension 54 has an upper end with integral attaching eyes 56 for connection thereof with a pin 58 (see FIG. 7) secured to the forward portion 40 of the mast assembly 36. Each lifting support sub-assembly 52 also includes a pair of integral shoes 60, each shoe circumscribing a portion of the intersection between the horizontal member 50 and its associated vertical rigid member 48. The rigid purline backrest assembly is thereby connectable to the forward portion 40 of the mast assembly 36 so as to extend on a plane X'-Y' generally parallel to the forward portion 40 of the mast assembly 36.
The purline supporting portion 42 also includes a rigid base frame assembly comprising a pair of elongate, parallel, substantially horizontal, spaced rigid base members 62 integrally connected to the purline backrest assembly; a transverse horizontal rigid base member 64 integrally connecting the forward ends of the longitudinal base members 62; and a pair of diagonal base members 66 interconnecting a central section of the transverse base member 64 and the horizontal member 50. Thus, the rigid base frame assembly is integrally connected to the lower end of the purline backrest assembly so as to extend forwardly of the purline backrest assembly on a plane X'-Z', generally parallel to the X-Z plane.
The panel supporting portion 44 includes a rigid C-frame assembly comprising a pair of spaced parallel lift arm sub-assemblies 68 and a lift arm cross member 70 integrally attached to the lift arm sub-assemblies 68. Each lift arm sub-assembly 68 includes a lift arm 72 connected at a rear end to longitudinal base member 62 by means of a hinge 74. Each lift arm sub-assembly also includes a telescoping lift arm extension 76 including locking means 78. Utilization of such lift arm extensions 76 allow the attachment 32 to be utilized with varying sizes of panels as shown by the arrows designated 79.
Diagonal members 80 are also attached to the lift arms 68 and lift arm cross member 70 for the required support. A narrow rigid stop member 82 integrally connected to the bottom of transverse horizontal base member 64 provides bottom support for the purline supporting portion 42 and, in addition, as a result of its extension beyond the transverse horizontal base member 64, provides a stop preventing rotation of the lift arm sub-assembly 68 below the elevation of the longitudinal horizontal base members 62.
Attached to the ends of telescoping lift arm extensions 76 is an adjustable support arm assembly 84. The support arm assembly 84 includes a support arm assembly cross member 85 connected to forward ends of the telescoping lift arm extensions 76. A pair of telescoping support arm extensions 86 are provided with locking means 88 to further accommodate different sizes of panels.
A hydraulic actuator 46 is connected at a first end to a central portion of the transverse horizontal base member 64 and at a second end to a central portion of the lift arm cross member 70 with appropriate conventional control means (not shown) for actuating hydraulic actuator 46. The panel supporting portion 44 may be rotated with respect to the purline supporting portion 42, as illustrated by arrow 90 in FIG. 9. Thus, an orientation as shown in FIG. 8 may be utilized to optimally carry the panel 20 in a horizontal position for optimal transportation and installation of the panel assembly 20 and retention of its structural integrity.
In this regard, it is noted that, in use, present Applicant typically stores the panel assemblies 16 in an orientation whereby the lower end of the purline 18 is raised above the ground sufficiently to allow the passing of the panel handler assembly 38 (except, of course, the vertical rigid members 48), while the panel handler assembly 38 is in the orientation shown in FIG. 6. The ends of the panel 20 are kept raised by a block of wood so that the panel 20 is substantially horizontal. The panel supporting portion 44 is then rotated to the position shown in FIG. 8 so that the support arm assembly 84, including the telescoping support arm extensions 86 substitute support for the panel 20 in this position for the wooden blocks when the panel assembly is transported for installation. This enables its structural integrity to be retained and provides easy installation.
It is noted that the fittings, gauges, controls, and flexible conduits necessary for providing a source of regulated power to actuate the hydraulic actuators of this invention are not shown, so as to provide a clear understanding of the novel features of the present invention. It is further noted that these control devices can be located at convenient locations, enabling an operator to maneuver the attachment 32 in the desired fashion.
Referring now to FIG. 10, the mast assembly, designated generally 36 is illustrated (shown with the panel handler assembly removed). The mast assembly 36 includes a connecting or a C-hook assembly 92, at the rear end, which connects to a horizontal pivot pin 94 of a male coupler of a boom head 34.
The C-hook assembly 92 is pivotally connected to a vertical upright sub-assembly 96 including a pair of two vertical, integrally connected, upright I beams 98 by a manner including an actuator and swivel means 100 which provides selective rotation along the Y-axis (i.e. φ y ) but prohibits motion along the other degrees of freedom.
The I beams 98, in turn, are connected to a mast frame or fork carriage assembly 102, which includes a front frame sub-assembly 104 and a rear frame sub-assembly 106, most clearly seen in FIG. 11. The rear frame sub-assembly 106 is connected to the I beams by a manner including a chain means 108, roller means 110, and vertically disposed hydraulic actuator means 112, which permits the desired selective translation of the mast frame assembly 102 relative to the vertical upright sub-assembly 96, along the Y-axis.
The rear frame sub-assembly 106 is connected to the front frame sub-assembly 104 by a manner, including horizontally disposed sideshift hydraulic actuator means 114, for permitting selective adjustment therebetween. An extension 116 on the rear frame sub-assembly 106 cooperating with hangers 118 of the front frame sub-assembly 104 provide the required engagement for sliding operation. Relative side shift between the rear frame sub-assembly 106 and the vertical upright sub-assembly 96 is prohibited by pairs of upper rollers 120, pairs of lower rollers 122 on each end of the I beams 98, and wheels 124 (see FIGS. 11 and 13). The hydraulic actuator 114 is carried at one end by the front frame sub-assembly 104 and at the other end by attaching means 125 secured to the rear frame sub-assembly 104 (see FIG. 10).
Referring now to FIG. 12, the mast assembly 36 is shown connected with the panel handler assembly 38. The lifting support sub-assembly 52 of the panel handler assembly 38 has attaching eyes 56 for engagement with pin 58. The lower part of the front frame sub-assembly 104 abuts rear surfaces 126 of the shoes 60 of the panel handler assembly 38 restricting relative rotation therebetween.
Referring now to FIG. 13 in conjunction with FIG. 12, it can be seen that the swivel means 100 at the upper end of the C-hook assembly 92 includes a pin boss assembly 128 for connecting ends of two horizontal, angularly disposed hydraulic cylinders 130 to the C-hook assembly 92. Each hydraulic cylinder 130 is connected at its opposite end to a respective ear assembly 132, each assembly 132 integral to a vertical I beam upright 98.
An upper triangular plate 134 is attached to the C-hook assembly 92 by means of a hinge assembly 136 which permits the desired selective rotation of the vertical upright sub-assembly 96 along the Y-axis (φ y ), the upper triangular plate 134 providing this motion in cooperation with hydraulic actuators 130 and a lower horizontal triangular plate 138 which is integral to the lower parts of the I beams 98. The lower triangular plate 138 is connected to the C-hook assembly 92 by means of a second hinge assembly 140 (see FIG. 12).
As noted, the desired translation of the mast frame assembly 102 relative to the I beams 98 is accomplished by means including a chain and roller means 108, 110. One end of each of two leaf chains 108 is secured to a chain anchor 142 which is secured to a bracket assembly 144 integral with vertical I beams 98. The other end of each leaf chain 108 is secured to a second chain anchor 146 secured to the rear frame sub-assembly 106. One end of the vertical hydraulic actuator 112 is connected to the roller means or bracket and pulley assembly 110 while the other end is connected to the rear frame sub-assembly 106. Thus, the vertical hydraulic actuator 112 and pulleys provide selective directed translation of the rear frame sub-assembly 106 with respect to the vertical uprights 98 along the Y-axis. (The assembly 110, in addition, carries rollers 148 (see FIG. 13) to accommodate hydraulic tubing (not shown) necessary for operation.)
Referring now to FIG. 14, a top view of vehicle 14 with the attachment 32 of the present invention, is shown. As denoted by arrow 150, the attachment 32 allows swivel (i.e. φ y rotation) of 50 degrees on either side of the longitudinal axis (Z-axis) of the vehicle. This allows efficient maneuvering between the columns.
Obviously, the boom 34, itself, provides coarse translation of the panel assembly 16; however, utilization of the attachment 32 provides another 6 feet of lift which becomes critical given a normal boom is only equipped to adjust to an angle of approximately 75 degrees. With the tight working conditions described, the ability to have fine adjustment is very desirable. Fine side shift adjustment along the X-axis is provided in the range of approximately 6 inches on either side of the Z-axis.
The support arm of the panel handler assembly 38 may be lifted to a height of between 12 inches and 60 inches to accommodate purlines varying in height from 18 inches to 50 inches. The lift arm assembly 72 is designed to extend to a maximum of 8 feet along the Z'-axis from the point of attachment to the mast assembly 36. The support arm assembly 84 is adjustable from a minimum length of 8 feet to a maximum length of 30 feet, to accommodate different panel widths.
In the fully lowered position, i.e. the lift arm 72 folded down, the lift arm sub-assembly 68 and support arm assembly 84 are at an elevation of 11 inches from the support floor. The support arm 84 can be raised from that 11 inch elevation to 70 inches. In addition to the advantages of easy adjustment, use of the telescoping extensions provides ease in transportation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
For example, although the panel handler assembly 38 has been described in connection with the mast assembly 36, it is emphasized that it may be used without concurrent utilization of the mast assembly 36. Or, it may be used in conjunction with another type of adjustment means. (Furthermore, the vertical mast 36 may be utilized without concurrent utilization of the panel handler assembly 38. However, the above described utilization of these two assemblies, in combination, provides the optimal attachment for multi-directional lifting and handling purposes.) If the panel handler assembly 38 is used without the mast assembly 36, the lifting support sub-assembly 52 is directly attached to the boom 34.
It is also emphasized that the attachment of the present invention may be used with panel assemblies different in shape than the purline/panel orthogonal arrangement described and may be utilized wherever it is desired that a construction work piece be lifted and supported, that construction work piece having portions thereon having different elevations. Thus, although the invention has been described in connection with its particular use with the panel assembly illustrated in the figures, in view of the above noted broader utility of the invention, it is understood that this described application is purely illustrative and not limiting in nature. | This apparatus relates to an attachment to the boom of a boom-type vehicle for lifting and supporting a panel assembly of the type having a panel and a purline. The purline is securely attached to the panel and disposed at an angle thereto. The attachment comprises attachment devices connectable to a forward end of the boom of the vehicle for supporting at least a portion of the purline and at least a portion of the panel. The attachment device provides selective movement between the purline, the panel, and the boom for permitting the panel assembly to be maneuvered in the desired manner at the construction site. A panel handler assembly is connectable to a forward portion of a mast assembly. The panel handler assembly includes a rearwardly disposed purline supporting portion securably connectable to the mast assembly; a forwardly disposed panel supporting portion rotatably attached to the purline supporting portion; and, devices for providing selective rotation of the panel supporting portion relative to the purline supporting portion along an axis parallel to a plane supporting a forward portion of the mast assembly. The attachment provides versatile multi-directional lifting and handling capabilities which have been unachievable in prior art attachments to boom-type forklifts. |
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FIELD OF THE INVENTION
A barrier installed in a curbside drain opening which detains solid trash from entering the drain when there is no or slow water flow, but which opens fully when a sufficiently high water flow rate occurs.
BACKGROUND OF THE INVENTION
A barrier installed in a curbside drain opening which detains solid trash at no or slow rate flow rates, but which opens when the rate is sufficiently high, is shown in Martinez U.S. Pat. No. 6,217,756. The objective of this patent, and of the instant invention, is to impede the entrance of solid trash into the drain from a gutter while permitting slow water flow, and to open up when the flow is heavy so as to pass it.
Of course, when a heavy flow of water arrives and the barrier opens, whatever solid trash is already detained at the opening, or is up the gutter, will be washed into the drain. However, when there is no flow, or only slow flow, the detained trash can readily be swept away by a street sweeper. In effect, this barrier keeps out of the downstream drain system trash which accumulates during dry periods if the street is properly swept.
Municipalities are well aware of the costs when trash enters a drainage system. Generally there is a catch basin into which water and trash that passed through the drain opening are deposited. This trash must be removed, usually on a periodic basis. A heavy cover is removed, and then depending on what is in there, a man must go into the basin properly equipped to clear it out. If for some reason the basin is not properly cleaned out, and a rapid flow of water arrives, the drain can be plugged, and a flood ensues. Proper maintenance is necessary.
Of even greater concern is what arrives downstream from the basin. Sooner or later, all material that is not removed near the source will reach a water system. In some states this is a river or lake. In others it is an ocean or a bay. In every such situation, there result troublesome accumulations of trash and often pollution. These events often occur at places where it is difficult to retrieve the trash, and sometimes it is too late, especially when soluble or small particles are involved and they are dispersed into the environment.
To counter the risk, and depending on the scope of the drainage system, catch dams are often provided downstream which must periodically be cleaned out at great expense. It is best practice to exclude trash from them to the maximum extent possible while they are dry, and while the trash is readily accumulated in condition for easier collection at the curbside.
Still, means for this purpose should not interfere with the primary objective of the drainage system, which is to protect the surrounding area against flooding when the flow is heavy, such as in hard rainstorms or thunderstorms. In those events, the system must be maximally open and cannot be permitted to plug up. Apparatus according to this invention helps to assure system open-ness, because it can prevent most of the trash from entering the system in the first place.
An inherent problem with known devices such as in the aforementioned Martinez patent is that, while they need to remain open during times of heavy flow, they should close when the flow slows, but still stay open in case the system has already opened and then backs up and floods the catch basin. The said patented device can lose its control function when the system backs up, and the barrier can close, which can result in a flooded condition.
It is an object of this invention to provide a barrier that is normally closed during no or slow water flow rates, is reliably open when the rates increase, and reliably closes when the water in the basin recedes.
Optionally, means can be provided to keep the barrier open whenever the water level in the basin rises above some reference level and there may be no adequate flow past the control to keep the barrier open. With this improvement the system's control devices cannot be overwhelmed by being immersed in standing water in a flooded basin.
BRIEF DESCRIPTION OF THE INVENTION
Apparatus according to this invention is intended to be installed in a curbside drain opening. Such openings receive water from a gutter, which often entrains solid trash such as leaves, cuttings, bottles, and papers. The opening is usually vertical and rectangular. At its lower edge is a lip across which water and whatever else is carried by it, will flow and pass.
The apparatus is installed as a controllable barrier between the gutter and a catch basin. Such a catch basin is generally accessible from above, open to flow from the opening and connected to a downstream drainage system. Such systems customarily drain to a place where rainfall ultimately arrives—a water treatment facility, a river, a bay, or an ocean.
These systems can be clogged up by trash at any point. It is best practice to keep the trash out as much as possible. According to this invention, the barrier of this invention stays closed when there is no or only slow water flow. This will exclude trash from the system, while permitting the flow of water at lesser flow rates. Trash detained in the gutter can be swept away at any time without entering the catch basin or anyplace else in the system.
According to this invention, the barrier is pivotally mounted to structure surrounding the curbside drain, adapted to remain across the drain opening when there is no or only slow flow of water from the gutter. Linkage is mounted to the structure and to the barrier to rotate the barrier between closed and opened positions.
An actuator responsive to the flow rate of water through the opening is positioned inside of the basin below the lower edge of the opening, where water flow at a higher flow rate will flow into a receptacle, but water at a slower rate will not. The actuator includes a receptacle which, when sufficiently filled, will cause the actuator to move the linkage and open the barrier.
According to this invention, as soon as the barrier is opened, the receptacle will tilt and dump its load of water. This eliminates the weight which opened the barrier. Without further provisions, the barrier would simply be closed again, even if the water flow continued. It is a feature of this invention that, after the receptacle has dumped its contents, it remains effective on the actuator so long as a sufficient water flow impacts on it.
Then, as an additional but optional feature, should the receptacle be immersed in a flooded basin, means can be provided to hold the barrier open until the water in the basin recedes below the flooded level.
The above and other features of this invention will be fully understood from the following detailed description and the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a region incorporating the invention;
FIG. 2 is a perspective inside view showing the presently-preferred embodiment of the invention installed in a catch basin;
FIG. 3 is a right hand side view of the apparatus of FIG. 2 in its closed condition;
FIG. 4 is a right hand side view of FIG. 3 , showing the system starting to open;
FIG. 5 is a right hand view showing the system fully open in a continuing rapid flow of water;
FIG. 6 is a right hand side view showing a flooded-out condition;
FIG. 7 is a perspective view of a frame useful in this apparatus;
FIG. 8 is an exploded view showing the relationship of several parts of the apparatus;
FIG. 9 is a perspective view as in FIG. 2 , showing a modified part of the apparatus, the system being closed; and
FIG. 10 is a side view of a portion of FIG. 9 , showing the system fully open.
DETAILED DESCRIPTION OF THE INVENTION
A typical installation for this invention is shown in FIG. 1. A curb 10 next to a gutter 11 has a drain opening 12 which is usually rectangular. The opening has a bottom edge 13 over which water will follow when it enters the opening.
In turn the opening enters into a catch basin 14 (FIG. 3 ). Essentially this is a small “room” with a top in which a manhole 15 or other entry arrangement is fitted with a removable cover 16 . From the catch basin, a conduit 17 leads into a drainage system, usually a storm drain intended to carry away water at flow rates which, if not carried away would flood surrounding areas. As stated before, these basins must be kept free of amounts of trash that could clog them, or depending on the nature of the trash, contaminate or cause flooding downstream.
Although the individual parts of the apparatus could be directly attached to structure of the curb and of the basin, it is best manufacturing procedure to provide a structure which can be fitted in or attached to the surrounding opening.
A frame 18 ( FIGS. 2 , 3 and 7 ) includes two springy mounting arms 22 , 23 formed to a V-shape. Brackets 24 , 25 are attached to the arms so this structure can be attached to the wall of the drain opening. As shown in FIG. 7 , these arms are springy, so as to cause them when installed to bear strongly against the wall of the drain opening. The dashed lines in FIG. 7 show the distorted, installed free ends, while in solid line are shown the undistorted ends prior to installation.
A brace 30 is attached to the two mounting arms to hold the base together. Attachment pins 31 , 32 , 33 and 34 provide for attachments which will later be described.
Barrier 41 is a flat structure with dimensions of length and of height. It is pivoted to pins 32 and 34 at the bottom edge 13 of the opening. When erect the barrier will occlude the opening, at least in part. It may conveniently be a grating or a grid of rods or wires, or a screen, depending on what is anticipated to be the type of trash to be detained and the anticipated rates of flow. In any event, some kind of space or clearance next to, beside or below the barrier, will be provided to enable the slow flow of water past the barrier when it is closed, and over edge 13 .
The slow flow ( FIG. 3 ) is designated by arrows 42 . This slow flow simply drips over the bottom edge, and into the basin, without having any effect on this device. Except, of course that trash which it brings to the opening will be detained by the closed barrier.
Importantly, at this time the barrier is locked closed. Attention is called to the over-center alignment of arms to be described as best shown in FIG. 3 . As will later be shown, mechanical forces against it will not open it. Most importantly, brooms or sweepers can sweep past it to carry away the trash without opening the barrier. Thus, the system's trash load is greatly reduced. The only trash which will ultimately enter the catch basin is what is present in the gutter when heavy water flow occurs. The trash load for what is most of the rest of the year will be excluded from the catch basin, and thereby from the rest of the system.
There remains to be disclosed the controls to maintain the drainage system mechanically closed to entry of trash while permitting slow flow of water, to open it while the flow is rapid, and to keep the closure open when the drainage system itself is flooded.
A tiltable receptacle 50 is pivotally supported from a pair of suspensions 51 , 52 that are hinged to the end walls 53 , 54 of the receptacle. The receptacle is an open topped container, preferably V-shaped, with a pair of side faces 55 , 56 and the two end walls. A bias flange 57 extends beyond side face 55 for a purpose to be described.
A trip chain 58 extends between an attachment point 59 near the bottom apex of the receptacle, and pin 60 on an arm of the frame. There preferably will be one of these chains at each end of the receptacle.
Actuator links 65 , 66 are mounted to arms 22 , 23 at each side. Together they mount and support a counterweight 67 . These links include identical levers 68 , 69 with rigidly joined arms 70 , 71 . These arms rotate with the counterweight. Pivot points 74 , 75 mount these links to the arms at their joinder.
A pivot bar 80 extends between the joinders 81 , 82 of the links 65 and 66 and mounting links 83 , 84 . Mounting links 83 and 84 are hinged to the suspensions 51 , 52 and to brackets 85 , 86 ( FIG. 8 ) on the closure. A limit flange 87 extends from arm 71 to contact arm 84 to limit the upward movement of suspension 52 .
The operation of this device as described to this point is as follows. Starting with the closed condition of FIG. 3 , the barrier is erect, and solid trash (not shown) will be detained in the gutter. Slow flow 42 of water drips over edge 13 , and does not enter the receptacle. This is the normal condition. The slow flow often will come from over-watering of lawns, the washing of cars, and light rains.
Heavier flows 43 , as shown in FIG. 4 will not only drip over the edge, but will project into the system, where some of it will fall into the receptacle. There it will accumulate and start to overcome the counterweight. Notice that until this time, as in FIG. 3 , force against the barrier was resisted by the aligned link elements, preferably with a slight over-center alignment.
The accumulated weight of water pulls down on the linkage, raises the counterweight and starts to open the barrier. Notice that the water continues to pour into the receptacle. The receptacle does not have a drain.
Next, as the receptacle fills sufficiently, the chain and the suspension are lowered. Soon the chain will trip the receptacle to the tilted position of FIG. 5 . One would expect the loss of weight in the receptacle to enable the counterweight to close the barrier. It would, except that with sufficiently high rates of flow, water will cascade down onto bias flange 57 . Its force on the flange will hold the receptacle in the tilted position, and the barrier open, so long as the high rate of flow persists (FIG. 5 ). When it stops, the counterweight will again return the system to its closed position, because the receptacle is empty, or sufficiently empty as to enable the closure to occur.
FIGS. 9 and 10 show that, instead of a bias flange on the receptacle facing the curbside, a lip 90 can be placed on the backside of the receptacle, preferably forming an open ended trough 91 . This trough will also be impacted by high rates of flow, and will tend to keep the barrier from closing, as before.
FIG. 6 illustrates a latch-open feature of the invention which will be effective to keep the barrier open when the downstream system in the catch basin is flooded. A float 100 is supported by arm 101 . A second arm 102 rigidly attached to arm 101 forms a lever. The arms are pivotally mounted to the frame at hinge 103 . A catch surface 104 on arm 102 can overlap the edge of the open barrier when the water level 105 in the catch basin rises to the extent shown, before it can flood out the receptacle. If the water rises above that, the float and catch surface keep the closure open so the flooding of the basin will not affect the closure.
This invention is not to be limited by the embodiments shown in the drawings and described in the description, which are given by way of example and not of limitation, but only in accordance with the scope of the appended claims. | A system to exclude trash from curbside drains during periods of no or slow water flow, but opening to permit full entry during heavier flow such as during heavy rains. The system may have a linkage preventing opening by force on its barrier, and to assure that it will remain open should downstream drainage systems become flooded. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 60/682,498, entitled “APPARATUS AND METHOD FOR OBTAINING DOWNHOLE SAMPLES” filed on May 19, 2005, which is hereby incorporated in its entirety.
BACKGROUND
[0002] The present invention relates to sampling downhole fluids in a wellbore penetrating a subterrean formation. In particular, this invention relates to techniques for collecting downhole fluid samples and retrieving the samples to a surface location.
[0003] Wellbores, which are also known as boreholes, are drilled for hydrocarbon prospecting and production. It is often desirable to perform various evaluations of the formations penetrated by a wellbore during drilling operations, such as during periods when actual drilling has temporarily stopped. In some cases, the drill string may be provided with one or more drilling tools to test and/or sample the surrounding formation. In other cases, the drill string may be removed from the wellbore, in a sequence called a “trip,” and a wireline tool may be deployed into the wellbore to test and/or sample the formation. The samples or tests performed by such downhole tools may be used, for example, to locate valuable hydrocarbon-producing formations and manage the production of hydrocarbons therefrom.
[0004] Such drilling tools and wireline tools, as well as other wellbore tools conveyed on coiled tubing, drill pipe, casing or other conveyors, are also referred to herein simply as “downhole tools.” Such downhole tools may themselves include a plurality of integrated modules, each for performing a separate function, and a downhole tool may be employed alone or in combination with other downhole tools in a downhole tool string.
[0005] More particularly, formation evaluation often requires that fluid from the formation be drawn into a downhole tool, or module thereof, for testing in situ and/or sampling. Various devices, such as probes and/or packers, are extended from the downhole tool to isolate a region of the wellbore wall, and thereby establish fluid communication with the formation surrounding the wellbore. Fluid may then be drawn into the downhole tool using the probe and/or packers.
[0006] A typical probe employs a body that is extendable from the downhole tool and carries a packer at an outer end thereof for positioning against a sidewall of the wellbore. Such packers are typically configured with one relatively large element that can be deformed easily to contact the uneven wellbore wall (in the case of open hole evaluation), yet retain strength and sufficient integrity to withstand the anticipated differential pressures. These packers may be set in open holes or cased holes. They may be run into the wellbore on various downhole tools.
[0007] Another device used to form a seal with the wellbore sidewall is referred to as a dual packer. With a dual packer, two elastomeric rings are radially expanded about a downhole tool to isolate a portion of the wellbore wall therebetween. The rings from a seal with the wellbore wall and permit fluid to be drawn into the downhole tool via the isolated portion of the wellbore.
[0008] The mudcake lining the wellbore is often useful in assisting the probe and/or dual packers in making the appropriate seal with the wellbore wall. Once the seal is made, fluid from the formation is drawn into the downhole tool through an inlet therein by lowering the pressure in the downhole tool. Examples of probes and/or packers used in various downhole tools are described in U.S. Pat. Nos. 6,301,959, 4,860,581, 4,936,139, 6,585,045, 6,609,568, and 6,719,049, and U.S. Patent Application Publication No. 2004/0000433, which are incorporated herein by reference.
[0009] Fluid is drawn into the down tool through an inlet in the probes or packers. Fluid flows into a flowline and is selectively delivered to a sample chamber or bottle for collection therein. Examples of sample chambers and related techniques used in downhole tools are depicted in U.S. Pat. Nos. 6,745,835, 6,688,390, 6,659,177, 5,803,186, 5,233,866, 5,303,775, and 5,377,755, among others. Sample chambers are containers typically provided with an internal piston that retains the collected fluid under pressure. Once fluid is collected in the sample chamber, the tool is retrieved to the surface, and the sample chambers are removed for further analysis. In some cases, the sample chambers are removed at the surface for evaluation. In other cases, the sample chambers are taken to an offsite facility for further testing.
[0010] Despite the advances in sampling technology, there remains a need to obtain samples without interrupting the downhole operations being performed by the downhole tool. In some instances, sample chambers may become defective, full or other wise inoperable during operations. These remains a need for techniques for obtaining samples more quickly and/or without having to remove the tool. In such cases, it is desirable to retrieve one or more sample chambers from the downhole tool without withdrawing the tool.
[0011] Techniques have been developed for retrieving, measurement and logging while drilling tools (MWD, LWD) from downhole drilling tools. These MWD and LWD tools are typically deployed into and retrieved from downhole drilling tools via wireline or slickline devices. In such cases, the component is sent downhole through a mud channel extending through the downhole drilling tool and operatively inserted into the bottom hole assembly of the downhole drilling tool. Examples of such devices and related techniques are described in U.S. Pat. No. 6,577,244. However, no known techniques exist for retrieving sample chambers from downhole devices or tools. Difficulty exists in maintaining samples under the desired pressure, and preventing contamination of the sample during extraction and/or transport.
[0012] A need therefore exists for a system and method capable of collecting a sample and transporting it to the surface without requiring the removal of the downhole tool. It is desirable that such a system be operable even under harsh drilling environments, such as offset drilling conditions. It is further desirable that such a system be capable of isolating the sample from contamination and/or damage during transportation to the surface. These and other features of the invention are set forth herein.
SUMMARY OF THE INVENTION
[0013] In an aspect, the invention relates to a downhole drilling tool positionable in a wellbore penetrating a subterranean formation. The tool includes a formation evaluation tool having fixed and retrievable portions. The fixed portion is operatively connected to a drill collar of the downhole tool. The fixed portion is for establishing fluid communication with a subterranean formation. The retrievable portion is fluidly connected to the fixed portion and retrievable therefrom to a surface location. The retrievable portion is for receiving a formation fluid from the subterranean formation.
[0014] In another aspect, the invention relates to a formation evaluation while drilling tool positionable in a wellbore penetrating a subterrean formation. The tool includes a fluid communication device extendable from the drilling tool for establishing fluid communication with the subterranean formation. The fluid communication device has an inlet for receiving formation fluid from the subterranean formation and at least one sample chamber for receiving the formation fluid. The sample chambers are operatively connected to the fluid communication device via at least one flowline. The sample chambers are also positioned in the drill collar and retrievable therefrom to the surface.
[0015] In yet another aspect, the invention relates to A method of performing formation evaluation via a downhole drilling tool positionable in a wellbore penetrating a subterranean formation. The method involves establishing fluid communication between a fixed portion of the downhole drilling tool and the formation, drawing a formation fluid from the formation and into the fixed portion, passing the formation fluid from the fixed portion to a retrievable portion of the downhole drilling tool and retrieving the retrievable portion of the downhole drilling tool to a surface location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] So that the above recited features and advantages of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof that 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.
[0017] FIG. 1 is a schematic view, partially in cross-section of drilling rig with a downhole drilling tool advanced into a wellbore via a drill string, the downhole drilling tool includes a formation evaluation assembly therein.
[0018] FIG. 2A is a schematic view of the formation evaluation assembly of FIG. 1 including a retrievable sampling tool.
[0019] FIG. 2B is a schematic view of an alternate formation evaluation assembly including an alternate retrievable sampling tool.
[0020] FIG. 2C is a schematic view of an alternate formation evaluation assembly including a retrievable sample chamber.
[0021] FIG. 3A is a schematic view of the retrievable sample chamber of FIG. 2C .
[0022] FIG. 3B is a schematic view of an alternate retrievable sample chamber.
DETAILED DESCRIPTION
[0023] Referring now to FIG. 1 , a conventional drilling rig and drill string are shown wherein a land-based platform and derrick assembly 10 is positioned over a wellbore 11 penetrating subsurface formation F. In the illustrated embodiment, the wellbore 11 is formed by rotary drilling in a manner that is well known. Those of ordinary skill in the art given the benefit of this disclosure will appreciate, however, that the present invention also finds application in directional drilling applications as well as rotary drilling, and is not limited to land-based rigs.
[0024] A drill string 12 is suspended within the wellbore 11 and includes a drill bit 15 at its lower end. The drill string 12 is rotated by a rotary table 16 , energized by means not shown, which engages a kelly 17 at the upper end of the drill string 12 . The drill string 12 is suspended from a hook 18 , attached to a traveling block (also not shown), through the kelly 17 and a rotary swivel 19 , which permits rotation of the drill string 12 relative to the hook 18 .
[0025] Drilling fluid or mud 26 is stored in a pit 27 formed at the well site. A pump 29 delivers drilling fluid 26 to the interior of the drill string 12 via a port in the swivel 19 , inducing the drilling fluid 26 to flow downwardly through the drill string 12 as indicated by directional arrow 9 . The drilling fluid 26 exits the drill string 12 via ports in a drill bit 15 , and then circulates upwardly through the region between the outside of the drill string 12 and the wall of the wellbore 11 , called the annulus, as indicated by direction arrows 32 . In this manner, the drilling fluid lubricates the drill bit 15 and carries formation cuttings up to the surface as it is returned to the pit 27 for recirculation.
[0026] The drill string 12 further includes a downhole tool or bottom hole assembly (BHA), generally referred to as 100 , near the drill bit 15 . The BHA 100 includes drill collars 150 housing various components capable of measuring, processing, and storing information, as well as communicating with the surface. One such component is a measuring and local communications apparatus 200 for determining and communicating the resistivity of formation F surrounding the wellbore 11 . Another component is a formation evaluation assembly 300 . The formation evaluation assembly 300 includes stabilizers or ribs 314 , and a probe 316 positioned in a stabilizer.
[0027] Referring now to FIG. 2A , the formation evaluation assembly 300 is positioned in a drill collar 150 . The formation evaluation assembly 300 includes a fixed section or portion 403 and a retrievable section or portion 400 . The drill collar 150 has an annulus 401 extending therethrough for the passage of mud or drilling fluid. As shown, the fixed portion 403 is positioned in the drill collar 150 with a passage defined and extending therethrough. The retrievable portion 400 is positioned centrally within the annulus 401 . However, it will be appreciated that the tools may be positioned and/or supported within the drill collar in a manner that facilitates formation evaluation and/or mud flow operations. The portions may be in one or more drill collars. The portions may be adjacent, or extended a distance across the downhole tool.
[0028] The probe 316 is positioned in the fixed portion 403 and extends therefrom to contact the wall of the wellbore 11 and establish fluid communication with an adjacent formation. The fixed portion 403 includes a pretest piston 404 and pressure gauge 406 . Other devices, such as sensors, fluid analysis, hydraulics, electronics, etc., may also be provided.
[0029] The retrievable portion 400 has a latching mechanism 408 as a downhole end thereof, and a fishing/wireline head 410 at an uphole end thereof. The latching mechanism 408 removably connects the retrievable sampling tool (or the retrievable portion 400 ) to the drill collar 150 . The fishing head 410 is preferably adapted for connection to a wireline 411 . Alternatively, a slickline or other retrieval mechanism may be used to facilitate retrieval to the surface. The retrievable portion 400 may also be deployed into the downhole tool or formation evaluation assembly 300 using a tractor, mud flow, gravity or other conveyance. The retrievable portion 400 is then secured in place using the latching mechanism 408 .
[0030] The wireline 411 may be used to provide power to the retrievable and/or fixed portions, as well as other portions of the downhole tool. In such cases, the downhole tool may be operated using power from the wireline 411 to supplement or replace power from mud flow. The downhole tool is thereby enable to operate in an LWD mode, or in wireline mode. In LWD mode, the downhole tool receives power from the flow of mud through a downhole generator (not shown). In wireline mode, the wireline 411 electrically conveys power to the downhole tool. The wireline mode permits operation when mud cannot be passed through the downhole tool, for example when the tool is ‘tripping.’
[0031] The latching mechanism 408 is adapted to make fluid connection of a flowline 402 between the retrievable portion 400 and the fixed portion 403 . The latching mechanism 408 includes a self-sealing mechanism (not shown) to seal the fixed portion 403 and prevent fluid flow therein when the retrievable portion 400 is detached. This self-sealing mechanism is preferably robust enough to withstand the high mud flow-rate in the mud channel following removal of the retrievable portion 400 .
[0032] The retrievable portion 400 includes a pump 412 and sample chambers or bottles 414 . One or more sample bottles of a desired size may be used. Preferably the sample chambers are slim to allow for passage of mud. Sample bottles longer than a drill collar may be used and extend through the retrievable portion 400 . The flowline 402 extends through the fixed portion 403 and the retrievable portion 400 . The flowline 402 fluidly connects the probe 316 to the sample chambers 414 in the retrievable portion 400 . Additional valving, sample chambers, pumps, exit ports, charging chambers and other devices may be provided in the sampling assembly to facilitate the formation evaluation process. While the pump 412 is depicted in the sampling tool or retrievable portion 400 , and the pretest and gauge are depicted as being in the drill collar portion or fixed portion 403 of the formation evaluation tool, these devices may be positioned in various locations about the formation evaluation tool.
[0033] Referring now to FIG. 2B , an alternate formation evaluation assembly 300 a is depicted. The formation evaluation assembly 300 a is similar to the formation evaluation assembly 300 of FIG. 2A , except that the fixed portion 403 a contains the probe 316 , and the retrievable portion 400 a contains the pretest piston 404 , pressure gauge 406 , electronics 502 and hydraulics 504 . With this configuration, additional components are positioned in the retrievable portion 400 a and may be retrieved to the surface for replacement or adjustment as necessary.
[0034] As depicted in FIG. 2B , the formation evaluation tool 300 a has no sample chambers or pumps. The configuration of FIG. 2B may be used for performing formation testing without sampling. However, these and other components may optionally be provided to enable sampling operations.
[0035] Referring now to FIG. 2C , another alternate formation evaluation assembly 300 b is shown having a retrievable portion 400 b and a fixed portion 403 b . This configuration is similar to the formation evaluation assembly 300 of FIG. 2A , except that the pump 412 has been removed from retrievable portion 400 b and positioned in the fixed portion 403 b.
[0036] FIGS. 3A and 3B depict flowline configurations for the downhole formation evaluation assembly. As shown in FIG. 3A , the flowline 402 branches into flowlines 602 and 604 . A valve 606 selectively permits fluid flow from the flowline 402 into a sample chamber 614 . When the valve 606 is closed, the flowline 402 may bypass the flowline 604 and the sample chamber 614 and proceed to other sample chambers or portions of the downhole tool. This enables a single flow line entering and exiting the bottle that will allow multiple bottles to be placed in series.
[0037] As shown in FIG. 3B , the flowline 402 branches to flowline 620 and 622 . Valves 624 and 626 permit fluid to selectively pass into flowlines 620 , 622 , respectively. In this case, the valves are located remotely from the bottles, for example within the fixed portion or latch section. In this configuration, the valves 624 and 626 permit operation without the use of electrically operated valves in the bottles. Such a configuration obviates the need for wires. A separate flow 622 is provided for each sample chamber in series.
[0038] Referring now to FIGS. 3A and 3B , the sample chamber 614 includes a piston 628 slidably positioned therein. The piston defines a sample cavity 630 and a buffer cavity 632 . The buffer cavity 632 has an exit port 634 in fluid communication with the wellbore. Other flowline configurations, valving and additional devices, such as nitrogen chambers, may also be used.
[0039] Preferably the pump 412 , which is shown in FIG. 2C , is positioned adjacent the sample chambers to circulate formation fluid near the valves 624 and 626 . The pump 412 may be positioned to minimize the amount of stagnant, contaminated fluid that will enter the sample chamber upon opening the valves.
[0040] It will be understood from the foregoing description that various modifications and changes may be made in the preferred and alternative embodiments of the present invention without departing from its true spirit. Furthermore, this description is intended for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open set or group. Similarly, the terms “containing,” having,” and “including” are all intended to mean an open set or group of elements. “A,” “an” and other singular terms are intended to include the plural forms thereof unless specifically excluded. | A downhole drilling tool positionable in a wellbore penetrating a subterranean formation is provided. The tool includes a formation evaluation tool having fixed and retrievable portions. The fixed portion is operatively connected to a drill collar of the downhole tool. The fixed portion is for establishing fluid communication with a subterranean formation. The retrievable portion is fluidly connected to the fixed portion and retrievable therefrom to a surface location. The retrievable portion is for receiving a formation fluid from the subterranean formation. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates an apparatus and method using expandable tubulars to complete a well. More particularly, the invention relates to the installation of an expandable sand screen. More particularly still, the invention relates to a single trip installation process to set a liner hanger in a wellbore and then expand a sand screen.
[0003] 2. Description of the Related Art
[0004] Hydrocarbon wells are typically formed with a central wellbore that is supported by steel casing. The casing lines a borehole formed in the earth during the drilling process. An annular area formed between the casing and the borehole is filled with cement to further support and form the wellbore.
[0005] Some wells are produced by perforating the casing of the wellbore at selected depths where hydrocarbons are found. Hydrocarbons migrate from the formation through the perforations and into the wellbore where they are usually collected in a separate string of production tubing for transportation to the surface of the well. In other instances, a lower portion of a wellbore is left open and not lined with casing. This “open hole” completion permits hydrocarbons in an adjacent formation to migrate directly into the wellbore where they are subsequently raised to the surface, possibly through an artificial lift system.
[0006] Open hole completions can provide higher production than cased hole completions and they are frequently utilized in connection with horizontally drilled boreholes. However, open hole completions leave aggregate material, including sand, free to invade the wellbore. Sand entering an open hole wellbore causes instability within the open hole which enhances the risk of complete collapse. Sand production can also result in premature failure of artificial lift and other downhole and surface equipment due to the abrasive nature of sand. In some instances, high velocity sand particles can contact and erode lining and tubing.
[0007] Sand can also be a problem where casing is perforated to collect hydrocarbons. Typically, casing is perforated with a perforating assembly or “guns” that are run into a wellbore and fired to form the perforations. Thereafter, the assembly is removed and a separate assembly is installed to collect the migrating hydrocarbons. The perforations also create a passageway for aggregate material, including sand to enter the wellbore. As with an open wellbore, sand entering the cased wellbore can interfere with the operation of downhole tools, clog screens and damage components, especially if the material enters the wellbore at a high velocity.
[0008] To control particle flow into a wellbore, well screens are often employed downhole. Conventional wellscreens are placed adjacent perforations or unlined portions of the wellbore to filter out particulates as production fluid enters a tubing string. One form of well screen recently developed is the expandable sand screen (ESS). In general, the ESS is constructed of different composite layers, including a filter media.
[0009] A more particular description of an ESS is found in U.S. Pat. No. 5,901,789, which is incorporated by reference herein in its entirety. That patent describes an ESS which consists of a perforated base pipe, a 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 sand screen is expanded. The ESS 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 expansion means like these, the ESS is subjected to outwardly radial forces that urge the expanding walls against the open formation or parent casing. The components of the ESS are expanded past their elastic limit, thereby increasing the inner and outer diameter of the tubular.
[0010] A major advantage to the ESS in an open wellbore is that once expanded, the walls of the wellbore are supported by the ESS. Additionally, the annular area between the screen and the wellbore is mostly eliminated, and with it the need for a gravel pack. A gravel pack is used with conventional well screens to fill an annular area between the screen and wellbore and to support the walls of the open hole. With an ESS, the screen is expanded to a point where its outer wall places a stress on the walls of the wellbore, thereby providing support to the walls of the wellbore to prevent dislocation of particles. Solid expandable tubulars are oftentimes used in conjunction with an ESS to provide a zonal isolation capability. In addition to open wellbores, the ESS is effectually used with a perforated casing to control the introduction of particulate matter into the cased wellbore via the perforations.
[0011] While an ESS can reduce or eliminate the inflow of particles into a wellbore, the screen must be installed and expanded in order to operate effectively. Any delay in the installation permits additional time for sand to enter the wellbore and the time period is especially critical between the formation of perforations in a casing wall and the expansion of screen against the perforations. The delays are especially critical if the newly formed wellbore is placed in an over balanced condition prior to expanding the ESS. An overbalanced condition permits fluids to enter the formations and hamper later production of hydrocarbons.
[0012] In current installation procedures of ESS the operator makes two trips downhole. In the first trip, the operator sets a liner hanger to secure the ESS in the wellbore. After returning from the first trip downhole, the operator must make a second trip with an expansion tool in order to expand the ESS.
[0013] There are several disadvantages to a multiple trip installation procedure. The biggest disadvantage relates to expensive downtime necessary to make both trips. Also, a delay between the first and second trips can cause well control problems due to fluid loss. For example, pressurized fluid in the wellbore used to actuate various mechanical components during the installation process can enter the formations causing formations to clog-up or collapse, restricting the flow of hydrocarbons. In addition, loss of drilling fluid increases the completion cost of the well. In other instances, a delay between perforating a casing and expanding a sand screen against the perforations increases the likelihood that solids from the formations will enter the wellbore. In addition to the foregoing, packers used to fix an ESS in a wellbore often have a relatively small inside diameter. These packer-like components remain in the wellbore and can cause access problems for remedial work required below the suspension device.
[0014] There is a need therefore, for an apparatus to reduce the time needed to install an expandable sand screen in a wellbore. There is a further need to set a sand screen in a wellbore and then expand the sand screen in a single trip. There is a further need for a method and apparatus to facilitate the setting of a liner hanger in a wellbore prior to the expansion of an ESS. Still further, there is a need for an apparatus to minimize the exposure to formation solids before expanding the ESS There is a further need for a single trip ESS apparatus that uses a liner hanger that does not restrict access within the wellbore after the ESS is expanded.
SUMMARY OF THE INVENTION
[0015] The present invention includes a method and apparatus for installing and expanding an ESS in a wellbore in a single trip. In one aspect of the invention, a liner hanger and expandable screen are provided and are run into the wellbore with an expansion tool and work string. After the hanger is set, the expansion tool is used to expand the screen. In another aspect, an annular area within the apparatus is utilized in order to set the hanger with pressurized fluid. Thereafter, cup packers used in sealing the annulus are lifted from the liner prior to expanding the screen. The expansion tool and work string are then removed leaving the expanded ESS and hanger in the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] 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.
[0017] 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.
[0018] [0018]FIG. 1 is a partial cross section view of an expansion tool assembly.
[0019] [0019]FIG. 2 is a partial cross section view of a liner and sand screen assembly.
[0020] [0020]FIG. 3A illustrates an upper portion of the expansion tool assembly and liner assembly.
[0021] [0021]FIG. 3B illustrates a middle portion of the expansion tool assembly and liner assembly.
[0022] [0022]FIG. 3C illustrates a lower portion of the expansion tool assembly and liner assembly.
[0023] [0023]FIG. 4 illustrates an annular area formed between the expansion tool assembly and liner assembly.
[0024] [0024]FIG. 5 illustrates the expansion tool assembly and liner assembly after a first ball has been dropped into a lower ball seat and sleeve.
[0025] [0025]FIG. 6 illustrates the expansion tool assembly and liner assembly after slips have been set to fix the liner in the wellbore.
[0026] [0026]FIG. 7 illustrates the lower ball seat and sleeve shifted to a second position relative to the liner assembly to reestablish a fluid pathway through the bore of the tool assembly.
[0027] [0027]FIG. 8 illustrates an upper ball seat and sleeve in a second position relative to the liner assembly.
[0028] [0028]FIG. 9 illustrates an upward movement of the tool assembly in relation to the liner assembly.
[0029] [0029]FIG. 10 illustrates the tool assembly lifted out of the liner assembly permitting dogs to clear the top of the liner assembly.
[0030] [0030]FIG. 11 is an enlarged view of FIG. 10, showing the expansion tool assembly suspended by dogs at the upper end of the liner assembly.
[0031] [0031]FIG. 12 illustrates downward movement of the expansion tool assembly in relation to the liner assembly and dogs in order to expand the ESS.
[0032] [0032]FIG. 13 illustrates the rotary expander tool expanding the sand screen.
[0033] [0033]FIG. 14 illustrates the expansion tool assembly as it is removed from the liner assembly after the screen has been expanded.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The present invention provides a method and apparatus to install an ESS in a wellbore and to expand the screen in a single trip. The invention includes a hanger which is used to set the screen in a wellbore before the screen is expanded by an expansion tool in the same trip into the wellbore.
[0035] [0035]FIG. 1 illustrates a partial cross section view of an expansion tool assembly 100 and FIG. 2 illustrates a partial cross section view of a liner and sand screen assembly 200 . While a portion of liner or non slotted tubular is shown in FIG. 1, it will be understood that the invention can be used with a section of liner above an expandable sand screen or with only a section of expandable sand screen. Further, while the Figures illustrate the invention in use with an open, noncased wellbore, it will be further understood that the methods and apparatus disclosed are equally usable in a cased wellbore with perforations formed therein. FIGS. 1 and 2 show the tool assembly 100 and the liner assembly 200 separated to illustrate the major components of each assembly. In use, the expansion tool assembly 100 is housed within assembly 200 . FIGS. 3 to 14 will fully describe the interface between the tool assembly 100 and the liner assembly 200 . In FIG. 1, the expansion tool assembly 100 includes a dust cover 110 at the upper end to seal the end of assembly 200 and to prevent wellbore contaminates from entering the liner. The assembly 100 further includes a carry nut 115 with male threads 130 that mates with female threads 205 near the top of the liner assembly 200 to secure the tool assembly 100 in the liner assembly 200 .
[0036] A carrying tool 125 is located at the lower portion of the assembly 100 to facilitate removal of the tool assembly 100 from the liner assembly 200 after expanding a screen 215 . A mud motor 120 is located adjacent to a rotary expander tool 105 at the lower end of the tool assembly 100 . In operation, fluid is pumped from the surface of the well down a bore of the tool assembly 100 and into the mud motor 120 . The mud motor 120 uses the fluid to rotate the rotary expander tool 105 , thereby expanding the screen 215 disposed at the lower end of the liner assembly 200 . A hydraulic liner hanger assembly 210 is located at the upper portion of the liner assembly 200 to secure the assembly 200 in a wellbore.
[0037] [0037]FIG. 3A illustrates the upper section of the expansion tool assembly 100 and the liner assembly 200 . The dust cover 110 sits on top of the liner assembly 200 . The carry nut 115 is shown threaded into the liner assembly 200 . An upper ball seat and sleeve 305 is located below the carry nut 115 and is secured to the tool assembly 100 by a first shear pin 310 . A first circumferential groove 330 is used in a later step to reestablish a fluid passageway in the bore of the assembly 100 . The liner hanger assembly 210 includes a plurality of cones 325 and slips 328 disposed about the circumference of the liner assembly 200 . The slips 328 include a tapered surface that mates with a corresponding tapered surface on the cone 325 . During the setting of the liner assembly 200 in the wellbore, the cones 325 are used to displace the slips 328 radially outward as an axial force is applied to the slip 328 in direction of the cones 325 .
[0038] [0038]FIG. 3B illustrates a middle section of the expansion tool assembly 100 and the liner assembly 200 . A lower ball seat and sleeve 385 is located below the slips 328 (not shown) and is secured in the tool assembly 100 by a second pin 380 . Below the lower ball seat and sleeve 385 is a second circumferential groove 340 which is used in a later step to reestablish a fluid passageway down the bore of the assembly 100 . A plurality of swab cups 390 used to seal an annular area between the tool assembly 100 and the liner assembly 200 are located below the second shear pin 380 . Expandable dogs 350 , shown in the retracted position, are located below the swab cups 390 . The dogs 350 are used to hold a portion of the tool assembly 100 above the top surface of the liner assembly 200 as will be described herein. A third shear pin 375 is located between the swab cups 390 and the dogs 350 to temporarily hold the dogs 350 and cups 390 around the work string. FIG. 3C illustrates a lower portion of the tool assembly 100 and the liner assembly 200 . As shown, the expander tool 105 on the tool assembly 100 is housed at an upper end of the expandable sand screen 215 . The screen 215 includes a funnel shaped opening to facilitate entry into the screen 215 by the expander tool 105 .
[0039] [0039]FIG. 4 illustrates an annular area formed between the expansion tool assembly 100 and liner assembly 200 . The annulus is created upon insertion of the tool assembly 100 into the liner assembly 200 . The annulus is separated into an upper annulus 355 , a middle annulus 360 and a lower annulus 365 . The carry nut 115 separates the upper annulus 355 from the middle annulus 360 . The swab cups 390 separate the middle annulus 360 from the lower annulus 365 . The middle annulus 360 serves as a fluid pathway between a first port 315 and a second port 320 which is later used to set the slips 328 that fix the liner 200 in the wellbore.
[0040] [0040]FIG. 5 illustrates the expansion tool assembly 100 and liner assembly 200 after a first ball 345 has been dropped into a lower ball seat and sleeve 385 . The view further illustrates, the liner assembly 200 prior to setting the slips 328 . As shown, there is no contact between the teeth 335 on the slips 328 and a casing 475 . At a later point the tapered portion of the slips 328 will be urged up cones 325 by a plurality of longitudinal members 415 that are connected to an annular piston 395 . The piston 395 has a top O-ring 405 and a bottom O-ring 410 for creating a fluid tight seal.
[0041] [0041]FIG. 6 illustrates the expansion tool assembly 100 and liner assembly 200 after the slips 328 have been set to fix the liner 200 in the wellbore. Ball 345 blocks fluid flow through the bore of the tool assembly 100 , thereby redirecting the fluid flow to a first aperture 420 formed in the sleeve 305 . The first aperture 420 is aligned with the first port 315 formed in a wall of the tool assembly 100 to form a fluid passageway to the annulus 360 . A first arrow 425 illustrates the fluid flow into the annulus 360 and a second arrow 430 illustrates fluid flow from the annulus 360 through a second port 320 . The fluid exiting the second port 320 acts on the piston 395 , thereby urging the piston 395 upward in the direction of the cones 325 . The longitudinal members 415 connecting the slips 328 to the piston 395 urges the slips 328 up the tapered portion of the cones 325 , thereby expanding the slips 328 radially outward in contact with the casing 475 . The teeth 335 formed on the outer surface of the slips 328 “bite” into the casing surface to hold the liner assembly 200 in position in the wellbore. FIG. 6 illustrates that the inner diameter of the assembly 200 is largely unobstructed by the set hanger and the bore is open to the passage of tools downhole.
[0042] [0042]FIG. 7 illustrates the lower ball seat and sleeve 385 shifted to a second position relative to the liner assembly 200 to reestablish a fluid pathway through the bore of the tool assembly 100 . After the liner assembly 200 is set in the casing 475 , the fluid becomes pressurized acting against the first ball 345 which is housed in the lower ball seat and sleeve 385 . At a predetermined pressure, pin 380 is sheared allowing the ball seat and sleeve 385 to shift downward to a second position. In the second position, a first by pass port 435 formed in the sleeve 385 aligns with the second circumferential groove 340 to reestablish a fluid pathway through the bore of the tool assembly 100 as illustrated by an arrow 432 .
[0043] [0043]FIG. 8 illustrates the upper ball seat and sleeve 305 in a second position relative to the liner assembly 200 to establish a fluid pathway through the bore of the tool assembly 100 . The flow path is established in order to provide a source of pressurized fluid to the expander tool 105 in order to expand the sand screen 215 at a lower end of the liner assembly 200 . The second ball 440 is dropped into the tool assembly 100 and lands on an upper seat and sleeve 305 which is held in place by pin 310 . Fluid thereafter becomes pressurized acting against the second ball 440 . At a predetermined pressure the pin 310 is sheared allowing upper ball seat and sleeve 305 to shift downward to the second position. In the second position, the ball seat and sleeve 305 aligns a second bypass port 450 with the first circumferential groove 330 to provide a fluid passage way. The fluid flow down the bore of the assembly 100 bypasses the ball 440 as illustrated by arrow 445 . In addition to reestablishing flow down the bore of the tool assembly 100 , the seat and sleeve 305 also misaligns the first aperture 420 and the first port 315 , thereby blocking fluid communication into middle annulus 360 .
[0044] [0044]FIG. 9 illustrates an upper movement of the tool assembly 100 in relation to the liner assembly 200 . After the liner assembly 200 has been set in the wellbore, the expansion tool 100 with the carry nut 115 is rotated clockwise, thereby removing the male threads 130 on the carry nut 115 from the female threads 205 on the liner assembly 200 . The tool assembly 100 is then lifted axially upward in relation to the liner assembly 200 as illustrated by a directional arrow 460 . A shoulder 455 on the tool assembly 100 urges the carry nut 115 upward with the tool assembly 100 as the tool assembly 100 is partially lifted from the liner assembly 200 .
[0045] [0045]FIG. 10 illustrates the tool assembly 100 lifted out of the liner assembly 200 permitting dogs 350 to clear the top of the liner assembly 200 . To prepare the tool assembly 100 to expand the screen 215 , the expansion tool assembly 100 is partially pulled from the liner assembly 200 exposing the dust cover 110 , carry nut 115 , swab cups 390 and dogs 350 . Upon removal from the liner assembly 200 , the dogs 350 expand outward. Pin 375 holds the various components together.
[0046] [0046]FIG. 11 is an enlarged view of FIG. 10, showing the expansion tool assembly 100 suspended by dogs 350 at the upper end of the liner assembly 200 . After the tool assembly 100 is lifted from the liner assembly 200 and the dogs 350 expanded, it is then lowered until the expanded dogs 350 rest on top of the liner assembly 200 . As shown, the dogs 350 are outwardly biased members that are constructed and arranged to ride along a tubular surface and then to extend outward when pulled out of contact with the tubular. With the components in position shown in FIG. 11, the expander tool 105 is ready to be lowered into the ESS 215 .
[0047] [0047]FIG. 12 illustrates downward movement of the expansion tool assembly 100 in relation to the liner assembly 200 and dogs 350 in order to expand the expandable sand screen 215 . A downward force is placed the tool assembly 100 , thereby exerting pressure on the pin 375 . At a predetermined pressure, the pin 375 is sheared, thereby allowing the mud motor 120 and expander tool 105 along with the carrying tool 125 to drop down into the liner assembly 200 while the dust cover 110 , the carry nut 115 , the swab cups 390 and the dogs 350 remain above the top of the liner assembly 200 . The tool assembly 100 is lowered until the expander tool 105 comes in contact with the ESS 215 .
[0048] [0048]FIG. 13 illustrates the rotary expander tool 105 expanding the sand screen 215 . Fluid is pumped from the surface of the well down the bore of tool assembly 100 into the mud motor 120 . The mud motor 120 provides rotational force to the expander tool 105 while causing radially extending rollers to extend outwards, thereby expanding the sand screen 215 into the borehole. FIG. 13 illustrates expanding a sand screen 215 in a vertical open hole. However, this invention is not limited to the one shown but rather can be used in many different completion scenarios such as casing that has been perforated.
[0049] [0049]FIG. 14 illustrates the expansion tool assembly 100 as it is removed from the liner assembly 200 after the ESS 215 has been expanded. As the tool assembly 100 is pulled upward, a top surface 470 of the carrying tool 125 contacts a bottom surface 465 of the dogs 350 , thereby urging the dogs 350 off the top of the liner assembly 200 . The entire tool assembly 100 is moved up out of the liner assembly 200 and then out of the wellbore. The ESS 215 allows hydrocarbons to enter the wellbore as it filters out sand and other particles. The expanded sand screen 215 is connected to production tubing at an upper end, thereby allowing the hydrocarbons travel to the surface of the well. In addition to filtering, the sand screen 215 preserves the integrity of the formation during production.
[0050] 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 includes a method and apparatus for setting a liner in a wellbore and then expanding a screen in the wellbore in a single trip. In one aspect of the invention, a liner and expandable screen is provided with a slip assembly to fix the liner in the wellbore. An expansion tool and work sting is run into the wellbore in the liner. After the liner is set, the expansion tool is used to expand the screen. In another embodiment, an annular area between the expansion tool and work string is utilized in order to set the slips. Thereafter, cup packers used in forming the annulus are lifted from the liner prior to expanding the screen. |
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This application is a continuation-in-part under 35 U.S.C. §120 of U.S. Pat. application Ser. No. 09/247,217, filed on Feb. 10, 1999, now U.S. Pat. No. 6,042,422, and herein expressly incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to traffic safety devices and, more specifically, to vertical panel display systems.
2. Description of the Related Art
Highway signs are generally used for promoting the safe passage of motor vehicles and/or pedestrians by advising of, for example, approaching unsafe driving conditions. These highway signs are generally provided with various highway legends, and are generally configured to flex in response to prevailing winds and wind gusts created by motor vehicles and the like.
It is known in the art to use a vertical panel system as a highway sign. In a typical vertical panel system, a vertical panel is on a collapsible support so that it folds down when impacted by a vehicle. This mitigates damage to the panel and the vehicle. A common example is an A-frame design consisting of two sides which are hinged together at the top. Each side has a panel attached to it. For support, the A-frame design is weighed down by sandbags. Upon impact, the A-frame folds flat. This design, while simple to build, is relatively unpredictable and requires at least two components, the A-frame and a sandbag, and maybe more than one sandbag.
An improvement on this idea is disclosed in U.S. Pat. No. 4,792,258 to Goff entitled “Collapsible Warning Barricade Apparatus” (“Goff”), which is incorporated herein in its entirety. Goff discloses a vertical panel pivotally attached to a base. The panel was maintained in a vertical position, with the use of a compression spring device that exerted a force on an automatic locking means at the pivot point. The automatic locking means has multiple elements that are coordinated to maintain the panel in an upright position until impact. Unfortunately, the design as disclosed in Goff is complicated to build and requires many parts.
It is also a problem with vertical panel systems that when they are impacted, the systems are dragged with the vehicle. As the base or support of the system is attached to the panel, both the panel and the base are damaged. Further, as the vehicle is dragging both the panel and the base, the vehicle incurs increased damage than if the panel was being dragged alone.
The prior art discloses a vertical panel system with a breakaway safety feature such that the panel separates from the base when impacted. This system is available under the trade name WindBreakers from Trafcon Industries Inc, 81 Texaco Road, Mechanicsburg, Pa. 17055. The WindBreakers' panel is attached to the rubber base via a breakaway pin that is inserted through the width of the panel. A disadvantage of the WindBreaker is that a replacement pin must be used to reattached the panel to the base as the original pin shears upon separation. Another disadvantage is that the WindBreaker panel flexes in the wind. An additional disadvantage is that the panel does not easily release to stack the bases and panels flat.
Another prior art system is disclosed in U.S. Pat. No. 5,670,954 to Junker. This system is similar to WindBreakers system discussed supra, in that a vertical panel 4 is secured to a base using a bolt and nut mechanical fastening combination. A disadvantage of this system is complexity. Additionally, the base securement is designed to be permanent, so there is no ability for the panel to break away from the base, short of the destruction of the system.
Still another prior art system is disclosed in U.S. Pat. No. 5,484,225 to Warner. This patent discloses a vertical panel system wherein a vertical panel is secured to a base without the use of mechanical fasteners, by means of a friction/compression fit. However, although this approach is an improvement over the systems discussed supra, it still has a number of problems. For example, to effect the panel/base attachment, the bottom edge of the panel is merely inserted into a slot in the base. There is no structure to prevent the vertical panel from rocking from side to side, and the engagement between the panel and base is subject to wear of the interior surface of the base slot over time, until at a particular point in time the friction/compression fit will be inadequate to properly support the panel. Additionally, there is no structure to assist a user in inserting the panel into the slot.
Therefore, it is desirable to have a vertical panel system which is collapsible upon impact, the panel is separable from the base during impact, is easily stacked, and made from relatively few parts. It is also desirable to have a panel that can be reattached to the base without replacing parts. It is also desirable to have the panel surface protected from scratches and mars while it is being hit or dragged. It is also desirable to have a panel that does not flex from the wind force.
SUMMARY OF THE INVENTION
The present invention provides an advantageous improved vertical panel system, which comprises a vertical panel having a panel with opposing first and second panel surfaces and a base edge. The system further comprises a base having a slot for engaging the base edge of the panel. Advantageously, an aperture is disposed in the panel in proximity to the base edge, which is of sufficient size to receive a foot of a user, for assisting in the engagement of the panel and the base.
In another aspect of the invention, there is provided a base for a vertical panel system, which comprises a center zone fabricated of vulcanized rubber, and an outer zone fabricated of recycled rubber. A slot is disposed in the center zone for receiving a base end of a vertical panel in engagement therewith. This arrangement solves a need to be environmentally responsible and cost effective by recycling rubber which would otherwise fill our landfills, yet provides great durability by using virgin vulcanized rubber in the zone of the base which includes the engagement slot.
In still another aspect of the invention, there is disclosed a method of assembling a vertical panel system comprised of a vertical panel having a base end and an aperture sufficiently large to accommodate a user's foot disposed adjacent to the base end. A base comprising a part of the system for ballasting the vertical panel has a slot for receiving the vertical panel base end. The inventive method comprises the steps of positioning the vertical panel over the base, so that the base end is in proximity to and just above the slot. Then, a user's foot is placed through the aperture, whereupon the user presses downwardly with his or her foot to apply downward force on the vertical panel, so that the base end of the vertical panel is inserted into and becomes engaged with the slot. This innovative method avoids the problem of using one's arms to press down from the top of the vertical panel, which can be a tiring and difficult job.
The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exploded perspective view of a vertical panel system with one panel according to an embodiment of the invention;
FIGS. 2 and 3 are perspective and plan views, respectively, showing details of assembly of the vertical panel system of FIG. 1;
FIG. 4 shows an exploded perspective view of a dual vertical panel system according to an alternative embodiment of the invention;
FIG. 5 is a plan view showing details of the engagement portion of the vertical panel system of FIG. 4;
FIGS. 6 and 7 are plan views showing details and positioning of reflective portions of Type I and Type II barricades, respectively;
FIG. 8 is a plan view of another alternative embodiment of the present invention;
FIG. 9 is a perspective view of the base portion of the vertical panel system illustrated in FIG. 8;
FIG. 10 is a perspective view of the vertical panel portion of the system of FIG. 8;
FIG. 11 is a view similar to FIG. 10 showing the application of reflective material to a front panel of the vertical panel portion; and
FIG. 12 is a view similar to FIG. 10 illustrating an alternative embodiment wherein a sign panel is attached to the vertical panel portion.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures, wherein like reference numerals refer to like elements throughout the figures, and referring specifically to FIG. 1, a vertical panel system 10 according to an embodiment of the invention comprises a vertical panel 12 and a base 14 . When a tab 16 extending from a lower end of the vertical panel 12 is inserted into a slot 46 in the base 14 , the assembled vertical panel system 10 resembles an inverted T with the base 14 being the cross member. The vertical panel system 10 is designed to remain standing in wind and gusts from bypassing vehicles while being able to separate into the panel 12 and base 14 upon impact. Because the vertical panel system 10 is able to separate, the damage to the impacting vehicle and the system is mitigated.
The vertical panel 12 is comprised of a panel 20 with opposing panel first and second surfaces 22 (only one panel surface shown). The panel 20 has a base edge 24 proximate to the base 14 and from which the tab 16 extends. The panel 20 also has a top edge 26 that opposes the base edge 24 . Two opposing side edges 28 of the vertical panel 12 extend between top edge 26 and the base edge 24 .
In the illustrated embodiment of the invention, the edges 24 , 26 , and 28 are raised above the panel surfaces, so that the first and second panel surfaces 22 are recessed into the panel 20 . Because the edges 24 , 26 , and 28 are raised, the edges get scraped during normal usage and wear and tear, rather than the panel surfaces 22 or anything on the panel surfaces. Examples of causes of scraping includes the system 10 being struck or the panel 20 skidding across the ground. The panel surfaces 22 may be reflective, either by having reflective material, such as sheeting, disposed thereon or the panel surfaces comprise reflective material. The panel surfaces 22 may have other indicia thereon. Whether it is reflective material or other indica on the panel surfaces, it is protected by the raised edges 24 , 26 , and 28 .
In a preferred embodiment of the invention, the raised edges 24 , 26 , and 28 protrude in a direction normal to the panel surfaces 22 . In other embodiments of the invention, the raised edges 24 , 26 , and 28 may extend above the panel surfaces in a direction other than normal to the panel surfaces. In some instances, it may be advantageous for only a portion of the edges 24 , 26 , and 28 to be raised, or the edges 24 , 26 , and 28 may be raised above only one of the panel surfaces. The edges 24 , 26 , and 28 may be integral to the panel 20 or may be a separate but attached component of the panel 20 .
In the illustrated embodiment of the invention, the vertical panel 20 is rectangular. Other embodiments of the invention may have vertical panels of other shapes. In the preferred embodiment of the invention, the vertical panel 12 is comprised of double wall blow molded plastic. Other embodiments of the invention may have a vertical panel comprised of other materials.
The tab 16 extends from a base edge 24 of the panel 20 and terminates at a tab bottom edge 30 . The tab 16 comprises two opposing side surfaces 32 (only one side surface is shown) that extend between two opposing side edges 34 . Each of the tab side surfaces 32 have two tab grooves 36 extending from the tab bottom edge 30 and towards the panel base edge 24 . In the preferred and shown embodiment of the invention, the tab bottom edge 30 is parallel to the panel base edge 24 and the tab grooves 36 extend perpendicularly to the bottom edge and the base edge. Other embodiments of the invention may have other relationships between edges 24 and 30 and the tab grooves 36 . The tab bottom edge 30 extends a length 31 that is shorter than the width 50 of the panel 20 .
In other embodiments of the invention, only one of the tab surfaces 32 may have tab grooves 36 . In other embodiments of the invention, there may be more or fewer than two tab grooves 36 on a tab side surface 32 . In the illustrated embodiment of the invention, the tab grooves 36 have a generally U-shaped profile (see FIG. 2 ). Other embodiments of the invention may have tab grooves with other suitable profiles. In the illustrated embodiment of the invention, the tab 16 and the panel 20 reside in generally the same plane. In other embodiments of the invention, the tab 16 may be oriented at a different angle to the panel 20 , such as a plane extending through the tab side edges 34 defines a plane that is normal to the panel 20 . In the illustrated embodiment of the invention, the panel 20 has one tab 16 . Other embodiments of the invention may have more than one tab. In the illustrated embodiment of the invention, the tab 16 is of a rectangular cube shape. Other embodiments of the invention may have tabs of other shapes. In the illustrated embodiment of the invention, the tab 16 is integral to the panel 20 . Other embodiments of the invention may have the tab 16 separably attached to the panel 20 .
The base 14 has a top surface 40 , a major axis 42 extending along the length of the base and a minor axis 44 extending along the width of the base. At the intersection of the axes 42 and 44 is a slot 46 . The slot 46 extends from the top surface 40 and into the base 14 . The slot 46 complements the tab 16 and the tab grooves 36 . The fit of the slot 46 with the tab 16 may be loose, snug, or it may be an interference fit. An interference fit of the slot 46 and the tab 16 may be suitable for embodiments of the invention in which the base is made of an elastomeric material, such as rubber. The slot 46 may extend through the base 14 or terminate in the base.
To assemble the vertical panel system 10 , the tab 16 is inserted into the slot 46 . In the illustrated embodiment of the invention, the vertical panel 12 is oriented along the minor axis 44 . Other embodiments of the invention may have the vertical panel oriented in other directions.
In the illustrated embodiment of the invention, the base 14 has a length 48 that is long enough to inhibit the vertical panel system 10 from tumbling in the direction of the major axis 42 when wind or gusts catches the vertical panel 20 . The panel base edge 24 extends a width 50 that is substantially equal to a width 52 of the base 14 .
Referring now to FIGS. 2 and 3, the tab 16 is shown partially and fully inserted into the slot 46 , respectively. The complementing slot 46 is shown with projections 47 extending into the grooves 36 in FIG. 3 . It is clearly shown in FIG. 3 that the width 50 of the panel 20 is approximately the same of the width 52 of the base 14 . Further, when the tab 16 is fully inserted into the slot 46 , the base edge 24 of the panel 20 is in contact with the upper surface 40 of the base 14 across the width 52 of the upper surface. This contact provides a stable fitting of the panel vertical panel 12 and the base 14 that resists the tab 16 from coming out of the slot 46 through repeated lateral movements of the vertical panel 12 in the direction of the minor axis 44 .
A significant advantage of the present invention over the prior art is that this “button” or “tongue and groove” engagement between the tab grooves 36 and the base projections 47 is a vast improvement over the mere friction/compression fit disclosed in the prior art, such as in the Warner '225 patent discussed supra. The advantages include increased durability, because wear and tear to the interface over time does not as severely affect the positive interface between the projections and grooves as it does a mere friction/compression fit, and improved stability, or, more specifically, the ability to resist rocking of the panel to the left or right side because of wind gusts due to passing traffic.
The base 14 is made of rubber in a preferred embodiment of the invention. The rubber base 14 provides ballast for the system 10 to inhibit tipping or moving the system while in use. Other embodiments of the invention may use any suitable ballasting type device as a base, such as a hollow plastic container filled with sand or another ballast or a frame that is secured in place with sand bags.
Referring now to FIG. 4, a dual paneled vertical panel system 100 has a vertical panel 112 with a lower panel 120 and an upper panel 121 that is mounted in a base 114 . In the illustrated embodiment, the panels 120 and 121 generally define a plane. Other embodiments of the invention may have the panels 120 and 121 at a different orientation relative to one another or to the ground.
The panels 120 and 121 preferably have raised edges 123 . A base edge 124 of the lower panel 120 is located distal to a top edge 127 of the upper panel 121 . A top edge 126 of the lower panel is located proximate to a base edge 125 of the upper panel 121 . A support member 102 extends between the lower panel top edge 126 and the upper panel base edge 125 . The support member 102 may be unitary with the two panels 120 and 121 or may be separably attached to the panels. Other embodiments of the invention may have different arrangements for the support member, including a plurality of support members or a support member that supports the two panels other than extending between the edges 125 and 126 . In a preferred embodiment the support member 102 is integrally molded (such as by injection molding) with the panels 120 , 121 .
A tab 116 extends downwardly from the base edge 124 of the lower panel 120 . The tab 116 has tab grooves 136 , tab side edges 134 , and a bottom edge 130 much like the tab grooves 36 , tab side edges 34 and a bottom edge 30 of the vertical panel system 10 . Additionally, tab 116 has shoulder portions 135 that laterally extend from the tab side edges 134 . The shoulder portions 135 result in the tab 116 expanding to a width 150 (FIG. 5) as it approaches the lower panel. In a preferred embodiment of the invention, the width 150 is approximately the same as the width 152 of the base 114 .
Referring now to FIG. 5 as well, only a lower portion 117 of the tab 116 is inserted in a slot 146 of the base 114 when the system 100 is assembled. The tab lower portion 117 extends between the tab bottom edge 130 to the shoulders 135 . FIG. 5 more clearly shows that the width 150 of the tab 116 is approximately the same as the width 152 of the base 114 . This results in the shoulder 135 making contact with the base upper surface 140 across the width 152 of the base 114 . The contact provides a very stable assembled system 100 as previously described in connection with the base edge 24 making contact with the base 14 .
In an embodiment of the invention, panel surfaces are sized and positioned to conform to Type I or Type II barricade requirements. More specifically, the reflective sheeting requirements of the Type I or Type II barricades are mounted to appropriately sized and positioned panel surfaces in a vertical panel system that embodies the invention.
Referring now to FIG. 6, the size and positioning of a reflective portion 200 of a Type I barricade is shown relative to the ground 202 . The reflective portion 200 has white stripes 204 that alternate with orange strips 206 . The stripes 204 and 206 are oriented at a right-facing 45 degree angle and have a width 208 of six inches. Other reflective portions of Type I barricades may have the stripes 204 and 206 oriented in a left-facing manner. The portion 200 preferably has a height 210 of 8 to 12 inches and a length 212 of at least 2 feet. The top 214 of the portion 200 is at least 3 feet above the ground 202 .
Referring now to FIG. 7, the size and positioning of an upper reflective portion 220 and a lower reflective portion 221 of a Type II barricade is shown relative to the ground 202 . The stripes 204 and 206 , the stripe width 208 , the stripe orientation, the height 210 and the length 212 of each reflective portion 220 and 221 is the same as for the reflective portion 200 . The portion 221 is positioned below the portion 220 . The top edge 214 of the upper portion 220 is preferably greater than 3 feet from the ground 202 .
In illustrated embodiments of the invention, the vertical panel has a contact surface that makes contact with the upper surface of the base. In the embodiment of the invention 10 shown in FIG. 1, the contact surface is the portion of the base edge 24 that extends beyond the tab 16 . In the embodiment of the invention 100 shown in FIG. 4, the contact surfaces are the shoulders 135 of the tab 116 . In preferred embodiments of the invention, the contact surface has an overall length that is approximately equal to the width of the base at the point of contact. The matching of the vertical panel contact surface length and the base width results in a laterally stable vertical panel system without having a vertical panel with excess material and the resulting higher manufacturing costs. Other, less preferred embodiments of the invention may have a vertical panel contact surface that does not extend across the width of the base. Additionally, other, less preferred embodiments of the invention may have portions of the contact surface extend beyond the width of the base.
Now with reference to FIGS. 9-11, a modified and preferably preferred embodiment of the invention is illustrated. In this embodiment, a vertical panel system 310 comprises a vertical panel 312 which is securable to a base 314 and includes a panel portion 322 . As in prior embodiments, the vertical panel 312 is preferably blow molded of plastic, though any known fabrication techniques may be employed. As in the prior embodiments, as well, the panel portion 322 (preferably, opposing panel portions) is recessed relative to the raised edges of the vertical panel, to protect from incidental damage any reflective sheeting 360 (see FIG. 11) which may be disposed on the panel portion surface 322 .
As shown in the FIGS. 9-11 embodiment, the top end 326 of the vertical panel 312 comprises a flange 362 having a pair of handle apertures 364 , for easy carrying of the vertical panel 312 , and a center mounting hole 366 for ready attachment of accessories. Such accessories may include a barricade light 368 , as shown in FIG. 8, which is secured to the vertical panel 312 by means of mechanical fasteners attached to the mounting hole 366 , and to a similar hole (not shown) in the light. The attachment mechanism is well known in the traffic safety product art for securing barricade lights to a variety of traffic safety products, typically barricades and traffic delineators. Other accessories might include a panel sign 370 , as shown in FIG. 12, which may be attached to the vertical panel 312 by means of mechanical fasteners 372 and 374 , wherein fastener 372 is secured to the mounting hole 366 and fastener 374 is secured to a second mounting hole extending through the vertical panel surface 322 . The sign 370 may have any desired message displayed thereon, and may preferably be comprised of a corrugated semi-rigid material, or any other suitable rigid or semi-rigid material. In one preferred embodiment, the sign 370 is 36 inches square, although other dimensions may be suitable as well.
Another significant improvement in the FIG. 9 embodiment is the employment of a foot aperture 376 , molded or cut into a bottom portion of the vertical panel surface 322 , adjacent to the bottom edge 324 of the vertical panel 312 . This foot aperture has been found by the inventors to be a significant advantage when inserting the tab portion 316 into the slot 346 in the base 314 to assembly the vertical panel system 10 , in that it permits a user to merely place his or her foot conveniently into the aperture 376 and use downward force generated by the act of stepping down with the inserted foot to press the vertical panel 312 into the slot 346 . Without using the aperture 376 , which in preferred embodiments is approximately 3 inches high by 5 inches wide, the panel 312 must be pressed into the slot by pushing downwardly on the top edge of the panel 312 using the arms. As the insertion forces necessary to complete the assembly are quite high, this can be a tiring procedure.
In a particularly preferred embodiment, gussets 378 are molded in the vertical panel surface 322 adjacent to each side edge of the aperture 376 . These gussets comprise raised portions or ridges, relative to the remaining vertical panel surface 322 , which provide strength at the bend point.
Still another preferred feature is the employment of a plurality of stacking lugs 380 on each edge of the vertical panel 312 , for assisting in stacking a plurality of vertical panels 312 together. Protruding stacking lugs on one side of each of the vertical panels engage complementary recesses on opposing sides of adjacent stacked vertical panels to thereby engage the vertical panels to one another, thus decreasing slippage of the stacked vertical panels relative to one another.
With respect to FIG. 9, in particular, the base 314 is an improved version of the bases shown in previous embodiments, in that carrying handles 382 have been molded or cut into opposing edges thereof. The base 314 is preferably molded of recycled rubber, such as crumb rubber, in order to reduce costs and to be environmentally responsible. However, Applicants have found that the use of crumb rubber in the vicinity of the slot 346 is not ideal, because it is much more prone to wear and tear (erosion) over time, shortening greatly the useful life of the base because the erosion will ultimately be too great to permit a proper friction/compression fit between the base and tab 316 . Accordingly, Applicants have developed an innovative solution whereby a zone 384 of virgin vulcanized rubber is insert-molded into the crumb rubber base during the fabrication process. The slot 346 is then formed in the vulcanized rubber zone, providing reinforcement from wear and tear due to repeated panel separation. In presently preferred embodiments, the base 314 is fabricated in two weights—28 pounds and 43 pounds.
Still another innovative feature is the employment of four raised anti-rotational foot pads 386 (FIG. 8) on the lower surface of the base 314 , to minimize movement from wind, or turbulence from passing vehicles. This is particularly important in the case of vertical panels, where it is important to maintain a zero degree orientation relative to passing traffic. Preferably, these feet 386 are molded into the extreme corners of the base, and may comprise in one preferred embodiment a size of three inches in diameter and ¼inch in height.
The vertical panels illustrated in the drawings are merely representative of the various shapes, sizes, and configurations which fall within the scope of the claimed invention. For example, vertical panel systems may be offered in various sizes, such as 36 inch ×8 inch, 24 inch ×12 inch, 24 inch ×8 inch, or 29 ½inch ×12 inch, and may be utilized in combination with different sized bases (such as the 28 and 43 pound bases which are presently preferred). Additionally, the reflective sheeting on the panel face may cover some or all of the available surface, depending upon application. As an alternative to the illustrated striped pattern, a vertical panel may accommodate a display sign, with a message for passing motorists.
Although presently preferred embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that many variations and/or modifications of the basic inventive concepts herein taught, which may appear to those skilled in the pertinent art, will still fall within the spirit and scope of the present invention, as defined in the appended claims. | A vertical panel system comprises a vertical panel having a panel with opposing first and second panel surfaces and a base edge. The system further comprises a base having a slot for engaging the base edge of the panel. An aperture is disposed in the panel in proximity to the base edge, which is of sufficient size to receive a foot of a user, for assisting in the engagement of the panel and the base. The base for the vertical panel system comprises a center zone fabricated of vulcanized rubber, and an outer zone fabricated of recycled rubber. The slot is disposed in the center zone. Thus, the combination solves a need to be environmentally responsible and cost effective by recycling rubber which would otherwise fill our landfills, yet provides increased durability by using virgin vulcanized rubber in the zone of the base which includes the engagement slot. |
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to plow blades for snow plows, earth working devices, and the like, and more particularly to a plow blade having carbide inserts along the bottom forward edge of the plow blade for improved impact and wear resistance.
[0003] 2. Background
[0004] Graders and snowplows are both well known and each has a relatively long moldboard which extends generally laterally of the surface being worked and is moved over the surface in a direction generally perpendicular to the length of the moldboard. Such support members are typically concave on the forward side and adapted for mounting beneath or in front of a power device, such as a truck or tractor. Such plows also typically include a detachable blade which may be attached, typically by bolting, to the lower edge of the support member so as to project downwardly from the support member. Such blades normally withstand most of the impact and abrasive wear to which the plow blade is subjected and as a result are typically made from a quality grade of steel. A lower edge of the blade forms the working surface of the blade.
[0005] Grader blades made of steel have the advantage of being relatively inexpensive, but also the disadvantage of wearing out extremely rapidly. Because blade edges are subjected to abrasive wear and impact damage, the wear rate can be extremely high at times. When a blade edge wears down beyond a predetermined point, it must be replaced with another blade edge. The replacement of blade edges is, of course, time consuming, represents down time for the equipment, and requires the maintenance of a replacement parts inventory. If a worn blade edge is not replaced, wear at the lower edge of the blade edge would continue until the support member suffers damage by exposure to the surface being worked on.
[0006] Thus, over the years, various techniques, such as impregnation and hardfacing of the blade cutting edge with carbide particles, and attachment of cemented carbide inserts into or onto the blade edge have been employed in attempting to prolong the life of the steel blade.
[0007] Blades with cemented carbide inserts, generally referred to as buttons in the industry, have a compact cylindrical shape. These compact inserts are disclosed in U.S. Pat. No. 5,813,474, for instance. The compact insert in FIG. 4 of U.S. Pat. No. 5,813,474 is at one end generally semispherical and at the other end has a blunt stepped section 46 . The semispherical section is more resistant to impact damage. In FIG. 2 of '474, a drilled hole in the steel blade body 24 with a compact insert 16 brazed therein is illustrated. As is shown at 38 in U.S. Pat. No. 5,813,474, the bottom of the drilled bore was drilled out by a standard drill bit and is conical. Braze material is placed into the drilled out bores and, next, the compact button is inserted into the bore and then the blade is heated, forming a braze between the compact button and the steel body. The bore does not cooperate with the compact insert like-a-glove, as seen in FIG. 2 of '474. At the bottom of the bore a generally conical space remains after insertion of the compact insert. This remaining conical space is filled with braze material. In this prior art design after the brazing process is complete, voids are much more likely to be present in this conical space in comparison to tight fitting members. Efforts at solving this problem in the industry have included manufacturing the bores with an end mill that forms a cylindrical bore having a flat circular bottom and have been successful in forming a tighter fit between the compact inserts and bores. Although successful in preventing the propensity of voids in the connecting braze, cutting out the bore with an endmill is a much more expensive and more time consuming machining operation in comparison to drilling out the bores with a standard drill.
[0008] The use of protruding lane marker reflectors on highways has grown significantly in popularity over recent years. These lane markers are typically attached to the road surface and extend slightly above the road surface. While these reflectors greatly improve lane visibility, they present a problem when the road must be plowed. When typical prior art carbide block/bar inserts within prior art blade edges impact the reflector lane markers, the carbide block/bar inserts, which are more susceptible to impact damage than steel, are sometimes damaged. Furthermore, because such prior art carbide block inserts are typically brazed adjacent to each other, carbide inserts adjacent to the damaged insert are susceptible to crack propagation damage. The same type of damage may also occur when such typical prior art carbide block inserts strike irregularities in the road surface, such as potholes or ruts.
[0009] In prior art blades, uniform cemented tungsten carbide bar inserts have been employed on blades to reduce and limit damage to the steel blades. Such blades are disclosed in the sales brochure “Kennametal snowplow blades and accessories” (1995), published by Kennametal Inc., AM95-17(5)F5. The cemented tungsten carbide bars are aligned side by side across the width of the blade. Steel blade edges having cemented wear resistant hard metal carbide block/bar inserts distributed along the lower edge of the blade edge have been employed in an attempt to prolong the life of the blade edge. Other examples of such block/bar inserts are disclosed in U.S. patents to Stephenson et al. (U.S. Pat. No. 3,934,654) and Stephenson (U.S. Pat. No. 3,529,677). The tungsten carbide bars/blocks brazed onto the steel body are positioned side-by-side across the width of the blade and are brazed to each other at their sides. A cemented tungsten carbide bar on these prior art blade designs would sometimes fracture/crack on account of an unusually large impact force. The crack in a cemented tungsten carbide bar of the prior art often was not limited to just a single bar, but would propagate into bars adjacent thereto along large portions of the width of the blade.
[0010] Generally speaking, the use of the two sets of tiered cemented tungsten carbide inserts in the bottom edge of a grader blade is known, for instance, in U.S. Pat. No. 4,770,253, to Hallissy et al. The blade in the front recess in Hallissy is made from tungsten carbide having a high cobalt content, 18%-22% cobalt by weight, so as to adapt it for impact wear resistance during use of the grader blade. The intermediate slot contains a second insert composed of cemented tungsten carbide containing 10% to 13% weight percent cobalt. The inserts are brazed to the steel blade body including the intermediate and rear sections thereof. However, in contrast to the construction of the grader blade of the present invention, the prior art Hallissy grader blade has tiered inserts and does not have an independent intermediate slot spaced from the front recess, with the inserts respectively disposed in the recess and the slot. In the present invention the front recess is formed along the forward bottom edge of the blade, whereas the intermediate slot is formed along and opens toward the bottom edge of the blade and is separated from the front recess of the steel blade body. In Hallissy '253 and other prior art, the cemented tungsten carbide bars are brazed together in side-by-side relation. These brazed together tungsten carbide bars function to form a unitary piece of cemented tungsten carbide that spans the width of the blade. If one of the cemented tungsten carbide inserts fractured due to an excessive impact force, a crack would propagate into adjacent carbide inserts across the connecting braze joints.
[0011] In the above discussed tiered insert designs, as shown in U.S. Pat. No. 4,770,253, the rearline row of insert bars is brazed into a recess in the steel blade and the frontline of insert bars is brazed onto the rearline row of inserts. The brazing together of the frontline and rearline inserts results in an inherent disadvantage in tiered insert designs. Whenever a front line insert is pried off, for instance by contact with an obstruction on the road whenever the vehicle is placed in reverse, the adjoining rear line insert typically is knocked off together with the front line insert. Not only is the loss of two insert bars of tungsten carbide expensive, the less wear resistant steel portion of the blade becomes exposed.
[0012] The use of the two lines of hard material spaced apart from each other along the bottom edge of a grader blade is also known in the prior art, Kengard A grader blade made and sold by Kennametal, see sales brochure “Kengard A grader blades,” Kennametal Inc., Latrobe, Pa., publication B84-19(5)A4;B83-145 (1983) discloses spaced hard material inserts. This prior art Kengard A grader blade has a front recess, and an intermediate slot spaced from the front recess, with the inserts respectively disposed in the recess and the slot. The front recess is formed along the forward bottom edge of the blade, whereas the intermediate slot is formed along and opens toward the bottom edge of the blade. The slot is defined between and spaced from the front recess and a rear surface of the blade by intermediate and rear bottom end sections of the steel blade body. The front recess contains a first insert composed of Kengard A material, a metal composite of tungsten carbide particles in a matrix of tough, work-hardening stainless steel. The intermediate slot contains a second line of inserts composed of cemented tungsten carbide containing 10 to 13 weight percent cobalt. The inserts are brazed to the steel blade body. However, the prior art Kengard A grade blade of such construction frequently experienced binder washout between the carbide particles in the composite metal matrix, braze failure due the inherent porosity of the matrix, and overall was not cost effective. The grader blade construction of the present invention eliminates these problems.
[0013] While many of these prior art blades would appear to operate reasonably well under the limited range of operating conditions for which they were designed, most seem to embody one or more shortcomings in terms of complexity, performance, reliability and cost effectiveness which make them less than an optimum design. Consequently, a need exists for a different approach to grader blade design, one which will more adequately address the kinds of wear and forces encountered by the lower end of the grader blade.
SUMMARY OF THE INVENTION
[0014] The present invention provides a grader blade designed to satisfy the aforementioned needs. The blade of the present invention is based on two sets of cemented carbide principle—the one forward cemented carbide for face wear resistance primarily to impacts and the other rearward cemented carbide for downpressure wear resistance. In particular, the blade of the present invention has a bottom edge with a forward portion thereof incorporating a pair of elongated cemented carbide inserts. A frontline of inserts is composed of, for instance, a cemented carbide composition of high cobalt content adapting it for impact wear resistance and a rear one of compact buttons is composed of, for instance, a cemented carbide composition of lower cobalt content adapting it for downpressure wear resistance.
[0015] Another object of the invention is to separate the cemented tungsten carbide block/bar inserts from each other by positioning a steel alloy spacer/shim therebetween, reducing the potential for impact damage cracks formed on the edge of the blade propagating along the width of the blade to other cemented tungsten carbide bars.
[0016] In the present invention, the compact inserts have a convex end that is inserted into a bore formed into the steel body of the blade with a standard drill bit. The convex end more closely approximates the conical inner end of the blind bore and significantly lessens the possibility of voids in the braze between the blade steel body and compact insert.
[0017] In an alternative embodiment, the improved blade edge comprises an edge body having a lower edge with a recess and separate slot in the bottom surface of the edge. Within the blade recess and blade slot are positioned generally cylindrical inserts separated by notched spacer means made from a ductile material.
[0018] These and other advantages and attainments of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings wherein there is shown and described an illustrative embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] While various embodiments of the invention are illustrated, the particular embodiments shown should not be construed to limit the claims. It is anticipated that various changes and modifications may be made without departing from the scope of this invention.
[0020] [0020]FIG. 1 is a front view of a blade constructed according to the present invention.
[0021] [0021]FIG. 2 is bottom view of the blade illustrated in FIG. 1.
[0022] [0022]FIG. 3 is an enlarged view of the circled section of the blade shown in FIG. 2.
[0023] [0023]FIG. 4 is an enlarged partial cross sectional view of the one circled section of the blade shown in FIG. 1.
[0024] [0024]FIG. 5 is a cross-sectional view of the blade taken along lines 5 - 5 shown in FIG. 1.
[0025] [0025]FIG. 6 illustrates a front view of second embodiment of the present invention.
[0026] [0026]FIG. 7 is bottom view of the blade illustrated in FIG. 6.
[0027] [0027]FIG. 8 is an enlarged view of the circled section of the blade shown in FIG. 6.
[0028] [0028]FIG. 9 illustrates a bottom view of a third embodiment of the present invention.
[0029] [0029]FIG. 10 is an enlarged view of the circled section of the blade shown in FIG. 9.
[0030] [0030]FIG. 11 illustrates a front view of a fourth embodiment of the present invention.
[0031] [0031]FIG. 12 is bottom view of the blade illustrated in FIG. 11.
[0032] [0032]FIG. 13 is an enlarged view of the circled section of the blade shown in FIG. 12.
[0033] [0033]FIG. 14 is an enlarged view of the one circled section of the blade shown in FIG. 11.
[0034] [0034]FIG. 15 illustrates a bottom view of a fifth embodiment of the present invention.
[0035] [0035]FIG. 16 is a cross-sectional view taken along lines 16 - 16 in FIG. 14.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0036] The present invention generally relates to blades for graders, snowplows and the like and, more particularly, is concerned with a grader blade which incorporates a pair of rows of inserts adapting its bottom forward edge for improved impact and downpressure wear resistance.
[0037] One embodiment of the plow blade invention is shown in FIGS. 1 - 5 . The plow blade 10 includes a plurality of openings 12 for receiving bolts or other connecting means to fix the blade to the blade support mold. While any suitable bolts may be used, the bolts may be in the form of plow bolts in which the heads are substantially flush with the working side of the blade and provide substantially no obstruction to the sliding of material over the edge front work surface of the blade edge. The use and spacing of such bolts with self-locking nuts are generally known in the art and will not be discussed in further detail here. The blade 10 is connected to a support mold board, having a member front work surface up to 18 feet long or longer and can be mounted beneath or in front of a power device such as a truck or tractor. The configuration of the front surface of a support member may be concave, flat, partially flat and partially concave, or may have any other suitable or desired configuration.
[0038] A support member for the blade 10 is typically mounted so that the length of the support member is generally parallel to the surface being worked on and is typically moved along the surface being worked on in a direction generally perpendicular to the length of the support member. Additionally, the support member is typically mounted such that it can be raised and lowered relative to the surface and tilted relative to the surface in the fore and aft direction and also in the lateral direction.
[0039] The blade has a steel body section 14 including a blade bottom edge section 16 including a bottom surface 41 generally perpendicular to the front work face of the bottom edge section. The blade body 14 may be made from any appropriate material, such as AISI 1020 to 1045 grade steel or AR 400 steel. The blade bottom edge section 16 in the embodiment illustrated in FIGS. 1 - 5 has attached thereto a plurality of hard material inserts 18 , 20 fixed thereto. The frontline inserts 20 are fixed within a recess 35 as best shown in FIGS. 3 & 5 and the rearline inserts are fixed within a plurality of holes 28 . The hard material inserts can be manufactured from cemented tungsten carbide, a diamond composite or other wear-resistant hard materials well-known in the industry. The front line inserts 20 on the forward section of the blade can be made from a different hard material than the rearline inserts. U.S. Pat. Nos. 4,715,253 and 4,715,450, for instance, disclose a frontline of insert bars being made from a cemented tungsten carbide composition with a large amount of cobalt in comparison to the rearline of bar inserts which are formed of cemented tungsten carbide with relatively less cobalt, providing for greater resistance to downward pressure. U.S. Pat. Nos. 4,770,253 and 4,715,450, both to Hallissy et al., are hereby incorporated into the specification in their entirety. Such a combination of hard materials in combination exhibits better durability than selecting just one composition for both the frontline and rearline inserts.
[0040] The rearline insert bars positioned into the slot in this prior art design, as discussed above, are made from a cemented tungsten carbide material with a lower percentage of cobalt so as to be more resistant to downward forces which, however, also makes it more brittle and likely to fracture. Fractures in brittle material also have a greater propensity to propagate. These fractures often propagate into and along adjacent bars brazed thereto resulting in catastrophic failure. The inserts on the frontline are made from a tougher, more ductile material with a higher percentage of cobalt in comparison to the rearline inserts and are not as likely to fracture and/or propagate said fracture. Accordingly, the present invention addresses this particular problem with brittle rearline inserts by using generally cylindrical compact inserts 18 for the rearline inserts. In FIG. 4 of the invention the compact inserts 18 are shown positioned in bores 28 drilled in the bottom section 16 of the blade body. In the present invention, the rearline inserts are not brazed together but are separated from each other by sections of the bottom edge section of the steel body 14 . In the present invention, whenever a fracture occurs in a rearline insert 18 , a crack will not propagate into the next closest rearline insert. The crack will dissipate at the boundary between the bottom edge section 16 of the steel body 14 and rearline insert 18 . The steel body 14 is made of a ductile steel alloy material that is less brittle than the hard material used for the rearline inserts 18 , generally cemented tungsten carbide with a low percentage of cobalt.
[0041] The bore 28 is formed by a standard drill bit creating a bore with a conical tip 29 at its most inner end 29 . While the insert holes may have any suitable configuration, the insert holes 28 in this embodiment have a generally cylindrical configuration, the typical shape in the industry. Accordingly, the hard material inserts may have any suitable configuration so long as the shape of the insert hole and hard material insert generally correspond in shape and size.
[0042] The semispherical end 19 of the rearline insert 18 is placed into the bore, in reverse fashion to the manner in which the insert is fitted into the bore in U.S. Pat. No. 5,813,474. The semispherical portion 19 more closely approximates the inner conical end 29 of the bore. The closer fit lessens the possibility of voids in the braze between the blade and inserts. While not shown, the end 19 could alternatively constitute a paraboloid, an ellipsoid or other convex configuration that more accurately approximates the inner end drill point configuration 29 of the hole. The exterior blunt end 17 of the rearline insert, it is admitted, is less resistant to impact damage than an insert having an exterior end that is convex. However, such prior art insert designs with an exterior end having a convex surface, as illustrated in U.S. Pat. No. 5,813,474, quickly flatten during blade use and become similar in shape to the exterior end 17 of the present invention.
[0043] In addition to the benefit of reducing voids in the braze by placing the convex end of the insert into the hole, an added benefit in assembly is also achieved. During assembly, it is easier for a person to position the semispherical end of the compact insert into the bore than attempting to place the blunter opposite end of the compact insert into the hole. The semispherical shape of the hard material insert helps self-center itself as it is manually positioned into the bore for brazing. In contrast to positioning the blunt end of the insert into the bore, see U.S. Pat. No. 5,813,474, which requires more precise manual alignment of the compact insert with the hole before it can be inserted into the hole.
[0044] FIGS. 6 - 8 illustrate a second embodiment of the invention. As shown in FIG. 7, the rearline inserts are generally cylindrical compact inserts 18 that are placed and brazed into cylindrical bores formed into the bottom edge of the steel body. The frontline inserts 20 in the second embodiment are not however directly brazed to each other as in the first embodiment. The tungsten carbide insert bars 20 are spaced from each other by steel body spacer means 34 . Spacer means 34 and frontline insert bars 20 are brazed together in recess 35 at the very bottom corner of the front face and bottom edge of the blade 10 . The spacer means 34 are made from a ductile steel alloy similar to the blade. The ductile spacer means 34 prevent crack propagation along inserts 20 . Any fracture to an insert is limited by the ductile steel spacer means and does not propagate beyond the boundary 36 formed at the interface between a spacer means and frontline insert.
[0045] FIGS. 9 - 10 disclose a third embodiment of the invention. In the third embodiment, both the frontline inserts 20 and rearline inserts 18 are cemented tungsten carbide bars separated by spacer means 34 . The spacer means 34 and bar inserts 20 are positioned in the recess 35 and brazed therein. Similarly, spacer means 34 and rearline bar inserts 18 are positioned inside a uniform slot 37 having a flat inward surface parallel to the bottom surface 41 of the blade, the slot 37 that spans the width of the blade and brazed therein. The center of the rearline insert bars is positioned directly behind the spacer means 34 in the frontline. It is believed that such an arrangement is likely to assist in reducing undesirable washout, as discussed below with respect to a similar embodiment shown in FIGS. 11 - 14 .
[0046] FIGS. 11 - 14 and 16 illustrate a fourth embodiment of the invention. In the fourth embodiment of the invention, generally cylindrical compact inserts are employed for both the frontline inserts 120 and the rearline inserts 118 . Spacer means 134 having semispherical notches at both ends are adapted to receive the inserts 118 and 120 . The tungsten carbide insert bars 120 are spaced from each other by steel body spacer means 134 . Spacer means 134 and frontline cylindrical inserts 120 are positioned in a recess 135 at the bottom of the front work face that forms a corner with the bottom edge of the blade 110 and brazed together onto the blade steel body 114 .
[0047] The uniform slot 137 and recess 135 , as illustrated in FIG. 16, both have a flat inward surface 138 parallel to the bottom surface 141 of the blade that spans the width of the bottom edge of the blade steel body. The spacer means 134 and inserts 118 are inserted within the slot 137 and recess 135 . The spacer means 134 and rearline cylindrical inserts 120 are positioned and brazed together into the slot 137 or recess 135 . This assembly method of placing inserts and spacer means into a slot and/or recess that spans the width of the blade is less expensive than drilling blind holes and manually inserting rearline cylindrical inserts into each bore.
[0048] An additional benefit to this method of assembly is that the compact inserts are not inserted into drilled out blind holes, but along with the spacers are placed into a slot having a flat horizontal inward bottom surface as illustrated in FIG. 16. The blunt end 117 of the insert 118 can be placed into the slot or recess into cooperation with the flat horizontal inward surfaces 138 / 139 . The blunt end 117 of the insert forms better contact with a flat inward surface 138 / 139 than the blunt surface does with the prior art inward conical shape of drilled out blind bores as discussed above. This more closely corresponding fit enables for improved brazing and precludes the braze void problem with drilled out blind bores. In this embodiment it is not necessary to reverse the orientation of the cylindrical compact insert 18 as discussed above to preclude voids. Accordingly, the convex 19 portion of the insert 18 can be oriented outward for improved impact resistance.
[0049] The frontline inserts 120 are uniformly spaced apart along the width of the blade. Gaps of uniform size accordingly span the width of the blade. During operation of the blade, material/snow flows around the inserts through the gaps, causing the steel body material within the gaps to wear “wash out” at a greater rate than accompanying steel on the bottom surface of the blade. The rearline inserts 118 are centrally positioned to help plug these high flow areas and redisperse the material/snow flow helping reduce accelerated “wash out.”
[0050] [0050]FIG. 15 shows a fifth embodiment of the invention that has only one row of hard material wear inserts across the width of the blade. The embodiment shown in FIG. 15, similar to the embodiments shown in FIGS. 7 and 9, includes hard material insert bars 20 . The insert bars 20 are spaced from each other by steel body spacer means 34 . Similar to the embodiment discussed above, the ductile spacer means 34 prevent crack propagation along inserts 20 . In addition, such a design is easier to manufacture and assemble than the single row compact insert blade shown in U.S. Pat. No. 5,813,474. The design shown in U.S. Pat. No. 5,813,479 requires more extensive machining and tooling to form the plurality of holes for receiving the compact inserts. The compact inserts in such a single row blade can be made from a cemented metal carbide, such as tungsten carbide, of a tough grade used in prior art blade designs. More specifically, the inserts 16 are believed suitable if made from a high shock WC grade of tungsten carbide having an 11% to 12.5% cobalt content. U.S. Pat. No. 5,813,474 is herein incorporated in its entirety.
[0051] In the prior art, cemented tungsten carbide bars that are positioned side-by-side with only braze separating them function to form a unitary piece of cemented tungsten carbide that spans the width of the blade. The embodiment of the present invention incorporates hard material inserts that are separated by ductile steel alloys and then brazed together. The ductile spacer means between the hard inserts minimizes the potential for damage to the blade by isolating fractures.
[0052] While particular embodiments of the invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from this invention. It is intended that the following claims cover all such modifications and all equivalents that fall within the spirit of this invention.
[0053] All patents and patent applications cited herein are hereby incorporated by reference in their entirety.
[0054] It is thought that the grader blade of the present invention and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts and steps thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely a preferred or exemplary embodiment thereof. | The present invention provides for carbide edge snowplow and grader blades that are durable and fracture resistant. The carbide along the blade edge and blade bottom which contacts the surface being treated is designed to limit the degree of fracture of the carbide. Carbide inserts along the edge and/or bottom are separated from each other by a steel alloy spacer/shim along the width of the blade. The spacer/shim reduces the potential for impact damage cracks that form in a carbide insert from propagating into adjacent inserts along the width of the blade. In one embodiment, the improved blade edge comprises an edge body having a lower edge with a recess and separate slot in the bottom surface of the edge. Within the blade recess and blade slot are positioned carbide block/bar inserts separated by spacer means made from a ductile material. |
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TECHNICAL FIELD
This invention relates to a hybrid dump bailer for use in a wellbore, and a method of using a hybrid dump.
BACKGROUND OF THE INVENTION
In subterranean wells, such as oil and gas wells, there are occasions when material, such as cement slurry or other chemicals, need to be introduced into the well bore. One common example is the introduction of cement slurry into a well bore to seal the well bore or the introduction of cement slurry above a bridge plug to seal off a section of the well bore. This is typically accomplished by what is commonly known in the industry as a dump bailer. Dump bailers are introduced or carried into a subterranean well on a conduit, such as wire line, electric line, continuous coiled tubing, threaded work string, or the like, and discharge or “dump” the cement slurry into the well bore.
There are two general types of dump bailers: (1) gravity feed bailers and (2) positive displacement bailers. Gravity feed dump bailers are some of the most commonly used dump bailers in the industry. One reason for this is its simplicity. However, gravity dump bailers present many drawbacks. Chief among them is the possibility of “stringing,” which occurs when the cement slurry does not completely discharge at the desired depth and the cement slurry is strung out through the well. Additionally, most gravity dump bailers include a seal, such as a ceramic disk, that is broken to allow the cement slurry to flow. The seal can be broken by a pin or, more frequently, shattered by an explosive charge. Positive displacement dump bailers address many of the deficiencies of the gravity dump bailers by elimination of the explosive charge and by providing force to expel the cement slurry out of the bailer.
There are several types of positive displacement dump bailers. Most positive displacement dump bailers rely on a sweep piston use to force the cement slurry or material out of the bailer. These systems may use a weight, either alone or with some actuating system, to force the piston down the bailer or the systems may use the pressure differential between atmospheric (well bore) pressure and the internal tool pressure to push the piston down the length of the bailer. While the positive displacement bailers overcome many of the deficiencies of the gravity dump bailers, they have several drawbacks. One of the main drawbacks is the use of bailer tubes, which hold the cement slurry. Because the sweep piston is forced through the bailer tubes, the bailer tubes must have a consistent inner diameter with a smooth wall bore to prevent the sweep piston from becoming lodged in the bailer tube and to reduce the friction between the pipe wall and the cement slurry. Additionally, because multiple bailer tubes are typically used, care must be taken not to damage the threaded connections. If the threaded connections are over tightened, the inner diameter of the bailer tube could neck down, causing the sweep piston to hang up.
Therefore there exists to address the shortcomings of the current art exists.
BRIEF SUMMARY OF THE INVENTION
In one aspect, the present invention utilizes a hybrid dump bailer for use in introducing material, such as cement slurry, into a well bore. The hybrid dump bailer includes a tool body having a longitudinal tool bore; at least one bailer tube; the bore including a piston with a seal rod and a pressure pulse piston with a connector rod and collet, wherein the collet has been configured to receive the seal rod; and a lower connection mechanism for connecting the tool body to bailer tubes. The dump bailer also includes a piston spring and a pressure pulse piston spring used to move the piston and pressure pulse piston.
Preferably, the hybrid dump bailer includes a head space above the piston and also includes a passageway, wherein the passageway is configured to allow fluid communication between the head space and tool body.
It is preferred that the hybrid dump bailer include a fluted connector, wherein the fluted connector and the lower tandem sub limits the travel of the pressure pulse piston.
It is also preferred that the hybrid dump bailer also includes a solenoid valve, wherein the solenoid valve can be remotely opened to allow fluid communication between the headspace and the upper solenoid housing.
In this aspect of the invention, the hybrid dump bailer also includes a plug, wherein the plug is secured in the bailer cage by a shear pin.
In another aspect, the present invention hybrid dump bailer includes a tool body having a longitudinal tool bore. The tool body also includes a top contact sub, a solenoid valve housing, a solenoid valve base, an inflow housing, a metering collet sub, a pressure chamber, a lower tandem sub, and a lower piston housing at least one bailer tube. The bore includes a piston with a seal rod and a pressure pulse piston with a connector rod and collet, wherein the collet has been configured to receive the seal rod; and an lower connection means for connecting the tool body to bailer tubes.
Preferably, the hybrid dump bailer also includes a piston spring and a pressure pulse piston spring.
It is also preferred that the hybrid dump bailer also includes a head space above the piston and a passageway through the solenoid valve base, wherein the passageway is configured to allow fluid communication between the head space and solenoid valve housing.
This aspect of the invention also includes a fluted connector, wherein the fluted connector and the lower tandem sub limit the travel of the pressure pulse piston.
It is also preferred that the hybrid dump bailer also includes a solenoid valve, wherein the solenoid valve can be remotely opened to allow fluid communication between the headspace and the upper solenoid housing.
The hybrid dump bailer also includes a plug, wherein the plug is secured in the bailer cage by a shear pin.
It is also preferred that the hybrid dump bailer where in the top contact sub, solenoid valve housing, solenoid valve base, inflow housing, metering collet sub, pressure chamber, lower tandem sub, and lower piston housing are connected by a threaded connection; however other connections such as welded connections are contemplated.
In another aspect, the invention provides a resetting tool for a hybrid dump bailer, which includes an inlet valve; a relief valve; a compression piston; and a compression rod.
Further aspects of the invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts one embodiment of the hybrid bailer of this invention in the ready to run position;
FIG. 1A schematically depicts a close up view of the contact sub and solenoid housing of the hybrid dump bailer of this invention;
FIG. 1B schematically depicts a close up view of the solenoid valve base and the inflow housing of the hybrid dump bailer of this invention;
FIG. 1C schematically depicts a close up view of the metering sub and pressure pulse chamber of the hybrid dump bailer of this invention;
FIG. 1D schematically depicts a close up view of the tandem sub and lower pressure pulse chamber of the hybrid dump bailer of this invention;
FIG. 1E schematically depicts a close up view of the lower sub and the bailer cage of the hybrid dump bail of this invention;
FIG. 2 schematically depicts one embodiment of the hybrid dump bailer of this invention after the tool has been run;
FIG. 3 shows a typical gel strength v. time curve for a cement slurry;
FIG. 4 schematically depicts the hybrid dump bailer and resetting tool of this invention; and
FIG. 5 schematically depicts the hybrid dump bailer and resetting tool of this invention once the tool case has been reset with the resetting tool.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, “a” or “an” means one or more than one. Additional, distal refers to the end of the element closest to the setting mandrel of the setting tool and proximal end refers to the end of the element closest to the firing head of the setting tool.
The methods and apparatus of the present invention will now be illustrated with reference to FIGS. 1 through 5 . It should be understood that these are merely illustrative and not exhaustive examples of the scope of the present invention and that variations which are understood by those having ordinary skill in the art are within the scope of the present invention.
Turning now to FIG. 1 , which shows hybrid bailer 100 loaded and energized to discharge cement slurry into a well bore. While this example will discuss the discharge of cement slurry into the well bore, it is also contemplated that the hybrid dump bailer 100 could be used to deposit other material such as sand and chemicals. The hybrid dump bailer 100 includes a tool body made up of top contact sub 10 , solenoid valve housing 20 , solenoid valve base 30 , inflow housing 40 , metering collet sub 51 , pressure pulse chamber 50 , lower tandem sub 60 , and lower piston housing 70 . Bailer tubes 81 , bottom sub 80 , and bailer cage 90 are also connected to the tool body to complete to hybrid dump bailer. Each section will be discussed in further detail below.
The top contact sub 10 , which is shown in close-up in FIG. 1A , is connected to solenoid valve housing 20 by a threaded connection. While other connections, such as welded connections, are contemplated, the threaded connection is preferred because it allows the top contact sub to easily be removed for service or replacement. To further seal the connection, o-rings 18 are used. Polymer and copolymer o-rings such as Buna-N or nitrile rubber are preferred; however, other materials are contemplated and the selection will depend on the service conditions the hybrid dump bailers are exposed to. The top contact sub 10 includes a central bore 12 , which houses a spring 14 and a contact pin 16 . The central bore 12 is lined with an insulating material 13 , such as polyether ether ketone (“PEEK”), to prevent top contact sub 10 from becoming energized. Other electrical insulators, such as ceramics, carbon, rubbers, and plastics, can also be used. When the top contact sub 10 is fully mated with solenoid valve housing 20 , spring 14 is compressed as contact pin 16 is connected to electrical contact receptacle 21 . The force exerted by compression of the spring 14 , forces the contact pin 16 to seat within the receptacle of contact receptacle 21 thereby passing electrical current from contact pin 16 to receptacle 21 .
Electrical contact receptacle 21 is located within solenoid valve housing 20 and is surrounded by PEEK insulator 23 . As discussed above, other insulating material may be used. The receptacle is connected to brass contact 22 . A ceramic electrical feed-thru 24 is connected to brass contact 22 . Feed-thru 24 passes electrical current from brass contact 22 to flex spring contact 25 and flex spring 26 , which is in contact with solenoid valve contact 27 . Solenoid valve housing 20 also includes an opening, which is plugged by plug 29 .
Solenoid valve base 30 and inflow housing 40 are shown in close-up in FIG. 1B . Solenoid valve base 30 is connected on top side to solenoid valve housing 20 and on the bottom side to inflow housing 40 by a threaded connection. As previously discussed other connection mechanisms, such as welded connections and the like, are contemplated; however, the threaded connection is preferred. Additionally, o-rings 38 are incorporated to seal the device. Solenoid valve base 30 has recess designed to receive solenoid valve 32 , a side opening, which is plugged by plug 33 , check valve 35 , and a passageway 36 . Check valve 35 is located in a passageway that provides fluid communication between the side opening and the bottom of solenoid valve base 30 . When plug 33 is removed, fluid is allowed to pass through check valve 35 and into head space 41 , which is created by the bottom of solenoid valve base 30 , inflow hosing 40 , and piston 42 . Check valve 35 prevents flow of fluid from head space 41 through the check valve to the side opening.
Passageway 36 connects head space 41 with solenoid valve 32 . When solenoid valve actuator 31 (see FIG. 1A ) is energized, the solenoid valve 32 opens, allowing fluid to flow from head space 41 through passage way 36 and into head space 28 of solenoid valve housing 20 (see FIG. 1A ). Passageway 36 also includes a side opening 37 . When solenoid valve base 30 is completely connected to solenoid valve housing 20 , side opening 37 is sealed. Solenoid valve housing 20 can be backed off from solenoid valve base 30 , thus exposing side opening 37 to allow any pressure in head space 41 to be bled off, should, for example, solenoid valve 32 not function properly.
As shown in FIG. 1C , inflow housing 40 is connected on its other end to metering collet sub 51 via a threaded connection. As previously discussed, this is the preferred connection; however, other connections are contemplated. Inflow housing 40 also includes inflow passageway 49 . This allows this section of bailer 100 to operate at atmospheric pressure. Piston 42 , which is located within the centre bore of inflow hosing 40 , is connected to seal rod 43 . A piston spring 44 is positioned between piston 42 and metering collet sub 51 .
Metering collet sub 51 has a central bore through which seal rod 43 passes. Seal rod 43 is designed to be received and held by collet 52 . Plug 33 is removed and a fluid is pumped through check valve 35 into head space 41 . Although hydraulic fluid is preferred, other fluids such as compressed air or other gases can be used. In normal operation, the pressure in head space 41 is increased to approximately 400 psig above ambient. This pressure provides the force necessary to push piston 42 down and compress piston spring 44 , thus forcing sealing rod 43 into collet 52 .
The other end of metering collet sub 51 is connected by threaded connection to pressure pulse chamber 50 . In addition to collet 52 , pressure pulse chamber 50 includes upper connector rod 53 , pressure pulse piston spring 54 , collet base 55 , fluted connector 56 (see, e.g. FIG. 1 ), inflow passageways 57 (see FIG. 1D ), and lower connector rod 58 . Collet 52 is connected to upper connector rod 53 via a threaded connection. The other end of upper connector rod 53 is connected to fluted connector 56 via a threaded connection. Again, other connection means, such as a welded connection, are contemplated; however a threaded connection is preferred to allow for ease of replacement of parts and assembly of the hybrid dump bailer. Pressure pulse piston spring 54 is located between collet base 55 and fluted connector 56 . Pressure chamber inflow passageways 57 , like inflow passageways 49 , allow well bore fluid to enter bailer 100 , thus equalizing the pressure difference between the well bore and the bailer. Because the pressure chamber is open to the atmosphere and well bore fluid is in the interior, connector 56 is fluted to allow fluid to flow past the connector.
Referring to FIG. 1D , lower connector rod 58 is connected to fluted connector 56 via a threaded connection. Lower connector rod 58 passes through tandem sub 60 , which is connected on its upper end to pressure chamber 50 and on its lower end to lower piston housing 70 via a threaded connection. Again, other connections are contemplated, but a threaded connection is preferred. The bottom end of lower connector rod 58 is connected to lower pressure pulse piston 71 . Lower piston housing 70 is connected at its lower end via threaded connection to bailer tube 81 . Depending on the amount of material to be introduced into the well bore, one or more bailer tubes may be connected.
One advantage of the invention is that the bailer tubes do not have to meet the exacting standards, nor do they need to be treated with as much care, as the prior art bailer tubes. The prior art bailer tubes had to be manufactured with exacting internal diameter tolerances because small restrictions in the inner diameter could cause mis-runs in gravity bailers. Moreover, in prior art positive displacement bailers, which force a piston through the bailer tubes to dump the cement, variances in the inner diameter, can cause the piston to hang up, also causing mis-runs. Further, extra care must be taken when making up a section of bailer tubes because over torqueing the connection can cause the inner diameter to narrow at the connection. The new design of this invention is not dependent on the consistency of the inner diameter. This allows the bailer tubes to be manufactured from less expensive material and methods.
Referring to FIG. 1E , the last bailer tube 81 is connected to bottom sub 80 . Bottom sub 80 has a plug 82 . Plug 82 is attached to bottom sub 80 by shear pin 83 . Shear pin 83 can be a screw or other pin which holds the plug in pace. In the preferred embodiment, shear pin 83 is a brass screw that has a hole drilled in the center of the screw to reduce the amount of shear force necessary to shear the screw to approximately 200-250 lb F . Alternative materials, such as metal alloys and plastics can also be used as long as the shear force can be controlled. Bottom sub 80 is then connected to bailer cage 90 . Bailer cage 90 includes many openings used to direct the dump material in the well. As shown in FIG. 2 , bailer cage 90 also serves to capture plug 82 so it can be reused.
Referring back to FIG. 1 , hybrid bailer 100 is shown in the ready-to-run position. In this position, hydraulic fluid, which has been pumped into head space 41 , forces piston 42 down, compressing piston spring 44 between piston 42 and collet base 51 . Collet 52 , which receives the distal end of seal rod 43 , is a spring finger collet that grips the distal end of seal rod 43 when pressure pulse piston spring 54 is compressed between fluted connector 56 and collet base 51 . Depending on the amount of cement slurry to be dumped, a number of bailer tubes 81 containing cement slurry are attached to the lower piston housing 70 . In the preferred embodiment, a water pad of the type know in the art is placed on top of the cement slurry.
Referring to FIG. 2 , once hybrid bailer 100 is lowered into the well bore to the location were the cement slurry is to be dumped, solenoid valve 32 is opened, allowing the hydraulic fluid to flow from head chamber 41 through passageway 36 and into void space 28 of solenoid valve housing 20 , thereby relieving the pressure in head chamber 41 . This allows spring 44 to push piston 42 up, thereby disconnecting rod 43 from collet 52 . Once rod 43 is disconnected from collet 52 , spring 53 then forces fluted connector 56 down, thereby accelerating pressure pulse piston 71 . As pressure pulse piston 71 accelerates it strikes the water pad creating a pressure pulse, or shock wave, that is transmitted to the cement slurry. The pressure pulse creates a force that shears shear pin 83 , there by freeing plug 82 , which travels to and is contained by the bottom of bailer cage 90 .
Once the cement slurry is mixed and added to the bailer tubes, the cement slurry begins to gel. This is due to a number of factors including: (1) the ionic charges from the various slurry components; (2) the density of the slurry; (3) the slurry remaining static in the bailer tubes; (4) the elevated temperatures and pressures the slurry is subject to prior to dumping; and (5) the long time delay between the time the slurry is mixed and the time it is dumped. Once the cement slurry begins to gel, it becomes static has a tendency to remain static. Thus, once the cement slurry gels, it resists flow. In gravity and positive displacement bailers, this is one of the most common causes of mis-runs and stringing of cement in the well bore. FIG. 3 shows a predicted cement slurry gel strength time curve. As shown in the time curve, once the cement slurry is mixed and poured into the bailer tube, it begins to quickly gain gel strength while the bailer is run in the well bore. It may take upwards of two hours from the time the cement is mixed before it is dumped into the well bore. Thus, to guarantee that the cement slurry will flow out of the dump bailer, pressure pulse piston 71 must create sufficient force to break the cement slurry gel. Once the gel is broken, the cement slurry has favorable rheological properties, allowing the cement slurry to flow out of bailer cage 90 . FIG. 3 shows that once hybrid bailer 100 is dumped, the shock wave breaks the gel causing the gel strength to quickly drop. Once the cement slurry is in the well casing, it once again becomes static and the gel strength rapidly increases until the cement is set.
Once hybrid bailer 100 has dumped the cement slurry into the well bore, it is raised to the surface and bailer tubes 81 are removed. Bailer cage 90 is also removed, cleaned, and plug 82 is recovered and shear pin 83 is removed. Plug 82 is then inspected and, if there is no damage, it is reinstalled in bailer cage 90 using a new shear pin 83 . Bailer tubes 81 are cleaned and inspected. Depending on the amount of cement slurry to be dumped, additional bailer tubes may be added or removed and the bailer tubes can then be refilled with cement slurry and a water pad.
Referring to FIG. 4 , hybrid bailer 100 is now reset by attaching lower piston housing 70 to resetting tool 200 . Resetting tool 200 includes inlet valve 205 , relief valve 210 , compression rod 220 , and compression piston 225 . Compression rod 220 is connected to compression piston 225 on one end and has a notch that mates with the bottom of pressure pulse piston 71 . Referring to FIG. 5 , after resetting tool 200 is attached to the bailer, relief valve 210 is closed and inlet valve 205 is opened, allowing a high pressure fluid to be introduced into resetting tool 200 . This fluid can be high pressure water, air, or any other fluid with sufficient pressure to force lower piston 71 up, thereby compressing pressure pulse piston spring 54 between connector 56 and collet base 55 . Once pressure pulse piston spring 54 has been compressed, plug 33 is removed. A solenoid valve 32 , which is normally closed, is energized to open so the hydraulic fluid can be pumped into head chamber 41 forcing piston 42 down, thereby compressing piston spring 44 and forcing rod 43 into collet 52 . Once head chamber 41 is charged, plug 33 is replaced, inlet valve 205 is closed, and resetting tool 200 is removed. Once removed, relief valve 210 is opened to relieve the pressure in resetting tool 200 . Finally, the bailer tubes can then be reattached and hybrid bailer 100 is ready to run again. | A hybrid dump bailer is disclosed herein comprising a bailer tubes for containing a material, such as cement slurry, to be dumped. The hybrid dump bailer comprises a pressure pulse piston that is accelerated by a spring causing a pressure pulse to expel the material to be dumped. The hybrid dump bailer further comprises a collet, a retaining rod, a piston, valve, and a supply of pressurized fluid which is holds the pressure pulse piston in place while the spring is compressed. Once the valve is opened, releasing the pressurized fluid, the retaining rod separates from the collet allowing the pressure pulse piston to accelerate can produce the pressure pulse to dump the material. |
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This is a continuation of application Ser. No. 07/447,301 filed Dec. 7, 1989 now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to an electrical connector used in a well head equipment for transmitting electrical signals between the inside and the outside of the well head. Such a connector is particularly important in oil wells which are fitted with permanent sensors, e.g. temperature or pressure sensors, since it serves to feed the sensors with electrical power and to transmit the signals from the sensors to a remote point at the surface.
For the purposes of the present description, the term "well head equipment" is used to designate all of the equipment situated between the production tubing of a well and the flow line coming out of the valve assembly or "Christmas tree". This term thus covers both well head equipments which are disposed in the air and equipments which are underwater, e.g. offshore.
Well head equipments are essentially constituted by two parts: the well head and the valve assembly (or Christmas tree).
In conventional manner, electrical connections are provided through well head equipments by means of connectors comprising pins and sockets which mate with one another when the valve assembly is installed on the well head. The sockets are mounted inside the valve assembly and they are connected to the outside of the valve assembly via a sealed electrical feedthrough. The pins are mounted on the hanger from which the production tubing is suspended and they are connected to the annular space lying between the casing and the tubing via a second sealed feedthrough.
However, such a connector suffers from several drawbacks. Firstly, since it is at a distance from the axis of the well head, it is necessary for the valve assembly to be in exact angular alignment and for both axial and radial positioning tolerances to be exact when the valve assembly is put into place on the well head. In addition, insulation losses may occur in the presence of a conducting fluid such as sea water if it invades the space enclosing the connector. Finally, the connector contact is not protected from galvanic corrosion phenomena.
More recently, an article which was published in the July 1988 edition of the journal "World Oil", at pages 43-44 and entitled "Electrically Controlled Subsea Safety Valve" describes an inductively coupled electrical connection for transmitting electrical power through a subsea well head for the purpose of powering a safety valve situated in the tubing. To this end, inductive coupling is provided by means of two concentric coils both of which are placed beneath the hanger from which the tubing is suspended. An outer coil is wound around the well head, and an inner coil is wound around the tubing.
However, this inductive-coupling connection for a subsea well head also suffers from drawbacks. In this connection the outer coil is an integral portion of the fixed parts of the well head, and any repair work on the outer coil requires major disassembly of the items constituting the well head.
The object of the invention is to provide an inductive-coupling connector which avoids the above-mentioned drawbacks, which is reliable, which withstands attack from the medium in which it is immersed, and which is easy to maintain.
SUMMARY OF THE INVENTION
The present invention provides an electrical connector for transmitting electrical signals between the outside and the inside of a well having a well head surmounted by a valve assembly adapted to be releasably connected to the well head. A tubing hanger member is suspended in the well head. The valve assembly and the hanger member respectively include first and second engageable mating portions for providing fluid communication between the valve assembly and the tubing when the valve assembly is connected to the well head. The electrical connector comprises at least two electrical coils arranged on the first and second mating portions respectively with the axes of said coils being in alignment with the axis of the well head, for providing inductive coupling when said first and second mating portions are engaged. First electrically conductive means are mounted on the valve assembly for electrically connecting the first coil to the exterior of the valve assembly and second electrically conductive means are mounted on said hanger member for electrically connecting the second coil to a space of the well below the hanger member.
Preferably, the coils are disposed concentrically when the valve assembly is installed on the well head, with a first one of said coils being adapted to be inserted inside the second one of said coils.
In a particular embodiment, the first coil is wound around a tubular member fixed to the valve assembly. The second coil is wound inside a sleeve which overlies the tubing hanger. The first and second conductive means comprise electronic circuits including DC/AC and AC/DC converting means.
In another embodiment, said two coils are identical and are superposed when the valve assembly is installed on the well head.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be best understood from the following description made with reference to the accompanying drawings, in which:
FIG. 1 is a diagram of a particular arrangement of an inductive-coupling connector in a well head equipment, with the valve assembly not yet connected to the well head;
FIG. 2 shows the same items as FIG. 1, except that the valve assembly is connected to the well head; and
FIG. 3 is a block diagram of an electronic circuit associated with the inductive-coupling connector.
DETAILED DESCRIPTION
With reference to FIGS. 1 and 2, a well head equipment essentially comprises a valve assembly 10 which is fixed in sealed manner on a well head 20 by means of a releasable locking assembly 13 and a sealing ring 18.
In conventional manner, the well head 20 is adapted to receive a casing hanger 21 for suspending the top end of a casing 30. Similarly, the casing hanger 21 is adapted to receive a tubing hanger 22 for suspending the top end of a production tubing 40. Sealing is provided firstly between the well head 20 and the casing hanger 21 and secondly between the hangers 21 and 22 by respective sealing rings 23 and 24.
The valve assembly 10 is fitted with valves 11 (with only one valve 11 being shown) for controlling the fluid flow from the well through the main duct 14. The bottom portion of the valve assembly 10 includes a bore 12 countersunk in the main duct 14 and receiving in sealed manner the top end of a tubular member 15 provided with sealing rings 16. The bottom end of the fluid connector member 15 is also provided with sealing rings 17 and is adapted to engage in sealed manner a mating portion of the tubing hanger 22 having a bore 25 therein. The tubular member 15 and the corresponding portion of the tubing hanger 22 are mating portions of a fluid connector for providing communication between the tubing and the valve assembly when the valve assembly is connected to the well head.
In accordance with the invention, the electrical connector comprises at least two coils 1A and 5A whose winding axes coincide with axis zz' of the well head 20, and which are fixed to the fluid connector mating portions on the valve assembly 10 and the tubing hanger 22 respectively.
In a particular embodiment of the invention, the inductive-coupling connector comprises firstly two electrical coils 1A and 1B wound around a first sleeve 1 which is fixed to the fluid connector tubular member 15, and secondly two electrical coils 5A and 5B wound inside a second sleeve 5 which is removably fixed to the top end of the tubing hanger 22.
When the valve assembly 10 is installed on the well head 20, the sleeve 1 is received in the sleeve 5 in such a manner that the coils 1A and 5A are disposed concentrically facing each other with a clearance of 2 mm therebetween, as are the coils 1B and 5B.
The winding of each coil is received in a groove which is at least partially coated in a highly ferromagnetic material such as ferrite. In addition, it is desirable to embed the windings in a sealing material which withstands pressure, temperature, and corrosion, e.g. an elastomer or a silicone-based resin.
The outputs from the coils 1A and 1B are connected to respective conventional sealed feedthroughs 2A and 2B which are connected in turn via conductors 3A and 3B to electronic circuits received in sealed boxes 4A and 4B situated on the outside of the valve assembly 10. These electronic circuits are described below with reference to FIG. 3.
Similarly, the outputs from the coils 5A and 5B are connected to second electronic circuits received in sealed boxes 6A and 6B located in the tubing hanger 22. The electronic circuits located in the boxes 6A and 6B are connected to sealed feedthroughs 7A and 7B which lead to conductors 8A and 8B situated in the annular space between the casing 30 and the tubing 40. The conductors 8A and 8B are connected to sensors (not shown) down the well.
The inductive-coupling connector as described above has the particular advantage of avoiding the need to position the valve assembly 10 accurately relative to the well head 20 while being put into place. It therefore constitutes a quick action electrical connector which is centered on and fully integrated with the fluid connector between the tubing hanger 22 and the valve assembly 10. In addition, the maintenance of such an electrical connector is facilitated by the fact that the coils 5A and 5B fixed to the tubing hanger are easily removable from the well head.
FIG. 3 is a block diagram showing the electronic circuit associated with the inductive-coupling connector and intended to provide an electrical connection between two sensors located downhole (not shown) and monitoring equipment on the surface (not shown). The two sensors may be used, for example, to measure temperature and pressure. In this case, the two sensors are supplied with electrical power by a common cable and the measuring signal to be sent to the surface is selected among the two possible measuring signals by reversing the power supply polarity. In order to simplify the description, only the circuit associated with the coils 1A and 5A is described.
Upstream from the connector, a first circuit which may be received in the above-mentioned box 4A, for example, is powered by a current source 50. The power supply electricity is rectified by a bridge 51 which feeds a converter 52 for transforming direct current into A.C. The frequency of the A.C. is controlled by a polarity detector 53 which is also powered by the current source 50. The output from the converter 52 feeds the coil IA directly.
Downstream from the connector, a second circuit received in the box 6A comprises a converter 55 powered by the coil 5A and serving to transform A.C. into D.C. A polarity selector 56 controlled by a frequency detector 57 selects the polarity of the D.C. applied to the cable 8A so as to select signals from one of the sensors down the well.
The voltage pulses generated by the sensors modulate the amplitude of the voltage at the terminals of the coil 5A via a synchronous impedance modulating converter 55. The converter 52 operates as a synchronous detector. It modulates the power supply voltage with voltage pulses after the power supply frequency has been filtered.
Such a circuit has the advantage of requiring only one inductive coupling connector for remote measurement from two sensors. As a result, the second circuit associated with the coils 1B and 5B could be used, for example, to serve as a backup circuit for use in the event of failure of the first circuit.
In another particular embodiment (not shown) the inductive-coupling connector comprises two coils of substantially identical diameter which are superposed when the valve assembly 10 is put into place on the well head 20.
Naturally, these two embodiments have been described purely by way of example, other ways of implanting the inductive-coupling connector could be envisaged without going beyond the scope of the invention. | The invention relates to an electrical connector for transmitting electrical signals between the outside and the inside of a well having a well head (20) terminated by a valve assembly (10). The connector comprises at least two inductively coupled electrical coils (1A, 1B; 5A, 5B) whose respective winding axes are aligned with the axis (zz') of the well head. The coils are integrated in the fluid connector interconnecting the valve assembly and the well head, with one of the coils being releasably fixed to the valve assembly (10) while the other coil is releasably fixed to the well head (20). |
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a division of application Ser. No. 682,698, filed May 3, 1976 now abandoned.
BACKGROUND OF THE INVENTION
The production of organic products in situ by heating and/or fracturing subsurface formations containing hydrocarbons, such as oil shale or coal beneath overburdens, is desirable but has generally been uneconomical since large amounts of energy are required for fracturing or heating the formation, for example, by injection of heated fluids, by subsurface combustion in the presence of an injected oxidizer, or by nuclear explosion. In the alternative, it has been either necessary to mine the oil shale or coal and convert it to the desired products such as pipe lineable oil or gas or other products on the surface resulting in substantial quantities of residue, particularly in the case of oil shale where the spent oil shale has a larger volume than the original oil shale. In addition, if the kerogen in the oil shale is overheated, the components may not flow or may decompose to undesirable products such as carbonized oil shale which will not flow through fractures formed in the oil shale. In addition, at temperatures above 1000° F., water locked in the shale will be released and the shale can decompose absorbing large amounts of heat and thus wasting input heating energy.
SUMMARY OF THE INVENTION
In accordance with this invention, alternating current electric fields are used to differentially heat a body containing hydrocarbon compounds so that substantial temperature gradients are produced in the body to produce high stresses in the body, such stresses producing conditions which readily fracture the body.
In accordance with this invention, fracturing, which is dependent on temperature gradient, is produced at temperatures substantially below temperatures at which rapid decomposition of the kerogen occurs. More specifically, two electrodes such as eight-inch pipes, extending as a parallel wire line from the surface through an overburden into an oil shale body, have alternating current power supplied to the surface end of the line at a frequency for which the spacing between the electrodes is less than a tenth of a wavelength in the body of oil shale. The length of the electrode from the surface is on the order of a quarter of a wavelength, or greater, of said frequency so that an electric field gradient is produced which is highest at the open circuited end of the line in the oil shale on the surfaces of the portions of the electrodes facing each other. Since heating of the kerogen in the oil shale body is a function of the square of the electric field, the rate of heating is most intense in these regions, producing a substantial thermal gradient between such regions and regions adjacent thereto, with the differential thermal expansion produced by such gradient producing stresses which fracture the formation in said regions.
This invention further provides that fluids may be injected into the formation to assist in the fracturing.
This invention further provides that following fracturing, the formation may be further heated by electric fields between the electrodes at the same and/or different frequency and/or electric field gradients.
This invention further provides that frequencies may be used in which a plurality of voltage nodes appear on the transmission line.
This invention further discloses embodiments of the invention wherein more than two electrodes are supplied with an electric field to reduce the intensity of the electric field gradient during the heating cycle adjacent the electrodes thereby more evenly heating the bulk of the shale oil subsequent to fracturing.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects and advantages of the invention will become apparent as the description thereof progresses, reference being had to the accompanying drawings wherein:
FIG. 1 illustrates an RF system embodying the invention;
FIG. 2 is a transverse sectional view of the system of FIG. 1 taken along line 2-2 of FIG. 1;
FIG. 3 is a four-electrode embodiment of the invention;
FIG. 4 shows curves of electric field and temperature versus distance for the system of FIG. 3; and
FIG. 5 shows an alternate embodiment of the system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, there is shown a body of oil shale 10 resting on a substratum 12 and positioned below an overburden 14. Oil shale body 10 may be from several feet to several hundred feet thick and generally comprises layers of material which are rich in kerogens from which organic products may be produced separated by layers of material which are lean in kerogens. Positioned in body 10 and extending through overburden 14 are a plurality of electrode structures 16 which, as as shown here by way of example, are hollow pipes of, for example, eight inches diameter which extend from from the surface to a point approximately midway through the body 10. Pipes 16 have apertures 18 in their lower ends to permit the products of the kerogen produced by heating to flow into the pipes 16 and to collect in sumps 20 beneath pipes 16 from whence they can be removed, for example, by pumps (not shown) on the ends of tubings 22, or formation gas pressure may be generated, if desired, to drive the products to the tops of tubings 22 when the valves 24 thereon are opened.
Pipes 16 are spaced apart by a distance in body 10 which is determined by the characteristics of the oil shale body, and the RF frequency to be used for processing the body. For example, if one megahertz is to be used, a spacing on the order of ten to forty feet is desirable. However, other spacings may be used depending upon the expense of drilling holes through the overburden 14 and into the oil shale body 10 as well as other factors. For other frequencies, the spacing between the pipes 16 may be different, preferably being approximately a tenth of a wavelength in the oil shale. To reduce undesirable radiation of the RF energy, the electrode spacing is preferably less than an eighth of a wavelength so that the pipes 16 may be energized in phase opposition from the RF source to produce the captive electric field between the pipes 16.
RF energy is produced by a generator 30 which supplies energy in phase opposition to impedance and phase adjusting elements 32 which are connected respectively to the pipes 16. The length of the pipes 16 from the point of connection of the impedance and phase adjust sections to their lower ends in body 10 is preferably made greater than a quarter wavelength at the operating frequency of generator 30. For example, if a quarter wavelength in the formation is approximately one hundred feet, the length of the pipes might usefully be between one hundred and one hundred fifty feet long. Under these conditions, pipes 16 are an open-ended parallel wire transmission line having a voltage node at their open ends as shown by the electric fields 34 and having a current node and, hence, low electric fields in the overburden 14.
A screen 36 is preferably positioned on the ground intermediate the pipes 16 and a ground connection from the generator 30 and the phase adjusting and impedance matching elements 32 to reduce the amount of radiation into the atmosphere from radiation escaping from the captive electric field between the pipes 16.
As shown in FIG. 2, the electric field concentrates immediately adjacent the pipes 16 and is reduced with distance away from the pipes 16 having a radial frequency variation which heats the oil shale formation in direct proportion to the square of the field intensity. Since the field intensity is concentrated in both the vertical and the horizontal planes, a maximum concentration is produced at the ends of the pipes 16. Such differential heat produces conditions in which the formation 10 will fracture at relatively low temperatures such as a few hundred degrees which is well below the temperature at which oil shale formation decomposition generally occurs. By applying sufficient energy such as gradients on the order of one to ten thousand volts per inch in such regions, such fracturing can be made to occur in very short periods of time such as a few minutes to a few hours. Furthermore, the positions of such fractures may be varied by pulling the pipes 16 up through the formation to position the ends at different locations.
Preferably, in operation the ends of electrodes 16 will be set at the highest level which it is desired to fracture in the formation 10, and fracturing will proceed. The electrodes will then be driven gradually down through the formation until the lowest level at which fracturing is to be performed has been reached. Preferably, such fracturing leaves unfractured regions for a few feet above the substratum 12 and below the overburden 14 to act as upper and lower caps of the area being fractured.
Follosing fracturing, the formation may be heated, for example, by subjecting the formation to a substantially lower average intensity electric field for a longer period of time to allow the heat to gradually dissipate by thermal conduction into the region between the pipes 16 over a period of hours to months. Following such heating to temperatures which preferably are below the decomposition temperature of the shale formation itself but above the temperature at which the kerogen will produce products which flow into the well bores such as the range of five hundred to a thousand degrees Fahrenheit, the valves 24 will be opened and the liquid collected in the pipes 16 forced to the surface by gas pressure in the formation 10. Substantial quantities of such gas will be produced from the heating, and such gas preferably will be used to drive the liquified products into the sumps 20. At this time, tubings 22 may be lowered into sumps 20 to force the liquids therein to the surface by gas pressure.
If necessary, the formation may be refractured by high intensity electric field to reopen passages in the shale which may gradually close due to overburden pressure or to fracture more deeply into the oil shale body 10, tubings 22 being withdrawn into pipes 16 during this process.
If desired, the interior of the pipes 16 may be pressurized before, during or after the application of RF fracturing energy, for example, by injection pumps 40 through valves 42 so that higher field gradients may be produced between the well electrodes 16 without corona conditions which may produce undesirably high localized temperatures at the surface of the electrodes 16.
Any desired material may be used for the pipes 16 such as steel or steel coated with noncorrosive high temperature alloys such as nickel chrome alloys, and other electrode configurations may be used. However, by the use of a single pipe, the least expense electrode structure from the standpoint of electrode insertion into the oil shale body is achieved, and such electrode structure may also be used to produce the products of the oil shale which are on heating converted to other products such as pipelineable oil.
Referring now to FIG. 3, there is shown a section of a four-electrode structure in which the electrodes 16 are generally of the same type illustrated in FIG. 1. In such a structure, the electrodes are preferably positioned equidistant at the corners of the square, and as shown in the heating mode, energy is supplied as indicated diagrammatically by the wires 50 out of phase from RF generator 52, which includes the impedance matching and phase adjusting structures, to opposite corners of the square so that adjacent electrodes along each side of the square are fed out of phase with RF energy and produce electric fields at a given instance with the arrows 54 as shown. Such a field pattern is substantially more uniform than the field pattern shown in FIG. 2 and, hence, is preferable for RF heating of body 10 since it allows for the oil shale body to become more completely heated in a shorter time period in the regions between the electrodes and below the unfractured portion of the oil shale at the overburden interface.
Referring now to FIG. 4, there is shown approximate curves of electric field intensity and temperatures for a line taken along 4--4 of FIG. 3. Curve 60 shows electric field intensity to be a maximum adjacent the electrodes 16 and to drop to a value 62, which is less than half the maximum, in the center of the electrode square. Such an electric field will produce heating of the oil shale to produce after a heating time of hours to days a curve of the approximate shape shown at 64 for the temperature gradient along line 4--4, the steepened portions of the heating curve 62 having been smoothed by conductive flow of heat through the formation in the period of hours to days. Further smoothing of the curve which may have peak temperatures of, for example, one thousand degrees Fahrenheit at points 66 and a low temperature of, for example, six hundred degrees Fahrenheit at points 68, constitutes a range at which heating of the kerogen in the oil shale will be sufficient to produce flow of the products of kerogen into the pipes 16.
Curve 70 shows a lower temperature range after production of some of the products of the oil shale, at which time additional RF heating and/or fracturing may be undertaken.
It should be clearly understood that the curves are shown by way of example to illustrate the principles of the invention and will vary in shape due to differences in thermal conductivity and absorption of RF energy by the oil shale formation as well as with the RF power level supplied by the generator and the time which passes during and after the RF heating of the oil shale. As an example, if an oil shale body comprising a cylinder on whose periphery well 16 is positioned having a diameter of fifty feet and a thickness, for example, of fifty feet with a twenty-five foot cap beneath the overburden 16 and a twenty-five foot line above the substratum 12 is to be heated using a voltage at the lower end of electrodes 16 of, for example, 100,000 volts with gradients adjacent the electrodes 16 of around one thousand volts per inch, the formation will act as a load on the ends of the transmission line which may be considered a four-wire transmission line which will absorb on the order of one to ten magawatts of energy from the generator 30 adding over one million BTU's per hour to the formation and raising the average temperature of the oil shale at a rate of one to ten degrees per hour, with the maximum electric intensity regions being raised in temperature at a rate on the order of ten to one hundred degrees per hour so that in less than a day regions adjacent the apertures 18 in the pipes 16 will produce a flow of the products of kerogen into the pipes 16. Under these conditions, it is desirable that RF heating be stopped or reduced when the temperature has reached a predetermined upper limit such as one thousand degrees Fahrenheit at points of maximum heating, for example, adjacent the lower ends of the electrodes 16. This temperature may be sensed by any desired means (not shown) such as by thermocouples or the circulation of fluids in the electrodes 16 past thermometers (not shown). The generator 30 is then either reduced in power or completely turned off, and gas and liquids are removed from the pipes 16 and the sumps 20. During this period which may be, for example, from days to months, the peak temperatures are reduced from the predetermined upper limit which may be chosen in the range from 500° F. to 1000° F. to temperatures of between one-half and three-quarters of the peak temperature. The valves 24 are then shut off and RF energy is again supplied by the generator 30 either in high intensity bursts to refracture the formation in accordance with the patterns of FIG. 2 or in the heating pattern of FIG. 3, or a combination of both, until the peak temperatures are again achieved whereupon the gas and/or fluid is again removed from the pipes 16. If desired, pumps may be positioned inside the pipes 16 rather than in sumps 20 so that they can be operated during the RF heating periods.
Referring now to FIG. 5, there is shown an alternate embodiment of the invention. Oil shale body 10 contains electrodes 70 spaced apart therein, electrodes 70 having apertures 72 adjacent the lower ends thereof through which products derived from kerogen in the oil shale may pass. At the RF frequency, electrodes 70, which may be, for example, six inches in diameter, are preferably one quarter wavelength long in the oil shale and spaced apart by distances on the order of one-half their length or one-eighth wavelength or less in the oil shale. As shown in FIG. 5, the horizontal scale is accentuated to illustrate details of the electrode and feed structure. For example, electrodes 70 at a frequency of one megahertz may be spaced apart by a distance of about forty to fifty feet and the length of electrodes 70 is, for example, about eighty to one hundred feet.
Electrodes 70 are positioned wholly within the shale body 10 and are supported at the ends of producing tubings 76 which extend to the surface of the formation and may be, for example, two-inch steel pipes. Pipes 76 act as the central conductors of coaxial cables in which the outer conductors are casings 78 which may be, for example, eight-inch inside diameter steel piped coated inside, for example, with copper. Conductors 76 are insulated from outer conductors 78 by insulating spacings 80 which are attached to pipes 76 and loosely fit in casings 78.
The lower ends of casings 78 have RF choke structures 82 consisting of relatively thin concentric cylinders 84 and 86 separated by cylinders of dielectric material 88. The upper ends of inner cylinders 84 are connected, as by welding, to the casings 78 and the lower ends of cylinders 84 and 86 are connected together at 90, as by welding, and the upper ends of outer cylinders 80 are insulated from the casings 78 by portions of the dielectric cylinders 80. Structuees 82 are electrically one-fourth wavelength long at the RF frequency and prevent RF energy existing as currents in the inner walls of the outer casings 78 from being conducted to the outer wall of the casings. With such a structure, the length of the casing 78 may be many hundreds of feet, for example, five hundred to a thousand feet long, to extend through thick overburdens 12. In such a structure, energy is fed from a generator 92 of RF energy having a frequency in the range from one hundred kilohertz to one hundred megahertz in phase opposition and suitably impedance matched in generator 92 to pipes 76 to produce a voltage therebetween. Generator 92 has a ground connection to a screen 94 on the surface of the formation which is connected to the outer casings 78 to act as a shield for any stray radiation produced by the electric fields between electrodes 70. The structure of FIG. 5 may be operated in the same fashion as that described in connection with FIGS. 1 through 4 for both fracturing and heating the oil shale formation 10, with production of the products of kerogen in the oil shale being produced by gas pressure in the formation driving both liquid and gas to the surface through tubes 76 where production is controlled by valves 96.
The generator 92 may be variable in frequency to shift the optimum resonant frequency as the dielectric constant of the medium such as the oil shale changes with temperature or upon change in the content of the oil shale by production of the products of kerogen therefrom, and the choke structure 82 will be effective over a 10% to 20% change in generator frequency.
This completes the description of the embodiments of the invention illustrated herein. However, many modifications thereof will be apparent to persons skilled in the art without departing from the spirit and scope of this invention. For example, the heating may be achieved by injection of hot gases through the tubes 76 after the formation has been fractures, and local overheating at the electrodes may be prevented by injecting a cooling medium, such as water, which will produce steam to absorb energy at the peak temperature regions adjacent the electrodes. In addition, the electrode structures need not be vertical and parallel as shown, but any desired electrode orientation such as horizontal electrodes driven into an oil shale formation from a mine shaft formed to the oil shale may be used. Accordingly, it is contemplated that this invention be not limited to the particular details illustrated herein except as defined by the appended claims. | A method and apparatus for fracturing and/or heating subsurface formations wherein an alternating current electric field is produced in the frequency range between 100 kilohertz and 100 meghertz between electrodes spaced apart in the formation and a radio frequency generator supplying a voltage between said lines with suitable loading structures tuned to the frequency of the generator to resonate the electrodes as a parallel wire transmission line which is terminated in an open circuit and produces a standing wave having a voltage node at the end of the line. |
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PRIORITY DOCUMENT
[0001] The present application claims priority from:
[0002] Australian Provisional Patent Application No 2012905435 titled “ROD HANDLER IMPROVEMENTS” filed on 11 Dec. 2012. The content of this application is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0003] The present invention relates to a handling means for drill rods, a drill rod support thereof, a method of operation for the handling means, and a drill rig employing the handling means and the drill rod support.
BACKGROUND
[0004] Drill rigs for drilling bore holes generally comprise an upstanding mast supporting a drill head which is movable along the mast. The drill head is provided with means which can receive and engage the upper end of a drill rod forming part of a drill string to drive the drill string and drill bit mounted to the lower end of the drill string. In addition, the drill head may have means for applying a downward force to the drill string to facilitate penetration.
[0005] The drill string comprises a number of lengths of drill rod which are connected end to end, where the length of drill rod generally is at the most equal to the height of the mast. During a drilling operation when the drill head has reached the lower end of the mast, the drill string is retained to the mast and the drill head is disconnected from the drill string and raised to the upper end of the mast. A fresh length of drill rod is then raised and positioned in the chuck of the drill head and then the lower end becomes engaged with the upper end of the drill string. Once the fresh length of drill rod has been put in place, the drilling operation can recommence until the drill head again reaches the lower end of the mast. During drilling activities which may extend for hundreds of meters, it is necessary to locate fresh lengths of drill rod into a drill string at very regular intervals.
[0006] Throughout this specification the term “drill rod” should be construed as including all forms of elongate members used in the drilling, installation and maintenance of bore holes and wells in the ground, and will include rods, pipes, tubes and casings which are provided in lengths and are interconnected for use in the borehole.
[0007] In practice however, not all drill rods are the same, they differ significantly. For instance, rods for diamond core drilling (hereinafter diamond rods) are much lighter and more delicate than rods for reverse circulation drilling (hereinafter RC rods), particularly at the threads, so a means suitable for handing RC rods is generally unsuitable for handling diamond rods, and vice versa.
[0008] It is against this background and the problems and difficulties associated therewith that the present invention has been developed.
[0009] Certain objects and advantages of the present invention will become apparent from the following description, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
SUMMARY
[0010] In a first aspect the present invention accordingly provides a drill rod support for a means for handling drill rods, the support defining a socket configured to receive a portion of a length of a drill rod, and clamping means disposed within the socket and movable between clamping and release positions with respect to the drill rod.
[0011] In one form, the clamping means comprises at least one movable portion, or jaw.
[0012] In one form, the clamping means comprises a plurality of jaws arranged radially about the socket.
[0013] In one form, the clamping means comprises three radially equi-spaced jaws.
[0014] In one form, the socket, and the or each jaw,, is elongate, each having a substantially parallel direction of elongation to the other.
[0015] In one form, the clamping means is self-centering, and as such always clamps the rod centrally with respect to the socket.
[0016] In an alternative, the clamping means may comprise one or more bands for encircling the drill rod and tightening about this.
[0017] In one form, the support further comprises drive means for the clamping means. In one form, the drive means comprises one or more actuators. In one form, the or each actuator drives the clamping means via a transmission system. In one form, in an alternative, the or each actuator drives the clamping means directly.
[0018] In one form, the clamping means is biased towards its release position by biasing means, so the drive means need only drive the clamping means into its clamping position. In one form, the biasing means comprises a spring device or element.
[0019] In one form, the drive means comprises a linear actuator which drives a jacking plate against the bias of the biasing means, the drill rod support further comprising a floating plate which will follow the jacking plate by virtue of being linked to the jacking plate by at least one connecting rod, the or each movable jaw following the floating plate by virtue of being operatively associated with this, and wherein the or each movable jaw is moved into its clamping position as it is driven against the bias of the biasing means.
[0020] In one form, the or each movable jaw comprises a guide follower operatively associated with a jaw guide disposed in the socket to drive the jaw into its clamping position as it is driven against the bias of the biasing means.
[0021] In one form, each guide follower comprises an inclined plane which will slide smoothly against an oppositely directed but similarly inclined plane of the jaw guide with any longitudinal movement driven by the linear actuator.
[0022] In one form, the drill rod support further comprises an elongate cylindrical housing defining the socket internally, where one end of the housing is open, and an opposing end is substantially closed by an end plate from which there depends the linear actuator.
[0023] In one form, the biasing means comprises a compression spring disposed over each of the connecting rods and between the end plate and the floating plate so as to maintain a predetermined spacing between these
[0024] In a further aspect, the invention may be said to reside in a drill rod support for a means for handling drill rods, the support comprising at least a pair of elongate jaws, at least one of which is movable between clamping and release positions with respect to a drill rod so that a full length of each jaw clamps the rod along its longitudinal axis when in the clamping position.
[0025] In a further aspect, the invention may be said to reside in a handling means for drill rods comprising a base, a drill rod support as described above, wherein the drill rod support depends from the base so as to so movable with respect to the base as to effect transfer of a length of drill rod from a drill rod storage position, to a position in line with a drill string, and vice versa.
[0026] In one form, the drill rod support depends from the base so as to rotatable about an axis transverse to a longitudinal axis of the drill rod support whereby the support can be moved between an upright position and a substantially horizontal position, as well as movable between a first position located adjacent the drill rod storage position and one or more positions clear of the first position, including the position in line with the drill string.
[0027] In one form, the socket is defined by a housing having an open end through which the drill rod is receivable and a closed end in opposed relation to the open end, said closed end being lowermost when the drill rod support is in its substantially upright position.
[0028] In one form, the direction of elongation of the socket extends between the open and closed ends of the housing.
[0029] In one form, the drill rod support depends from an arm which is rotatably supported from the base for rotation about a substantially upright axis.
[0030] In a further aspect, the invention may be said to reside in a drill rig comprising a handling means as described above.
[0031] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate by way of example the principles of the invention. While the invention is described in connection with such embodiments, it should be understood that the invention is not limited to any embodiment. On the contrary, the scope of the invention is limited only by the appended claims and the invention encompasses numerous alternatives, modifications and equivalents. For the purpose of example, numerous specific details are set forth in the following description in order to provide a thorough understanding of the present invention.
[0032] In order to further understand the invention, preferred embodiments, will now be described. However, it will be realised that the scope of the invention is not be confined or restricted to the details of the embodiments described below. Variations and alterations that would be readily apparent to a person skilled in the art are deemed as being incorporated within the scope of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0033] Embodiments of the present invention will be discussed with reference to the accompanying drawings wherein:
[0034] FIG. 1 is an isometric view of a drill mast for a drilling rig;
[0035] FIG. 2 is a detail view of a lower end of the drill mast of FIG. 1 ;
[0036] FIG. 3 is a side view of a rod support from the drill mast of FIG. 1 ;
[0037] FIG. 4 is a cross-sectional view through the rod support of FIG. 3 ;
[0038] FIG. 5 is an isometric view of the rod support'of FIG. 1 , minus a guard cage for the jack and jacking plate;
[0039] FIG. 6 is a side view of the rod support of FIG. 5 ;
[0040] FIG. 7 is a cross-sectional view through the rod support of FIG. 5 ;
[0041] FIG. 8 is an end view of the rod support of FIG. 5 ;
[0042] FIG. 9 is a cross-sectional view through the connecting rods of the rod support of FIG. 5 ;
[0043] FIG. 10 is a plan view of an end plate from the rod support of FIG. 5 ;
[0044] FIG. 11 is a plan view of a jacking plate from the rod support of FIG. 5 ;
[0045] FIG. 12 is a plan view of a floating plate from the rod support of FIG. 5 ;
[0046] FIG. 13 is a side view of a housing from the rod support of FIG. 5 ;
[0047] FIG. 14 is a cross-sectional view through the housing of FIG. 12 ;
[0048] FIG. 15 is a view of a gripping face of a jaw from the rod support of FIG. 5 ;
[0049] FIG. 16 is a side view of the jaw of FIG. 15 ;
[0050] FIG. 17 is view of a guide following face (opposite to the gripping face) of the jaw of FIG. 15 ;
[0051] FIG. 18 is cross-sectional view through the jaw of FIG. 15 ;
[0052] FIG. 19 is an isometric view of the rod support of FIG. 1 , minus the housing and guard cage, which are removed for improved visibility of the internal assembly;
[0053] FIG. 20 is a drive end view of the rod support internals of FIG. 19 , illustrating all of the moving components in a rod release position; and
[0054] FIG. 21 is a drive end view of the rod support internals of FIG. 19 , illustrating all of the moving components in a rod gripping position.
[0055] In the following description, like reference characters designate like or corresponding parts throughout the figures.
DESCRIPTION OF EMBODIMENTS
[0056] Referring now to FIG. 1 , where there is illustrated a drill rig 10 for support by a vehicle (not shown) and comprising a mast 12 which can be pivoted between an upright operative position as shown in the drawings, and a horizontal position (not shown), in which it lies along a substantially central axis of the vehicle to facilitate transportation.
[0057] Optionally the drill rig 10 can be configured so that it can be transported by a vehicle and then left in a stationary position when de-coupled from the vehicle.
[0058] The drill mast 12 supports a drill head 14 which, in use, drives the drill string (not illustrated) rotationally via a drive motor accommodated in the drill head 14 , as well as driving the drill string into and out of a bore hole via a feed system.
[0059] The drill rig 10 comprises a drill rod handling means which is intended to simplify the transfer of a drill rod from a storage bin to a position in line with the drill string, in which the drill rod can be engaged with the drill head 14 at its upper end and engage with the drill string at its lower end, and to also simplify the removal of a length of drill rod from a drill string.
[0060] The drill rod handling means can be incorporated into a drill rig 10 either as an attachment or as an integral part of the drill rig.
[0061] Referring now to FIG. 2 , wherein, in the illustrated embodiment the drill rod handling means comprises a linear actuator 15 which is supported to one side of the drill mast 12 clear a front face of the drill mast 12 . The linear actuator 15 comprises an upstanding shaft 17 which is substantially parallel to the main axis of the drill mast, one end 18 of which is fixed to a base of the mast. The other end of the shaft 17 is received within a closed cylinder 19 and is provided with a seal whereby the space defined between the seal and each end of the cylinder 19 comprises a separate enclosed space. The cylinder 19 is slideably received within a support block 20 mounted to the side of the drill mast which facilitates longitudinal displacement of the cylinder 19 through the support block 20 . The enclosed spaces within the cylinder 19 are connected to a source of fluid pressure whereby the displacement of the cylinder along the shaft 17 can be controlled to cause the cylinder 19 to move upwardly or downwardly with respect to the drill mast 12 through the support block 20 .
[0062] The upper end of the cylinder 19 has a first rotary actuator 21 mounted to it whereby the drive shaft of the first rotary actuator 21 is mounted to the cylinder 19 while the body of the first rotary actuator 21 is supported in such a way as to prevent relative rotation between the body thereof and the mast 12 , but which will permit longitudinal displacement there between. As a result, the cylinder 19 is capable of being turned about its central axis through the action of the first rotary actuator 21 and is capable of being displaced upwardly and downwardly with respect to the drill mast by the linear actuator 15 .
[0063] The lower end of the cylinder 19 is provided with a radial arm 23 which is provided at its outer end with an upstanding support plate 24 which is generally tangential to the radial axis of the cylinder 19 . The support plate 24 rotatably supports a drill support 1 which is rotatable about an axis which is transverse to the central axis of the cylinder 19 . The rotation of the drill rod support 1 is controlled by means of a second rotary actuator 26 which takes the form of a hydraulic motor and which controls the rotation of the drill rod support 1 on the support plate 24 about its axis of rotation.
[0064] Referring now to FIGS. 3 through 20 , where it can be seen that the drill rod support 1 comprises an elongate cylindrical housing 100 defining a generally tubular socket 1 A internally. One end of the housing 100 is open, and an opposing end is closed by an end plate 102 bolted to the housing 100 . Extending around an opening to the socket 1 A is a tapered guide ring 103 shaped to guide the end of a drill rod into the socket 1 A.
[0065] Secured to an outer-side of the end plate 102 is an hydraulically powered jack 104 (drive means) having a piston rod 105 which bears against, and thereby drives, a jacking plate 106 . The jack 104 and the jacking plate 106 are enclosed by a guard cage 107 .
[0066] From the jacking plate 106 there extends a plurality of connecting rods 108 , which extend through apertures 103 (see FIG. 9 ) in the end plate 102 to a floating plate 110 disposed within the socket.
[0067] Disposed over each of the connecting rods 108 and between the end plate 102 and the floating plate 110 is a compression spring 112 biased to maintain a predetermined spacing between these.
[0068] A jaw 150 locates in each one of a set of three radially equi-spaced jaw slots 140 (clamping means) formed into an inner wall of the housing 100 , and each of the jaws 150 is keyed to the jacking plate 106 and so follows the movement of this. These jaws 150 can be replaced once worn, and are interchangeable for instances where specially adapted jaws are required for certain types or sizes of drill rod.
[0069] Referring now to FIG. 12 , where it can be seen that the floating plate 110 comprises a set of three radially equi-spaced guide slots 112 , and a set of three radially equi-spaced, T-shaped retaining slots 114 , the purpose of all of which will be discussed in greater detail below.
[0070] Referring now FIG. 14 , where it can be seen that the socket 1 A defined by the housing 100 is generally circular in cross-section, with the exception that this comprises the set of three radially equi-spaced jaw slots 140 , and a set of three radially equi-spaced guide splines 142 .
[0071] The guide splines 142 are elongate splines extending lengthwise along the inner wall of the housing 100 . The guide splines 142 extend from the closed end of the housing 100 and end where the jaw slots 150 begin. In use, for each guide spline 142 there is a guide slot 112 in the floating plate 110 which will run along the guide spline 142 with a sliding fit.
[0072] The jaw slots 140 are elongate slots extending lengthwise along the inner wall of the housing 100 . One of the jaws 150 will locate in each of these jaw slots 140 .
[0073] Each of the jaw slots 140 comprise a pair of side walls separated by a floor. Each floor comprises a lengthwise extending jaw guide 144 , where this jaw guide 144 is characterised by a pair of substantially identical but longitudinally spaced apart inclined planes 146 . The purpose of these jaw guides 144 and the inclined planes 146 will be described in greater detail below.
[0074] Referring now to FIGS. 15 through 18 , where it can be seen that each of the jaws 150 comprises a T-shaped head portion 151 which is engaged with one of the T-shaped retaining slots 114 in the floating plate 110 , so that in use, each of the jaws 150 follows the movement of the floating plate 110 .
[0075] Each of the jaws 150 further comprises a gripping face 152 (with carbide inserts 152 A), and an oppositely directed guide follower 154 characterised by a pair of substantially identical but longitudinally spaced apart inclined planes 156 . Once assembled, the inclined planes 156 of the guide follower 154 will bear against the oppositely directed but similarly inclined planes 146 of the jaw guides 144 in the housing 100 , and slide smoothly against these with any longitudinal movement driven by the floating plate 110 .
[0076] This smooth sliding action will be assisted by grease supplied via journals extending through the jaws 150 .
[0077] Referring now to FIGS. 20 and 21 , where it can be seen how in use, the piston rod 105 of the jack 104 will drive the jacking plate 106 outwardly (with respect to the housing 100 ) against the bias of the springs 112 , and the floating plate 110 will follow by virtue of being tied to the jacking plate 106 by the connecting rods 108 .
[0078] The jaws 150 will similarly follow the floating plate 110 by virtue of being tied to this.
[0079] As the jaws 150 are drawn downwardly within the housing 100 they arc simultaneously driven inwardly (by the sliding of the inclined planes 156 of the guide follower 154 over the inclined planes 146 of the jaw guides 144 ) to clamp upon any drill rod inserted therein.
[0080] Because there are there equi-spaced jaws 150 , the clamping means is self-centering, so the drill rod (irrespective of diameter) will be centralised in the socket 100 A. Moreover, because the jaws 150 are elongate, these clamp lengthwise along a portion of the drill rod, making for secure retention of the drill rod in the drill rod support 1 .
[0081] When force provided by the jack 104 is removed, the springs 112 will bias the floating plate 110 upwardly, resulting in the return of the jaws 150 to their respective retracted, or home positions, and release of any drill rod in turn.
[0082] A vehicle supporting the drill rig 10 is generally configured so that drill rods are located in a bin lying alongside the drill mast 12 .
[0083] When it becomes necessary to insert a new drill rod into position in a drill string, the drill rod support 1 can be positioned over an end of a drill rod lying in the bin. The clamping means is then activated (as described above) so that the end of the drill rod is secured in the drill rod support 1 .
[0084] The second rotary actuator 26 is then actuated, causing the drill rod support 1 (and drill rod with it) to rotate into a substantially upright position with the innermost end of the tubular socket 1 A lowermost and the drill rod extending upwardly from the socket 1 A. With the drill rod so supported, the first rotary actuator 21 is then activated to cause the base plate 23 to move until the drill rod is substantially in alignment with the centreline of the drill head 14 and therefore the drill string. The support 23 can then be raised by the linear actuator 15 to cause the drill rod to be raised until its uppermost end becomes engaged with an adapter sub 13 with a lowermost tapered end 13 a (to aid alignment) depending from the drill head 14 . Once the upper end of the drill rod is engaged with the adapter sub 13 , the clamping means in the drill rod support 1 are released and the drill rod support 1 can be lowered away from the drill rod and returned to a home position. The lower end of the drill rod is then lowered to the drill string with the guidance of a lower guide 16 (to aid alignment), and then engaged with the drill string, whereupon drilling can recommence.
[0085] When it becomes necessary to remove a length of drill rod from the drill string, the lower end of the drill rod is disengaged from the drill string and the drill rod is then raised with the drill head 14 . The drill rod support 1 is then positioned so that the lower most end of the drill rod can be received within the tubular socket 1 A of the drill rod support 1 . The clamping means is then activated (as described above) so that the end of the drill rod is secured in the drill rod support 1 . Once the drill rod has been so secured by the drill rod support 1 , the upper end of the drill rod is disengaged from the drill head 14 . The drill rod can be then lowered by lowering the base plate 23 in order that the upper end of the drill rod clears the drill head 14 . The drill rod is then carried by the drill rod support 1 to a position beside the drilling mast 12 and is lowered to a horizontal position at which the clamping means in released so that the drill rod can be deposited into the bin.
[0086] It will be apparent from all of the above, that the drill rod support 1 disclosed herein can accommodate drill rods of various sizes, and retain drill rods of various sizes securely. Moreover, it will be apparent that a handling means comprising the drill rod support can position drill rods of various sizes relative to a drill string (and drill head), with a high degree of positional accuracy and no (or at least minimal) misalignment relative to the drill string and drill head.
[0087] Throughout the specification and the claims that follow, unless the context requires otherwise, the words “comprise”, and “include” and variations such as “comprising” and “including” will be understood to imply the inclusion of a stated integer or group of integers, but not the exclusion of any other integer or group of integers.
[0088] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement of any form of suggestion that such prior art forms part of the common general knowledge.
[0089] It will be appreciated by those skilled in the art that the invention is not restricted in its use to the particular application described. Neither is the present invention restricted in its preferred embodiment with regard to the particular elements and/or features described or depicted herein. It will be appreciated that the invention is not limited to the embodiment or embodiments disclosed,, but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention as set forth and defined by the following claims. | A handler for drill rods, a drill rod support thereof, a method of operation for the handler, and a drill rig employing the handler and the drill rod support is provided. The drill rod support includes a socket configured to receive a portion of a length of a drill rod, and a clamping device disposed within the socket and movable between clamping and release positions with respect to the drill rod. |
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of the U.S. Provisional Applications in the following table, all of which are hereby incorporated by reference:
U.S. PROVISIONAL APPLICATIONS
Serial
T&K #
Number
Title
Filing Date
TN 1599
60/177,999
Toroidal Choke Inductor for
Jan. 24, 2000
Wireless Communication and
Control
TH 1599x
60/186,376
Toroidal Choke Inductor for
Mar. 2, 2000
Wireless Communication and
Control
TH 1600
60/178,000
Ferromagnetic Choke in
Jan. 24, 2000
Wellhead
TH 1600x
60/186,380
Ferromagnetic Choke in
Mar. 2, 2000
Wellhead
TH 1601
60/186,505
Reservoir Production
Mar. 2, 2000
Control from Intelligent
Well Data
TH 1602
60/178,001
Controllable Gas-Lift Well
Jan. 24, 2000
and Valve
TH-1603
60/177,883
Permanent, Downhole,
Jan. 24, 2000
Wireless, Two-Way
Telemetry Backbone Using
Redundant Repeater, Spread
Spectrum Arrays
TH 1668
60/177,998
Petroleum Well Having
Jan. 24 2000
Downhole Sensors,
Communication, and Power
TH 1669
60/177,997
System and Method for Fluid
Jan. 24, 2000
Flow Optimization
TS6185
60/181,322
Optimal Predistortion in
Feb. 9, 2000
Downhole Communications
System
TH 1671
60/186,504
Tracer Injection in a
Mar. 2, 2000
Production Well
TH 1672
60/186,379
Oilwell Casing Electrical
Mar. 2, 2000
Power Pick-Off Points
TH 1673
60/186,394
Controllable Production
Mar. 2, 2000
Well Packer
TH 1674
60/186,382
Use of Downhole High
Mar. 2, 2000
Pressure Gas in a Gas Lift
Well
TH 1675
60/186,503
Wireless Smart Well Casing
Mar. 2, 2000
TH 1677
60/186,527
Method for Downhole Power
Mar. 2, 2000
Management Using
Energization from
Distributed Batteries or
Capacitors with
Reconfigurable Discharge
TH 1679
60/186,393
Wireless Downhole Well
Mar. 2, 2000
Interval Inflow and
Injection Control
TH 1681
60/186,394
Focused Through-Casing
Mar. 2, 2000
Resistivity Measurement
TH 1704
60/186,531
Downhole Rotary Hydraulic
Mar. 2, 2000
Pressure for Valve
Actuation
TH 1705
60/186,377
Wireless Downhole
Mar. 2, 2000
Measurement and Control For
Optimizing Gas Lift Well
and Field Performance
TH 1722
60/186,381
Controlled Downhole
Mar. 2, 2000
Chemical Injection
TH 1723
60/186,378
Wireless Power and
Mar. 2, 2000
Communications Cross-Bar
Switch
The current application shares some specification and figures with the following commonly owned and concurrently filed applications in the following table, all of which are hereby incorporated by reference:
COMMONLY OWNED AND CONCURRENTLY
FILED U.S. PATENT APPLICATIONS
Serial
T&K #
Number
Title
Filing Date
TH 1599ff
09/769,047
Choke Inductor for Wireless
Jan. 24, 2001
Communications and Control
TH 1600ff
09/769,048
Induction Choke for Power
Jan. 24, 2001
Distribution in Piping
Structure
TH 1603ff
09/768,655
Permanent Downhole,
Jan. 24, 2001
Wireless, Two-Way
Telemetry Backbone Using
Redundant Repeater
TH 1668ff
09/769,046
Petroleum Well Having
Jan. 24, 2001
Downhole Sensors,
Communication, and Power
TH 1669ff
09/768,656
System and Method for Fluid
Jan. 24, 2001
Flow Optimization
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a gas-lift well having a controllable gas-lift valve, and in particular, to a controllable gas-lift valve which communicates with the surface and is powered using the tubing string and casing as the conductor.
2. Description of Related Art
Gas-lift wells have been in use since the 1800's and have proven particularly useful in increasing efficient rates of oil production where the reservoir natural lift is insufficient (see Brown, Connolizo and Robertson, West Texas Oil Lifting Short Course and H. W. Winkler, Misunderstood or Overlooked Gas - lift Design and Equipment Considerations , SPE, p. 351 (1994)). Typically, in a gas-lift oil well, natural gas produced in the oil field is compressed and injected in an annular space between the casing and tubing and is directed from the casing into the tubing to provide a “lift” to the tubing fluid column for production of oil out of the tubing. Although the tubing can be used for the injection of the lift-gas and the annular space used to produce the oil, this is rare in practice. Initially, the gas-lift wells simply injected the gas at the bottom of the tubing, but with deep wells this requires excessively high kick off pressures. Later, methods were devised to inject the gas into the tubing at various depths in the wells to avoid some of the problems associated with high kick off pressures (see U.S. Pat. No. 5,267,469).
The most common type of gas-lift well uses mechanical, bellows-type gas-lift valves attached to the tubing to regulate the flow of gas from the annular space into the tubing string (see U.S. Pat. Nos. 5,782,261 and 5,425,425). In a typical bellows-type gas-lift valve, the bellows is preset or pre-charged to a certain pressure such that the valve permits communication of gas out of the annular space and into the tubing at the pre-charged pressure. The pressure charge of each valve is selected by a well engineer depending upon the position of the valve in the well, the pressure head, the physical conditions of the well downhole, and a variety of other factors, some of which are assumed or unknown, or will change over the production life of the well.
Referring to FIG. 1 in the drawings, a typical bellows-type gas-lift valve 310 has a pre-charge cylinder 312 , a metal bellows 314 , and entry ports 316 for communicating gas from the annular space outside the tubing string. Gas-lift valve 310 also includes a ball 318 that sealingly engages a valve seat 319 when valve 310 is in a closed position. When gas-lift valve 310 is in an open position, ball 318 no longer engages valve seat 319 , thereby allowing gas from the annular space to pass through entry port 316 , past ball 318 , and through exit port 320 . Several problems are common with bellows-type gas-lift valves. First, the bellows often loses its pre-charge, causing the valve to fail in the closed position or changing its setpoint to operate at other than the design goal, and exposure to overpressure causes similar problems. Another common failure is erosion around valve seat 319 and deterioration of the ball stem in the valve. This leads to partial failure of the valve or at least inefficient production. Because the gas flow through a gas-lift valve is often not continuous at a steady state, but rather exhibits a certain amount of hammer and chatter as ball 318 rapidly opens and closes, ball and valve seat degradation are common, leading to valve leakage. Failure or inefficient operation of bellows-type valves leads to corresponding inefficiencies in operation of a typical gas-lift well. In fact, it is estimated that well production is at least 5-15% less than optimum because of valve failure or operational inefficiencies. Fundamentally these difficulties are caused by the present inability to monitor, control, or prevent instabilities, since the valve characteristics are set at design time, and even without failure they cannot be easily changed after the valve is installed in the well.
Side-pocket mandrels coupled to the tubing string are known for receiving wireline insertable and retrievable gas-lift valves. Many gas-lift wells have gas-lift valves incorporated as an integral part of the tubing string, typically mounted to a pipe section. However, wireline replaceable side pocket mandrel type of gas-lift valves have many advantages and are quite commonly used (see U.S. Pat. Nos. 5,782,261 and 5,797,453). Gas-lift valves placed in a side pocket mandrel can be inserted and removed using a wireline and workover tool either in top or bottom entry. In lateral and horizontal boreholes, coiled tubing is used for insertion and removal of the gas-lift valves. It is common practice in oilfield production to shut off production of the well periodically and use a wireline to replace gas-lift valves. However, an operator often does not have a good estimate of which valves in the well have failed or degraded and need to be replaced.
It would, therefore, be a significant advantage if a system and method were devised which overcame the inefficiency of conventional bellows-type gas-lift valves. Several methods have been devised to place controllable valves downhole on the tubing string but all such known devices typically use an electrical cable or hydraulic line disposed along the tubing string to power and communicate with the gas-lift valves. It is, of course, highly undesirable and in practice difficult to use a cable along the tubing string either integral with the tubing string or spaced in the annulus between the tubing string and the casing because of the number of failure mechanisms present in such a system. The use of a cable presents difficulties for well operators while assembling and inserting the tubing string into a borehole. Additionally, the cable is subjected to corrosion and heavy wear due to movement of the tubing string within the borehole. An example of a downhole communication system using a cable is shown in PCT/EP97/01621.
U.S. Pat. No. 4,839,644 describes a method and system for wireless two-way communications in a cased borehole having a tubing string. However, this system describes a communication scheme for coupling electromagnetic energy in a transverse electric mode (TEM) using the annulus between the casing and the tubing. The system requires a toroidal antenna to launch or receive in a TEM mode, and the patent suggests an insulated wellhead. The inductive coupling of the system requires a substantially nonconductive fluid such as crude oil in the annulus between the casing and the tubing, and this oil must be of a higher density that brine so that leaked brine does not gather at the bottom of the annulus. This system does not speak to the issue of providing power to the downhole module. The invention described in U.S. Pat. No. 4,839,644 has not been widely adopted as a practical scheme for downhole two-way communication because it is expensive, has problems with brine leakage into the casing, and is difficult to use. Another system for downhole communication using mud pulse telemetry is described in U.S. Pat. Nos. 4,648,471 and 5,887,657. Although mud pulse telemetry can be successful at low data rates, it is of limited usefulness where high data rates are required or where it is undesirable to have complex, mud pulse telemetry equipment downhole. Other methods of communicating within a borehole are described in U.S. Pat. Nos. 4,468,665; 4,578,675; 4,739,325; 5,130,706; 5,467,083; 5,493,288; 5,574,374; 5,576,703; and 5,883,516.
It would, therefore, be a significant advance in the operation of gas-lift wells if an alternative to the conventional bellows type valve were provided, in particular, if the tubing string and the casing could be used as the communication and power conductors to control and operate a controllable gas-lift valve.
All references cited herein are incorporated by reference to the maximum extent allowable by law. To the extent a reference may not be fully incorporated herein, it is incorporated by reference for background purposes and indicative of the knowledge of one of ordinary skill in the art.
SUMMARY OF THE INVENTION
The problems outlined above are largely solved by the electrically controllable gas-lift well in accordance with the present invention. Broadly speaking, the controllable gas-lift well includes a cased wellbore having a tubing string positioned and longitudinally extending within the casing. The position of the tubing string within the casing creates an annulus between the tubing string and the casing. A controllable gas-lift valve is coupled to the tubing to control gas injection between the interior and exterior of the tubing, more specifically, between the annulus and the interior of the tubing. The controllable gas-lift valve is powered and controlled from the surface to regulate the fluid communication between the annulus and the interior of the tubing. Communication signals and power are sent from the surface using the tubing and casing as conductors. The power is preferably a low voltage AC at conventional power frequencies in the range 50 to 400 Hertz, but in certain embodiments DC power may also be used.
In more detail, a surface computer having a modem imparts a communication signal to the tubing, and the signal is received by a modem downhole connected to the controllable gas-lift valve. Similarly, the modem downhole can communicate sensor information to the surface computer. Further, power is input into the tubing string and received downhole to control the operation of the controllable gas-lift valve. Preferably, the casing is used as the ground return conductor. Alternatively, a distant ground may be used as the electrical return. In a preferred embodiment, the controllable gas-lift valve includes a motor which operates to insert and withdraw a cage trim valve from a seat, regulating the gas injection between the annulus and the interior of the tubing, or other means for controlling gas flow rate.
In enhanced forms, the controllable gas-lift well includes one or more sensors downhole which are preferably in contact with the downhole modem and communicate with the surface computer, although downhole processing may also be used to minimize required communications data rate, or even to make the downhole system autonomous. Such sensors as temperature, pressure, hydrophone, microphone, geophone, valve position, flow rates, and differential pressure gauges are advantageously used in many situations. The sensors supply measurements to the modem for transmission to the surface or directly to a programmable interface controller operating the controllable gas-lift valve for controlling the fluid flow through the gas-lift valve.
Preferably, ferromagnetic chokes are coupled to the tubing to act as a series impedance to current flow on the tubing. In a preferred form, an upper ferromagnetic choke is placed around the tubing below the tubing hanger, and the current and communication signals are imparted to the tubing below the upper ferromagnetic choke. A lower ferromagnetic choke is placed downhole around the tubing with the controllable gas-lift valve electrically coupled to the tubing above the lower ferromagnetic choke, although the controllable gas-lift valve may be mechanically coupled to the tubing below the lower ferromagnetic choke. It is desirable to mechanically place the operating controllable gas-lift valve below the lower ferromagnetic choke so that the borehole fluid level is below the choke.
Preferably, a surface controller (computer) is coupled via a surface master modem and the tubing to the downhole slave modem of the controllable gas-lift valve. The surface computer can receive measurements from a variety of sources, such as downhole and surface sensors, measurements of the oil output, and measurements of the compressed gas input to the well (flow and pressure). Using such measurements, the computer can compute an optimum position of the controllable gas-lift valve, more particularly, the optimum amount of the gas injected from the annulus inside the casing through the controllable valve into the tubing. Additional enhancements are possible, such as controlling the amount of compressed gas input into the well at the surface, controlling back pressure on the wells, controlling a porous frit or surfactant injection system to foam the oil, and receiving production and operation measurements from a variety of other wells in the same field to optimize the production of the field.
The ability to actively monitor current conditions downhole, coupled with the ability to control surface and downhole conditions, has many advantages in a gas-lift well.
Gas-lift wells have four broad regimes of fluid flow, for example bubbly, Taylor, slug and annular flow. The downhole sensors of the present invention enable the detection of flow regime. The above referenced control mechanisms-surface computer, controllable valves, gas input, surfactant injection, etc.—provide the ability to attain and maintain the desired flow regime. In general, well tests and diagnostics can be performed and analyzed continuously and in near real time.
In one embodiment, all of the gas-lift valves in the well are of the controllable type in accordance with the present invention. It is desirable to lift the oil column from a point in the borehole as close as possible to the production packer. That is, the lowest gas-lift valve is the primary valve in production. The upper gas-lift valves are used for annular unloading of the well during production initiation. In conventional gas-lift wells, these upper valves have bellows pre-set with a margin of error to ensure the valves close after unloading. This means operating pressures that permit closing of unloading valves as each successive valve is uncovered. These margins result in the inability to use the full available pressure to lift at maximum depth during production: lift pressure is lost downhole to accommodate the design margin offset at each valve. Further, such conventional valves often leak and fail to fully close. Use of the controllable valves of the present invention overcomes such shortcomings.
In an alternate embodiment, a number of conventional mechanical bellows-type gas-lift valves are longitudinally spaced on the tubing string in a conventional manner. The lower-most valve is preferably a bellows-type valve which aids in unloading of the well in the normal manner. The bellows-type valve's pre-charged pressure is set normally. That is, the unloading pushes annular fluid into the tubing through successively deeper gas-lift valves until the next to the last gas-lift valve is cleared by the fluid column. Production is then maintained by gas injection through a controllable gas-lift valve located on the tubing string, which as outlined above receives power and communication signals through its connection to the tubing and a grounding centralizer. While only one controllable gas-lift valve is described, more can be used if desired, depending upon the characteristics of a particular well. If the controllable gas-lift valve fails, the production is diverted through the lowest manual valve above the controllable gas-lift valve.
Construction of such a controllable gas-lift well is designed to be as similar to conventional construction methodology as possible. That is, after casing the well, a packer is typically set above the production zone. The tubing string is then fed through the casing into communication with the production zone. As the tubing string is made up at the surface, a lower ferromagnetic choke is placed around one of the conventional tubing string sections for positioning above the bottom valve, or a pre-assembled joint prepared with the valve, electronics module, and choke may be be used. In the sections of the tubing string where it is desired, a gas-lift valve is coupled to the string. In a preferred form the downhole valve is tubing conveyed, but a side pocket mandrel for receiving a slickline insertable and retrievable gas-lift valve may also be used. With the side-pocket mandrel, either a controllable gas-lift valve in accordance with the present invention can be inserted, or a conventional bellows-type valve can be used. The tubing string is made up to the surface, where a ferromagnetic choke or other electrical isolation device such as an electrically insulating joint is again placed around the tubing string below the tubing hanger. Communication and power leads are then connected through the wellhead feed through to the tubing string below the upper ferromagnetic choke or other isolation device.
In an alternative form of the controllable gas lift well, a pod having only a sensor and communication device is inserted without the necessity of including a controllable gas-lift valve in every pod. That is, an electronics module having pressure, temperature or acoustic sensors or other sensors, a power supply, and a modem may be tubing conveyed or inserted into a side pocket mandrel for communication to the surface computer or with other downhole modules and controllable gas lift valves using the tubing and casing as conductors. Alternatively, such electronics modules may be mounted directly on the tubing (tubing conveyed) and not be configured to be wireline replaceable. If directly mounted to the tubing an electronic module or a controllable gas-lift valve may only be replaced by pulling the entire tubing string. In an alternative form, the controllable valve can have its separate control, power and wireless communication electronics mounted in the side pocket mandrel of the tubing and not in the wireline replaceable valve. In the preferred form, the electronics are integral and replaceable along with the gas-lift valve. In another form, the high permeability magnetic chokes may be replaced by electrically insulated tubing sections. Further, an insulated tubing hanger in the wellhead may replace the upper choke or such upper insulating tubing sections.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional front view of a prior art, bellows-type gas-lift valve.
FIG. 2 is a schematic front view of a controllable gas-lift well according to one embodiment of the present invention, the gas-lift well having a tubing string and a casing positioned within a borehole.
FIG. 3 is a schematic front view of the tubing string and casing of FIG. 2, the tubing string having side pocket mandrels positioned thereon.
FIG. 4A is an enlarged schematic front view of the side pocket mandrel of FIG. 3 and a controllable gas-lift valve, the valve having an internal electronics module and being wireline retrievable from the side pocket mandrel.
FIG. 4B is a cross-sectional side view of the controllable gas-lift valve of FIG. 4A taken at IV—IV.
FIGS. 5A-5C are cross-sectional front views of a controllable valve in a cage configuration according to one embodiment of the present invention.
FIG. 6 is an enlarged schematic front view of the tubing string and casing of FIG. 2, the tubing string having an electronics module, sensors, and a controllable gas-lift valve operatively connected to an exterior of the tubing string.
FIG. 7 is an enlarged schematic front view of the tubing string and casing of FIG. 2, the tubing string having a controllable gas-lift valve permanently connected to the tubing string.
FIG. 8 is a cross sectional side views of the controllable gas-lift valve of FIG. 7 taken at VIII—VIII.
FIG. 9 is a schematic of an equivalent circuit diagram for the controllable gas-lift well of FIG. 2, the gas-lift well having an AC power source, the electronics module of FIG. 4, and the electronics module of FIG. 6 .
FIG. 10 is a schematic diagram depicting a surface computer electrically coupled to an electronics module of the gas-lift well of FIG. 2 .
FIG. 11 is a system block diagram of the electronics module of FIG. 10 .
FIG. 12 illustrates a disposition of chokes and controllable gas-lift valves to provide control of the valves when the tubing-casing annulus is partially filled with conductive fluid. and
FIG. 13 depicts a time-series chart showing the relationships between degree of opening of a gas-lift valve, annulus pressure, tubing pressure, and lifted fluid flow regimes.
DETAILED DESCRIPTION OF THE INVENTION
As used in the present application, a “valve” is any device that functions to regulate the flow of a fluid. Examples of valves include, but are not limited to, bellows-type gas-lift valves and controllable gas-lift valves, each of which may be used to regulate the flow of lift gas into a tubing string of a well. The internal workings of valves can vary greatly, and in the present application, it is not intended to limit the valves described to any particular configuration, so long as the valve functions to regulate flow. Some of the various types of flow regulating mechanisms include, but are not limited to, ball valve configurations, needle valve configurations, gate valve configurations, and cage valve configurations. The methods of installation for valves discussed in the present application can vary widely. Valves can be mounted downhole in a well in many different ways, some of which include tubing conveyed mounting configurations, side-pocket mandrel configurations, or permanent mounting configurations such as mounting the valve in an enlarged tubing pod.
The term “modem” is used generically herein to refer to any communications device for transmitting and/or receiving electrical communication signals via an electrical conductor (e.g., metal). Hence, the term is not limited to the acronym for a modulator (device that converts a voice or data signal into a form that can be transmitted)/demodulator (a device that recovers an original signal after it has modulated a high frequency carrier). Also, the term “modem” as used herein is not limited to conventional computer modems that convert digital signals to analog signals and vice versa (e.g., to send digital data signals over the analog Public Switched Telephone Network). For example, if a sensor outputs measurements in an analog format, then such measurements may only need to modulate a carrier to be transmitted-hence no analog-to-digital conversion is needed. As another example, a relay/slave modem or communication device may only need to identify, filter, amplify, and/or retransmit a signal received.
The term “sensor” as used in the present application refers to any device that detects, determines, monitors, records, or otherwise senses the absolute value of or a change in a physical quantity. Sensors as described in the present application can be used to measure temperature, pressure (both absolute and differential), flow rate, seismic data, acoustic data, pH level, salinity levels, valve positions, or almost any other physical data.
The term “electronics module” in the present application refers to a control device. Electronics modules can exist in many configurations and can be mounted downhole in many different ways. In one mounting configuration, the electronics module is actually located within a valve and provides control for the operation of a motor within the valve. Electronics modules can also be mounted external to any particular valve. Some electronics modules will be mounted within side pocket mandrels or enlarged tubing pockets, while others may be permanently attached to the tubing string. Electronics modules often are electrically connected to sensors and assist in relaying sensor information to the surface of the well. It is conceivable that the sensors associated with a particular electronics module may even be packaged within the electronics module. Finally, the electronics module is often closely associated with, and may actually contain, a modem for receiving, sending, and relaying communications from and to the surface of the well. Signals that are received from the surface by the electronics module are often used to effect changes within downhole controllable devices, such as valves. Signals sent or relayed to the surface by the electronics module generally contain information about downhole physical conditions supplied by the sensors.
The terms “first end” and “second end” as used herein are defined generally to call out a side or portion of a piping structure, which may or may not encompass the most proximate locations, as well as intermediate locations along a called out side or portion of the piping structure. Similarly, in accordance with conventional terminology of oilfield practice, the descriptors “upper”, “lower”, “uphole” and “downhole” refer to distance along hole depth from the surface, which in deviated wells may or may not accord with absolute vertical placement measured with reference to the ground surface.
Referring to FIG. 2 in the drawings, a petroleum well according to the present invention is illustrated. The petroleum well is a gas-lift well 210 having a borehole 211 extending from a surface 212 into a production zone 214 that is located downhole. A production platform is located at surface 212 and includes a hanger 22 for supporting a casing 24 and a tubing string 26 . Casing 24 is of the type conventionally employed in the oil and gas industry. The casing 24 is typically installed in sections and is cemented in the borehole during well completion. Tubing string 26 , also referred to as production tubing, is generally a conventional string comprising a plurality of elongated tubular pipe sections joined by threaded couplings at each end of the pipe sections, but may alternatively be continuously inserted as coiled tubing for example. The production platform includes a gas input throttle 30 to control the input of compressed gas into an annular space 31 between casing 24 and tubing string 26 . Conversely, output valve 32 permits the expulsion of oil and gas bubbles from the interior of tubing string 26 during oil production.
An upper ferromagnetic choke 40 or insulating pipe joint, and a lower ferromagnetic choke 42 are installed on tubing string 26 to act as a series impedance to electric current flow. The size and material of ferromagnetic chokes 40 , 42 can be altered to vary the series impedance value. The section of tubing string 26 between upper choke 40 and lower choke 42 may be viewed as a power and communications path (see also FIG. 9 ). Both upper and lower chokes 40 , 42 are manufactured of high permeability magnetic material and are mounted concentric and external to tubing string 26 . Chokes 40 , 42 are typically insulated with shrink wrap plastic and encased with fiber-reinforced epoxy to withstand rough handling.
A computer and power source 44 having power and communication feeds 46 is disposed outside of borehole 211 at surface 212 . Communication feeds 46 pass through a pressure feed 47 located in hanger 22 and are electrically coupled to tubing string 26 below upper choke 40 . Power and communications signals are supplied to tubing string 26 from computer and power source 44 .
A packer 48 is placed within casing 24 downhole below lower choke 42 . Packer 48 is located above production zone 214 and serves to isolate production zone 214 and to electrically connect metal tubing string 26 to metal casing 24 . Similarly, above surface 212 , the metal hanger 22 (along with the surface valves, platform, and other production equipment) electrically connects metal tubing string 26 to metal casing 24 . Typically, the electrical connections between tubing string 26 and casing 24 would not allow electrical signals to be transmitted or received up and down borehole 211 using tubing string 26 as one conductor and casing 24 as another conductor. However, the disposition of upper and lower ferromagnetic chokes 40 , 42 around tubing string 26 alter the electrical characteristics of tubing 26 , providing a system and method to provide power and communication signals up and down borehole 211 of gas-lift well 210 .
A plurality of conventional bellows-type gas-lift valves 50 are operatively connected to tubing string 26 (see discussion of FIG. 1 in the Background of the Invention). The number of conventional valves 50 disposed along tubing string 26 depends upon the depth of the well and the well lift characteristics. A controllable gas-lift valve 52 in accordance with the present invention is attached to tubing string 26 as the penultimate gas-lift valve. In this embodiment, only one controllable gas-lift valve 52 is used.
Referring now to FIG. 3 in the drawings, the downhole configuration of bellows-type valve 50 and controllable valve 52 , as well as the electrical connections with casing 24 and tubing string 26 , is depicted. The pipe sections of tubing string 26 are conventional and where it is desired to incorporate a gas-lift valve in a particular pipe section, a side pocket mandrel 54 , commonly available in the industry, is employed. Each side pocket mandrel 54 is a non-concentric enlargement of tubing string 26 that permits wireline retrieval and insertion of either bellows-type valves 50 or controllable valves 52 downhole.
Referring still to FIG. 3, but also to FIGS. 4A and 4B, a plurality of bow spring centralizers 60 may be installed at various locations along the length of tubing string 26 to center tubing string 26 relative to casing 24 . When located between upper and lower chokes 40 , 42 , each bow spring centralizer 60 includes insulators 62 to electrically isolate casing 24 from tubing string 26 . A power and signal jumper wire 64 electrically connects controllable valve 52 to tubing string 26 at a point between upper choke 40 and lower choke 42 . Although controllable valve 52 is shown below lower choke 42 , the valve 52 could be disposed above lower choke 42 such that controllable valve 52 is electrically coupled to tubing string 26 without using a power jumper. A ground wire 66 provides a return path from controllable valve 52 to casing 24 via electrically conductive centralizer 60 . While jumper wire 64 and ground wire 66 are illustrated schematically in FIGS. 3 and 4A, it will be appreciated that in commercial use jumper wire 64 and ground wire 66 may be insulated and predominantly integral to a housing of side pocket mandrel 54 .
It should be noted that the power supplied downhole through tubing string 26 is effective only when annulus 31 does not contain an electrically conductive liquid between upper choke 40 and lower choke 42 . If an electrically conductive liquid is present in the annulus 31 between the chokes 40 , 42 , the liquid will cause a short circuit of the current in tubing string 26 to casing 24 .
Use of controllable valves 52 may be preferable to use of conventional bellows valves for several reasons. For example, conventional bellows valves 50 (see FIG. 1) often leak when they should be closed during production, resulting in inefficient well operation. Additionally, conventional bellows valves 50 are usually designed to use sequentially decremented operating presssures resulting in the inability to make use of full available lift pressure, therefore resulting in further inefficiency.
Referring more specifically to FIGS. 4A and 4B, a more detailed illustration of controllable gas-lift valve 52 and side pocket mandrel 54 is provided. Side pocket mandrel 54 includes a housing 68 having a gas inlet port 72 and a gas outlet port 74 . When controllable valve 52 is in an open position, gas inlet port 72 and gas outlet port 74 provide fluid communication between annular space 31 and an interior of tubing string 26 . In a closed position, controllable valve 52 prevents fluid communication between annular space 31 and the interior of tubing string 26 . In a plurality of intermediate positions located between the open and closed positions, controllable valve 52 meters the amount of gas flowing from annular space 31 into tubing string 26 through gas inlet port 72 and gas outlet port 74 .
Controllable gas-lift valve 52 includes a generally cylindrical, hollow housing 80 configured for reception in side pocket mandrel 54 , and is furnished with a latching method to leave and retrieve the valve using a tubing accessible method such as slickline. An electronics module 82 is disposed within housing 80 and is electrically connected to a stepper motor 34 for controlling the operation thereof. Operation of stepper motor 84 adjusts a needle valve head 86 , thereby controlling the position of needle valve head 86 in relation to a valve seat 88 . Movement of needle valve head 86 by stepper motor 84 directly affects the amount of fluid communication that occurs between annular space 31 and the interior of tubing string 26 . When needle valve head 86 fully engages valve seat 88 as shown in FIG. 4B, the controllable valve 52 is in the closed position.
Seals 90 are made of an elastomeric material and allow controllable valve 52 to sealingly engage side pocket mandrel 54 . Slip rings 92 surround a lower portion of housing 80 and are electrically connected to electronics module 82 . Slip rings 92 provide an electrical connection for power and communication between tubing string 26 and electronics module 82 .
Controllable valve 52 includes a check valve head 94 disposed within housing 80 below needle valve head 86 . An inlet 96 and an outlet 98 cooperate with inlet port 72 and outlet port 74 when valve 52 is in the open position to provide fluid communication between annulus 31 and the interior of tubing string 26 . Check valve 94 insures that fluid flow only occurs when the pressure of fluid in annulus 31 is greater than the pressure of fluid in the interior of tubing string 26 .
Referring to FIGS. 5A, 5 B, and 5 C in the drawings, another embodiment of a controllable valve 220 according to the present invention is illustrated. Controllable valve 220 includes a housing 222 and is slidably received in a side pocket mandrel 224 (similar to side pocket mandrel 54 of FIG. 4 A). Side pocket mandrel 224 includes a housing 226 having a gas inlet port 228 and a gas outlet port 230 . When controllable valve 220 is in an open position, gas inlet port 228 and gas outlet port 230 provide fluid communication between annular space 31 and an interior of tubing string 26 . In a closed position, controllable valve 220 prevents fluid communication between annular space 31 and the interior of tubing string 26 . In a plurality of intermediate positions located between the open and closed positions, controllable valve 220 meters the amount of gas flowing from annular space 31 into tubing string 26 through gas inlet port 228 and gas outlet port 230 .
A motor 234 is disposed within housing 222 of controllable valve 220 for rotating shaft 236 . Pinion 236 engages a worm gear 238 , which in turn raises and lowers a cage 240 . When valve 220 is in the closed position, cage 240 engages a seat 242 to prevent flow into an orifice 244 , thereby preventing flow through valve 220 . As shown in more detail in FIG. 5B, a shoulder 246 on seat 242 is configured to sealingly engage a mating collar on cage 240 when the valve is closed. This “cage” valve configuration with symmetrically spaced and opposing flow ports is believed to be a preferable design since the impinging flow minimizes erosion when compared to the alternative embodiment of a needle valve configuration (see FIG. 4 B). More specifically, fluid flow from inlet port 228 , past the cage and seat juncture ( 240 , 242 ) permits precise fluid regulation without undue fluid wear on the mechanical interfaces.
Controllable valve 220 includes a check valve head 250 disposed within housing 222 below cage 240 . An inlet 252 and an outlet 254 cooperate with gas inlet port 228 and gas outlet port 230 when valve 220 is in the open position to provide fluid communication between annulus 31 and the interior of tubing string 26 . Check valve head 250 insures that fluid flow only occurs when the pressure of fluid in annulus 31 is greater than the pressure of fluid in the interior of tubing string 26 .
An electronics module 256 is disposed within the housing of controllable valve 220 . Electronics module is operatively connected to valve 220 for communication between the surface of the well and the valve. In addition to sending signals to the surface to communicate downhole physical conditions, the electronics module can receive instructions from the surface and adjust the operational characteristics of the valve 220 .
While FIGS. 4A, 4 B, and FIGS. 5A-5C illustrate the embodiments of the controllable valve in accordance with the present invention, other embodiments are possible without departing from the spirit and scope of the present invention. In particular, patent publication WO02/059457, entitled “Downhole Motorized Control Valve” describes yet another embodiment and is incorporated herein by reference. Referring to FIG. 6 in the drawings, an alternative installation configuration for a controllable valve assembly is shown and should be contrasted with the slide pocket mandrel configuration of FIG. 4 A. In FIG. 6, tubing 26 includes an annularly enlarged pocket, or pod 100 formed on the exterior of tubing string 26 . Enlarged pocket 100 includes a housing that surrounds and protects the controllable gas-lift valve assembly and an electronics module 106 . In this mounting configuration, gas-lift valve assembly is rigidly mounted to tubing string 26 and is not insertable and retrievable by wireline. A ground wire 102 (similar to ground wire 66 of FIG. 4A) is fed through enlarged pocket 100 to connect electronics module 106 to bow spring centralizer 60 , which is grounded to casing 24 . Electronics module 106 is rigidly connected to tubing string 26 and receives communications and power via a power and signal jumper 104 . The electronics module 106 in this configuration is not insertable or retrievable by wireline.
Enlarge pocket 100 includes a housing that surrounds and protects controllable the gas-lift valve assembly and an electronics module 106 . In this mounting configuration, gas-lift valve assembly is rigidly mounted to tubing string 26 and is not insertable and retrievable by wireline. A ground wire 102 (similar to ground wire 66 of FIG. 4A) is fed through enlarged pocket 100 to connect electronics module 106 to bow spring centralizer 60 , which is grounded to causing 24 . Electronics module 106 is rigidly connected to tubing string 26 and receives communications and power via a power and signal jumper 104 . The electronics module 106 in this configuration is not insertable or retrievable by wireline.
Controllable valve assembly includes a motorized cage valve 108 and a check valve 110 that are schematically illustrated in FIG. 6 . Cage valve 108 and check valve 110 operate in a similar fashion to cage 240 and check valve head 250 of FIG. 5 A. The valves 108 , 110 cooperate to control fluid communication between annular space 31 and the interior of tubing string 26 .
A plurality of sensors are used in conjunction with electronics module 106 to control the operation of controllable valve and gas-lift well 210 . Pressure sensors, such as those produced by Three Measurement Specialties, Inc., can be used to measure internal tubing pressure, internal pod housing pressures, and differential pressures across gas-lift valves. In commercial operation, the internal pod pressure is considered unnecessary. A pressure sensor 112 is rigidly mounted to tubing string 26 to sense the internal tubing pressure of fluid within tubing string 26 . A pressure sensor 118 is mounted within pocket 100 to determine the differential pressure across cage valve 108 . Both pressure sensor 112 and pressure sensor 118 are independently electrically coupled to electronics module 106 for receiving power and for relaying communications. Pressure sensors 112 , 118 are potted to withstand the severe vibration associated with gas-lift tubing strings.
Temperature sensors, such as those manufactured by Four Analog Devices, Inc. (e.g. LM-34), are used to measure the temperature of fluid within the tubing, housing pod, power transformer, or power supply. A temperature sensor 114 is mounted to tubing string 26 to sense the internal temperature of fluid within tubing string 26 . Temperature sensor 114 is electrically coupled to electronics module 106 for receiving power and for relaying communications. The temperature transducers used downhole are rated for −50 to 300° F. and are conditioned by input circuitry to +5 to +255° F. The raw voltage developed at a power supply in electronics module 106 is divided in a resistive divider element so that 25.5 volts will produce an input to the analog/digital converter of 5 volts.
A salinity sensor 116 is also electrically connected to electronics module 106 . Salinity sensor 116 is rigidly and sealingly connected to the housing of enlarged pocket 100 to sense the salinity of the fluid in annulus 31 .
It should be understood that the alternate embodiments illustrated in FIGS. 4A, 5 C and 6 could include or exclude any number of the sensors 112 , 114 , 116 or 118 . Sensors other than those displayed could also be employed in either of the embodiments. These could include gauge pressure sensors, absolute pressure sensors, differential pressure sensors, flow rate sensors, tubing acoustic wave sensors, valve position sensors, or a variety of other analog signal sensors. Similarly, it should be noted that while electronics module 82 shown in FIG. 4B is packaged within valve 52 , an electronics module similar to electronics module 106 could be packaged with various sensors and deployed independently of controllable valve 52 .
Referring to FIGS. 7 and 8 in the drawings, a controllable gas-lift valve 132 having a valve housing 133 is mounted on a tubing conveyed mandrel 134 . Controllable valve 132 is mounted similar to most of the bellows-type gas-lift valves that are in use today. These valves are not wireline replaceable, and must be replaced by pulling tubing string 26 . An electronics module 138 is mounted within housing 133 above a motor 142 that drives a needle valve head 144 . A check valve 146 is disposed within housing 133 below needle valve head 144 . Stepper motor 142 , needle valve head 144 , and check valve 146 are similar in operation and configuration to those used in controllable valve 52 depicted in FIG. 4 B. It should be understood, however, that valve 132 could include a cage configuration (as opposed to the needle valve configuration) similar to valve 220 of FIG. 5 A. In similar fashion to FIG. 4B, an inlet opening 148 and an outlet opening 150 are provided to provide a fluid communication path between annulus 31 and the interior of tubing string 26 .
Power and communications are supplied to electronics module 138 by a power and signal jumper 140 connected between electronics module 138 and housing 133 . Power is supplied to housing 133 either directly from tubing string 26 or via a wire (not shown) connected between housing 133 and tubing string 26 . A ground wire 136 couples electronics module 138 centralizer 60 for grounding purposes.
Although not specifically shown in the drawings, electronics module 138 could have any number of sensors electrically coupled to the module 138 for sensing downhole conditions. These could include pressure sensors, temperature sensors, salinity sensors, flow rate sensors, tubing acoustic wave sensors, valve position sensors, or a variety of other analog signal sensors. These sensors would likely be connected in a manner similar to that used for sensors 112 , 114 , 116 , and 118 of FIG. 6 .
Referring now to FIG. 9 in the drawings, an equivalent circuit diagram for gas-lift well 210 is illustrated and should be compared to FIG. 2 . Computer and power source 44 includes an AC power source 120 and a master modem 122 electrically connected between casing 24 and tubing string 26 . As discussed previously, electronics module 82 is mounted internally within a valve housing that is wireline insertable and retrievable downhole. Electronics module 106 is independently and permanently mounted in an enlarged pocket on tubing string 26 . Although not shown, the equivalent circuit diagram could also include depictions of electronics module 256 of FIG. 5A or electronic module 138 of FIG. 8 .
For purposes of the equivalent circuit diagram of FIG. 9, it is important to note that while electronics modules 82 , 106 appear identical, both modules 82 , 106 being electrically connected between casing 24 and tubing string 26 , electronics modules 82 , 106 may contain or omit different components and combinations such as sensors 112 , 114 , 116 , 118 . Additionally, the electronics modules may or may not be an integral part of the controllable valve. Each electronics module includes a power transformer 124 and a data transformer 128 . Data transformer 128 is electrically coupled to a slave modem 130 .
Referring to FIG. 10 in the drawings, a block diagram of a communications system 152 according to the present invention is illustrated. FIG. 10 should be compared and contrasted with FIGS. 2 and 9. Communications system 152 includes master modem 122 , AC power source 120 , and a computer 154 . Computer 154 is coupled to master modem 122 , preferably via an RS 232 bus, and runs a multitasking operating system such as Windows NT and a variety of user applications. AC power source 120 includes a 120 volt AC input 156 , a ground 158 , and a neutral 160 as illustrated. Power source 120 also includes a fuse 162 , preferably 7.5 amp, and has a transformer output 164 at approximately 6 volts AC and 60 Hz. Power source 120 and master modem 122 are both connected to casing 24 and tubing 26 .
Communications system 152 includes an electronics module 165 that is analogous to module 82 in FIG. 4B, module 256 in FIG. 5B, module 106 in FIG. 6, and module 138 in FIG. 8 . Electronics module 165 includes a power supply 166 and an analog-to-digital conversion module 168 . A programmable interface controller (PIC) 170 is electrically coupled to a slave modem 171 (analogous to slave modem 130 of FIG. 9 ). Couplings 172 are provided for coupling electronics module 165 to casing 24 and tubing 26 .
Referring to FIG. 11 in the drawings, electronics module 165 is illustrated in more detail. Amplifiers and signal conditioners 180 are provided for receiving inputs from a variety of sensors such as tubing temperature, annulus temperature, tubing pressure, annulus pressure, lift gas flow rate, valve position, salinity, differential pressure, acoustic readings, and others. Some of these sensors are analogous to sensors 112 , 114 , 116 , and 118 shown in FIG. 6 . Preferably, any low noise operational amplifiers are configured with non-inverting single ended inputs (e.g. Linear Technology LT1369). All amplifiers 180 are programmed with gain elements designed to convert the operating range of an individual sensor input to a meaningful 8 bit output. For example, one psi of pressure input would produce one bit of digital output, 100 degrees of temperature will produce 100 bits of digital output, and 12.3 volts of raw DC voltage input will produce an output of 123 bits. Amplifiers 180 are capable of rail-to-rail operation.
Electronics module 165 is electrically connected to master modem 122 via casing 24 and tubing string 26 . Address switches 182 are provided to address a particular device from master modem 122 . As shown in FIG. 11, 4 bits of addresses are switch selectable to form the upper 4 bits of a full 8 bit address. The lower 4 bits are implied and are used to address the individual elements within each electronics module 165 . Thus, using the configuration illustrated, sixteen modules are assigned to a single master modem 122 on a single communications line. As configured, up to four master modems 122 can be accommodated on a single communications line.
Electronics module 165 also includes PIC 170 , which preferably has a basic clock speed of 20 MHz and is configured with 8 analog-to-digital inputs 184 and 4 address inputs 186 . PIC 170 includes a TTL level serial communications UART 188 , as well as a motor controller interface 190 .
Electronics module 165 also contains a power supply 166 . A nominal 6 volts AC line power is supplied to power supply 166 along tubing string 26 . Power supply 166 converts this power to plus 5 volts DC at terminal 192 , minus 5 volts DC at terminal 194 , and plus 6 volts DC at terminal 196 . A ground terminal 198 is also shown. The converted power is used by various elements within electronics module 165 .
Although connections between power supply 166 and the components of electronics module 165 are not shown, the power supply 166 is electrically coupled to the following components to provide the specified power. PIC 170 uses plus 5 volts DC, while slave modem 171 uses plus 5 and minus 5 volts DC. A motor 199 (analogous to motor 84 of FIG. 4B, motor 234 of FIG. 5A, and motor 142 of FIG. 8) is supplied with plus 6 volts DC from terminal 196 . Power supply 166 comprises a step-up transformer for converting the nominal 6 volts AC to 7.5 volts AC. The 7.5 volts AC is then rectified in a full Wave bridge to produce 9.7 volts of unregulated DC current. Three-terminal regulators provide the regulated outputs at terminals 192 , 194 , and 196 which are heavily filtered and protected by reverse EMF circuitry. Modem 171 is the major power consumer in electronics module 165 , typically using 350+ milliamps at plus/minus 5 volts DC when transmitting.
Modem 171 is typically a wideband digital modem having an IC/SS power line carrier chip set such as models EG ICS 1001, ICS 1002 and ICS 1003 manufactured by National Semiconductor. Modem 171 is capable of 300-3200 baud data rates at carrier frequencies ranging from 14 kHz to 76 kHz. U.S. Pat. No. 5,488,593 describes the chip set in more detail and is incorporated herein by reference. Any modem with an adequate data rate may be substituted for this choice of specific components.
PIC 170 controls the operation of a suitable valve control motor 199 through, for example, stepper motor controller 200 such as model SA1042 manufactured by Motorola. Controller 200 needs only directional information and simple clock pulses from PIC 170 to drive stepper motor 199 . An initial setting of controller 200 conditions all elements for initial operation in known states. Stepper motor 199 , preferably a MicroMo gear head, positions a rotating stem control valve 201 (analogous to needle valve heads 86 , 108 , and 144 of FIGS. 4B, 6 , and 8 , respectively), which is the principal operative component of the controllable gas-lift valve. Alternatively, motor 199 could position a cage analogous to cage 240 of FIG. 5 A. Motor 199 provides 0.4 inch-ounce of torque and rotates at up to 500 steps per second. A complete revolution of stepper motor 199 consists of 24 individual steps. The output of stepper motor 199 is directly coupled to a 989:1 gear head, and the output shaft from the gearhead may thus rotate at a maximum of 1.26 revolutions per minute, and can exert a maximum torque of 24.7 inch-pounds. This produces the necessary torque to open and close needle valve 201 . The continuous rotational torque required to open and close needle valve 201 is 3 inch-pounds with 15 inch-pounds required to seat and unseat the valve 201 .
PIC 170 communicates through modem 171 to the surface modem 122 via casing 24 and tubing string 26 . PIC 170 uses a MODBUS 584/985 PLC communications protocol, with commands and data ASCII encoded for transmission.
As noted previously with reference to FIG. 2, the embodiments thus far described for providing power and communications for controllable gas lift valve 52 are restricted to the well condition where annular space between tubing 26 and casing 24 is cleared of conductive fluid. In some circumstances for example during the unloading or kickoff processes, it may desirable to allow all of the valves in a gas lift well to be powered and controlled from the surface.
FIG. 12 illustrates an embodiment in which power and communications may be established for valves when the annulus 31 is only partially cleared of conductive fluid. As in the previous embodiments, surface equipment 44 includes an AC power source and communications device coupled by conductors 46 to tubing 26 and casing 24 . An upper choke 40 impedes AC which would otherwise be electrically short-circuited through hanger 22 , and the AC is thus directed down tubing string 26 to downhole equipment. At each location where it is desired to place a downhole electronics module 50 there is a choke 41 which creates an impedance to AC and therefore generates a voltage on the tubing 34 between the tubing above and below the choke. This voltage is connected by wires 64 and 66 to each electronics module 50 , and thus the voltage developed by the action of each choke 41 may be used to transfer power and communications signals to its corresponding electronics module 50 . Connections 64 , 66 , and the action of chokes 41 , also allow communications signals from each module 50 to be impressed on tubing 34 and received at surface equipment 44 . When the level of conducting fluid 182 is at level 1 of FIG. 12, none of the chokes will function to power their modules, since AC between tubing and casing is electrically short-circuited by fluid 182 before it reaches any of the chokes. However, when the fluid level is at level 2 , the upper choke 41 is effective since there is no longer an electrical short-circuit between tubing and casing above the upper choke 41 , and a potential difference can be developed on the tubing section that passes through the upper choke. Thus power and communications become available for the electronics module above level 2 . The same principle applies to the intermediate levels: as the surface of fluid 182 is driven downwards past levels 3 , 4 and 5 , the corresponding electronics modules at these levels become operable. The lowermost module is energized by choke 42 , and becomes operable when the fluid 182 is as illustrated in FIG. 12, below the lowest choke 42 .
Operation
FIG. 13 demonstrates the benefit of the availability of data and a method to respond to observations with a downhole control action. The chart of FIG. 13 presents a time series trend of three values. The first value is valve position 401 , expressed as a percent of full open (full open=100%) which is quantified by referencing the Y-axis on the right side of the plot. The second value is annulus pressure 402 , which is quantified by referencing the Y-axis scale on the left side of the plot. The annulus pressure is the pressure of the lift gas being supplied to the well and is upstream of the downhole controllable gas lift valve. The third value is the tubing pressure 403 , which is quantified by referencing the Y-axis on the left side of the plot. The tubing pressure is the pressure in the production tubing downstream of the controllable gas lift valve.
In a typical oil well, reducing the pressure in the tubing by injecting bubbles of gas into the liquid column above the point of lift gas injection into the tubing results in a decreased back-pressure on the reservoir. The decrease in back-pressure results in increased differential pressure from the reservoir to the tubing and therefore flow from the reservoir to the tubing and to the surface. An increase in downhole tubing pressure creates an increased back pressure on the reservoir, which decreases flow, even to the point of stopping inflow from the reservoir completely. It is important that the tubing pressure remain low and stable in order to achieve stable production rates from the reservoir to the surface and to the production facilities. Unstable flow causes upset conditions in production facilities due to the large changes in flow rate over short periods of time. Large surges in liquid and gas production can upset production processes creating inefficient and possibly hazardous conditions.
As previously discussed, conventional gas lift valves are configured before installation using information available at the time of configuration. As the well conditions change over time, the original configuration of the gas lift valve may no longer be appropriate for the new conditions. The effect of this miss-match is shown in FIG. 13 .
A gas lift valve port that is inappropriately large has been created by fully opening the downhole controllable gas lift valve as shown at 404 . The reservoir fluids are allowed to fill the tubing, causing the pressure to increase at 405 . Gas is introduced into the annulus, causing the annulus pressure to increase at 406 . The gas does not flow from the annulus to the tubing as the annulus pressure is less than the tubing pressure. The downstream pressure must be less than the upstream pressure in order to initiate flow. Gas does not flow from the tubing back into the annulus due to the presence of a reverse-flow check valve which prevents such backflow.
When the annulus pressure 406 increases sufficiently to exceed the tubing pressure 405 , gas flow is initiated into the tubing, the tubing pressure is reduced as the gas reduces the density of the tubing fluids via injection of bubbles into the liquid column at 407 . As the tubing pressure drops, the annulus pressure also begins to decline at 408 as the gas is flowing from the annulus to the tubing at a rate higher than gas is being introduced into the annulus from the surface. The gas flow rate from the annulus to the tubing is a function of the downhole controllable gas lift valve opening position which is 100%, and the differential pressure between the annulus and the tubing. If the gas flow out of the annulus into the tubing exceeds the injection rate into the annulus at the surface, the annulus pressure falls. If the gas flow out of the annulus into the tubing is less than the injection rate into the annulus at the surface, the annulus pressure increases.
If annulus outflow exceeds inflow for an extended period of time, the pressure difference between the annulus and the tubing may decline to level where insufficient gas enters the tubing to keep the fluids aerated to the degree required to maintain a low tubing pressure as shown at 409 . At that point, the tubing pressure begins to increase, 410 , as the density increases. The annulus pressure increases, 411 , also as the differential pressure between the annulus and tubing is so small that the gas flow rate into the tubing from the annulus is less than the rate of gas input into the annulus at the surface.
At some point, 412 , the pressure differential between the annulus and the tubing increases sufficiently for the volume of gas entering the tubing to reduce the density and cause the pressure to decrease, 413 . This begins another “heading” cycle that originally began at 407 . Left unchecked, such cycles repeat continuously. The surges of liquids and gas delivered to the producing facilities and the surges of lift gas demanded from the supply system generally influence not only the well suffering from the cause, but also affect other wells in the system. It is therefore desirable to correct this problem as quickly as possible. Conventional gas lift installations require that the well be closed in (stopping production) and remedial service work be performed on the well to remove the improperly sized or eroded valve and replace with one that has been configured for the new producing conditions. This results in significant cost and deferment of oil production.
In the case of a downhole controllable gas lift valve, the flow capacity of the valve can be adjusted without any service work or loss of production by closing the valve to some degree, such as closing from 97% open to 52% open as shown at 414 . The result of this action is to present excessive flow out of the annulus into the tubing, which causes the upstream (annulus) pressure to stabilize, 415 , and also the downstream (tubing pressure) to stabilize, 416 .
With downhole data available in real-time, a further adjustment, 417 , of the downhole controllable gas lift valve maintains stable annulus pressure, 418 , and tubing pressure, 419 , but causes the tubing pressure to decline slightly from the previous pressure. This pressure decline slightly reduces the back pressure on the reservoir, slightly increasing production rate as a result. A conventional gas lift system cannot provide the data or the ability to make such small adjustments, which enable continuous optimization of the producing system via feedback and response loops.
To illustrate the benefit of independent control for every lift gas valve in a well, FIG. 12 may be used to describe a process for unloading a gas lift well based on the methods of the present invention.
Typically the unloading process starts with the annulus 31 filled with completion fluid 182 , to level 1 of the well as illustrated in FIG. 12 . The completion fluid 182 is normally a brine which is electrically conductive, and thus creates an electrical connection between tubing 34 and casing 24 . Each downhole module 50 controls a motorized gas lift valve which may be opened to permit fluid, either liquid or gas, to pass from the annulus 31 to the interior of tubing 34 . At the start of the unloading process all of these lift gas valves are open, but none of the modules 50 can be powered since the completion fluid creates an electrical short circuit between the tubing 26 and the casing 24 at a point above all of the chokes 41 , 42 .
To initiate the unloading process, lift gas under pressure from a surface supply is admitted to the annulus 31 , and starts to displace the completion fluid through the open lift gas valves of each of the downhole modules 40 , thus driving down the level of the completion fluid. When the level of the completion fluid has reached level 2 indicated on FIG. 12, the first module 50 immediately above level 2 becomes powered and thus controllable, since the tubing and casing above level 2 are no longer electrically short-circuited above level 2 . The lift gas valve associated with the module immediately above level 2 may now be regulated to control the flow of lift gas into the tubing 34 . The rising column of lift gas bubbles lightens the liquid column between this first valve and the surface, inducing upwards flow in the production tubing. At this point in the unloading process therefore, the uppermost lift gas valve is passing gas under control from commands sent from surface equipment 44 , and the other lift gas valves are open to pass completion fluid but cannot yet be controlled.
Completion fluid continues to be expelled through the lower open valves until the completion fluid level reaches level 3 . The module 50 immediately above level 3 becomes powered and controllable as described with reference to the valve at level 2 , so that lift gas flow through the valve at level 3 may now be regulated by commands sent from the surface. Once this flow is established, the lift gas valve at level 2 may be closed, and lift of fluids in the tubing 34 is thus transferred from level 2 to level 3 .
In like manner, as the completion fluid continues to be expelled and its surface passes levels 4 and 5 , the gas lift valves at these levels become powered and controllable at progressively greater depths. As gas lift progresses down the tubing, the valves above are closed to conserve lift gas, which is directed to only the lowermost lifting valve. At the end of the unloading process, only the gas lift valve at choke 32 is open, and all valves above it are closed.
This method for controlling the unloading process ensures that each valve is closed at the correct moment. In existing practice and without benefit of means to control directly the lift gas valves, the cycling of the intermediate valves between open and closed is implemented by using pre-set opening and closing pressures. These preset values are chosen using design calculations which are based on incomplete or uncertain data. The consequence is that in existing practice the valves frequently open and close at inappropriate times, causing lift instability, excessive wear or total destruction of the valves, and also inefficiencies in lift gas usage from the need to specify the valve presets with pressure margins which reduce the range of gas pressures which can be made available for lift during the unloading and production processes.
A large percentage of the artificially lifted oil production today uses gas-lift to help bring the reservoir oil to the surface. In such gas-lift wells, compressed gas is injected downhole outside the tubing, usually in the annulus between the casing and the tubing and mechanical gas-lift valves permit communication of the gas into the tubing section and the rise of the fluid column within the tubing to the surface. Such mechanical gas-lift valves are typically mechanical bellows-type devices (see FIG. 1) that open and close when the fluid pressure exceeds the pre-charge in the bellows section. Unfortunately, a leak in the bellows is common and renders the bellows-type valve largely inoperative once the bellows pressure departs from its pre-charge setting unless the bellows fails completely, i.e. rupture, in which case the valve fails closed and is totally inoperative. Further, a common source of failure in such bellows-type valve is the erosion and deterioration of the ball valve against the seat as the ball and seat contact frequently during normal operation in the often briney, high temperature, and high pressure conditions around the ball valve. Such leaks and failures are not readily detectable at the surface and probably reduce a well's production efficiency on the order of 15 percent through lower production rates and higher demands on the field lift gas compression systems.
The controllable gas-lift well of the present invention has a number of data monitoring pods and controllable gas-lift valves on the tubing string, the number and type of each pod and controllable valves depends on the requirements of the individual well. Each of the individual data monitoring pods and controllable valves is individually addressable via wireless spread spectrum communication through the tubing and casing. That is, a master spread spectrum modem at the surface and an associated controller communicates to a number of slave modems. The data monitoring pods report such measurements as downhole tubing pressures, downhole casing pressures, downhole tubing and casing temperatures, lift gas flow rates, gas valve position, and acoustic data (see FIG. 6, sensors 112 , 114 , 116 , and 118 ). Such data is similarly communicated to the surface through a slave spread spectrum modem communicating through the tubing and casing.
The surface computer (either local or centrally located) continuously combines and analyzes the downhole data as well as surface data, to compute a real-time tubing pressure profile. An optimal gas-lift flow rate for each controllable gas-lift valve is computed from this data. Preferably, pressure measurements are taken at locations uninfluenced by gas-lift injection turbulence. Acoustic sensors (sounds less than approximately 20 kilohertz) listen for tubing bubble patterns. Data is sent via the slave modem directly to the surface controller. Alternatively, data can be sent to a mid-hole data monitoring pod and relayed to the surface computer.
In addition to controlling the flow rate of the well, production may be controlled to produce an optimum fluid flow state. Unwanted conditions such as “heading” and “slug flow” can be avoided. As previously mentioned, it is possible to attain and maintain the most desirable flow regime. By being able to determine such unwanted bubble flow conditions quickly downhole, production can be controlled to avoid such unwanted conditions. A fast detection of flow conditions allows the correction of any flow problems by adjusting such factors as the position of the controllable gas-lift valve, the gas injection rate, back pressure on tubing at the wellhead, and even injection of surfactant.
Even though many of the examples discussed herein are applications of the present invention in petroleum wells, the present invention also can be applied to other types of wells, including but not limited to water wells and natural gas wells.
One skilled in the art will see that the present invention can be applied in many areas where there is a need to provide a controllable valve within a borehole, well, or any other area that is difficult to access. Also, one skilled in the art will see that the present invention can be applied in many areas where there is an already existing conductive piping structure and a need to route power and communications to a controllable valve in a same or similar path as the piping structure. A water sprinkler system or network in a building for extinguishing fires is an example of a piping structure that may be already existing and may have a same or similar path as that desired for routing power and communications to a controllable valve. In such case another piping structure or another portion of the same piping structure may be used as the electrical return. The steel structure of a building may also be used as a piping structure and/or electrical return for transmitting power and communications to a valve in accordance with the present invention. The steel rebar in a concrete dam or a street may be used as a piping structure and/or electrical return for transmitting power and communications to a controllable valve in accordance with the present invention. The transmission lines and network of piping between wells or across large stretches of land may be used as a piping structure and/or electrical return for transmitting power and communications to a controllable valve in accordance with the present invention. Surface refinery production pipe networks may be used as a piping structure and/or electrical return for transmitting power and communications to a controllable valve in accordance with the present invention. Thus, there are numerous applications of the present invention in many different areas or fields of use.
It should be apparent from the foregoing that an invention having significant advantages has been provided. While the invention is shown in only a few of its forms, it is not just limited but is susceptible to various changes and modifications without departing from the spirit thereof. | A gas-lift well having a controllable gas-lift valve is provided. The well uses the tubing and casing to communicate with and power the controllable valve from the surface. Induction chokes at the surface and downhole electrically isolate the tubing from the casing. A high band-width, adaptable communication system is used to communicate between the controllable valve and the surface. Additional sensors, such as pressure, temperature, and acoustic sensors, may be provided downhole to more accurately assess downhole conditions. The controllable valve is varied opened or closed, depending on downhole conditions, oil production, gas usage and availability, to optimize production and assist in unloading. While conventional, bellows-type, gas-lift valves frequently fail and leak—often undetected—the controllable valve hereof permits known precise operation and concomitant control of the gas-lift well. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/892,870 filed on Aug. 28, 2007 which claims priority from U.S. Provisional Application No. 61/027,228 filed on Feb. 8, 2008 both incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to wall structures and in particular to log wall structures.
[0003] Log construction has been known for many decades as typified by the log cabin. For many years the logs have been notched so that at a corner, logs forming one wall of a structure can be laid on top of and at an angle alternating with logs from an intersecting wall. Although a number of materials may be used to form the “logs” used as wall members, including various types of composite materials, the wall members are typically milled from wood. The term “logs” will be used throughout this disclosure to include all types of materials that simulate a horizontal wooden log and includes different cross sections, either machined, hand-hewn or in a natural state.
[0004] The assembly of buildings from logs has been performed using traditional techniques. Where hand hewn logs are used, the builder individually fits each log to ensure a proper fit. Whilst this is traditionally done at the final site of the building it has become more common to assemble the shell of the building at a convenient remote location and then disassemble the logs for transportation. The building is then reassembled at the intended site and finished.
[0005] Log buildings using manufactured logs have the logs machined and cut at the factory to provide the desired floor plan. The logs are then transported to the site where the building is assembled.
[0006] In either case, assembly of the building at the final site requires the relocation of skilled workmen, the provision of tools and equipment for assembly at the site and the exposure of the partially assembled structure to a potentially inclement environment.
[0007] In practical use, traditional construction is usually limited to right angle corners because of the complexity of the angled notches required for non-right angle corners. More recently, posts have been introduced that can be milled with longitudinal faces at a range of desirable angles such that wall members having square-cut ends can be attached by spikes to the posts to form right-angle or non-right angle corners.
[0008] To form a tight connection between the logs and the posts, split key members have been used that engage cooperating undercut recesses in the end of the log and a face of the post. In U.S. Pat. No. 6,050,033 there is disclosed a spline arrangement in which the log and post are connected by a key formed by a pair of wedges. The key is expandable and secures the log to the post. A first section of the key member is fitted into place to engage the recesses in the post and the log and then a second section of the key member is inserted and tapped into place beside the first section of the key member. The cross-sections of the split key member are wedge-shaped and tighten the joint as the second portion of the key member is tapped into place.
[0009] It is necessary to ensure that the interconnecting butt joints are tight and provide an effective seal, but at the same time accommodate relative movement between logs whilst maintaining the seal. This is particularly an issue in wooden log construction because of the shrinkage of the logs as they dry. This causes the logs to settle and move vertically down. However, in some circumstances the connection of the key to both the log and the post as shown in U.S. Pat. No. 6,050,033 may inhibit such movement and as a result a gap is created between adjacent logs in the log walls.
[0010] Similar considerations apply where a pair of walls intersect, such as where an internal wall meets an external wall. This may occur between the locations of the posts and a secure butt joint between the intersecting walls is required.
[0011] It is an object of the present invention to obviate or mitigate the above disadvantages.
SUMMARY OF THE INVENTION
[0012] According to one aspect of the invention, a building structure comprises a vertically extending longitudinal face, a plurality of horizontal logs extending from said longitudinal face and having an end face in abutment with the longitudinal face. An undercut channel is provided in the longitudinal face and extends along the face. At least one of the end faces has a recess aligned with the undercut channel and a spline assembly extends between the longitudinal face and the log to secure the log to the post. The spline assembly includes a key located in and extending between the undercut channel and the recess and a slide member in one of the undercut channel and the recess. The slide member co-operates with the key to facilitate relative sliding movement of the logs and the post.
[0013] A further aspect of the invention provides a spline assembly to secure a log to a face of a log wall of a building. The spline assembly includes a slide member for insertion into an undercut channel in a vertical face and a key for insertion into said slide member and a recess in said log to extend between said log and inhibit separation thereof.
[0014] A still further aspect of the invention provides a method of assembling a log to a vertically extending face comprising the steps of providing an undercut channel in a longitudinal face, inserting a slide member in the undercut channel providing a recess in the log, aligning the recess with the slide member undercut channel, inserting a key into the key slide to extend between the post and the log, and securing the key to the recess, whereby relative movement between the log and the post is accommodated by relative sliding movement between the key slide and the key.
[0015] The face may be provided as a face of the post or as a face of an intersecting wall.
[0016] A further aspect of the invention is the provision of a building having walls formed from one or more wall sections. At least one of the wall sections has a plurality of logs interconnected at opposite ends by a respective post. A spline assembly secures the posts to the logs. The wall section is secured to an adjacent wall section by spline assemblies connecting the posts of the adjacent wall sections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The principles of the various aspects of the invention may better be understood by reference to the accompanying illustrative drawings which depict features of examples of embodiments of the invention, and in which:
[0018] FIG. 1 is a perspective view of a building.
[0019] FIG. 2 is a view on the line II-II of FIG. 1 showing components as assembled.
[0020] FIG. 3 is a view similar to FIG. 2 with the components in a expanded position.
[0021] FIG. 4 is an exploded perspective view of the components shown in FIG. 3 .
[0022] FIG. 5 is a perspective view of a key member used in the embodiment of FIGS. 1 to 4 .
[0023] FIG. 6 is a rear perspective of the key member of FIG. 5 .
[0024] FIG. 7( a )-( k ) is a schematic representation of the steps of assembling the building of FIG. 1 .
[0025] FIG. 8 is an exploded view of components used at a corner of the building of FIG. 1 .
[0026] FIG. 9 is an exploded perspective view of an alternative embodiment of the building.
[0027] FIG. 10 is an enlarged view of the assembly shown in FIG. 9 .
[0028] FIG. 11 is a view in the direction of arrow XI-XI of FIG. 10 .
[0029] FIG. 12 is a exploded perspective view of a further embodiment of building structure.
[0030] FIG. 13 is a plan view of FIG. 12 in the direction of arrow XIII-XIII.
[0031] FIG. 14 is a plan view similar to FIG. 13 showing a further step in the assembly of the building.
[0032] FIG. 15 is a view similar to FIG. 14 showing a yet further step in the assembly of the building.
[0033] FIG. 16 is a view similar to FIG. 15 showing a still further step in the assembly of the building.
[0034] FIG. 17 is an enlarged plan view of a component used in the building of FIGS. 12 to 16 .
[0035] FIG. 18 is a view similar to FIG. 17 showing the component of FIG. 17 in an expanded position.
[0036] FIG. 19 is a view similar to FIG. 17 of an alternative embodiment of the component.
[0037] FIG. 20 is a view similar to FIG. 17 of a further embodiment of the component shown in FIG. 17 .
[0038] FIG. 21 is a still further alternative embodiment of the component shown in FIG. 17 .
[0039] FIG. 22 is a view similar to FIG. 12 showing a further step in the assembly of a building.
[0040] FIG. 23 is a perspective view of a further embodiment of a building.
[0041] FIG. 24 is a view on the line XXIV-XXIV of FIG. 23 .
[0042] FIG. 25 is a perspective view of a yet further embodiment of building.
[0043] FIG. 26 is a view on the line XXVI-XXVI of FIG. 25 .
[0044] FIG. 27 is a schematic plan view of a building assembled from the embodiments shown in the proceeding figures.
[0045] FIG. 28 is a section through an alternative embodiment of post used in the building structures in the proceeding figures.
[0046] FIG. 29 is a plan view of the post of FIG. 28 assembled into a wall structure.
[0047] FIG. 30 is a plan view of a pair of wall structures utilizing the post of FIG. 28 being connected.
[0048] FIG. 31 is a plan view similar to FIG. 29 showing a further stage in the assembly of a building structure.
[0049] FIG. 32 is a plan view of the assembly of FIG. 31 in a further stage of assemble.
[0050] FIG. 33 is a section of a component used to manufacturer posts for use in the building structures shown in the proceeding embodiments.
[0051] FIG. 34 is a view of the component of FIG. 33 in a first stage of manufacturer.
[0052] FIG. 35 is an end view of the components produced in FIG. 35 in a further stage of manufacturer.
[0053] FIG. 36 is a plan view of a section of wall formed using the components of FIG. 35 .
[0054] FIG. 37 is a plan view showing assembly of a pair of wall sections of FIG. 36 .
[0055] FIG. 38 is a plan view similar to FIG. 37 of a further stage in the assembly of the wall sections.
[0056] FIG. 39 is a view similar to FIG. 38 showing a further step in the assembly of wall sections.
[0057] FIG. 40 is a view similar to FIG. 27 showing the assembly of a building using the post sections described with respect to FIGS. 28 through 39 .
DETAILED DESCRIPTION OF THE INVENTION
[0058] The description that follows and the embodiments described therein are provided by way of illustration of examples of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention. In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are not necessarily to scale and in some instances proportions may have been exaggerated in order more clearly to depict certain features of the invention.
[0059] Referring therefore to FIG. 1 , a building 1 includes log walls 2 that intersect at a corner 6 . The log walls 2 are supported on a foundation wall 3 , that may be poured concrete or laid cement block, and have openings for windows 4 . The log walls 2 will support a roof or additional framed storey in a conventional manner. Each of the log walls 2 is formed from logs 11 that are laid horizontally one on top of the other and are secured to posts 10 to form an integral structure. The posts 10 may be located at corners 6 and at intermediate locations 7 along the log walls 2 , depending on the overall plan of the building 1 .
[0060] Each of the logs 11 is machined to an uniform cross section and have complementary tongues and grooves formed on abutting upper and lower faces 13 a , 13 b ( FIG. 4 ). A sealant, typically in the form of a mastic tape, or foam tape is located between the tongue and groove and compressed by the log to form an effective seal. The particular form of tongue and groove forms no part of the present invention and a variety of configurations may be used, such as that shown in U.S. Pat. No. 5,020,289.
[0061] It will be appreciated that the log walls 2 extend along the periphery of the building 1 and the logs 11 are cut to the required length to conform to the desired floor plan.
[0062] Each of the posts 10 extends vertically the height of the log wall 2 and each post 10 has a pair of generally planar faces 12 , 14 , that are disposed at the required included angle. Where the post 10 is located at the corner 6 of the building 1 , typically, the planar faces 12 , 14 intersect at right angles but other included angles can be provided, as shown in FIG. 7 . Where the posts are at intermediate locations the planar faces 12 , 14 are oppositely directed.
[0063] As can best be seen in FIG. 2 and FIG. 4 , which illustrates a corner 6 , each of the logs 11 has an end face 16 that extends between the upper and lower faces 13 a , 13 b to butt against one of the planar faces 12 , 14 of the post 10 . The end face 16 has a part cylindrical slot 17 extending between the upper and lower faces 13 a , 13 b of the log 11 and intersecting the end face 16 so as to define a re-entrant recess in the end face 16 .
[0064] Sealant slots 18 are provided along the length of each of the planar faces 12 , 14 of post 10 . The sealant slots 18 are dimensioned to accept sealant materials, typically in the form of butyl or impregnated foam tapes 19 that are exposed to the end face 16 when a log 11 is butted against post 10 .
[0065] Each of the planar faces 12 , 14 has an undercut channel 20 extending along the length of the post 10 . The undercut channel 20 has a parallel sided body portion 22 which opens to an enlarged socket 24 . Inclined flanks 26 connect the body portion 22 to the enlarged socket 24 . The width of the body portion 22 corresponds to that of the opening of part cylindrical slot 17 at the end face 16 .
[0066] The logs 11 are held against the respective planar face 12 , 14 by the spline assembly generally indicated at 30 in FIG. 4 . The spline assembly 30 includes a key 32 and a slide member, referred to as key slide 70 . The key 32 has a pair of key members 33 that are identical to one another and have a length slightly less than the corresponding height of the log 11 . For example, with a log of nominal 12 ″ height, the key 32 will typically be 10″ in length.
[0067] The key members 33 are best seen in FIGS. 5 and 6 . Each key member 33 is molded from a plastics material and has an outer shell 34 with a hollow interior 36 with reinforcing ribs 38 integrally molded with the outer shell 34 . In cross section, each of the key members 33 is similar to one half of the void formed between the part cylindrical slot 17 , undercut channel 20 and the key slide 70 so that a pair of key members 33 may be inserted within the void.
[0068] Each of the key members 33 has an enlarged head 40 connected by a neck 42 to a flared shoulder 44 . The enlarged head 40 has an arcuate undersurface 46 terminating in radial step 48 . Each end of the key members 33 has a tapered terminal section 50 on the neck 42 and the flared shoulder 44 to facilitate insertion in to the key slide 70 . End walls 52 enclose the shell at each end up to a median plane 54 . A flange 56 projects outwardly from the median plane 54 at one end and extends one half the length of the key member 33 . A slot 58 having a depth slightly greater than that of the flange 56 is molded into the key member 33 in alignment with the flange 56 over the balance of the length of the key member 33 . A notch 59 is formed in each end wall 52 beside the flange 56 and slot 58 respectively.
[0069] The flange 56 and slot 58 are arranged such that when two key members 33 are placed back to back, that is with the interior of the shells 34 facing one another, the flange 56 of one is received in the slot 58 of the other, so a continuous barrier is provided along the length of the key members 33 . It will be noted from FIG. 5 that the arcuate undersurface 46 has embossments 60 molded along its length. The embossments 60 are in the form of letters in the embodiment shown that project slightly above the arcuate undersurface 46 . Similar embossments 62 , 64 are molded on the neck 42 and above the radial step 48 .
[0070] As can best be seen in FIGS. 2 , 4 and 8 , the slide member or key slide 70 , is provided to promote relative sliding movement between a log and the post. As shown, the key slide 70 of the spline assembly 30 is an elongate channel member arranged to be a sliding fit within the enlarged socket 24 of the undercut channel 20 . The key slide 70 generally extends the full height of the post 10 as a continuous member, although it could made from multiple shorter pieces arranged end to end, and is inserted into the enlarged socket 24 of undercut channel 20 after machining of the post 10 . The key slide 70 is dimensioned to have contact with the parallel sided body portion 22 of the undercut channel 20 , inclined flanks 26 and enlarged socket 24 in its free body state so as to be retained within the undercut channel 20 during transport of the post 10 and subsequent assembly of the log walls 2 and the post 10 .
[0071] As can best be seen in FIGS. 2 , 3 and 8 , the key slide 70 has an outer surface that conforms substantially to the enlarged socket 24 . The key slide 70 has a base 71 with upstanding walls 72 projecting from opposite sides of the base 71 . The upstanding walls 72 project to form a throat 74 that extends into the body portion 22 with the inwardly directed surfaces of the throat 74 radiussed so as to provide a rolling contact between the junction of the neck 42 and the flared shoulder 44 of each of the key members 33 ( FIG. 3 ). The key slide 70 is of substantially uniform thickness so as to be a snug sliding fit within the enlarged socket 24 and allow the neck 42 and flared shoulder 44 of key 32 to be a sliding fit within the key slide 70 .
[0072] The key slide 70 is formed of a suitable material having the requisite thermal insulation qualities, low surface friction, hardness and durability. A thermo-plastic material such as polyethylene or polypropylene is suitable. Polypropylene has a relatively low surface friction to facilitate insertion and to provide a smooth sliding surface between the key 32 and the key slide 70 .
[0073] The assembly of the log walls 2 shown in FIG. 1 is best seen with reference to the sequence represented in FIG. 7 where the walls intersect at an obtuse angle, rather than right angle. Initially, a flashing F is secured to the foundation wall 3 and two rows of butyl tape 80 are applied toward the exterior of the building. The paper covering found on the butyl tape 80 is left in situ to allow for slight adjustment of the initial course of logs 11 .
[0074] With the two rows of butyl tape 80 installed on the flashing F, the post 10 with the key slide 70 inserted in the channel 20 is placed on the foundation wall 3 and foam tape 19 inserted into each of the sealant slots 18 on one planar face 12 of the post 10 ( FIG. 7 b ). The surface of the foam tape 19 immediately adjacent the work area is revealed by removal of the paper covering, which progresses along the length of the post 10 as the log wall 2 is assembled.
[0075] The initial log 11 is then placed against the post 10 with the end face 16 in abutment with the planar face 12 ( FIG. 7 c ). In this position, the part cylindrical slot 17 is aligned with the undercut channel 20 . An asphalt impregnated foam pad 82 conforming to the shape of the part cylindrical slot 17 and undercut channel 20 is inserted from the top of the log 11 ( FIG. 7 d ) and pushed down in the part cylindrical slot 17 until it reaches the top of the foundation wall 3 .
[0076] To secure the log 11 to the post 10 , a key member 33 is inserted, as shown in FIGS. 7 e to 7 g . Prior to insertion of the key member 33 lengths of sealant tape 84 , 86 are applied to the neck 42 directly on embossment 62 and to the enlarged head 40 directly on embossment 64 of each key member 33 ( FIG. 5 ). The sealant tape 84 , 86 , is not initially in engagement with the parallel sided body portion 22 or the part cylindrical slot 17 during insertion and the sealant tape 84 , 86 therefore remains in situ during insertion of the key member 33 . The sealant tape 84 , 86 is held in situ during insertion by the inherent adhesiveness of the surface of the sealant tape 84 , 86 that is against the key member and by engagement with the embossments 62 , 64 molded on the surface of the outer shell 34 . When initially placed on the key member 33 , the sealant tape 84 , 86 is in a compressed state as it has been removed from a roll of tape and progressively expands to its free body state. Each of the key members 33 is inserted into the key slide 70 in post 10 individually such that the flared shoulder 44 may pass through the throat 74 of the key slide 70 ( FIGS. 7 e and 7 f ). The first of the key members 33 is inserted with the flange 56 lower most. The other of the key members 33 may then be inserted into the key slide 70 above the first key member 33 and the two key members 33 slid together axially. The flange 56 on one key member 33 is received in the slot 58 of the other key member 33 as the key members 33 slide together to form the key 32 .
[0077] With the key members 33 assembled, they form the key 32 and may be pushed as a unit into the part cylindrical slot 17 ( FIG. 7 g ) until they are flush with the bottom of the grooves provided in the top surface 13 a of the log 11 . At this time, the sealant 84 , 86 has not expanded to its free body state, thereby avoiding contact with the walls of the part cylindrical slot 17 or parallel sided body portion 22 of the undercut channel 20 . The key members 33 and key slide 70 are dimensioned such that the key 32 may slide relatively easily along the key slide 70 and into the part cylindrical slot 17 . Typically a clearance in the order of ⅛ of an inch on the diameter is provided between the arcuate undersurface 46 and the cylindrical wall of the part cylindrical slot 17 . However, the flared shoulders 44 extend laterally into key slide 70 within the enlarged socket 24 so as to inhibit removal of the key 32 . With the key 32 correctly positioned, the key members 33 are forced apart within the part cylindrical slot 17 by insertion of a spike 88 along the length of the key member 33 ( FIG. 7 h ). The spike 88 is inserted into the notch 59 provided adjacent the flange 56 and acts as a wedge to separate the key members 33 . The enlarged head 40 is dimensioned to prevent removal from the part cylindrical slot 17 in the locked condition as seen in FIG. 3 . The flanges 56 act as a barrier to prevent lateral movement of the spike 88 from between the key members 33 and to cause a uniform spreading of the key 32 within the part cylindrical slot 17 . The relatively small surface area of the reinforcing ribs 38 reduces the friction on the spike 88 and reduces the downward force transferred to the key members 33 by the spike 88 . The initial spreading of the key 33 members also brings the embossments 60 in to engagement with the walls of part cylindrical slot 17 to inhibit further upward or downward movement.
[0078] The spike 88 separates the key members 33 within the part cylindrical slot 17 but the inner edges of the flared shoulders 44 within the key slide 70 remain in contact with one another. As can be seen from a comparison between FIGS. 2 and 3 , spreading of the key members 33 causes a rolling action about the curved surfaces of the throat 74 of the key slide 70 so as to provide essentially an outward force that is readily resisted by the material in the post 10 , as opposed to a torque acting so as to break off the material at the body portion 22 of the undercut channel 20 . At the same time, the sealant tape 84 , 86 expands and is compressed against the enlarged head 40 and part cylindrical slot 17 as well as the neck 42 and undercut channel 20 to provide a continuous uniform seal within the undercut channel 20 and part cylindrical slot 17 respectively. The spreading of the key members 33 as shown in FIG. 3 causes the log 11 to be drawn tightly against the face of the post 10 causing the foam tape 19 in sealant slots 18 to be similarly compressed to form a continuous seal. An asphalt impregnated foam pad 90 is then placed onto the top of the key 32 to ensure a proper seal between adjacent key 32 ( FIG. 7 i ). However, the reduced spreading within the key slide 70 in combination with the low friction material of the key slide 70 facilitates sliding movement of the key 32 down the key slide 70 .
[0079] With the initial log in situ, a similar procedure is followed with the log on the opposite planar face 12 of the post 10 to provide the first row of logs 11 ( FIG. 7 j - 7 k ). The upper surface 13 a of the log 11 is then prepared by applying sealant strips 87 to the sealant grooves on the upper surface 13 a of each log 11 and the next log 11 placed in position. The key 32 is then inserted as described above and the process continues up each side of the post 10 until the full height of the log wall 2 has been attained.
[0080] During assembly, the weight of each of the logs 11 is sufficient to induce sliding between the key 32 and the key slide 70 to accommodate downward vertical sliding movement of the logs 11 and compression of the sealant strips 87 . Optionally, a thru-bolt may be inserted vertically through the log walls 2 and tensioned to force the logs 11 together. As the logs dry, the weight of the logs 11 and the tension in the thru bolt if used, is sufficient to force the key 32 to slide within the key slide 70 and maintain a sealed relationship with the adjacent log 11 and the post 10 . The engagement of the embossments 60 with the part cylindrical slot 17 ensures the key 32 moves with the logs 11 and slides within the key slide 70 .
[0081] Thus, the spline assembly 30 provides a relatively low friction slide member in the post 10 that permits key 32 to slide in a controlled manner within the key slide 70 . The key 32 is secured to respective ones of the logs 11 by expansion of the key members 33 so as to move with the logs 11 relative to the post 10 . In this manner, the integrity of the log walls 2 is maintained by inhibiting gaps from opening between the logs 11 . As well as maintain a seal between planar face 12 and the end face 16 .
[0082] The above embodiment is described in the context of securing a vertical post 10 to logs 11 to form a corner 6 . A similar arrangement may be used where a pair of log walls intersect at a location other than where a post 10 is provided. Typically this would be where an interior log wall intersects an exterior log wall although it will be appreciated that the technique may be used to interconnect two exterior walls or two interior walls.
[0083] Referring therefore to FIGS. 9 through 11 , in which like components are identified with like reference numerals to the embodiment of FIGS. 1 through 8 but with a suffix “a” added for clarity, an intersecting log wall 90 made from logs 11 a is perpendicular to the length of the logs 11 a of an exterior log wall 2 a . A vertical recess 92 is formed in the exterior log wall 2 a extending the full height of the intersecting log wall 90 . Typically this will be the full height of the log wall 2 a , but in some applications the intersecting wall 90 may terminate at less than the full height of the exterior wall 2 a . The recess 92 has a minimum width corresponding to the width of the logs 11 a of the intersecting wall 90 and has a depth sufficient to extend into the log 11 a beyond any surface formations such as bevels formed on the edge of the logs 11 a.
[0084] An undercut channel 20 a is cut in the logs 11 a at the base of the recess 92 and has a profile corresponding to that of the channel 20 formed in the post 10 described above with respect to FIGS. 1 through 8 . Similarly, end faces 16 a of the logs 11 a of the interior wall 90 are formed with part cylindrical slots 17 a that, when assembled, are aligned with the undercut channel 20 a.
[0085] In the preferred embodiment, a key slide 70 a is inserted into the enlarged socket 24 a of the undercut channel 20 a to receive a key 32 a . The key slide 70 a may be inserted from the top of the wall 2 a if space permits. However, to facilitate assembly of the intersecting wall 90 after the exterior walls 2 a are capped with a roof or second storey, the key slide 70 a is modified to facilitate insertion into the enlarged socket 24 a . As can be seen from FIGS. 9 and 11 , base 71 a has a central groove 102 that provides a living hinge at the midpoint of the base 71 a . The groove 102 permits the base 71 a to be folded at the hinge and thereby reduce the lateral extent of the key slide 70 a so it may pass through the body portion 22 a of the undercut channel 20 a . Once inserted, the base 71 a may be unfolded and force the wall 72 a of the key slide 70 a into the enlarged socket 24 a.
[0086] With the key slide 70 a inserted in the enlarged socket 24 a of the undercut channel 20 a , the intersecting wall 90 may be assembled by positioning the end faces 16 a of the logs 11 a against the base of the recess 92 . The keys 32 a may then be inserted to bridge the undercut channel 20 a and part cylindrical slots 17 a and expanded to lock the keys 32 a in situ as described above. It will be understood that the foam tapes 19 a may be placed in the sealant slots 18 a in the recess 92 of the logs 11 a and the keys 32 a in a similar manner to that described above to ensure an air tight connection between the walls.
[0087] The recess 92 may be formed in individual logs 11 a of wall 2 a prior to assembly or may be routed after the exterior walls 2 a have been assembled. This latter arrangement increases the flexibility of modifying the building after its initial assembly although the routing of the recess 92 , the sealant slots 18 a and the undercut channel 20 a during manufacture of the logs 11 a is to be preferred.
[0088] It will also be appreciated that where the intersecting wall 90 is intended as an interior wall, maintaining a seal between adjacent logs is not as critical as where it is an exterior wall. In this case, the key slide 70 a may be omitted allowing for the direct connection between the wall 2 a and the wall 90 using the keys 32 a.
[0089] A further application of the connection between the post 10 and logs 11 forming a wall 2 is shown in the embodiment of FIGS. 12-17 , in which like components will be identified with like reference numerals with a suffix “b” added for clarity.
[0090] In the embodiment of FIGS. 12-17 , the connection is formed at an intermediate location 7 on the wall, as shown in FIG. 1 . Referring therefore to FIG. 12 , the wall 2 b is formed by a pair of log wall sections 100 are each formed from logs 11 b connected at each end to a post 10 b using the key 32 b as described above with respect to FIGS. 1-8 . Each of the wall sections thus comprises a pair of posts 10 b with logs 11 b extending between them and secured thereto. The wall sections 100 may be connected end to end to one another when an extended wall 2 b is required for the building 1 . As can be seen in FIG. 22 , each wall section 100 is assembled with the logs 11 b extending slightly above the post 10 b to allow for shrinkage as the logs 11 b dry. Where thru bolts are used they may be installed during assembly of the section 100 to enhance the integrity of the wall section.
[0091] As shown in FIG. 13 each of the posts 10 b has a planar face 12 b that abuts the end face 16 b of the logs 11 b and an oppositely directed planar face 14 b that is designed to abut a corresponding face 14 b of a post 10 b of an adjacent wall section 100 . The planar face 14 b of post 10 b is formed with a part cylindrical slot 103 (similar to the part cylindrical slot 17 b formed in the planar face 16 b in log 11 b ) so that when the faces 14 b abut, the part cylindrical slots 103 are aligned and define a waisted void 110 having a “figure of 8” cross section.
[0092] To secure the posts 10 b to one another, an elongate “figure of 8 ” shaped key 112 is inserted into the void 110 . The elongated key 112 can best be seen in FIGS. 17 and 18 .
[0093] The elongated key 112 is formed from two identical key members 113 that extend the full length of the post 10 b . Each of the key members 113 has a pair of enlarged heads 40 b extending to either side of a waisted central portion 114 so that, in cross section, each of the key members 113 is similar to one half of the waisted void 110 formed between the abutting part cylindrical slots 103 in the posts 10 b.
[0094] A pair of flanges 56 b project outwardly from the key members 113 and a pair of slots 58 b having a depth slightly greater than that of the flange 56 b are molded into each of the key members 113 . As shown in FIG. 17 , the key members 113 may be placed back to back with the flanges 56 b of one of the key members engaging the slots 58 b of the other of the key members. Each of the enlarged heads 40 b is formed with a radial step 48 b . The key members 113 are preferably extruded from a plastics material and so have a uniform cross section. Alternatively, the key members may be formed from wood or plywood without flanges.
[0095] To assemble the wall 2 b from wall sections 100 , the sections 100 are placed end to end, as shown in FIG. 12 , with the faces 14 b of posts 10 b in alignment. Sealant tape 19 b is applied in the sealant slots 18 b on the face of one of the posts 10 b to form an effective seal as the faces 14 b are drawn together. The key members 113 are prepared, by applying the sealant tape 86 to the enlarged head 40 b above the radial step 48 b and the key 112 is inserted between the posts 10 b with the sealant tape in a compressed state. Once inserted, spikes 88 b are inserted between the key members 113 and driven downward as shown on FIG. 16 to separate the key members 113 and thereby spread key 112 as shown in FIG. 18 . Whilst it is theoretically possible to insert two elongated single spikes 88 b along the entire length of the key 112 , in practice, it is easier to insert a series of spikes 88 b end to end. To facilitate the insertion of such spikes 88 b , each of the spikes 88 b is formed without a head and with a countersink to receive the pointed end of a subsequent spike 88 b . Therefore, the spikes 88 b may be inserted progressively between key members 113 , to spread the key 112 over the entire length of the post. The outer surface of the spikes 88 b may be coated with a lubricant, such as a “wax” if required, to facilitate insertion over the entire length of the key 112 . The key members 113 may be extruded from a relatively low friction material. The spreading of the key 112 causes the posts 10 b to be drawn toward one another and abut along the opposed faces 14 b.
[0096] It will be appreciated that it is not necessary to form the key members 113 as a single component and shorter lengths of key member 113 may be stacked in the void 110 without jeopardizing the integrity of the connection between the posts 10 b . However, the insertion of multiple spikes 88 b suggests that a continuous key members 113 is to be preferred.
[0097] With the wall sections 100 aligned and connected to one another, as shown in FIG. 22 , the rigidity of the exterior wall 2 b is increased by placement of straps 120 across the posts 10 b . The steel straps 120 extend along the upper surface of the logs 11 b and are secured by nails or screws to the logs 11 b to inhibit a hinging action about a vertical axis at the posts 10 b . Clearance is provided between the strap 120 and the upper end of the posts 10 b , to facilitate log wall shrinkage and settlement. A foam pad 125 is placed between the strap and the post 10 b to inhibit air movement over the top of the post.
[0098] The strap 120 may also provide a support for additional structural members, such as a joist or rafter. A yoke 122 attached to strap 120 may be dimensioned to receive standard section lumber and provides a nailing point to secure the structural member. The yoke 122 is maintained in alignment with the upper surface of the logs 11 b as they shrink by virtue of the strap 120 .
[0099] Alternative embodiments of the key 112 are shown in FIGS. 19 , 20 and 21 . In the embodiment of FIG. 19 , each of the key members 113 has a pair of flanges 56 b to one side of the waisted central portion 114 and a pair of grooves 58 b to the other side. This still permits the key members 113 to be placed back to back and to constrain the spikes 88 b.
[0100] In the embodiment of FIG. 20 , the end face of the body is offset with projecting flanges 115 that serve to define an air cavity between the post 10 b and the key member 113 . This enhances the insulative properties to reduce heat transfer across the posts 10 b.
[0101] Similarly, in the embodiment of FIG. 21 , the key members 113 are formed to provide a void between them when assembled to provide a further air cavity in the key 112 .
[0102] In some buildings, it is necessary to integrate conventional frame construction with log construction. The connection system described above can be adapted for these circumstances, as illustrated in FIGS. 23 to 26 .
[0103] Referring firstly to the embodiment of FIGS. 23 and 24 , in which like reference numerals will denote like components with a suffix V added for clarity, a wall section 100 c , formed by posts 10 c and logs 11 c , is connected to a framed wall section 200 of conventional construction and having a top plate 202 and studs 204 , 206 and a post 10 a . It will of course be appreciated that the framed wall section 200 includes the additional components normally associated with frame construction, such as a bottom plate, lintels and the like.
[0104] The end stud 204 is nailed to a post 10 c , that has a part cylindrical slot 17 c along the face 14 c . The posts 10 c of the wall section 100 c and framed wall section 200 are aligned with the respective faces 14 c in abutment and a key 112 c inserted to connect the wall section 100 c to wall section 200 .
[0105] In the embodiment of FIGS. 25 and 26 , an elongated keyspline 32 d and keyslide 70 d is used to connect a framed wall section 200 d to a post 10 d . The wall section 100 d has a recess 92 d corresponding in width to the width of the post 10 d . An undercut channel 20 d is formed in each of the base of recess 92 d and a part cylindrical slot 17 d formed in the post 10 d . A key 32 d is inserted and spread to secure the wall sections 100 d , 200 d , to one another.
[0106] If required, a post 10 may be secured to the wall section 100 as shown in FIGS. 25 and 26 to stiffen the wall along its length. In this case, a stud wall 200 would not be utilised so as to minimise the protrusion in to the room.
[0107] It will be seen from the above that embodiments are provided to form a corner between a post and two walls, to connect walls that intersect between posts and to connect walls end to end.
[0108] The arrangement of connections between the post and logs may be integrated into a single building as illustrated schematically in FIG. 27 to permit a panelised construction technique to be used. In this arrangement, a corner unit indicated at 300 consists of a post 10 with logs 11 connected to its oppositely directed faces 12 , 14 . The logs 11 extend to and are secured at opposite ends to a face of the posts 10 b that is directed toward the post 10 in the manner shown in FIGS. 1-4 so that the unit 300 defines a panelised corner unit. The intermediate wall indicated at 302 is formed by a wall section 100 constructed as shown in FIG. 12 to 16 and has a pair of posts 10 b with a logs 11 b extending between opposed faces. The post 10 b of the wall section 100 is joined to the post 10 b of the corner unit 300 using the formations in the form of recesses 17 and keys 112 to form an integral exterior wall 2 . A further corner unit 300 is connected at the opposite end of the wall section 100 . The exterior periphery of the building shown in FIG. 27 may thus be built from four corner units 300 and a pair of wall sections 100 , which may be either log or frame construction.
[0109] An interior wall 304 may be joined to the exterior wall section 100 using the connection as shown in FIGS. 9 through 11 . A further connection in the exterior wall is made at the post 10 connecting the two corner units 300 using a connection similar to that shown in either FIGS. 9 through 12 or FIGS. 13 through 18 .
[0110] It will be seen that the arrangement of self contained wall units permits a panelised building to be assembled from previously constructed wall units each of which utilizes formations in the posts and a key to connect logs to posts or post to post or log walls to log walls or framed walls to log wall. In each case, provision is made for proper sealing between the keys and the logs to maintain the integrity of the walls and where key slides are used, relative movement between the logs is facilitated.
[0111] A further embodiment particularly suitable for providing a panelized construction technique is shown in FIGS. 28 through 40 , although it will be appreciated that the components illustrated in these figures may be utilized in the construction of a non-panelized building as illustrated for example, in FIG. 7 .
[0112] Referring to FIG. 28 , the post 10 d is formed from laminations of different lumber for stability and economy of manufacturer. As shown in FIG. 28 outer laminations 400 are machined from a premium quality wood, such as a white pine or cedar, and the balance of the laminations 402 are machined from a lower premium wood, such as construction grade spruce/pine/fur. The faces 12 d , 14 d extend between the laminations 400 and have formations machined in them to provide the re-entrant part cylindrical recess 17 d in the face 14 d and the undercut channel 20 d in the face 12 d . The face 14 d is also machined to have an upstanding tongue 404 to one side of the recess 17 d and a complimentary groove 406 to the opposite side. Sealant grooves 408 , 410 are provided adjacent the tongue 404 and groove 406 respectively. The sealant grooves 412 are also provided on the face 12 d to either side of the channel 20 .
[0113] The post 10 d is secured to logs 11 d by a spline assembly 30 d as shown in FIG. 29 . A key slide 70 d is inserted into the channel 20 d and the key 32 inserted after placement of the end face 16 d of each of the logs 11 d against the face 12 d . The key 32 d is expanded by means of the spike 88 d as described above to secure the logs 11 d to the post 10 d . A post 10 d may be connected at opposite ends of the log 11 d such that the logs 11 d and posts 10 d form a self contained wall unit 100 d.
[0114] To facilitate transportation of the units 100 , the lower most log 11 d is secured to the posts 10 d by screws driven through the post and into the log. This inhibits the relative movement between the lowermost post and log while still permitting such movement with the balance of the logs.
[0115] Where tie bolts are used, as described above, they are inserted and provide convenient locations to permit hoisting of the wall units during transportation and assembly.
[0116] To assemble a pair of wall units 100 d , the units are oriented such that the faces 14 d are opposed. In this position, as can be seen in FIG. 30 , the tongue 404 of one post 10 d is aligned with the groove 406 of the opposed posts 10 d and the recesses 17 are aligned. Sealing strips are located in the grooves 408 , 410 and the post 10 d brought into abutment as shown in FIG. 31 .
[0117] With the post 10 d abutting, an elongate “figure of 8 ” shape key 112 d is inserted to bridge the aligned recesses 17 d . Any suitable form of key 112 may be used, such as one of the embodiments shown in FIGS. 17-21 and preferably is similar to that shown in FIG. 14 or 15 with notches for the spikes 88 . The key 112 d can then be expanded using spikes 88 as described above with respect to FIG. 12 to 15 . The key 112 d may be either a single continuous extrusion extending the full length of the post 10 d or may be individual shorter lengths of key, again as described above with respect to FIGS. 12 through 15 .
[0118] With the key 112 d expanded as shown in FIG. 32 a secure connection is made between the wall sections 100 . The engagement of tongue 404 and groove 406 locates the posts 10 b in a lateral direction as well as providing a more tortuous path to inhibit air infiltration. The seals located in the grooves 408 , 410 also enhance the air lightness of the connection between the walls.
[0119] It will be noted from FIG. 32 that with the posts 10 d secured to one another, the outer laminations 400 cover the joint between the posts and thereby provide a continuous pleasing appearance to the exterior surface of the post.
[0120] The manufacturer and use of the posts 10 e used at the corners 6 may also be enhanced to facilitate the panelized construction of the building. As shown in FIG. 33 , a post 10 c is formed with undercut channels 20 e on opposite faces. The post 10 e is again laminated from exterior laminations 400 e and internal laminations 402 e as described above with respect to FIG. 28 . Sealant grooves 412 are machined into the faces 12 e , 14 e to accommodate sealing strips upon further assembly.
[0121] The post 10 e is then slit into two components 510 along a separation plane inclined at 45 degrees to the median plane of the post. The inclination of the cut will vary depending upon the included angle of the corner to be formed, but for a 90 degree corner, the 45 degree cut is required. After cutting, two corner posts 510 are formed that are identical in section. Inversion of one component end over end provides two components that when assembled with the cut faces in abutment, define a 90 degree corner post, as described below. A different angle of cut will of course provide a different inclined angle. As shown in FIG. 35 , each has a part cylindrical re-entrant recess 17 e machined along its cut face. This recess 17 e may be machined using a cannon ball router bit with the recess 17 e located at the mid point of the cut face 512 . The corner post components 510 can be connected at opposite ends of logs 11 e as shown in FIG. 36 using spline assemblies 30 e installed as described above. The logs 11 e and the post components 510 form a wall unit 100 e that can be assembled with like wall units to form a corner. Again, the lowermost log is secured to the post component with screws to inhibit sliding movement and the tie bars used as hoist points.
[0122] To form a corner 6 , as shown in FIG. 37 , a pair of wall units 100 each having a corner component 510 at one end are brought into alignment such that the cut faces 512 abut. Sealant grooves are machined into the cut face to receive sealant strips and are offset from adjacent strips so as to provide four separate seal locations along the cut face 512 . With the corner units in abutment as shown in FIG. 38 , a key 112 e is inserted to bridge the aligned recesses 17 e and connect the sections 100 c at right angles to one another. Thereafter, spikes 88 e may be inserted into the key 112 e to expand the key and secure the corner components 510 into a unitary post 10 e at a corner.
[0123] It will be noted with respect to FIGS. 37 through 39 that the exterior laminations 400 extend around both exposed surfaces of the corner and thereby enhance the aesthetics. At the same time, it will be appreciated that the wall units 100 may be made as linear units for ease of transportation and subsequently assembled at corners by the insertion of the spikes 100 .
[0124] With the arrangement shown in FIGS. 28 through 39 , it is apparent that a panelized structure may be assembled readily as shown schematically in FIG. 40 . Each of the wall units is formed by a pair of posts 10 connected by logs 11 which extend between the faces of the posts directed toward one another. The formations provided on the other face facilitates connection to an adjacent post through the “figure of eight keys 112 .” The wall units 100 are therefore flat self contained units that are readily transported and assembled into the required configuration at the site. | A building structure comprises a post having a vertically extending longitudinal face. A plurality of horizontal logs extends from said longitudinal face and has an end face in abutment with said longitudinal face. The post having an undercut channel in said longitudinal face and extends along said post. At least one of said end faces has a recess aligned with said undercut channel, and a spline assembly extends between said post and said log to secure said log to said post. The spline assembly includes a key located in and extends between said channel and said recess and an insert in one of said undercut channel and said recess. The insert co operates with said key to facilitate relative sliding movement therebetween. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of priority to PCT/US2006/061251 filed 27 Nov. 2006, which is incorporated herein by reference in its entirety for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND
In a drilled well, representative samples of rock are often cored from the formation using a hollow coring bit and transported to the surface for analysis. To collect these core samples, a number of coring methods may be used, including conventional coring and sidewall coring. With conventional coring, the drillstring is first removed from the wellbore and then a rotary coring bit with a hollow interior for receiving the cut core sample is run into the well on the end of the drillstring. Sidewall coring, on the other hand, involves removing the core sample from the bore wall of the drilled well. There are generally two types of sidewall coring tools, rotary and percussion. Rotary coring is performed by forcing an open, exposed end of a hollow cylindrical coring bit against the wall of the bore hole and rotating the coring bit against the formation. Percussion coring uses cup-shaped percussion coring bits, called barrels, that are propelled against the wall of the bore hole with sufficient force to cause the barrel to forcefully enter the rock wall such that a core sample is obtained within the open end of the barrel. The barrels are then pulled from the bore wall using connections, such as cables, wires, or cords, between the coring tool and the barrel as the coring tool is moved away from the lodged coring bit. The coring tool and attached barrels are finally returned to the surface where core samples are recovered from the barrels for analysis
In a typical percussion coring tool, an explosive device is used to propel the barrel from the tool into the surrounding formation. This explosive device is usually electrically fired, meaning an electrical current is used to initiate the explosion. Because these explosive devices are electrically initiated, they may be inadvertently initiated by stray voltage, static charge buildup, and radio frequency energy. In populated areas, sources of radio frequency may include CB radio, cellular telephones, radar, microwaves used for special communication and heat generation, conventional radio signals, power lines, high power amplifiers, high frequency electrical transformers, coaxial cables, etc. With respect to locations offshore, another source of radio frequency is powerful land-based transmitters used to communicate with equipment located on offshore platforms. Given the vast number of stray radio frequency sources, shutting these sources down temporarily so that sidewall percussion coring may be performed is impractical, if not impossible, particularly in congested areas near land-based oil and gas fields.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more detailed description of the present invention, reference will now be made to the accompanying drawings, wherein:
FIG. 1 is cross-sectional view of one embodiment of a voltage activated igniter;
FIG. 2 is a schematic illustration of the electrical circuit for the voltage activated igniter depicted in FIG. 1 ;
FIG. 3 is a cross-sectional view of one embodiment of a core gun comprising a voltage activated igniter;
FIG. 4 is an end view of the core gun depicted in FIG. 3 ; and
FIGS. 5A to 5D depict a typical sequence for removing a core sample using a sidewall percussion coring tool comprising the voltage activated igniter depicted in FIG. 1 .
DETAILED DESCRIPTION
Various embodiments of a sidewall percussion coring tool comprising a voltage activated igniter and its method of use will now be described with reference to the accompanying drawings. In the drawings and description that follow, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in the interest of clarity and conciseness.
Embodiments of the sidewall percussion coring tool and methods disclosed herein may be used in any type of application, operation, or process where it is desired to perform sidewall percussion coring service. Moreover, the tool and its methods of use are susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements unless specifically noted and may also include indirect interaction between the elements described. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
FIG. 1 illustrates a cross-sectional view of a representative voltage activated igniter 100 comprising a housing 105 having a bore 110 therethrough, an explosive charge 115 , a bleeder resistor 120 , a capacitor 125 , a semiconductor bridge (SCB) 130 , and a spark gap 135 for protecting the igniter 100 against accidental initiation. The SCB 130 and the spark gap 135 are connected by a pair of electrically conductive wires 140 , 145 to a means (not shown) for introducing an electrical charge into the SCB 130 The electrical charge is introduced to the SCB 130 by applying positive DC voltage across the leads 150 using any suitable means in the art, such as but not limited to, electrical wiring run downhole from the surface or a battery. The housing 105 at one end is sealed with a seal cap 155 and, surrounding that, a pressure seal boot 160 . In other embodiments, the seal cap 155 may be replaced with a radio frequency attenuator 163 . At the opposite end of the igniter 100 , a venting tube 160 is inserted into and extends from the explosive charge 115 . An end seal cap 165 acts as a barrier between the explosive charge 115 and the surrounding environment.
The housing 105 of the voltage activated igniter 100 includes a bore 110 therethrough, the diameter being sufficient to permit inclusion of an SCB 130 within the bore 110 . The thickness of the housing wall varies, typically ranging from 0.075″ to 0.125 inches thick. The housing 105 is comprised of substantially any material of high impedance, such as, for example, aluminum, steel, stainless steel, brass, and rigid plastics. Regardless of the housing 105 material, it must be suitable for high temperature applications, i e., temperatures up to 400 degrees Fahrenheit or above.
The explosive charge 115 may be introduced into the housing 105 as a powder and thereafter compressed by application of, for example, a ram to the explosive 115 at the end 170 of the housing 105 . The explosive charge 115 comprises any suitable explosive material known in the art, such as but not limited to, granular cyclotetramethylene tetranitramine (HMX), hexanitrostilbene (HNS), bis(picrylamino) trinitropyridine (PYX), trinitrotrimethylenetriamine (RDX) and mixtures thereof. The end 170 of the housing 10 is sealed by a thin metal or plastic disk that is pressed into place or by a thin layer of epoxy to provide a seal 165 on the exposed end of the explosive 115 in the bore 110 of igniter 100 .
The SCB 130 is positioned within the housing 105 such that it will be in contact with or at least close proximity to the explosive charge 115 . Preferably, the SCB 130 is positioned such that it will be in contact with the surface of the explosive charge 115 exposed in the bore 110 . The SCB 130 may be any suitable, commercially available semiconductor bridge in a size capable of insertion within the housing 105 . Suitable SCBs are available from, for example, Thiokol Corporation, Elkton, Md. and SCB Technologies, Inc., Albuquerque, N. Mex. The SCB 130 may be activated by any suitable electrical charge, including but not limited to, an electrical charge of approximately 173 volts at an amperage of approximately 0.010 amps. It is to be understood, however, that other SCBs suitable for initiating the deflagration reaction with the explosive charge 115 in the igniter 100 may be used.
The SCB 130 is connected by an electrically conductive wire 175 to a spark gap 135 . The spark gap 135 protects the igniter 100 against accidental initiation by an electrostatic discharge, stray voltage, radio frequency energy, or other unintended sources of electrical current. The spark gap 135 has a voltage threshold, for example, 150 to 158 volts, before passage of an electrical charge to the SCB 130 occurs. This prevents accidental initiation by unintended electrical charges below the threshold. Spark gaps 135 are available with various ratings, and igniters 100 may be prepared using different spark gaps 135 to permit controlled initiation of individual or multiple explosive charges in response to different electrical charges transmitted from an electrical source. Suitable spark gaps 135 are available from, for example, Reynolds Industries, Okyia, and Lumex Opto.
The SCB 130 and spark gap 135 are provided with electrically conductive wires 140 , 145 that provide an electrical connection that extends outside the housing 105 . At the connection end 173 of the igniter 100 , the housing 105 may be sealed with plastic resins or similar materials 155 that bond to the housing 105 to seal the various components within the housing 105 . The electrically conductive wires 140 , 145 pass through the seal cap 155 , leaving the leads 150 exposed for application of an electrical charge. Alternatively, the housing 105 may be sealed by insertion of a radio frequency attenuator 163 , in lieu of the seal cap 155 , having passageways therethrough to allow the wires 140 , 145 to extend from the housing 105 . A radio frequency attenuator 163 may reduce the strength of any radio signal present to a level whereby the signal is incapable of accidental initiation of the igniter 100 . Suitable radio frequency attenuators 163 include the MN 68 ferrite device available from Attenuation Technologies, La Plata, Md.
FIG. 2 depicts an electrical circuit for the voltage activated igniter 100 comprising the spark gap 135 connected to the SCB 130 by the electrically conductive wire 175 , the capacitor 125 , the bleeder resistor 120 , and the explosive charge 115 . The explosive charge 115 includes a pyrotechnic 180 and a secondary explosive 185 in contact with the SCB 130 The capacitor 125 is utilized to store electrical energy sufficient to pass through the spark gap 135 and initiate the SCB 130 . The bleeder resistor 120 is used to slowly drain the capacitor 125 in the event the capacitor 125 is partially charged during an interrupted firing of the igniter 100 Typically, the capacitor 125 is selected to provide a capacitance of 3.5 mF, while the bleeder resistor 120 provides a 10,000 to 20,000 ohm resistance. Although FIG. 2 illustrates a single capacitor 125 and a single resistor 120 , one skilled in the art may readily appreciate that multiple capacitors of varied capacitances and/or multiple resistors of varied resistances may be employed to perform these same functions. Moreover, FIGS. 1 and 2 depict illustrations for only one embodiment of a voltage activated igniter. One skilled in the art may readily appreciate that various other combinations of the disclosed components, e.g. explosive materials, SCBs, and spark gaps, may be utilized to produce the same result, namely a voltage activated igniter that is immune to stray voltage, static discharge buildup, and radio frequency energy.
FIGS. 3 and 4 depict cross-sectional and end views, respectively, of a sidewall percussion coring tool 200 that utilizes at least one voltage activated igniter 100 to propel at least one barrel 215 into the surrounding formation. In some embodiments, including those depicted by FIGS. 3 and 4 , the sidewall percussion coring tool 200 is a core gun. The tool 200 utilizes one or more voltage activated igniters 100 to ignite one or more quantities of core load explosive 210 . Once ignited, the core load explosive 210 detonates, propelling the core barrel 215 into the surrounding formation. The at least one voltage activated igniter 100 is positioned inside cavity 190 within the tool body 195 . Leads 150 extend from the outer end of the igniter 100 and may be attached to electrical wiring (not shown) used to apply an electrical charge to the igniter 100 . The connector end 173 of the igniter 100 , including the leads 150 and any attached electrical wiring, is sealed by an outer seal 205 .
The core barrel 215 , which will be propelled into the surrounding formation to collect a core sample, is seated on the core explosive load 210 The core barrel 215 includes the barrel shaft 220 through which a slot 225 passes, a seal plug 230 , and a seal plug retainer pin 235 . A core barrel retainer cable 240 passes through slot 225 of the barrel shaft 220 . Each end of the core barrel retainer cable 240 is wrapped multiple times around and attached to a cable retainer pin 245 , which is securely fastened to the tool body 195 . The seal plug 230 provides a means of sealing the cable 240 within slot 225 at the base of the barrel shaft 220 , while the seal plug retainer pin 235 locks the seal plug 230 to the barrel shaft 220 . When the core load explosive 210 detonates, the core barrel 215 is propelled into the formation while remaining tethered to the tool body 195 by the core barrel retainer cable 240 and the cable retainer pins 245 .
FIGS. 5A through 5D schematically depict one embodiment of a sequence of operations wherein the sidewall percussion coring tool 200 , comprising multiple voltage activated igniters 100 , is used to collect core samples. FIG. 5A depicts one representative sidewall percussion coring service environment comprising a coiled tubing system 300 on the surface 305 and one embodiment of a sidewall percussion coring tool 200 being lowered into a wellbore 310 on coiled tubing 315 . The coiled tubing system 300 includes a power supply 320 , a surface processor 325 , and a coiled tubing spool 330 . An injector head unit 335 feeds and directs the coiled tubing 315 from the spool 330 into the wellbore 310 . Although this figure depicts the use of coiled tubing 315 to lower the sidewall percussion coring tool 200 within the wellbore 310 , one skilled in the art may readily appreciate that any similar means, for example, wireline, may be used.
FIG. 5B depicts the sidewall percussion coring tool 200 , shown in FIG. 5A , at the desired position in the wellbore 310 after run-in is complete. In this position, the igniters 100 are activated to propel the core barrels 215 into the surrounding formation 340 , wherein each igniter 100 ignites the explosive charge 115 contained within it and subsequently detonates the core load explosive 210 in contact with it via a venting tube 160 to propel a single core barrel 215 .
Firing of each igniter 100 is accomplished by applying positive DC voltage across its leads 150 . In some embodiments, the DC voltage source may be electrical wiring run from the surface 305 into the wellbore 310 along with and attached to the tool 200 . In other embodiments, the DC voltage source may be a battery(s) attached to or housed within the tool 200 . As the positive DC voltage is applied to the leads 150 , the capacitor 125 charges until a threshold level is reached, for example, between 130 and 160 volts, at which point the fixed voltage gap breaks down. Upon gap discharge, current flows through the SCB 130 , causing it to vaporize. Vaporization of the SCB 130 generates plasma gases that ignite the pyrotechnic 180 . The burning pyrotechnic 180 , in turn, causes a deflagration reaction to begin in the secondary explosive 185 . Hot gases resulting from burning of the pyrotechnic 180 and the secondary explosive 185 of the explosive charge 115 pass through the venting tube 160 to ignite and subsequently detonate the core load explosive 210 . Upon detonation of the core load explosive 210 , the core barrel 215 is propelled into the formation 340 . As shown in FIG. 5C , a single core barrel 215 is depicted as having been propelled into the formation 340 . One skilled in the art may readily appreciate that a single, multiple, or all core barrels 215 housed within the sidewall percussion coring tool 200 may be deployed into the formation 340 in the same fashion.
As depicted in FIG. 5D , the sidewall percussion coring tool 200 and attached core barrels 215 may be removed from the wellbore 310 by retracting the coiled tubing 315 . As the coiled tubing 315 is retracted and the tool 200 is pulled towards the surface 305 , the core barrel retainer cable 240 remains securely fastened both to the core barrel 215 and the tool 200 , thereby pulling the core barrel 215 from the formation 340 wall. Once extracted from the formation 340 , each core barrel 215 contains a core sample of the formation 340 , which may retrieved from the core barrel 215 for analysis after the tool 200 reaches the surface 305 .
While various embodiments of and methods of using a sidewall percussion coring tool comprising at least one voltage activated igniter have been shown and described herein, modifications may be made by one skilled in the art without departing from the spirit and the teachings of the invention. The embodiments described are representative only, and are not intended to be limiting. Many variations, combinations, and modifications of the applications disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. | An apparatus and methods for sidewall percussion coring service are disclosed. In some embodiments, the side-wall percussion coring tool includes a voltage activated igniter, explosive material, and a core barrel in communication with the explosive material, wherein activation of the igniter causes detonation of the explosive material to propel the core barrel from tool. Some method embodiments for performing sidewall percussion coring service using the disclosed sidewall percussion coring tool include positioning the tool within a wellbore, activating the voltage activated igniter housed within the tool, detonating the explosive material within the tool with the voltage activated igniter, propelling a core barrel from the tool into the surrounding formation by detonation of the explosive material, retrieving the core barrel from the formation, and removing the tool from the wellbore. |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Application PCT/FR03/002952 filed on Oct. 8, 2003, and published in French as International Publication WO 2004/035960 on Apr. 29,2004 and claims priority of French patent application number 02.13025 filed on Oct. 14, 2002, the complete contents of these applications being incorporated by reference herein.
BACKGROUND OF THE INVENTION
The invention relates to an assembly module made of synthetic material and having the appearance of tiling for floor and/or wall coverings.
The invention relates to the technical field of covering floors and walls with prefabricated modules which may be of the tiling, ceramic, terracotta or parquet type, or made of woven or nonwoven materials of the carpet type, or of synthetic materials.
The use of square modules is well known per se and they have become popular because they are practical to lay and change in the event of damage. Furthermore, there is the possibility of laying out the modules in personalized decorative configurations, which presents an undeniable advantage.
Modules in the form of tiling in ceramic, terracotta and similar materials have the disadvantage that they are heavy, their edges chip easily and they can be damaged by impact. In addition, their properties and capacities in terms of heat and/or sound insulation are very limited. Moreover, when laying them it is necessary to first prepare a smooth screed. This demands a degree of skill.
The use is also known of modules in the form of tiles made from woven or nonwoven textiles of the carpet type. In addition to the great deformability of this type of tiles, there are the conventional drawbacks that they collect dust, acarids, and are difficult to clean.
Also known are modules in the form of tiles made of synthetic material that look like tiling. These are described in patent EP 203 042 MONDO, comprising a layered structure with a thick part forming a core and two layers of flexible, substantially inextensible synthetic material, between which is an intermediate separating layer. The covering thus made in the form of tiles is delimited along its sides by tapered peripheral edges which define rounded edges on the upper face.
Also known, from patent EP 625 170, are tiles made of synthetic material having a multilayer ceramic appearance.
The tiles thus made in particular in patents EP 203 042 and EP 625 170, are placed edge to edge when assembled and binders, glues or the like are used on the one hand to bond them to the relevant support surface and on the other hand to join them together. In this case, said binder is inserted into the space for jointing of the tiles at their rounded edges, as shown for example in the MONDO patent.
Although advantageous, the various embodiments mentioned above do not allow for a variation in the decorative effect, the tiles being essentially square.
Furthermore, when positioned edge to edge in assembly, the binder or glue part is generally flush with their upper plane and the desired imitation-ceramic effect is lost.
BRIEF SUMMARY OF THE INVENTION
The applicant decided to research a new design of assembly module for floor and/or wall coverings that could optimize all the current knowledge and uses with their properties.
The applicant therefore decided to research an optimized design of this type of module made of synthetic material which allows a better reproduction of the ceramic tile effect.
Another aim was to break away from the conventional effects of positioning the tiles in squares through a new design of the module.
These aims and others will emerge from the rest of the description.
According to a first characteristic of the invention, the assembly module for floor and/or wall coverings is of the type comprising at least an associated two-layer structure, a first layer being a polymer base layer highly loaded with mineral fillers contributing to the rigidity of the module, and a second layer made from a printed polymer film defining the decorative part of the module, and the protection of the decorative part, said module being noteworthy in that the outer surface of the rigidifying base layer is designed to form a spacer means in the form of a plate of dimensions substantially greater than the format of the module, over all or part thereof, to constitute, after abutment of the modules and/or edge jointing of the plate edges, a zone for receiving a jointing such as a material binder, a mastic and the like.
According to another characteristic, the module is laid out in a configuration of varied shapes and dimensions with the spacer means corresponding to the shapes and dimensions and outline of the module, the final covering presenting an assembly of identical or different modules depending on the decorative effect chosen, each module consisting of a pattern.
According to another characteristic, the module is designed to itself represent an assembly of several modules including the appearance of fitting-together and jointing zones.
According to another characteristic, the module comprises a third layer in the form of a transparent polymer film.
According to another characteristic, the module comprises a fourth layer superposed on the third layer and being defined by a protective polymer varnish.
These and other characteristics will clearly emerge from the rest of the description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the module according to the invention with a two-layer structure, with the spacer means.
FIG. 2 is an exploded perspective view of the module according to the invention in four layers, with the spacer means.
FIG. 3 is a profile view of the module according to FIG. 2 .
FIG. 4 is a view of a set of pre-positioned modules according to the invention in the implementation according to FIGS. 1 and 2 .
FIG. 5 is a view in cross section along the line A-A of FIG. 4 .
FIGS. 6 and 7 are diagrammatic views illustrating the module according to the invention with the printed films in different positions.
FIG. 8 is an overall view of two modules of different configurations intended to be assembled according to a specific pattern.
FIG. 9 is a view according to FIG. 8 , with the modules assembled.
FIG. 10 is a view of a single module according to the invention, laid out flat, the module itself being decorated with several modules together with depiction of the jointing zones.
FIG. 11 is a variant view of a module according to the invention with an internal depiction in the form of a disk.
FIGS. 12 and 13 are views of modules laid out flat, according to two ways of assembling them together.
FIG. 14 is a perspective partial view of two adjacent modules of the type shown in FIGS. 1-3 prior to positioning of a jointing seal in a channel formed atop abutting spacer means.
FIG. 15 is a cross-sectional view of a junction formed by adjacent modules and having a jointing seal provided in said channel.
DETAILED DESCRIPTION
To give a clearer idea of the subject of the invention, preferred embodiment will now be described in a non-limiting manner with the figures of the drawings.
The assembly module for wall and floor coverings according to the invention bears the general reference (1). It may be made in the form of a square tile, in the form of a rectangular strip, or in other forms. It is a thick, rigid tile, shown in a first non-limiting example in a square format, of variable dimensions which may be, by way of non-limiting example, of the order of 300 to 500 millimeters each side. The module is made in the form of a multilayer structure with at least two layers (Cl) (C 2 ). The first layer is the bottom base layer intended to come into contact with the floor and/or wall surface, and it is made of polymer highly loaded with mineral fillers. This first layer is associated on its upper face with a second layer (C 2 ), defined by a printed polymer film, contributing to the decorative part of the module, and the protection of the decorative part. Said layers may possibly receive a third layer (C 3 ) consisting of a transparent polymer film, and a fourth layer (C 4 ) in the form of polymer varnish of the polyurethane or some other type. This varnish may contain special agents that give a structured, rough, etc. Surface. The module is made with a multilayer structure and may have a thickness of around 4 to 8 millimeters, the base layer (C 1 ) constituting the bulk of this thickness. Referring to FIGS. 6 and 7 , the printing may be placed on the underside of the second layer, or on the top side of said layer, with a third, protective layer.
Preferably, said thickness may be around 6 millimeters. The mass per unit area is from 8 kg/m 2 to 16 kg/m 2 , and preferably around 12 kg/m 2 .
The upper peripheral edging ( 1 . 1 ) of the module may be rounded, chamfered, beveled, or have any other profile, on each of its edges to fulfill a dual role, namely on the one hand to protect the surface film, i.e. either the printed film or the transparent film, or both, to prevent it scratching off owing to wear. Furthermore, this rounded edging confers on the module a ceramic effect. The printed polymer film constituting the second layer is made with the desired decorative effect. The layers are joined together by various manufacturing techniques, such as calendering, or hot pressing, by way of non-limiting example.
The module according to the invention is designed and provided, under the bottom layer (C 1 ), with a specific spacer means ( 2 ). The spacer means is made of any suitable material with a degree of rigidity, and it is characterized by being of substantially larger dimensions than the module so that it protrudes, over all or part of the module, in the manner of a peripheral surround ( 2 a ). The spacer means has straight edges ( 2 b ) so that it is possible when creating a decorative effect to lay out a set of modules as shown in FIG. 4 . The junction between the edgings of every two spacers defines a lower flat reception zone ( 3 ) at the level of the module creating a channel for the positioning of a jointing seal ( 4 ). This embodiment is even more similar to the known presentations of tiling and how the tiles are laid.
The spacer means is advantageously made directly with the rigidifying base layer and, being thus made of the same material, the whole is then obtained in a single step, by pressing, or by machining or other methods.
The module thus presents this characteristic appearance as shown in the figures of the drawings, with this bottom part consisting of the spacer.
As a variant, the spacer may be made of a different material from the base layer and be either attached to it or bonded by any suitable means, or obtained during manufacture. The spacer may protrude only partially from the format of the tile. For example, this protrusion may be made only on two adjacent sides of the module, if the module is square. All other arrangements may be envisioned to help create decorative effects.
The spacer also makes it possible to have very regular dimensions. Depending on the embodiment, it is possible to have different spacing seal widths based on the laying-out of several modules to create various esthetic effects.
This original arrangement of the invention is particularly advantageous since it considerably, increases the scope for creation of decorative effects, on the receiving floor or wall surfaces.
FIGS. 8 and 9 show an embodiment of two modules of different shapes, the first being a square with one corner cut off and the second a smaller square. The assembly of these shapes is partially depicted in FIG. 9 .
In FIG. 11 , by virtue of its spacer part the module is of square section for example, but an inner decorative part represents, in a novel, original manner, a ceramic in the form of a disk.
In FIG. 10 , the module according to the invention is made with a single base including the bottom part forming the spacer. According to this solution, the module itself consists of a decorative part representing an arrangement of smaller modules. In this embodiment, the zones for jointing between the small modules are also shown.
Thus, according to the invention, sets of modules with multiple decorative effects are obtained.
Also shown in FIGS. 12 and 13 are two variants depicting the assembling of modules. In general, the protruding spacer means has, around its periphery, male and female assembly means for the fitting together of several modules.
According to the embodiment of FIG. 12 , this spacer means of the module, depicted by way of example in the form of a square tile, has two adjacent sides where the protruding part comprises a plurality of projections 2 a ′ that correspond in number, themselves protruding from the protruding zone 2 a ′ of the spacer.
The other two sides have, in said zone 2 b ′, notches ( 2 c ) whose profile corresponds to and complements said projections 2 a ′, to allow their engagement. Thus, this embodiment not only ensures that the modules can be fit together but also the positioning and location of the modules with respect to one another is facilitated.
In the variant of FIG. 13 , the spacer is shaped with a plurality of projections ( 2 d ), with a dovetail profile, being arranged along the sides of the module in respective offset positions, and complementary spaces ( 2 e ) between two consecutive projections to allow fitting-together and interlinking.
The advantages of the invention lie in the fact that the modules thus constituted are both rigid and lightweight and are, by virtue of the base layer, almost undeformable, the spacer part allowing their relative positioning. Furthermore, the implementation of this invention makes it possible to obtain modules offering better acoustic insulation, better heat insulation and better impact strength.
Another advantage is that the modules may be cut by any means. Furthermore, it is also possible to envision manufacturing plates of modules on which are marked zones for breaking and shearing by a cutter, jigsaw or the like, for the formats in question. The modules are lighter than tiling and are easy to lay.
The module thus designed according to the invention is positioned on the floor or wall covering and is held in place using an adhesive that either may be made integral with the module at the time of manufacture, by removing the protection for the adhesive layer, or it is the support plane that is provided with and directly receives the adhesive.
In an advantageous embodiment, use may be made of a binder glue dispensed using a dispenser such as a glue gun, by way of non-limiting example. Glue is deposited in spots spread out over each module, so that it is applied partially, in a varied arrangement, and, after jointing the modules to one another, the module-layer can fill the spaces in the junction parts of the spacer. Thus, laying is quick and presents no particular problems. The thickness of each module easily absorbs differences in level at the surface of the floor or wall to be covered. | A module includes at least an associated two-layer structure with one first layer being a polymer base layer highly loaded with mineral fillers contributing to the rigidity of the module, and a second layer made from a printed polymer film defining the decorative part of the module, and the protection of the decorative part. An outer surface of a rigidifying base layer is designed to form a spacer means in the form of a plate of dimensions substantially greater than the format of the module, over all or part thereof, to constitute after abutment of the modules and/or edge jointing of the plate edges, a zone for receiving a sealant such as a binder, putty and like bonding. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional Application No. 61/774,749 filed on Mar. 8, 2013. The disclosure of Provisional Application No. 61/774,749 is hereby incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to a building panel such as a floor panel, a wall panel, a ceiling panel, a furniture component or the like, which is provided with a mechanical locking system comprising a displaceable tongue.
TECHNICAL BACKGROUND
[0003] Building panels provided with a mechanical locking system comprising a displaceable tongue cooperating with a tongue groove for vertical locking is known and disclosed in, e.g., FR 2 975 717. The mechanical locking system in FR 2 975 717 has a displaceable tongue comprising an outer element which is pushed by a wedge part of a removable inner part of the tongue into a tongue groove, for vertical locking of adjacent edges of two floorboards. A drawback with this known system is that the locking strength is rather low.
[0004] The above description of various known aspects and drawback is the Applicant's characterization of such, and is not an admission that any of the above description is considered as prior art.
[0005] Although the description in the present disclosure relates to a floor panel, the description of techniques and problems thereof is applicable to other applications as well. For example, the description is also applicable to panels for other purposes, such as wall panels, ceiling panels, furniture panels and components, etc.
SUMMARY
[0006] It is an object of embodiments of the present disclosure to provide an improvement over the above described conventional techniques.
[0007] A further object of embodiments of the present disclosure is to provide building panels, such as floorboards, provided with a locking system that comprises a tongue that improves the vertical locking of the floorboards.
[0008] Another object of embodiments of the present disclosure is to provide a more efficient production method, which requires less complicated production equipment.
[0009] At least some of these and other objects and advantages that will be apparent from the present disclosure have been achieved by certain embodiments of the building panels described herein. The building panels, such as floorboards, are provided with a locking system that comprises a displacement groove at a first edge of a first floorboard and a tongue groove at a second edge of a second floorboard. A tongue is arranged in the displacement groove and is configured to cooperate, in a second position, with the tongue groove for vertical locking of the first edge and the second edge. The tongue comprises, in a first position, an inner element and an outer element. The inner element is removable along the displacement groove, and is configured to cooperate with the outer element to obtain a displacement of the outer element towards the tongue groove and thereby obtain the second position. The inner element and the outer element are preferably configured to vertically overlap each other in the first position to obtain an increased contact surface between a surface of the displacement groove and the outer element of the tongue in the second position. The inner element and the outer element are arranged such that the increased contact surface takes up a moment of force that arises on the tongue when a load is applied on the first or the second floorboard. The inner element in the first position may be arranged above or below the outer element. The inner element in the first position may also be arranged partly above partly behind the outer element, or may be arranged partly below the outer element and partly behind the outer element.
[0010] The entire outer element is in the first position preferably arranged within the displacement groove.
[0011] The outer element maybe provided with a guiding groove at either an inner and upper edge of the outer element or at an inner and lower edge of the outer element, wherein at least a part of the inner element in the first position is arranged in said guiding groove. The outer element may be provided with a guiding groove at an inner surface of the outer element, between an upper surface and lower surface of the outer element, wherein at least a part of the inner element is arranged in said guiding groove in the first position. The guiding groove facilitates the removal of the inner element by guiding the inner element in a controlled manner and provides a groove without obstructions and desired friction. The guiding groove preferably extends essentially along the whole longitudinal length of the outer element. This embodiment of the outer element provides for a simple production of the outer element for example by plastic profile extrusion and cutting of the profile in the desired length.
[0012] The inner element preferably comprises a first protruding part configured to cooperate with the guiding groove, to obtain said displacement of the outer element.
[0013] The first protruding part in the first position is preferably arranged outside of the outer element and/or in a recess of the outer element. When the inner element is removed by a displacement along the displacement groove and preferably in the guiding groove, the outer element is gradually pushed into the tongue groove to obtain the second position.
[0014] The first protruding part may be wedge shaped or of an essentially spherical shape. Such shapes facilitate the displacement of the inner element. The outer element may also be provided with guiding surfaces at the location of the first protruding part in the first position. The first protruding part is preferably elastic, to make it easier to displace the first protruding part over irregularities in the displacement groove. The first protruding part may comprise an elastic material and may be provided with a recess to increase the elasticity.
[0015] The inner element is preferably provided with a second protruding part, preferably configured such that the second protruding part is easy to grasp by an installer of the floorboards. The second protruding part may also be configured such that the inner element is secured in the correct position.
[0016] The cross section of the inner element may be L-shaped or rectangular or of an essentially circular shape.
[0017] The inner element may comprise plastic and may be produced by injection molding or extrusion. An extruded inner element of plastic may be provided with the first and or the second protruding part by heating and compressing a part of the extruded profile in a press tool.
[0018] The inner and outer element may be produced in one piece by injection molding of plastic and connected together by a connection configured to break when the inner element is displaced or when the tongue is inserted into the displacement groove.
[0019] The building panels may comprise a wood-based core, preferably made of at least one of MDF, HDF, OSB, WPC (Wood Powder Composite), and particleboard, or of plastic, such as vinyl or PVC.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present disclosure will by way of example be described in more detail with reference to the appended schematic drawings, which illustrate several embodiments.
[0021] FIGS. 1-3 show a known locking system with a tongue comprising an inner and an outer element.
[0022] FIGS. 4-7 show a tongue comprising a guiding groove at an inner edge, according to embodiments of the present disclosure.
[0023] FIGS. 8 and 9 each shows a tongue from a top view, according to embodiments of the present disclosure.
[0024] FIGS. 10 and 11 show cross-sections of a tongue comprising an L-shaped inner element, according to embodiments of the present disclosure.
[0025] FIGS. 12-15 show tongues comprising a guiding groove at an inner surface, according to embodiments of the present disclosure.
[0026] FIGS. 17-19 show a method for producing an inner element of a tongue, according to embodiments of the present disclosure.
[0027] FIG. 20 shows an embodiment of an inner element of a tongue, according to an embodiment of the present disclosure.
[0028] FIGS. 21 and 22 show a tongue with an inner element having a circular cross-section, according to an embodiment of the present disclosure.
[0029] FIGS. 23-25 show a displacement groove provided with recess, according to an embodiment of the present disclosure.
[0030] FIG. 26 shows a tongue from a top view, according to an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0031] FIGS. 1-3 show floorboards provided with a known locking system which comprises a tongue 20 having an inner element 21 and an outer element 22 . The tongue 20 is arranged in a displacement groove 24 at a first edge 1 b of a first floorboard. FIG. 1 shows a position during assembling of the first floorboard. The first floorboard is arranged in a second row and is connected at a third edge to a fourth edge of a third floorboard in first row. A second floorboard is arranged in an angled position with a third edge adjacent the fourth edge of the third floorboard and a second edge 1 c of the second floorboard is arranged adjacent the first edge 1 b of the first floorboard.
[0032] FIG. 2 shows a cross-section of the first edge 1 b and the second edge 1 c after the second floorboard is angled down and connected to the third floorboard in the first row. The first edge 1 b and the second edge 1 c are in FIG. 2 locked together in the horizontal direction, and the inner element 21 and the outer element 22 of the tongue 20 are arranged in a first position. The first edge 1 b and the second edge 1 c are in the first position vertically un-locked. To lock the first edge 1 b and the second edge 1 c in the vertical direction, the inner element 21 is displaced and removed along the first edge 1 b . The inner element 21 is provided with a protruding part. The protruding part pushes the outer element 22 of the tongue 20 into a tongue groove 23 at the second edge 1 c of the second floorboard when the inner element 21 is displaced and removed.
[0033] FIG. 3 shows a cross-section of the first edge 1 b and the second edge 1 c in a second position. The inner element 21 of the tongue 20 is in the second position displaced and removed. The outer element 22 of the tongue 20 cooperates with the tongue groove 23 at the second edge 1 c of the second floorboard for vertical locking of the first edge 1 b and the second edge 1 c.
[0034] An embodiment of the present disclosure is shown in FIG. 4 and FIG. 5 , with an inner and outer element 31 , 30 of the tongue 10 arranged in a displacement groove 32 at a first edge 1 b of a first floorboard. FIGS. 4 and 5 illustrate the first position and the second position, respectively, of the inner and outer elements 31 , 30 . The outer element 30 of the tongue 10 extends below the inner element 31 of the tongue 10 , such that the inner element 31 vertically overlaps the outer element 30 . The inner element 31 is in this embodiment arranged in a guiding groove 60 at an inner and upper edge of the outer element 30 . The width x of a first contact surface between a lower surface of the outer element 30 of the tongue 10 and the displacement groove 32 is increased, as compared to the known locking system shown in FIG. 3 , in order to improve the strength of the locking system and minimize the offset in height between the first edge 1 b and the second edge 1 c when a load is applied, in the second position, on the first floorboard.
[0035] The second position in which the outer element 30 is pushed into the tongue groove 33 at the second edge 1 c is shown in FIG. 5 . The outer element 30 is pushed into tongue groove 33 by a first protruding part 36 (see FIGS. 8 and 9 ) arranged on the inner element 31 , when the inner element 31 is removed and displaced along the first edge 1 b . A load applied on the first edge 1 b will be taken up by a second contact surface, between an upper surface of the outer element 30 of the tongue 10 and the displacement groove 32 , and a third contact surface between a lower surface of the outer element 30 of the tongue and the tongue groove 33 . Since the second contact surface and the third contact surface are displaced, the load applied will result in a moment of force, which is taken up by the first contact surface. In order to increase the strength of the locking system, the width x of the first contact surface is preferably larger than the width y of the third contact surface, and preferably the width x is about twice ore more the width y. For the purpose of reducing the momentum that arises when a load is applied on the first edge 1 b , the horizontal distance between the second and the third contact surfaces should be as small as possible, preferably less than about 1 mm and more preferably less than about 0.5 mm. This applies also to the embodiments described below.
[0036] The locking system additionally comprises in this embodiment a locking strip 6 , which protrudes horizontally from the first edge 1 b . The locking strip 6 is provided with a locking element 8 which cooperates with a locking groove 14 provided at the second edge 1 c for horizontal locking of the first edge 1 b and the second edge 1 c . A load applied on the second edge 1 c is preferably taken up by a strip contact surface between an upper surface of the locking strip 6 and a lower surface of the second edge 1 c.
[0037] In order to push the first edge 1 b and the second edge 1 c vertically against each other, a lower surface of the tongue groove 33 at the third contact surface is preferably arranged with an angle β 1 in relation to the horizontal plane of the floorboards. The angle β 1 may be in the range of about 5° to about 20°, and preferably about 15°.
[0038] In the embodiment shown in FIGS. 6 and 7 , the tongue 10 is arranged in a displacement groove 32 at the second edge 1 c . The inner element 31 of the tongue 10 is for this embodiment preferably arranged in a guiding groove 60 at an inner and lower edge of the outer element 30 of the tongue 10 to obtain an increased first contact surface between an upper surface of the outer element 30 of the tongue 10 and the displacement groove 32 . Also, in this embodiment the first contact surface takes up a momentum force resulting from a load applied at the first edge 1 b , in a similar way as described for the embodiment shown in FIGS. 4 and 5 . In order to push the first edge 1 b and the second edge 1 c vertically against each other, an upper surface of the tongue groove is preferably arranged with an angle β 2 in relation to the horizontal plane of the floorboards. The angle β 2 may be in the range of about 5° to about 20°, and preferably about 15°.
[0039] FIGS. 8 and 9 show top view embodiments of an elongated tongue 10 , to be arranged in a displacement groove 32 at a first edge 1 b of a first floorboard. The elongated tongue comprises an inner element 31 , and an outer element 30 . The inner element 31 is arranged in a guiding groove 60 at an inner edge of the outer element 30 . The inner element 31 is preferably a bar element of an elongated shape and is provided at a first short edge with a first protruding part in the form of a wedge shaped element 36 . The wedge shaped element is in a prefered embodiment guided by the guiding groove during the displacement of the inner element. The wedge shaped element 36 is configured to push the outer element 30 into a tongue groove 33 of an adjacent second edge 1 c of a second floorboard when the inner element 31 is removed and displaced along the first edge 1 b . The wedge shaped element 36 is, before the displacement, preferably arranged adjacent and at least partly outside a first short edge of the outer element 30 as shown in FIG. 8 . A second edge of the inner element 31 is preferably provided with a gripping part 37 that facilitates the displacement of the inner element 31 . FIG. 9 shows that the first short edge of the outer element 30 may be provided with first chamfer 38 that guides the wedge shaped element 36 into the guiding groove 60 . The gripping part 37 is, before displacement of the inner element 31 , preferably arranged adjacent a second short edge of the outer element 30 and preferably outside the second edge. As shown in FIG. 9 the inner element 31 may be provided with a second protruding part 40 , for a correct positioning of the inner element 31 , that before displacement of the inner element is preferably arranged in a notch or in a second chamfer 39 provided at the second short edge of the outer element 30 . The outer element 30 may have a uniform cross-section from the first short edge to the second short edge. A uniform cross-section makes it possible to produce the outer element 30 at low cost, by e.g., extrusion of plastic. Also the inner element 31 may have uniform cross-section with the exception of the protruding part (wedge shaped element) 36 at the first edge. For the purpose of obtaining a correct position of the inner element 31 , a prefered embodiment of the present disclosure comprises the first chamfer 38 and the second chamfer 39 , which cooperate with the first protruding part 36 and the second protruding part 40 , respectively.
[0040] FIGS. 10 and 11 show an embodiment of the tongue 10 comprising an L-shaped inner element 31 arranged in a corresponding guiding groove at an inner edge of the outer element 30 .
[0041] FIGS. 12-15 show an embodiment of the tongue 10 comprising inner element 31 arranged in a guiding groove 60 at an inner surface of the outer element 30 . FIG. 13 shows that outer edges 42 , 43 of the outer element 30 may be chamfered in order to guide the outer element 30 into the tongue groove 33 . FIG. 14 shows a cross section of the tongue 10 and that the guiding groove 60 may be provided with chamfered edges 41 . FIG. 15 shows a cross section of the tongue 10 in a plane indicated by AA in FIG. 14 . The inner element 31 in this embodiment is provided with friction elements 44 that avert that the inner element 31 from falling out before the floorboards are installed. The first protruding part 36 is provided with a recess 45 that makes its most protruding part 46 more resilient. The most protruding part 46 may be, during the displacement of the inner element 31 , compressed during, e.g., entrance of the inner element 21 into the guiding groove 60 , or at any irregularities in the displacement groove 32 . Also the other embodiments of the tongue 10 may be provided with a friction element 44 on the inner element 31 and/or on the outer element 30 , and/or a recess 45 in the first protruding part 36 .
[0042] A method for producing the first protruding part 36 and/or the second protruding part 40 of the inner element 31 is illustrated in FIGS. 17-19 . A plastic blank 50 of an elongated shape is displaced into a press tool comprising a first part 55 and a second part 56 . The first part 55 and the second part 56 are displaced against each other and a protruding part 35 at a first short edge of the plastic blank 50 is formed under heat and pressure. The process may be repeated for a second short edge of the plastic blank 50 . The method may also comprise the step of forming the second protruding part 35 simultaneously and essentially in the same manner as the first protruding part 35 . The produced first and/or second protruding part 35 may be of, for example, an essentially spherical shape or wedge shaped. FIG. 20 shows an inner element 31 that may be produced according to the method illustrated in FIGS. 17-19 . The inner element 31 preferably has an essentially circular cross-section and preferably comprises protruding parts 35 of an essentially spherical shape.
[0043] FIGS. 21 and 22 show that an inner element 31 with a circular cross section may be combined with a displacement groove 32 having an inner surface 62 , which is smaller than the opening of the displacement groove 32 . The inner surface 62 may be provided with a round shaped bottom that facilitates the displacement of the inner element 31 .
[0044] An upper or lower surface of the displacement groove 32 may be provided with a recess 34 having an angled surface at an angle β 3 to the horizontal plane. The angle β 3 may be in the range of about 3° to about 10°. An embodiment of the recess 34 is shown in FIGS. 23-25 . The recess 34 and the angled surface has the effect that the outer element 30 of the tongue 10 tilts and the outer element 30 is restrained from being displaced back into the displacement groove 32 after the outer element 30 is pushed into the tongue groove 33 by the inner element 31 . Such a recess 34 may be provided in locking systems comprising any type of the disclosed displaceable tongue.
[0045] A prefered embodiment of the tongue 10 is shown in FIG. 26 . The inner element 31 and the outer element 30 are produced in one piece by injection moulding of plastic. The inner element 31 and the outer element 30 are connected together by a connection 47 configured to break when the inner element is displaced or when the tongue is inserted into the displacement groove. | Building panels, such as floorboards, provided with a mechanical locking system. The mechanical locking system includes a displacement groove at a first edge of a first floorboard and a tongue groove at a second edge of a second floorboard A tongue is arranged in the displacement groove and is configured to cooperate, in a second position, with the tongue groove for vertical locking of the first and the second edge. The tongue includes, in a first position, an inner element and an outer element. The inner element is removable along the displacement groove, and is configured to cooperate with the outer element to obtain a displacement of the outer element towards the tongue groove and thereby obtain the second position. Said inner element and said outer element vertically overlap each other. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to mine roof bolts, and more particularly relates to mine roof bolts constructed of pretensioned, multi-strand steel cable.
2. Description of the Prior Art
In the art of mine roof support, there are two major categories of bolt systems wherein mine roof bolts are anchored in bore holes drilled in the mine roof, the bolts' purpose being to reinforce the unsupported rock formation above the mine roof. These two categories of mine roof bolt systems are: (1) tension-type systems, and (2) passive-type systems. In each system, it is common practice to, first, drill a hole through the mine ceiling into the rock formation above to a depth appropriate for the type of rock formation to be supported. A mine roof bolt and roof plate are then anchored in the bore hole to support the mine roof and maintain the rock formation in place.
In tension-type mine roof bolt systems, an expansion shell type anchor is installed on the end of the bolt. The bolt and expansion shell anchor are inserted up into the bore hole until the roof plate is against the mine roof. The bolt is then rotated to thread a tapered plug section of the expansion shell down toward the bolt head, in order to expand the jaws of the expansion shell against the interior wall of the bore hole to thereby hold the mine roof bolt in place within the bore hole.
In passive-type mine roof bolt systems, the passive-type bolt is not attached to an expansion shell or similar device at the free (upper) end of the bolt, but rather is retained in place within the rock formation by a rapid-curing resin material that is mixed in the bore hole as the bolt is rotated and positioned within the bore hole. In theory, the resin bonds the bolt to the rock formation along the total length of the bolt within the bore hole in the rock formation. It is also common practice to use resin with a tensiontype mine roof bolt to retain the bolt within the mine roof bore hole.
In these passive-type mine roof bolt systems, one or more resin cartridges are inserted into the bore hole prior to (ahead of) the mine roof bolt. Forcing the mine roof bolt into the bore hole while simultaneously rotating the bolt ruptures the resin cartridge(s) and mixes the two resin components within the annulus between the bolt shank and bore hole wall. Ideally, the resin mixture totally fills the annulus between the bolt shank and bore hole wall along the total length of the bolt and bore hole. The resin mixture penetrates the bore hole wall and into the surrounding rock formation to adhere the bolt to the rock formation.
When extremely long mine roof bolts are necessary, it is common practice to attach two or more bolt sections together by couplers to result in a "roof bolt" of sufficient length appropriate for the particular type of rock formation. These couplers between bolt sections, being of a larger diameter than the bolt shanks, prevent the mixed resin from flowing downwardly (resin return) within the bore hole annulus from the first (upper) bolt section to the lower section(s). Therefore, the anchoring of the bolt to the bore hole wall within the rock formation is, effectively, only along the length of the first (upper) bolt section wherein the resin totally fills the annulus between the bolt section and the bore hole wall.
To alleviate this problem, it has been common practice simply to drill a larger bore hole in the rock formation that will enable the resin to flow around the coupler(s) as the bolt is being rotated within the bore hole to mix the resin. Although this does effect the desired result (resin return around the coupler(s) within the annulus between the bolt shank and bore hole wall), it creates another problem that, depending on the type of rock formation, may be more dangerous than the problem that is corrected by a larger bore hole. Specifically, the bonding effectiveness of the resin bonding material to hold the mine roof bolt in place within the bore hole is considerably weakened by virtue of the increased distance between the bolt shank and bore hole wall, and the sheer volume of resin material necessary to totally fill the annulus with the resin bonding material. Additionally, by virtue of their specific makeups, mine roof rock formations that actually require long (fifteen feet or longer) mine roof bolts are more susceptible to movement and shifting within the rock formation, than are more solid rock formations that require only shorter mine roof bolts.
Another common problem with using mine roof bolt sections coupled together in such rock formations that require longer (coupled) mine roof bolts, this shifting of the rock formation (shear) causes the bolt couplers to fracture. When this happens, of course, the effective holding length of the mine roof bolt is instantly decreased. In many instances, there is no or very little resin adhesive material around the broken bolt shank to help stabilize the rock formation. Therefore, in almost all instances, this shortened mine roof bolt is ineffective to safely prevent the mine roof rock formation from further shifting and potential collapse.
It is therefore an object of the present invention to provide an improved mine roof bolt that does not require an oversized mine roof bore hole in order to effect full and complete resin return within the annulus between the bolt shank and bore hole wall along the total length of the bolt shank.
It is another object of the present invention to provide an improved mine roof bolt that is available in various lengths without the use of bolt shank couplers that are susceptible to fracture when the mine roof rock formation shifts.
It is a further object of the present invention to provide an improved mine roof bolt having an inherently rough outer surface that aids in effecting complete mixture of the resin bonding material, and also includes crevices within the mine roof bolt shank that permit penetration of the resin bonding material int the bolt shank for more effective resin bonding thereto.
It is a still further object of the present invention to provide an improved mine roof bolt that will easily bend for installation into a bore hole that is considerably deeper than the height of the mine at the installation location, and will also bend with a shifting rock formation, and fully retain its bonding within the rock formation along the total length of the mine roof bolt without breaking when the rock formation shifts.
SUMMARY OF THE INVENTION
The improved mine roof bolt of the present invention is constructed of a length of pre-stressed, multi-strand steel cable, commonly formed of six individual pre-stressed steel strands spirally wrapped around a seventh steel strand. The head of the bolt is formed by positioning a two-piece tapered plug around the stranded steel cable at one end, and then slipping a hexagonal- or other drive-headed internally tapered collar around the tapered plug. Pressing the internally tapered hexagonal head collar down over and against the two-piece tapered plug urges serrations on the interior circumference of the plug sections to "bite" into the stranded steel cable to form a rigid hexagonal bolt head on the cable that further tightens against the steel strands as tension is applied to the mine roof bolt.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial conventional view of the improved mine roof bolt of the present invention, illustrating the two-piece tapered plug and, in section, the internally tapered hexagonal head collar.
FIG. 2 is an end view of the improved mine roof bolt.
FIG. 3 is a perspective view of one section of a two-piece tapered plug.
FIG. 4 is a perspective view of an alternative embodiment of one section, of a two-piece tapered plug.
FIG. 5 is a side elevation view of the improved mine roof bolt positioned in the mine roof bore hole under the resin cartridge, the mine roof plate, spherical washer, and internally tapered hexagonal head being shown in section.
FIG. 6 is a view of the improved mine roof bolt of FIG. 5, shown in installed position within the mine roof bore hole, with the resin material thoroughly mixed and completely filling the annulus around the shank of the mine roof bolt.
FIG. 7 is a graph of tensile strength vs. elongation for a 9/16 inch diameter improved mine roof bolt of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and initially to FIG. 1, the improved mine roof bolt is shown, generally illustrated by the numeral 10. The mine roof bolt comprises a shank 12 made up of a length of pre-stressed steel stranded cable, which in the embodiment shown, is made up of six peripheral steel strands 14 spirally wrapped around a central steel strand 16 (more clearly shown in FIG. 2).
At one end of the pre-stressed steel stranded cable is affixed a two-piece tapered plug 20 which comprises two identical diametrically opposed essentially half-cylinders that define the outer surface of a right conical frustum. The frusto-conical outer surface 22 of the two-piece tapered plug 20 is designed to engage a mating inside frusto-conical surface of an internally tapered hexagonal head collar 26. Although the collar 26 is shown as a hexagonal head, obviously a square head or any other shaped head that accepts a mine roof bolt driver mechanism and boom should function adequately for the intended purpose.
FIG. 2 is an end view of the improved mine roof bolt of the present invention, and illustrates how the two-piece tapered plug fits concentrically around the pre-stressed steel stranded cable shank of the bolt, and also nests concentrically within the internally tapered hexagonal head collar 26. Note that the individual sections of the two-piece tapered plug 20 are not fully semi-frusto-conical. When functionally positioned within the hexagonal head collar 26 and around the pre-stressed steel stranded cable roof bolt shank 12, the two individual plug sections 20 define a diametric space 28 between the two plug sections to enable the plug sections to be urged together slightly when pressed against the pre-stressed steel stranded cable.
FIG. 3 is a perspective view of one section of the two-piece tapered plug 20 and more clearly shows a series of serrations or knurls 30 that define the inner essentially semi-tubular surface of the tapered plug. These serrations 30 are designed to "bite" into the pre-stressed steel stranded cable defining the roof bolt shank 12 as the two-piece tapered plug 20 is urged further into the hexagonal head collar 26 to define a rigid hex-head of the improved mine roof bolt.
Creating this rigid hex-head on the mine roof can be accomplished in either of two ways: (1) By pressing the two-piece tapered plug 20 and pre-stressed steel stranded cable bolt shank 12 into the hexagonal head collar 26 as the mine roof bolt is factory-manufactured; or (2) After having cut the pre-stressed steel stranded cable to the desired length at the mine site, assembling the pre-stressed steel stranded cable, two-piece tapered and hexagonal head collar 26, and then tensioning the pre-stressed steel stranded cable against the hexagonal head collar, or otherwise pressing the tapered plug and cable-into the collar. In either instance, the "head" of the improved mine roof bolt 10 should be rigid and secure enough to remain intact as the mine roof bolt is being inserted into the mine roof bore hole, forced up into the bore hole against the resin capsule, and rotated or spun within the mine roof bore hole in order to rupture the resin capsule and mix and distribute the resin material.
FIG. 4 is a perspective view of one section of an alternative embodiment of a two-piece tapered plug, shown at 32. This alternative embodiment tapered plug includes a different type of knurl 34 formed in a diamond pattern resulting from diagonally oriented serrations. Those skilled in the art will appreciate that this diamond pattern knurl will better retain the tapered plug 32 on the pre-stressed steel stranded cable against both torsion as the improved mine roof bolt 10 is rotated during installation, and against tension as the bolt remains in place within mine roof rock formation to retain the rock formation in place.
FIG. 5 illustrates the improved mine roof bolt and its arrangement as inserted up into a mine roof bore hole. Assuming that the improved mine roof bolt has previously been assemble as shown in FIG. 1, and the two-piece tapered plug 20 pressed into the hexagonal head collar 26 to define a rigid bolt head, the user first places a spherical washer 40 having a partial spherical surface 42 over the bolt shank and down against the hexagonal head collar 26, as shown. Next, the user slips on a dome mine roof plate 44, the through-hole of the roof plate having an angled surface 46 that mates with the partial spherical surface 42 of the spherical washer 40. Those skilled in the art will appreciate that this spherical washer 40 and the angled surface 46 of the dome mine roof plate 44 define "ball and socket"-like arrangement that permits the improved mine roof bolt and dome mine roof plate to be used in mine roofs wherein (1) the bore holes are angled or otherwise not normal to the surface of the mine ceiling 48, (2) the mine ceiling surfaces are extremely rough or otherwise uneven, or (3) a combination of (1) and (2) that results in the entrance to the mine roof bore hole not being exactly normal to the mine ceiling surface at the location of the mine roof bore hole. Additionally, such an arrangement permits the improved mine roof bolt 10 to shift slightly as the rock formation above shifts, and still maintain an essentially uniform force of the dome mine roof plate 44 against the mine ceiling 48.
To this end, the inventor has determined that, alternatively, the hexagonal head 26 of the improved mine roof bolt of the present invention and the spherical washer may be formed as a single piece. This simplifies installation and more easily maintains the mine roof bolt in alignment with the roof plate during rotation of the mine roof bolt in the roof bore hole.
The spherical washer 40 and dome mine roof plate 44 having been installed on the improved mine roof bolt 10, the user then inserts a resin cartridge 50 into the mine roof bore hole 38, followed by the improved mine roof bolt of the present invention. The user then forces the improved mine roof bolt 10 upwardly into the mine roof bore hole 38 under the force of the boom (not shown), while simultaneously rotating the mine roof bolt to rupture the resin cartridge 50 and thoroughly mix and distribute the resin material contained therein. Continued rotation of the improved mine roof bolt 10 after the dome mine roof plate 4 has been urged against the mine ceiling 48, further mixes and distributes the resin material within the annulus between the pre-stressed steel stranded cable and the mine roof bore hole 38, and causes the resin material to be forced into the cracks and crevices within the mine roof bore hole 38, and also into the crevices and spaces between the individual peripheral steel strands 14 of the pre-stressed steel stranded cable. After the resin material is thoroughly mixed, the assembled bolt is held in place against the mine ceiling 48, as shown in FIG. 6, by the boom, for a period of time sufficient to permit the resin to cure.
FIG. 7 is a graph of n le strength vs. elongation for a 9/16 inch diameter cable mine roof bolt of the present invention. When pulled in tension until fracture, the improved mine roof bolt begins to yield at approximately 57,000 pounds of force, and will withstand over 60,00 pounds of force before fracturing.
As the graph of FIG. 7 illustrates, the fracture of the seven strand cable mine roof bolt actually occurs in a stepped progression, rather than all at once. Typically, one, two, or three individual cable strands will fail at approximately 60,000 pounds, the remaining four, five, or six strands remaining intact to continue to support the rock formation above the mine roof. These remaining four to six strands will continue to withstand from 25,000 to 35,000 pounds of force before the next set of one, two, or three strands fails in tension. The steel cable strands remaining intact after the second set of strands fails (from one to four) will continue to withstand approximately 15,000 pounds of force before ultimate total failure of the mine roof bolt.
By comparison, a conventional 158 inch diameter smooth shank mine roof bolt will fail at under approximately 30,000 pounds of force, at approximately one-half of the maximum force of approximately 60,000 pounds that a 9/16 inch diameter cable mine roof bolt will withstand before the initial partial failure.
It is important to note that when the 9/16 inch cable mine roof bolt "fails" at 60,000 pounds, its failure is only partial, in that four to six steel strands remain intact through the first "stepped failure". Therefore, the improved mine roof bolt of the present invention remains intact after initial "failure" to continue to support the rock formation to permit the rock formation to stabilize with the mine roof bolt intact and still able to withstand approximately 30,000 pounds of force before a subsequent "failure" occurs.
It should also be noted that the multi-strand cable defining the shank of the improved mine roof bolt of the present invention fractures at the point of attachment to the two-piece tapered plug, leaving the total length of the steel cable shank remaining in the mine roof bolt bore hole to continue to support the rock formation. This is to be contrasted with conventional mine roof bolts formed of shank sections collared together that generally fracture either at the collar or along one of the shaft sections. In the event the collar has prevented complete resin return along the total length of the bolt section(s), that portion of the mine roof bolt below the fracture, if not resin-bonded into the rock formation, is rendered totally ineffective as structural support, and likely will even fall out of the mine roof bore hole.
It is this aspect of the improved mine roof bolt of the present invention that permits it to better withstand rock formation lateral movement, in that the cable mine roof bolt (1) will not fracture along the shank or coupler (there is not coupler), but will fracture at the hexagonal head, and (2) will remain intact along its total length of the shank within the bore hole, even following a partial "stepped fracture".
It should be obvious to those skilled in the art that the improved mine roof bolt of the present invention, not utilizing mine roof bolt shank couplers, does not require an overly large bore hole in the mine roof. Therefore, less potential damage is done to the structural integrity of the rock formation above the mine roof. Additionally, less resin adhesive is required in the bore hole, and the resin that is in the bore hole is more effective, in that the bonding distance between the bolt shank surface and the inside surface of the bore hole wall is considerably smaller. Also, the improved mine roof bolt, not utilizing bolt shank couplers, does not have the problem of bolt or coupler fracture when the mine roof rock formation shifts.
Lastly, the improved mine roof bolt, not utilizing bolt shank couplers and, in addition, having a rough outer surface to the shank, facilitates complete mixture of the resin material and complete distribution of the resin material along the total length of the mine roof bolt shank and mine roof bore hole wall.
Inasmuch as the improved mine roof bolt of the present invention is constructed of a multi-strand cable rather than a solid shank, the mine roof bolt will bend sufficiently to follow the path of an irregular bore hole. The multi-strand, flexible cable mine roof bolt can also be bent to facilitate installation into a bore hole that requires a roof bolt that is considerably longer than the height of the mine at the location of the mine roof bore hole, and will also bend rather than break, when the mine roof rock formation shifts.
From the foregoing it will be seen that this invention is one well adapted to attain all of the ends and objects herein set forth, together with other advantages which are obvious and which are inherent to the apparatus. It will be understood that certain features and subcombinations are of utility and may be employed with reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. As many possible embodiments may be made of the invention without departing from the scope of the claims. It is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | An improved mine roof bolt is constructed of pre-tensioned, multi-strand steel cable. The bolt head is constructed of a hexagonal-or other drive-headed collar having an internally tapered frusto-conical bore therethrough, and a tapered plug having a frusto-conical outer surface that engages the frusto-conical inner surface of the drive collar. The tapered plug has an internal bore essentially concentric with the outer frusto-conical surface, and is adapted to fit over the multi-stranded steel cable, the hexagonal head drive collar fitting over the tapered plug such that pressing the tapered plug and steel cable into the inner frustoconical bore of the hexagonal-head drive collar causes serrations on the internal bore of the tapered plug to be urged down against, and bite into, the steel cable, resulting in a solid hexagonal head for the cable bolt. The tapered plug is in actuality, a pair of essentially identical diametrically opposed semi-frusto-conical tapered sections that more easily compress together to bite into the multi-strand steel cable. The improved mine roof bolt is intended for use in passive-type mine roof systems. |
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BACKGROUND OF THE INVENTION
This invention relates in general to protectors for property and, in particular,for an inflatable protector for houses, trailers or other types of structures.
DESCRIPTION OF THE PRIOR ART
In the prior art various types of protectors for structures have been devised however, these structures have been expensive to construct and once constructed have had an unpleasant aesthetic appearance. Also, the prior art structures have proven inoperative in that they not only did not protect the property they enclosed, they were incapable of protecting themselves from such natural forces as hurricanes and tornadoes.
Various types of protective devices have been proposed in the prior art. For example, U.S. Pat. No. 3,548,904 discloses a cargo blanket which includes fluid impervious compartments capable of being inflated to form a protective cover.
U.S. Pat. No. 3,783,766 discloses a bag-like cover which provides a sealed enclosure for equipment which is susceptible to atmospheric deterioration.
U.S. Pat. No. 4,206,575 discloses an insulating and weatherproof cover for a mobile home which has an outer waterproof layer and an inner foam-type layer bonded thereto.
U.S. Pat. No. 4,283,888 discloses a covering of interlaced mineral fibers which forms a heat insulating and protected roof structure.
U.S. Pat. No. 4,858,395 discloses a fire resistant sheet which can be draped over a structure to envelope and protect the structure.
SUMMARY OF THE INVENTION
This invention consists of a framework that can be erected over the structure that is to be protected. The framework has a plurality of telescoping supports that are securely anchored to the ground. A plurality of inflatable panels, with rims attached, are designed to be attached to the telescoping supports and when inflated will enclose the structure to be protected. When deflated the panels and frames will be enclosed in a covered trench that encircles the structure to be protected.
It is an object of the present invention to provide an inflatable structure protector that is esthetically pleasing and unobtrusive when not in use.
It is also an object of the present invention to provide a structure protector that is easily and conveniently erected around the structure to be protected.
These and other objects and advantages of the present invention will be fully apparent from the following description, when taken in connection with the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a structure with the protective enclosure in its nonuse position.
FIG. 2 shows the protective enclosure in its in-use position.
FIG. 3 shows the holder for the inflatable portion of the protector and a portion of the protector in an inflated condition.
FIG. 4 shows the holder for the inflatable portion of the protector and a portion of the protector in an deflated condition.
FIG. 5 is a partial view of a part of the holder showing the air intake openings.
FIG. 6 is a partial view of another part of the holder.
FIG. 7 is a partial view of the inflated panels interlocked.
FIG. 8 is a partial view of one of the panels as it is interlocked and sealed at the bottom of the panel.
FIG. 9 is a view of one of the supporting posts for the protective enclosure.
FIG. 10 is a view of one of the supporting posts for the protective enclosure in an arched over position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the present invention with some of the telescoping support posts 4 erected around the sides of a structure 2. Although only two telescoping support posts 4 are shown in FIG. 1, it is understood that this is for illustration purposes only. The total number of telescoping support posts 4 that will be used will depend on the size of the structure to be protected. Also, in FIG. 1 only the protective panel members 6 around the sides of the house are shown. It should be understood that other protective panel members 6 will also be placed at the front and the rear of the structure 2, but are not shown in FIG. 1 for the sake of clarity. Also shown in FIG. 1 are the air pumps 14 with air supply tube 27 which will supply air to the inflatable panel members 6 which will be explained below . Element 15 is a supply tank for hydraulic fluid and 16 is a supply pipe for supplying the hydraulic fluid to the telescoping support posts 4 as will be described below.
FIG. 2 shows the protective enclosure with the panel members 6 inflated and the telescoping support posts 4 fully extended to encircle and protect the structure 2 (shown in FIG. 1). It should be noted that the telescoping support posts 4 shown in FIG. 2 only have telescoping portions 5, 7, and 8 shown. The number of telescoping portions may vary depending on the size of the structure to be protected.
The telescoping support posts 4 can be made of a variety of material such as steel or plastic. The exact type of material is not critical to the invention except it must be able to withstand the forces that the protector is likely to encounter.
The panel members 6 are shown partially in FIGS. 3 and 4. it should be noted that the panels are shown as rectangular in the drawings, however, this shape is not critical and the panels can be other shapes such as, but not limited to, oval or circular. Actually the panel members 6 can be virtually any shape but the oval or rectangular shapes are preferred. Each panel member 6 consists of a composite bag-like structure that is air tight. The inner side 21 of the panel members 6 (that is the side that faces the structure 2) and the edges of the panel members 6 will be constructed of a rubber or plastic material. The outer side 22 of the panel members 6 (that is the side that faces away from the structure 2) will be constructed of a rubber or plastic material that has flexible steel belts woven throughout the material, similar to the way steel belts are woven into steel belted radial tires for an automobile.
The panel members 6 are shape in a bellows-like configuration (as seen in FIG. 4) so that they may expand or contract as air is pumped into or extracted from the panel members 6, as will be more fully explained below. Each panel member 6 has attached thereto a number of rim pieces 9. The exact number of rim pieces 9 will vary depending on the size of the panel members 6 and the size of the structure 2 to be protected.
The rim pieces 9 will be be made from metal such as steel or aluminum, or they could be made from a plastic such as Nylon or Teflon, and they will be vulcanized or otherwise permanently attached to the panel members 6. The ends of the rim pieces 9 are L-shaped and will interlock with the L-shaped recesses 10 within the carrier 26. The carriers 26 will be attached to the telescoping supports 4 by rings 13 connected to the carrier 26 by rods 12 which will raise the panel members 6 as the panel members 6 are inflated with air.
Each of the panel members 6 will have an opening which will connect to and be sealed with the opening 25 in element 11 connected to the carrier 26 so that air pipes or tubes 27, shown in FIG. 1, can connect an air pump 14 to each of the panels. A single air pump can be used to supply air to all the panels or multiple pumps can be used to supply air to different panels, depending on the size of the structure to be protected.
When not needed the telescoping supports 4 and the panel members 6 will be stored in a trench 3 (as seen in dotted lines in FIG. 1) that surrounds the structure 2. The trench can be lined with concrete or some other material that will prevent the sides from collapsing, and will be large enough to house the telescoping supports 4 and the panel members 6 and the various equipment needed to raise the telescoping supports 4 and the panel members 6, such as motors, gears, and hydraulic pumps.
Attached to each top of the panel members 6 will be a flange 23 which will interlock with a similar flange 24 on an adjacent panel member 6 to secure the panels together at the top of the structure to be protected (see FIG. 7) One of the panel members 6 can have a weight 17 attached in any conventional manner, which will help pull the bottom of the panel members 6 away from the top of the panel members 6 when it is necessary to lower the protective structure. The weight will help the interlocking panels disengage so the panels can be lowered when they are not needed.
Hydraulic lines 16 will be connected to one or more reservoirs 15 with appropriate pumps (not shown) that will supply pressure to raise the supports 4 from the trench 3 to surround the structure to be protected. The pumps could be operated by electricity but should have a battery back up in case the electric service is interrupted by a storm. The pumps could also be operated manually. The same would be true for the air pumps that supply air to inflate the panel members 6.
In addition, the lowermost panel member 6 would have a lip 20 which will engage a lip 18 on a support 19 (as shown in FIG. 8) which will be mounted within the trench 3. This would help seal and structurally support the bottom of the panel members 6.
When the structure protector is needed, the first step will be to activate the motors that will raise the telescoping supports 4, and at the same time start the air pumps that will inflate the panel members 6. The motors can be activated by any of the normal means such as switches, or the entire system could be controlled by a computer system. There could be a separate motor for panels and telescoping supports on each side and end of the structure or one motor could be connected to all the panels and telescoping supports depending on the size of the structure to be protected.
The panel members 6 will continue to expand until they reach the top of the structure where the interlocking flanges 23, 24 will engage. It should be noted that the flanges 23, 24 could be provided with cooperating sloped surfaces to make it easier for the top panels to ride over one another if needed.
Any natural forces, such as hurricanes and the resultant debris which are blown by the hurricane winds, which hit the structure protector will tend to be, first, channeled over the structure due to its arched shape. Second, the air trapped inside the panel members 6 will form an additional layer of protection, similar to the way a radially belted tire protects itself from road hazards such as curbs, glass, and nails.
As the telescoping supports are raised, the top most part 8 of the support, which is made from a coil spring like structure will bend (as shown in FIG. 10) from the weight of the emerging panels. This will allow the top of section 8 to move toward the center of the roof of the structure until the flanges 23, 24 on adjacent panel members 6 engage and interlock. The flanges can be helped to interlock by adjusting the amount of air in the panels and using the motors to raise and lower the telescoping supports. For example, once the flange 23 passes over the flange 24, a little air could be let out of the panels attached to flange 23. This will allow the flange 23 to sink toward the flange 24. Then by lowering the telescoping supports, the flanges 23, 24 will move relative to one another and inter lock.
When the storm is over, the structure protector can be removed in the reverse order from which it was erected. The telescoping supports will be raised until the flanges 23, 24 are clear of each other, air will be removed from the panels that the flange 24 is attached to until the weight 17 pulls the panels down to the point that flanges 23, 24 will not engage as the telescoping supports are lowered. The pneumatic pumps will be reversed so that air is removed from the panel members 6. As the air is removed, the panels will collapse back into the trench 3. Also, the hydraulic motors will be reversed to lower the telescoping supports 4 back fully into the trench.
Although the Structure Protector and the method of using the same according to the present invention has been described in the foregoing specification with considerable details, it is to be understood that modifications may be made to the invention which do not exceed the scope of the appended claims and modified forms of the present invention done by others skilled in the art to which the invention pertains will be considered infringements of this invention when those modified forms fall within the claimed scope of this invention. | A framework that can be erected over the structure that is to be protected. The framework has a plurality of telescoping supports that are securely anchored to the ground. A plurality of inflatable panels, with rims attached, are designed to be attached to the telescoping supports and when inflated will enclose the structure to be protected. When deflated the panels and frames will be enclosed in a covered trench that encircles the structure to be protected. |
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FIELD OF THE INVENTION
[0001] This application relates generally to dredge assemblies and, more particularly, to a modular, size-adjustable cutter suction dredge (“CSD”) assembly.
BACKGROUND OF THE INVENTION
[0002] Dredges and, in particular, CSDs are used to remove material (e.g., rock, sand, clay, etc.) from the bottom, floor, bed or other surface of lakes, rivers, oceans, seas, harbors or other waterways. Existing CSDs typically include a floating barge that carries an elongated ladder, boom or similar structure. The ladder is typically pivotally connected to the barge such that it can be lowered from a hoisted position to an operative position where the ladder is in proximity to the waterway bed or surface to be dredged. A rotating cutter head is typically located near a free end of the ladder such that, in its operative position, teeth on the cutter head engage the waterway bed or surface to loosen material to be dredged. A mixture of loosened material and water collected at the cutter head is drawn into a suction pipe connected to the ladder and pumped to a desire location where the material is discharged.
[0003] The ladder construction and its connection to the barge in existing CSDs, however, must be very strong and rigid to resist the torque created by the interaction of the cutter head on the surface to be dredged (“cutter torque”). Otherwise, the ladder will have a tendency to rotate or windup due to the cutter torque. Moreover, dredging with existing CSDs is difficult at depths over 45 meters (148 feet). The length of the conventional ladder, for dredging at depths of 45 meters or greater, is susceptible to bending. Such bending is caused by the ladder's weight (inertia), as well as the forces or cutter torque developed as a consequence of cutting the waterway bed or surface.
[0004] To address these problems, strengthening components have been incorporated in the ladder and at its connection point at the hull of the barge to compensate for the increased operational depths and to resist cutter torque. Reinforcing a conventional ladder to operate at such depths, however, is expensive and a time-consuming process. This process requires extensive redesign of the ladder and its connection to the hull, a significant number of additional components, and a great deal of steelwork. In addition, the weight of the reinforced ladder is significant and expensive hoisting winches are often necessary to lift the ladder from its operating position.
[0005] Furthermore, because the ladder structure has been reinforced to operate at a greater depth and to resist cutter torque, and its weight increased as a result, the suction pump that draws the dredged material cannot be located at the end of the ladder near the cutter head. Consequently, suction capability can become compromised due to the increased distance between the pump and the waterway bed or surface to be dredged.
[0006] Also, reinforcing the ladder to operate at such depths leads to decreased flexibility with respect to assembling and disassembling the CSD. Moreover, transportation of the CSD becomes difficult.
SUMMARY OF THE INVENTION
[0007] To overcome these and other deficiencies in conventional dredges, a modular, size-adjustable dredge assembly is provided that includes a hull and an adjustable length dredge ladder pivotally connected to the hull. The dredge ladder includes a front section that is coupled to a rotatable cutter head for loosening material to be dredged and a rear section that is pivotally connected to the hull to permit the ladder to selectively move from a hoisted position where the ladder floats to an operative position where the cutter head engages a surface to be dredged. The front section of the ladder includes a plurality of releasably interconnected hollow pipe sections that form a first fluid tight channel therein in which water is selectively permitted to enter to increase the weight of the ladder to achieve the desired cutter pressure and to withstand the cutter torque. The rear section of the ladder includes a plurality of releasably interconnected hollow pipe sections that form a second fluid tight channel to increase the bouyancy of the ladder. Additional pipe sections may be added or removed from the rear section to adjust the length of the ladder.
[0008] Similarly, the hull may include a fore section platform, an aft section platform, and a second plurality of releasably interconnected hollow pipe sections for longitudinally connecting the fore section platform to the aft section platform. The length of the hull is adjustable by adding or removing pipe sections from the second plurality of releasably interconnected hollow pipe sections.
[0009] The foregoing specific objects and advantages of the invention are illustrative of those that can be achieved by the present invention and are not intended to be exhaustive or limiting of the possible advantages which can be realized. Thus, these and other objects and advantages of this invention will be apparent from the description herein or can be learned from practicing this invention, both as embodied herein or as modified in view of any variations which may be apparent to those skilled in the art. Accordingly, the present invention resides in the novel parts, constructions, arrangements, combinations and improvements herein shown and described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying figures best illustrate the details of the preferred apparatus, system and method of the present invention. Like reference numbers and designations in these figures refer to like elements.
[0011] FIG. 1 is a perspective view of the dredge assembly in accordance with a preferred embodiment of the present invention;
[0012] FIG. 2 is a perspective view of the fore section platform of the preferred dredge assembly illustrated in FIG. 1 ;
[0013] FIG. 3 is a perspective view of the aft section platform of the preferred dredge assembly illustrated in FIG. 1 ;
[0014] FIG. 4A is a perspective view of a preferred pontoon utilized in fore and aft•section platforms illustrated in FIGS. 2 and 3 ; FIG. 4B is a side view of two interconnected pipe sections utilized in the hull of the preferred dredge assembly illustrated in FIG. 1 ;
[0015] FIG. 4C is a side view of two interconnected pipe sections utilized in the dredge ladder of the preferred dredge assembly illustrated in FIG. 1 ;
[0016] FIG. 5 is a perspective view of the preferred fore section platform illustrated in FIG. 2 with the dredge ladder in the hoisted position;
[0017] FIG. 6 is a perspective view of the preferred aft section platform illustrated in FIG. 3 with the dredge ladder in the hoisted position;
[0018] FIG. 7 is a perspective view of the preferred fore section platform illustrated in FIG. 5 with the dredge ladder in a partially lowered position; FIG. 8A is a side elevation view of the preferred dredge assembly illustrated in FIG. 1 with the dredge ladder fully lowered for dredging in deep water;
[0019] FIG. 8B is a perspective view of the preferred dredge assembly illustrated in FIG. 8A ;
[0020] FIG. 9A is a side elevation view of the preferred dredge assembly illustrated in FIG. 1 with the dredge ladder partially hoisted;
[0021] FIG. 9B is a perspective view of the preferred dredge assembly illustrated in FIG. 9A ;
[0022] FIG. 10A is a side elevation view of the preferred dredge assembly illustrated in FIG. 1 with the dredge ladder substantially hoisted; and
[0023] FIG. 10B is a perspective view of the dredge assembly illustrated in FIG. 10B .
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring now to the drawings and, in particular, to FIG. 1 , a dredge assembly 1 , such as a CSD, has a hull 5 that preferably includes at least a fore section platform 10 and an aft section platform 20 . As discussed in greater detail below with respect to FIG. 2 , the platforms 10 , 20 are comprised of a plurality of interconnected pontoons 11 . The platforms 10 , 20 are preferably connected to one another by at least two substantially parallel pipe sections 30 . Each pipe section 30 is preferably formed from a series of interconnected standard industrial pipes 31 a and 31 b . Each pipe 31 a and 31 b preferably has sealed, “blind” (closed) flanges best seen in FIG. 4B . The hull 5 is illustrated to include an additional pontoon 11 positioned between the aft and fore section platforms 10 , 20 , but could be eliminated, or replaced by several pontoons sections 11 .
[0025] The pontoons 11 may be made from any suitable material, preferably ship building steel. The size of the pontoons 11 are preferably the same dimensions as standard cargo containers or a high cube (“hicube”) containers (e.g., 20 ft. (L)×8 ft. (W)×4 ft. (H); 20 ft. (L)×6 ft. (W)×8 ft. (H); 20 ft. (L)×8 ft. (W)×8 ft. (H); 40 ft. (L)×8 ft. (W)×4 ft. (H); 40 ft. (L)×8 ft. (W)×6 ft. (H); 40 ft. (L)×8 ft. (W)×8 ft. (H)) to facilitate convenient transportation of the pontoons. In this manner, conventional container corners (lockings) may be mounted on the corners of the pontoons to allow them to be handled and transported in the same manner as standard containers.
[0026] A dredge ladder 40 is pivotally secured at its rear most end (aft end) to the aft section platform 20 . The front most end (fore end) of dredge ladder 40 may be lowered to the bottom of the waterway for dredging and subsequently raised, or hoisted, for stowage using a network of ladder-hoist winches 16 a , ladder-hoist pulleys 16 b and ladder-hoist wires or cables 16 c.
[0027] As shown in FIG. 2 , the fore section platform 10 comprises a plurality of pontoons 11 , preferably disposed in a relatively intimate, side-by-side manner. A control cabin 15 , for example, may be provided on a portion of the upper surface 12 of the fore section platform 10 from which dredge control and operation may be carried out. Although the fore section platform 10 is illustrated in FIG. 2 as being comprised of five pontoons 11 , the actual number of pontoons 11 may be varied so as to either increase or decrease the overall length of the hull to accommodate differing dredging situations, fore section platform 10 surface area 12 requirements, or buoyancy requirements, etc.
[0028] Each pontoon 11 is preferably positioned and secured to its neighboring pontoon(s) 11 by way of at least two substantially parallel series of interconnected standard industrial pipe sections 31 a and 31 b , portions of which extend, in a water-tight matter, through pontoons 11 from the front side 13 to the rear side 14 of the fore section platform 10 . Extreme ends 31 c and 31 d of the interconnected pipe sections 31 a and 31 b securing pontoons 11 of the fore section platform 10 , for example, are shown in FIG. 5 . A single pontoon 11 is shown in FIG. 4A . Also included on the fore section platform 10 , are a number of winches 16 a , pulleys 16 b , and cables 16 c , as shown in FIGS. 2, 5 & 7 , which form a part of the network of ladder-hoist winches, ladder-hoist pulleys, and ladder-hoist wires that lower, raise, hoist, secure, stow, control the cutter torque, or otherwise operate the dredge ladder 40 .
[0029] As shown in FIG. 3 , the aft section platform 20 comprises a plurality of pontoons 11 preferably disposed in a spaced-apart, side-by-side manner. Although the aft section 20 is illustrated in FIG. 3 as being comprised of five pontoons 11 , the actual number of pontoons 11 may be varied so as to either increase or decrease the overall length of the hull to accommodate differing dredging situations, aft section platform 20 surface area 22 requirements, or buoyancy requirements, etc. Each pontoon 11 is preferably secured, near its opposing lateral ends, to each of its neighboring pontoon(s) 11 by way of at least the two substantially parallel series of interconnected standard industrial pipes 31 a and 31 b , portions of which extend, in a water-tight manner, through the pontoons 11 from the front side 23 to the rear side 24 of the aft section platform 20 . In the preferred embodiment, the pontoons 11 forming the aft section platform 20 are spaced apart from one another, as opposed to the close positioning of the pontoons 11 of the fore section 10 . The spacing of the pontoons 11 used with the aft section platform 20 is greater than the spacing used to form the fore section platform 10 . This greater spacing of the pontoons 11 distributes the greater overall weight of the aft section 20 over a larger surface area of the water contributing to greater buoyancy and stability to the dredge assembly 1 . Various enclosures 25 a and 25 b , which, for example, house the engine, electrical controls or power plant, may be included on a portion of the upper surface 22 of the aft section platform 20 .
[0030] As shown in FIG. 1 , the two substantially parallel pipe sections 31 , respectively formed from the series of interconnected standard industrial pipes 31 a and 31 b , have opposing end portions that are used to form both the fore section platform 10 and the aft section platform 20 . The pipes 31 a and 31 b may be made from any suitable material, preferably ship building steel. Pipe sections 31 are continuous and connect the fore section platform 10 with the aft section platform 20 to form the hull 5 of the dredge assembly 1 . The actual number of interconnected pipes 31 a and 31 b forming the hull 5 is not limited to the specific number illustrated in the figures, but may be varied to increase or decrease the overall length of the hull to accommodate differing dredge situations or to accommodate varying lengths of the dredge ladder 40 discussed further below.
[0031] An example of two interconnected standard industrial pipe sections 31 a or 31 b is shown in FIG. 4B . The pipe sections 31 a or 31 b are preferably interconnected to each of their respective neighboring pipe sections 31 a and 31 b by way of their respective sealed, “blind” (closed) flanges F. Any suitable known securing means, such as, for example, conventional nut and bolt combinations or couplings, may be used to interconnect the respective pipe sections 31 a and 31 b.
[0032] As discussed above with respect to the pipe sections 31 a and 31 b used to form the fore and aft section platforms 10 , 20 , all of the interconnected pipes 31 a and 31 b are secured to their neighboring pipes 31 a and 31 b in a water-tight manner, including the interconnected pipes disposed intermediate of the fore and aft section platforms 10 and 20 . Due to the buoyancy of each pipe section 31 a and 31 b , resulting from the water-tight seal trapping air within each pipe section 31 a and 31 b , the collective buoyancy of the interconnected series of pipe sections 31 a and 31 b increases their overall buoyancy, stability and structural integrity due to their tendency to float. To further increase overall buoyancy and structural integrity of the two lengths of interconnected pipe sections 31 a and 31 b , one or more pontoons 11 may be positioned along the lengths thereof, as shown in FIG. 1 .
[0033] The dredge ladder 40 , as shown in FIG. 1 , preferably comprises a ladder after part 40 a and a ladder front part 40 b . The ladder after part 40 a , as seen in FIGS. 1-3 and 5 - 7 , is preferably constructed from two substantially parallel pipe sections 41 , respectively formed from a series of interconnected standard industrial pipes 42 a and 42 b preferably having “blind” (closed) flanges. The pipe sections 42 a and 42 b used to form the ladder after part 40 a are similar to the pipe sections 31 a and 31 b . The pipes 42 a and 42 b may be made from any suitable material, preferably ship building steel. The pipe sections 42 a and 42 b are preferably either the same size or larger than the pipe sections 31 a and 31 b . Each pipe section 42 a and 42 b is preferably secured to its neighboring pipe section 42 a and 42 b using blind “closed” flanges to create a water-tight seal throughout their interconnected length to increase their overall buoyancy as a result of air being internally trapped therein.
[0034] An example of two interconnected standard industrial pipe sections 42 a or 42 b is shown in FIG. 4C . The pipe sections 42 a , 42 b are preferably interconnected to each of their respective neighboring pipe sections 42 a , 42 b by way of their respective sealed, “blind” (closed) flanges F. Any suitable known securing means, such as, for example, conventional nut and bolt combinations or couplings, may be used to interconnect pipe sections 42 a and 42 b . The overall buoyancy of the sealed, interconnected pipe sections 40 a and 40 b counter the accumulated weight of the pipes 40 a and 40 b to provide a dredge ladder 40 exhibiting a substantially zero net load. On the basis of the substantially zero net load, the length limitations of the dredge ladder 40 become virtually non-existent, resulting in a dredge ladder 40 that may conceivably extend to any required length. When hoisted to the horizontal position under the hull 5 , as shown in FIGS. 5, 7 , 8 , 10 A & 10 B, the entire dredge ladder 40 will float (i.e., have substantially zero net load). In this way, the network of ladder-hoist winches 16 a , ladder-hoist pulleys 16 b , and ladder-hoist wires or cables 16 c remain unloaded while the ladder 40 is in the hoisted position. Also, when hoisted to the horizontal position, components (e.g., cutter head 43 , cutter motor 44 , suction pump and motor 45 , suction pipe, and discharge conduit 26 ) located on the ladder 40 are preferably just above water level to facilitate maintenance, while the ladder pipe sections remain just below water level.
[0035] The ladder after part 40 a , as shown in FIGS. 1, 3 & 6 , is pivotally attached to the aft section platform 20 by way of any sufficient conventional pivoting means (not shown), preferably disposed between the lateral ends of at least one pontoon 11 of the aft section platform 20 and the end portions of the ladder after part 40 a.
[0036] In the preferred embodiment, the ladder front part 40 b , as shown in FIGS. 1, 5 & 7 , has a generally triangular shape and includes a cutter head 43 , cutter motor 44 for driving the cutter head 43 , an underwater suction pump and motor 45 , and hydraulic cylinders 46 a and 46 b for providing cutter head orientation. The ladder front part 40 b includes a pump mounting section 47 and a pivotal cutter head mounting section 48 .
[0037] Preferably, the pump mounting section 47 has a generally isosceles trapezoidal shape and is constructed from a plurality of standard industrial tubing or pipes having “blind” (closed) flanges, similar to pipes 31 a , 31 b , 42 a , and 42 b . The rear portion of the pump mounting section 47 preferably includes at its opposing lateral sides, angled pipe sections 47 a and 47 b with “blind” (closed) flanges, which interface with the respective adjacent closed flanges of pipe sections 42 a and 42 b of the front end of the ladder after part 40 a . The standard industrial tubing forming the pump mounting section 47 and pipe sections 47 a and 47 b may be made from any suitable material, preferably ship building steel.
[0038] The tubing forming the pump mounting section 47 is preferably hollow and sealed at their respective ends using “blind” (closed) flanges. Each tube preferably includes a water intake opening or hole for allowing water to be introduced therein adding weight to the dredge ladder 40 when an increase of pressure is needed on the cutter head 43 depending on the properties of the soil being dredged. In addition, the ability to increase the weight of the dredge ladder 40 by adding water therein functions to control cutter torque on the ladder, such that the majority of forces are concentrated on the ladder front part 40 b and are transferred to the pontoons 11 via the wire or cable system 16 . As such, the forces acting on the ladder after part 40 a and its pivoting connection to the aft section platform 20 remain low, thereby permitting use of a ladder after part 40 a with reduced torque resistant properties.
[0039] In one embodiment, a closing plug (not shown) may be used to seal the water inlet openings when the tubing is filled with the desired volume of water. Each tube also preferably includes a conventional valve (not shown) to permit the water to be discharged or drained from the tubing forming the pump mounting section 47 using an air compressor. Draining of the tubing forming the pump mounting section 47 serves to reduce the weight of the dredge ladder and the associated pressure on the cutter head 43 , as well as to facilitate maintenance of the structure and to prevent the water from freezing during stoppages in the winter.
[0040] It is understood that the tubing forming the pump mounting section 47 may be filled and/or drained “on-line” during the dredging operation to facilitate, among other things, increasing or decreasing the pressure on the cutter head. Alternatively, the tubing may be filled with water manually after the dredge is assembled prior to the dredging operation to achieve the desired cutter pressure and to resist cutter torque depending on the properties of the soil being dredged.
[0041] As best shown in FIGS. 5 & 7 , the cutter head section 48 is pivotally attached to the extreme front portion of the pump mounting section 47 using any conventional mounting that will allow the desired pivotal motion. Movement of the cutter head 43 , via movement of the pivotal cutter head mounting section 48 , is preferably accomplished by way of hydraulic cylinders 46 a and 46 b disposed between the pump mounting section 47 and the cutter head section 48 . Regardless of the relative position of the cutter head mounting section 48 or the actual depth that the ladder front part 40 b is submerged, the relative distance between the cutter head 43 and the suction pump 45 , which pumps dredged material loosened by the cutter head 43 away from the cutter head 43 , remains in close proximity thereto. Thus, the suction pump and cutting head are separated by a distance that is substantially independent of the ladder length.
[0042] In operation, dredged material loosened by the rotating cutter head 43 is drawn into an inlet conduit connected to the inlet of pump 45 . Suction pump 45 then pumps the dredged material to the waterway surface through a suction or discharge conduit 26 connected to the outlet or discharge of the suction pump 45 and preferably mounted on the dredge ladder 40 . The conduit 26 is preferably a series of interconnected industrial pipe sections 26 a , which, like the ladder after part 40 a , may be made smaller or larger depending on the number of pipes 26 a needed for the depth obtained. Preferably, the suction conduit 26 is connected at the surface to the inlet of a second pump 28 , located, for example, on the aft section platform 20 , which assists in pumping the dredged material through the conduit 26 to the surface. The second pump 28 then discharges the dredged material to a desired location through a conduit connected to the outlet of the pump. It is understood that more than one pump can be utilized for removing the dredged material and that the invention is not limited to the number of pumps illustrated in the figures.
[0043] The pontoon sections 11 and pipes 31 a , 31 b , 42 a , 42 b may be selected from standard, commercially available and readily transportable elements, preferably having a size and shape facilitating shipment using standard cargo transport containers, such as 20 or 40 TEU (twenty-foot equivalent units). In this manner, the modular dredge assembly may be readily disassembled, transported by sea, air and/or rail, and then readily reassembled on-site prior to use.
[0044] In addition, because of the modular design, the parts of the dredge assembly can be used to retrofit existing dredges. The tubular or support components that separate the fore and aft section platforms of the hull can be replaced with the interchangeable, discrete pipe sections, as can the ladder. Thus, an existing dredge device can be converted into a more flexible system.
[0045] Although illustrative embodiments have been described herein in detail, it should be noted and understood that the descriptions and drawings have been provided for purposes of illustration only, and that other variations both in form and detail can be added thereupon without departing from the spirit and scope of the invention. The terms and expressions have been used as terms of description and not terms of limitation. There is no limitation to use the terms or expressions to exclude any equivalents of features shown and described or portions thereof. | A modular, size-adjustable dredge assembly including a hull and an adjustable length dredge ladder pivotally connected to the hull. The dredge ladder includes a front section that is coupled to a rotatable cutter head for loosening material to be dredged and a rear section that is pivotally connected to the hull to permit the ladder to selectively move from a hoisted position where the ladder floats to an operative position where the cutter head engages a surface to be dredged. The front section of the ladder includes a first plurality of releasably interconnected hollow pipe sections that form a first fluid tight channel therein in which water is selectively permitted to enter to increase the weight of the ladder to achieve the desired cutter pressure and to control cutter torque. The rear section of the ladder includes a plurality of releasably interconnected hollow pipe sections that form a second fluid tight channel to increase the bouyancy of the ladder. The hull may include a fore section platform, an aft section platform, and a second plurality of releasably interconnected hollow pipe sections for longitudinally connecting the fore section platform to the aft section platform. The length of the hull and/or ladder is adjustable by adding or removing pipe sections from the first and second plurality of releasably interconnected hollow pipe sections. |
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The invention relates to a chain guide for a driving chain of a mining machine, in particular for a plow chain for moving a winning plow, comprising driving and/or return stations which are provided on or can be arranged on end regions of the mining machine and have driving or return sprockets for the driving chain, and comprising at least one chain guide element which is arranged in spatial proximity to the sprockets at the driving and/or return station and can be adjusted, or is engaged in operational use, transversely to the direction of movement of the chain against its load strand and/or return strand.
BACKGROUND OF THE INVENTION
A chain guide arrangement on a mining machine is known (DE 20 2004 000 924 U) in which a chain guide element is formed by a hold-down device which has a pressure surface and can be inserted into an accommodating pocket in the region of the chain guide in such a way that it can be put, with a pin receptacle open on one side, onto a hinge pin arranged in the region of the accommodating pocket and is then pivoted about said hinge pin into the pocket until its bottom pressure surface presses against the driving chain and it can be locked in this position by a locking arrangement. It is possible to quickly exchange the hold-down device together with the pressure surface formed thereon for a new chain guide element of corresponding design, whereby downtimes in the event of wear of the pressure surface of the hold-down device can be minimized. At the same time, the known chain guide elements, past which the driving chain is moved with a considerable pressure force and at a considerable speed, is subjected to high wear, and therefore it is necessary to exchange it within relatively short time intervals in order to ensure the proper operation of the mining machine.
SUMMARY OF THE INVENTION
An object of the invention is to avoid these disadvantages and provide a chain guide of the type mentioned at the beginning with which the wear in the region of the chain guide element is markedly reduced.
This object is achieved by the invention in that the chain guide element has at least one pressure roller which is adjusted or can be adjusted against the chain links of the driving chain.
Through the use of a pressure roller on the chain guide element, sliding contact between said chain guide element and the driving chain is at least largely prevented, for the peripheral speed at which the pressure roller rotates is the same as the passage speed of the chain, against which it presses in order to guide it. Even if coal dust or other material, possibly also abrasive material, gets between chain and pressure roller, the wear caused by this on the pressure roller track, which in a preferred configuration of the invention can be adapted to the envelope curve defined by the chain links, is only slight, for which reason it is not necessary to exchange the chain guide element substantially formed by the pressure roller until after a period of use considerably longer than was the case with the chain guide elements used hitherto.
The pressure roller is preferably rotatably mounted on a roller axle and can be exchanged together with the latter. The roller axle, in a construction unit with the pressure roller which is rotatably mounted thereon, is then removed and exchanged for a corresponding new part, wherein the downtimes of the mining machine are reduced to a minimum. The pressure roller can then be arranged or mounted in an especially advantageous manner on an attachment which can be interchangeably inserted or is interchangeably inserted in the entry region of the driving and/or return station. In this especially advantageous design, the pressure roller is therefore arranged on an attachment which can be interchangeably inserted in an accommodating pocket and which can then also contain still further components of the chain guide, such as, for example, a catch, known per se, for the chain, said catch being used when the driving or return sprockets of the driving or return stations are exchanged in order to keep the chain tensioned during such maintenance work.
According to an advantageous configuration, the roller axle of the pressure roller can be supported on one or more bearing blocks which are preferably interchangeably fitted in an accommodating pocket. In this case, a bottom bearing block and a top bearing block can preferably be provided on both sides of the roller. In this configuration, the bearing blocks can more preferably be secured against release in the accommodating pocket by means of a preferably hinged lid. Alternatively, the bearing blocks can be secured against release in the accommodating pocket by means of at least one sliding bolt. In this configuration, it is especially advantageous if a top bearing block is provided with sliding guides for sliding bolts. The sliding guides can consist in particular of hook-like strips which vertically fix and at the same time guide in a horizontally movable manner the one sliding bolt or preferably the two sliding bolts displaceable relative to one another. In this case, retaining blocks having locking pockets which face one another are more preferably fitted above the accommodating pocket, and/or the sliding bolts have locking lugs which engage in the locking pockets in the locking state in order to secure the top bearing block against release in the locking state of the locking bolts.
In an especially preferred configuration having form-fitting bolt securing for the bearing blocks, a pair of sliding bolts are provided, wherein each sliding bolt has a U-shaped base having three legs, of which one marginal leg and an intermediate leg are provided, on outer sides facing away from one another, with guide strips for form-fitting engagement in sliding guides, and of which the second marginal leg has a through-hole for a securing screw. A bottom axle receptacle for the roller axle can be arranged directly at the bottom of the recess and can preferably be fixedly formed on or fastened to the attachment.
In particular if it is necessary to guide and keep under tension especially long and/or heavy chains using a chain guide element according to the invention, a design which has a plurality of pressure rollers which are arranged one behind the other in the passage direction of the chain and are adjusted against the chain can be advantageous, as a result of which the requisite, high pressure force can be distributed over a plurality of rollers and the surface pressures between chain and running surface of the pressure rollers can be kept low or reduced. The pressure roller can be adjusted against the chain under the effect of at least one spring element and/or of at least one shock absorber, thereby making it possible for the chain to yield in a direction transversely to its passage direction, for example if shock-like loads occur, but without the pressure roller lifting from the chain, not even temporarily, and thereby no longer being able to perform its guide function, even if only briefly.
These and other objects, aspects, features, developments, embodiments and advantages of the invention of this application will become apparent to those skilled in the art upon a reading of the Detailed Description of Embodiments set forth below taken together with the drawings which will be described in the next section.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail and illustrated in the accompanying drawings which form a part hereof and wherein:
FIG. 1 shows a chain guide for a driving chain of a coal plow in longitudinal section;
FIG. 2 shows a chain guide according to FIG. 1 in an oblique perspective illustration from above, partly in section;
FIG. 3 shows the pressure roller used in the chain guide according to FIGS. 1 and 2 , in section;
FIG. 4 shows an attachment which can be inserted in the chain guide according to FIGS. 1 and 2 and has a pressure roller accommodated therein, in a perspective illustration, according to a first embodiment variant;
FIG. 5 shows an attachment which can be inserted in the chain guide according to FIGS. 1 and 2 and has a pressure roller accommodated therein, in a perspective exploded illustration, according to a second embodiment variant;
FIG. 6 shows a longitudinal section through the attachment according to FIG. 5 in the fitted state of the pressure roller; and
FIG. 7 shows a perspective detailed view of the sliding bolt pair.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring now to the drawings wherein the showings are for the purpose of illustrating preferred and alternative embodiments of the invention only and not for the purpose of limiting the same, FIGS. 1 and 2 show a scraper chain conveyor at one of its end regions, said scraper chain conveyor being provided, in a manner known per se, with a plow guide for a coal-winning plow. The plow (not shown) is driven by means of a driving chain 11 which is accommodated in a chain box 10 lying below the conveying plane.
To this end, the arrangement has a first chain passage 13 for the load strand 14 of the driving to chain and a second chain passage 15 through which the return strand 16 of the driving chain runs. Located at the end regions of the chain passages 13 , 15 is a driving station 17 having a driving sprocket 18 , around which the driving chain 11 is looped and with which the chain is pulled through the chain passages in a known manner. Arranged in the transition region 19 between the second chain passage 15 and the driving station 17 is a chain guide 20 having a chain guide element 21 which pushes the return strand of the chain downward and thereby deflects said return strand out of the chain passage for the return strand toward the driving sprocket 18 and which has a pressure roller 22 , or consists substantially of such a pressure roller, which presses from above with its track 23 against the driving chain 11 and thereby deflects the chain toward the driving sprocket and keeps the chain under tension.
The chain guide 20 , which consists of an attachment 25 interchangeably fitted into a gap 24 above the chain passage 15 at the transition region 19 of the mining machine, is shown in more detail in a first embodiment in FIGS. 3 and 4 . It can be seen that the attachment 25 consists of a housing having two side walls 26 and a rear end wall 27 , wherein the two side walls 26 are provided with upwardly open recesses as accommodating pockets 40 for bearing blocks 28 , 28 A which accommodate a roller axle 29 for the pressure roller 22 in a rotationally fixed manner. The accommodating pocket 40 is defined at the rear by the end wall 27 and at the bottom and at the front by the respective side wall 26 . Both bearing blocks 28 , 28 A are formed congruently with the circumferential wall of the accommodating pocket 40 and are accommodated in the latter in a form-fitting manner. The bottom bearing block 28 , if need be, may also be fixedly anchored in the accommodating pocket and, for example, welded in place for this purpose. The top bearing block 28 A, once the nuts 41 have been released from the two vertically disposed threaded rods 42 anchored in the bottom bearing block 28 or in the side wall 26 , can be removed upward, as a result of which the roller axle 29 is exposed and can then also be removed together with the pressure roller 22 from the bottom bearing block 28 and exchanged for another pressure roller 22 plus roller axle 29 .
The pressure roller 22 is rotatably mounted on the roller axle 29 with two tapered roller bearings 30 in back-to-back arrangement and is provided with lateral sealing covers 31 to prevent the ingress of coal dust or other contaminants. It can be seen in particular in FIG. 3 that the track 23 of the pressure roller 22 has a concave shape adapted to the envelope curve 34 defined by the chain links 33 , such that the pressure roller, when it acts on the chain, not only keeps said chain under tension and deflects it, but at the same time also prevents lateral running of the chain.
During operation, the pressure roller 22 accommodated in the attachment 25 or in the accommodating pocket 24 is covered at the top by a hinged lid 35 which prevents, to the greatest possible extent, coal dust or rock fragments from reaching the roller but, after it has been opened, allows easy access to the pressure roller 22 and thus enables dust or other contaminants which have nonetheless settled in the region of the pressure roller and/or in the accommodating pocket to be removed again with simple means. If it should transpire during such an inspection that the functioning of the roller is no longer reliably ensured due to wear, said roller can be exchanged quickly and simply by the lid 35 mounted on one side on the hinge spindle 45 being swung open and then, as described above, by the bearing blocks 28 , 28 A being opened and by the pressure roller 22 together with its roller axle 29 being lifted out and exchanged for a new roller with roller axle. If both the bottom bearing block 28 and the top bearing block 28 A sit loosely in the accommodating pocket 40 , i.e. in such a way as to be removable upward here, the lid 35 can at the same time form the securing element which presses the bearing blocks 28 , 28 A downward into the accommodating pocket 40 and secures them against release. However, the lid 35 can also hold only the top bearing block 28 A in the closed position.
FIGS. 5 and 6 show an alternative configuration of a chain guide 120 according to the invention, which again consists substantially of an attachment 125 which, via the side wall 126 , here the rear side wall 126 , designed as a bearing plate having strip-shaped edges, can be fastened to a spill plate, designed for accommodating the bearing plate, of a driving station of a plow installation. In the exemplary embodiment of the attachment 125 shown, the front side wall 126 , only shown in FIG. 6 , can be fastened to a spar or a side spill plate of the driving station via a tilting hinge 160 , as a result of which, provided the retaining hooks for the rear side wall 126 are released, the entire attachment 125 can be pivoted in order to be able to carry out, for example, repair work on a scraper chain conveyor laid parallel to the plow installation. As in the previous exemplary embodiment, a catch 161 is also pivotably linked between the two chain walls 126 in the case of the attachment 125 in order to be able to secure the chain strand of the plow chain for repairs when the closing lid 162 is removed or swung up. An accommodating pocket 140 is again formed in the left-hand half of the attachment 125 , in which accommodating pocket 140 a pressure roller 122 rotatably mounted on a bearing axle 129 and forming the actual chain guide element 121 can be interchangeably fastened, wherein the pressure roller 122 can be pressed in an adjustable manner, or with its track, as already described further above, against a plow chain (not shown in FIGS. 5 and 6 ). In the operating state, the plow chain passes through a passage opening 151 in the end wall 127 , here the front end wall 127 , and a passage opening 152 in the end wall 127 A, here the rear end wall 127 A. In the fitted state of the attachment 125 at the driving station, the top chain guide passage for the plow chain adjoins the front passage opening 151 , whereas the plow chain behind the rear passage opening 152 enters the driving or return sprocket for the plow chain. With the pressure roller 122 , the plow chain can be preloaded downward between both passage openings 151 , 152 , thereby enabling the top chain strand of the plow chain to enter the plow chain sprocket (not shown) with low wear in an optimum manner without the plow chain coming into contact with, for example, the edges of the rear passage opening 152 . As in the previous exemplary embodiment, here, too, the pressure roller 122 and roller axle 129 are designed as a construction unit, for which reason the entire pressure roller 122 can be exchanged for another pressure roller without any problems and quickly if wear has occurred at the envelope curve of the pressure roller 122 or the mounting thereof.
In order to enable the pressure roller 122 together with roller axle 129 to be exchanged as simply as possible and at the same time achieve stable and reliable locking of the roller axle 129 even in the event of disproportionately high vertical forces on the pressure roller 122 , the roller axle 129 , with its two axle journals 129 A which project laterally beyond the pressure roller 122 , is inserted in axle receptacles 155 in a rotationally fixed manner, wherein the bottom axle receptacle 155 is formed directly on a wall section 126 A of the side wall 126 , here the front side wall 126 , and the rear bottom axle receptacle is formed on a rear wall section in the rear side wall 126 . In this case, the axle receptacle 155 can either consist of a correspondingly integrally formed recess in the wall section 126 A or, as shown in FIG. 5 , can be formed inside a ring segment 156 which is welded to the wall section 126 A and could also be exchanged in the event of repair if the axle receptacle 155 is worn. The axle receptacle 155 together with ring segment 156 therefore forms a bottom bearing block in the attachment 125 of the chain guide 120 , this bearing block being formed fixedly and in one piece on the attachment 125 , whereas only a top bearing block designated overall by reference numeral 128 can be removed. The top bearing block 128 at the same time forms the lid for the pressure roller 122 , and the bearing block 128 has two side webs 171 which in this case have a rectangular cross section and can be inserted in an accurately form-fitting manner into the correspondingly congruently designed accommodating pockets 140 in the wall sections 126 A. Both side webs 171 are provided at their bottom edge with further ring segments 176 , which, like the bottom ring segments 156 on the wall sections 126 A, each form one half of the axle receptacle, here therefore the top half of the axle receptacle 155 , and, in the fitted state, accommodate the axle journal 129 A in a rotationally fixed manner between both ring segments 156 , 176 , said axle journal 129 A having a noncircular, preferably approximately oval cross section in the exemplary embodiment shown.
The bearing block 128 designed as a lid is provided with a cover web 172 which connects the two side webs 171 and above which two lateral, approximately L-shaped hook strips 173 are welded on, which form, with their undercut sections, sliding guides for two sliding bolts 190 of identical design, with which the locking position of the top bearing block 128 can be secured in order to prevent unintentional release of the bearing block 128 and in this respect also the displacement of the roller axle 129 of the pressure roller 122 .
Reference will now first be made to FIG. 7 , in which the two sliding bolts 190 of identical design, which are used as a pair of sliding bolts 190 , are shown. Each sliding bolt 190 has a substantially U-shaped basic body 191 having a short marginal leg 192 , a longer marginal leg 193 and an intermediate leg 194 which runs perpendicularly to both marginal legs 192 , 193 . Both the intermediate leg 194 and the end face of the longer marginal leg 193 are each provided at the margin with a step, as a result of which guide strips 195 and 196 are formed on the marginal leg 193 and intermediate leg 194 , respectively, with which the sliding bolts 190 can each be secured in a form-fitting manner to the strips ( 173 , FIG. 5 ), forming the sliding guide, in such a way as to be guided in a vertically fixed and horizontally movable manner. The shorter marginal leg 192 in each case is dimensioned in such a way that, in the fitted state, the guide strip 196 on the intermediate leg 194 and the substantially shorter guide strip 195 on the end face of the marginal leg 193 lie such as to be plane-parallel relative to one another. Due to the U-shaped configuration, the respectively shorter marginal leg 192 plunges into the intermediate space 197 between the two marginal legs 192 , 193 , and the distance between the two longer marginal legs 193 can be reduced by pushing apart the two shorter marginal legs 192 . Only in this position, which is not shown in the figure, can the top bearing block ( 128 , FIG. 5 ) be fitted or removed in the accommodating pocket in order to open or close the mounting for the roller axle ( 129 , FIG. 5 ). To lock the bearing block by a form fit, the longer marginal legs 193 are provided on the outside with locking lugs 198 , the top sides of which taper in a wedge shape toward the free ends and which, for locking the bearing block 128 , as shown in FIG. 6 , to engage in locking pockets 165 which are formed on retaining blocks 166 , which in turn are fitted on the top surfaces of the two end walls 127 , 127 A with locking pockets 165 facing one another.
In order to prevent the sliding bolts 190 from being released from one another and from the locking position, even during vibrations, and at the same time in order to be able to apply as high a clamping force as possible, in each case the shorter marginal leg 192 is provided with a through-hole 199 , through which a clamping screw 180 passes. The distance between the two shorter marginal legs 192 can be reduced via the clamping screw 180 , as a result of which the distance between the two outer, longer marginal legs 193 increases and the locking lugs 198 engage correspondingly deeper in the locking pockets 165 .
The invention is not restricted to the exemplary embodiments shown and described, but rather various modifications and additions are conceivable without departing from the scope of the invention. It is thus possible, for example, to provide a plurality of pressure rollers arranged one behind the other in the passage direction of the chain in order to provide a guide for the chain over a longer distance, said guide working largely free of wear. It is also possible to adjust the pressure roller against the chain under the effect of a spring element and/or of a shock absorber, whereby reliable contact between roller and chain is always ensured, even during shock-like loads on the driving chain. The chain guide according to the invention can alternatively or additionally act on the load strand of the driving chain and is of course suitable not only for a plow chain but also, for example, for driving chains of scraper chain conveyors. The bearing blocks can also be inserted in accommodating pockets which are formed directly on the side cheeks of the driving or return stations.
Further, while considerable emphasis has been placed on the preferred embodiments of the invention illustrated and described herein, it will be appreciated that other embodiments, and equivalences thereof, can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. Furthermore, the embodiments described above can be combined to form yet other embodiments of the invention of this application. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. | A chain guide for a driving chain of a winning plow or the like, the chain guide being provided with a chain guide element which is arranged in spatial proximity to the sprockets at a driving or return station and is against the chain transversely to the direction of movement of the latter, provision is made according to the invention for the chain guide element to have at least one pressure roller which can be adjusted against the chain links of the driving chain, as a result of which the wear on the chain guide element is considerably reduced. |
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FIELD OF INVENTION
This invention relates to an electronic system for initiating the operation of a machine or a device and, more particularly, to a system which uses an electronically-controlled code to open a lock, start a machine, etc . . . .
BACKGROUND OF INVENTION
The conventional key-operated mechanical lock has been in existence for years, but suffers a number of important drawbacks, including its ability of being opened by master keys which are often easily available to unauthorized persons. Furthermore, burglars are becoming more and more sophisticated in their techniques of securing entries through doors equipped with mechanical locks. In order to overcome the above drawbacks, several types of electro-mechanical locks have been developed. However, these locks, too, have not completely solved the security problem. Electronically-operated locks using optical scanning devices for reading code patterns on a card or on a ring worn by a person, have also been developed. However, the known optical scanners require that the key unit be positioned in a specific orientation with respect to the scanner and/or moved in a specific direction, in order to properly detect the code patterns.
OBJECT OF INVENTION
It is the object of the present invention to provide a system which requires no specific orientation or displacement of the key unit, which has a code pattern of limited size and which provides quick operation of the machine, device, etc . . . .
SUMMARY OF INVENTION
The system in accordance with the present invention comprises a key unit having a code pattern mounted on a circle around the center thereof, a first rotating sensor excentrically mounted with respect to the center of the key unit and adapted to scan the code pattern on the key unit and generate a first output signal which is representative of the code appearing on the key unit, a second sensor adapted to detect the rotational speed of the first rotating sensor and to generate a second output signal which is representative of the rotational speed of the first rotating sensor, a signal-processing circuit responsive to the first and second output signals for generating a control signal which is independent of the rotational speed of the rotating sensor, and an electrically-operated device responsive to said control signal to perform a given function when a valid code is generated.
The code pattern may be a series of dark and light bars on a support with a predetermined bar spacing and having a print contrast signal greater than 90%, and the rotating sensor may be an optical scanner adapted to direct on optical signal at the code pattern on the key unit and detect the amplitude of the signal reflected by the code pattern. The code pattern may alternatively be a series of radial magnets mounted on a support with a predetermined magnet spacing, and the rotating sensor be a Hall-Effect device.
In a preferred embodiment of the invention, the rotating sensor is mounted in the face of a motor-operated disc, having its axis of rotation aligned with the center of the key unit, the rotating sensor being located at a pedetermined distance from the center of the key unit. A series of dark and light bars are painted on the edge of the disc, and the speed sensor is an optical scanner adapted to direct an optical signal at the code pattern on the edge of the disc and detect the amplitude of the signal effected by such a code pattern.
The signal-processing circuit comprises a first circuit responsive to the first and second output signals for detecting the start of the code pattern, a second circuit responsive to the first and second signal and to thus start a signal for generating a code program, and a comparator gate for comparing the code program with a predetermined reference code and for generating the above-mentioned control signal when the code program matches the predetermined reference code.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be disclosed, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a side view of an electronic system in accordance with the present invention;
FIG. 2 is a view taken along line 2--2 of FIG. 1;
FIG. 3 is a front view of a key unit having a circular code pattern consisting of a series of dark and light bars printed on a suitable support;
FIG. 4 is a front view of a key unit having a circular code pattern consisting of a series of magnets mounted on a suitable support;
FIG. 5 is an alternative embodiment of that shown in FIG. 2;
FIG. 6 is a view taken along line 6--6 of FIG. 1;
FIG. 7 is a general block diagram of the signal-processing circuit;
FIG. 8 is a more detailed block diagram of the circuit of FIG. 7;
FIG. 9 is a series of waveforms produced at the output of some of the elements of FIG. 8;
FIG. 10 is a more detailed block diagram of the circuit shown in FIG. 8; and
FIG. 11 is a series of waveforms produced at the output of some of the elements of FIG. 10.
DETAILED DESCRIPTION OF INVENTION
Referring to FIG. 1, there is shown a side view of an embodiment of a system in accordance with the invention which is enclosed in a housing 10 having a window 12 for the insertion of a key unit (not shown). A disc 14 is secured to the shaft 15 of a micro-motor 16, which is mounted on the bottom of the housing by a holder plate 18 and bolts 20. A second disc 22 is secured to the edges of board 14 by bolts 24. The two discs are mounted co-axially and held apart a predetermined distance by spacers 26. The axis of discs 14 and 22 is aligned with the center of the window 12.
As shown in FIG. 2, a sensor 28 is mounted on disc 22 at a predetermined distance "d" (about 2-2.5 mm) from the axis of the board for scanning a key which is adapted to be inserted in window 12. As shown in FIG. 3, the key face is provided with a code pattern consisting of a series of dark bars 30 located a predetermined distance apart on a shiny metallic surface, or printed on paper, with a print contrast of greater than 90%. A code start 32 is also provided by grouping together four consecutive bars. The spacing of the dark bars depends on the code pattern, the smaller distance the greater the number of available codes. A bar spacing, of 0.5 mm at the edge of a key having a diameter of 5.0-7.5 mm, will provide a code pattern having over one million codes which can be easily sensed by an optical reflective type sensor, such as the HEDS-1000. The above key may be mounted on a ring, a lighter head or any other devices to be carried by a person. The diameter of the key is such as to fit loosely in the window 12 in the housing 10. The sensor is mounted at a distance from the axis of the disc 22 corresponding to the spacing of the code patterns on the center of the key. It will be noted that the distance at which the sensor is mounted from the axis of the disc 22, depends on the size of the optical key, i.e. the number of bars and the spacing therebetween. Such distance should be minimized to reduce the size of the key as much as possible.
The distance between the sensor 28 and the key, when positioned behind a glass 33 held in window 12, should be kept close to the specification of the optical sensor. Such distance may be adjusted by moving the motor longitudinally in the holder plate 80 or varying the length of the spacer 26 between discs 14 and 22.
FIG. 4 of the drawings shows an alternative embodiment of the key unit which consists of a plurality of permanent magnets 34 spaced by non-magnetic material. A Hall-Effect sensor device is used instead of an optical sensor. As commonly known, when a magnetic field is applied particularly across the direction of the current flow in a Hall-Effect device, a force is produced perpendicular to both the field and the current flow, producing a so-called Hall-Effect rotation. Applicant has found that Hall-Effect devices made of GaAs or InSb can produce a voltage of suitable amplitude to be detected by conventional circuitry. The spacing between the permanent magnets on the key would be about the same as with the printed bar code pattern and the diameter of the key may typically be between 7.5-8.5 mm. The Hall-Effect device 36 would then be mounted at a distance "d" between 3.9-4.25 mm from the axis of the board 22, as shown in FIG. 5, in order to align it with the radial magnets on the key. As it will be easily understood, when the permanent magnet is directly facing the Hall-Effect device, maximum output voltage will be obtained, whereas minimum output voltage will be detected when the Hall-Effect device is located between two permanent magnets.
Referring back to FIG. 1 of the drawings, a number of equally-spaced dark and light bars 40 are printed on the edge of disc 22. The number of bars 40 is a multiple (here four) of the bars on the key for a purpose to be disclosed later. A sensor 42 is mounted on a board 44, which is secured to the bottom of the housing 10 by bolts 46. Spacers 48 are provided to adjust the distance of the sensor 42 from the board 44. Sensor 42 is provided for detecting the rotational speed of the sensor 28 mounted on board 22 for a purpose to be disclosed later.
The discs 14 and 22 are preferably printed circuit boards for mounting the various elements 50 of the processing circuit to be disclosed later. A number of slip-rings 52, insulated by spacers 54, are secured to the motor shaft 15 by locking screws 55. As shown in FIG. 6, the power applied to the sensor and to the processing circuit is fed through contact springs 56 which are secured to the edge of an insulating board 58 by bolts 60. The insulating board is secured to the bottom of the housing through spacers 62. The wires from the electronic components of the circuit boards 14 and 22 are connected to soldering lugs 63 on the slip-rings 52. The wires leading to the slip-rings further away from the printed circuit boards pass through opening 64 in in the slip-rings.
FIG. 7 of the drawings illustrates a block diagram of a signal processor circuit for initiating the operation of an electrically-operated device (such as a relay), using the previously-disclosed key and sensors 28 and 42. In the remaining portion of the description, sensor 28 will be called the DATA sensor, whereas sensor 42 will be referred to as the CLOCK sensor. The analog signals appearing at the output of the DATA and CLOCK sensors are fed to conventional digitizers (not shown) for producing digital pulses, such as shown in FIG. 9 of the drawings, for processing by digital circuitry.
Referring to FIGS. 7 and 8 and to the waveforms shown in FIG. 9, there is shown the required circuitry for detecting the start of the code pattern. Corresponding elements in FIGS. 7 and 8 are identified by the same reference characters. The clock pulses are used in the data-processing circuit for synchronizing the operation of the system independent of the speed of the motor which drives the DATA sensor. The waveform of the clock pulses is shown in the first line of FIG. 9. This signal is fed to a conventional divider by 2 flip-flop Q1, the output pulses of which have a width twice that of the original clock pulses, as shown in the second waveform of FIG. 9 of the drawings. These pulses are fed to the clock input of a conventional 3-count shift register Q2. The data pulses originating from the sensor 28 are also fed to shift register Q2. When the data pulse 32, which is set at four-bar widths, as mentioned previously, reaches the shift register, the outputs Qa, Qb, and Qc of the register all become high. The outputs Qa, Qb, and Qc of the shift register Q2 are connected to AND gate Q3, and when Qa, Qb, and Qc are high, the output of Q3 turns high, as shown by the waveform happening in the fourth line of FIG. 9 to trigger flip-flop Q5. The output Q of this flip-flop is connected to the first input of a AND gate Q4 having its output connected to a flip-flop Q6. When the data pulse turns low, the second input of AND gate Q4 turns high through inverter Q7 and the output of gate Q4 turns high to trigger flip-flop Q6. The output Q of flip-flop Q6 turns high to generate the start signal which is illustrated in the last waveform of FIG. 9.
A RC circuit, including resistor R1 and capacitor C1, is provided for resetting flip-flops Q5 and Q6 and shift register Q2 a predetermined time interval after data have ceased to appear at the output of the sensor.
Referring now to FIGS. 7 and 10 and to the waveform shown in FIG. 11, there is shown the circuitry required to process the code detector by the sensors 28. The clock pulses and the start pulse are fed to an AND gate Q8, the output of which is fed to a conventional 4-count circuit including flip-flops Q9 and Q10, which are connected in cascade and have their respective outputs Q connected to the input of a AND gate Q11. The output of gate Q11 turns high for a clock pulse width at every fourth pulse originating from the clock sensor 42, as shown by the waveform of the second line of FIG. 11, so as to be in synchronism with the data sensor 28. The output of the AND gate Q11 is fed to the clock input of a shift register Q12 which has a plurality of outputs Qa-Qn. The data are fed to the shift register and appear at the outputs Qa-Qn as a binary code having a number of digits corresponding to the code pattern appearing on the key. This binary code is the code program which is applied to predetermined inputs of a gate circuit Q13 which will operate a timer T when the state of the output Qa-Qn (high or low) of the shift register matches the preset state of the inputs of gate circuit Q13. The output of the timer T is connected to the base of a transistor Tr through a resistor R. Transistor Tr is connected in the circuit of a relay R2 which is energized from a source Vcc when the transistor is rendered conductive. Timer T is set so that the relay will remain operative for a period of time sufficient to operate the machine or lock, or any suitable device, when the right code key is used. A protective diode D1 is connected across the relay R2 to protect the transistor Tr against back voltages when the relay is cut off.
The start pulse is also applied to the reset terminal of flip-flops Q9 and Q10, as well as to the reset terminal of shift register Q12 to reset the processing circuit at the beginning of each code pattern.
In the afore-described circuits, the electronic components are identified as follows, as a preferred example:
______________________________________Q7 (1/2) and Q5 (1/2) = SN54L S 112AQ6 and Q9 (1/2) = SN 54 LS 11aAQ10 (1/2) = 54 LS 112AQ4, Q8, Q11 = SN 5408Q3 (1/3) = SN 54H11Q13 = SN 54 H21 (Example)Timer T = LM555Tr = 2 N 4237Q2 = SN 5496 (3/5)Q7 (1/6) = SN 5416______________________________________
Although the invention has been disclosed with reference to a preferred embodiment, it is to be understood that other alternatives are also envisaged, and that the invention is to be limited by the scope of the following claims only. | A system for initiating the operation of an electronically-operated device is disclosed. The system comprises a key unit having a code pattern mounted on a circle around the center thereof, a first rotating sensor eccentrically mounted with respect to the center of the key unit and adapted to scan the code pattern on the key unit and generate a first output signal which is representative of the code appearing on the key unit, a second sensor adapted to detect the rotational speed of the first rotating sensor and to generate a second output signal which is representative of the rotational speed of the first rotating sensor, a signal-processing circuit responsive to the first and the second output signals for generating a control signal which is independent of the rotational speed of the rotating sensor, and an electrically-operated device responsive to the control signal to perform a given function when a valid code is generated. |
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[0001] This application claims the benefit of provisional application Serial No. 60/384,675 filed May 31, 2002.
[0002] This application is a continuation-in-part of my prior application Ser. No. 10/092,741 filed Mar. 7, 2002, the complete disclosure of which is hereby incorporated by reference herein. This application is also a continuation-in-part of my prior application Ser. No. 10/134,229 filed Apr. 26, 2002, the complete disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates to mechanical fasteners. More particularly, the invention relates to mechanical fasteners suitable for suspending fixtures such as acoustic tile ceilings, pipes, lighting fixtures, electrical cables, HVAC equipment etc.
[0005] 2. State of the Art
[0006] Current practice in the construction trade and building industry is to suspend fixtures with wires which are fastened to a wall or ceiling. An example of a state of the art apparatus for suspending fixtures is illustrated in prior art FIG. 1. The apparatus generally includes an angle bracket 10 having two holes 12 , 14 , a fastener 16 (typically a nail or a screw), and a length of wire 18 (often six to eight feet long). The method for using the apparatus includes attaching the wire 18 through one of the holes 14 , inserting the fastener 16 through the other hole 12 , and fastening the fastener 16 to a wall or ceiling 20 . An exemplary bracket and fastener are illustrated in U.S. Pat. No. 5,178,503 and U.S. Pat. No. 4,736,923.
[0007] The apparatus shown in FIG. 1 is often used to suspend fixtures from cement, stone, or other masonry material ceilings, typically in commercial buildings. The wires 18 are attached to ceiling tile grids, pipe brackets, HVAC ducts, lighting fixtures, etc. Because a relatively large variety of equipment is hidden above a suspended acoustic tile ceiling in a commercial building, the wires 18 are often six to eight feet long.
[0008] The fastener 16 is usually pre-fit into the hole 12 of the bracket 10 during manufacture. However, the wire 18 (usually 12 gauge galvanized steel) must be manually attached to the bracket 10 by inserting a free end of the wire through the hole 14 , looping the wire onto itself and twisting it as shown in FIG. 54 . This is often done by hand with a pair of pliers or may be done with the aid of a hand operated (or drill operated) crank such as the “wire tying fixture”, item number 00052075, sold by Hilti, Inc., Tulsa, Okla. These methods of attaching the wire to the bracket present several disadvantages.
[0009] The most apparent disadvantage is the cost of labor for the labor intensive task of twisting the wire. In order to be reasonably secure and satisfy some municipal codes, approximately eight inches of the wire must be twisted eight to ten turns about itself. In practice, many workers only twist the wire three or four times about itself. Still, the work is time consuming. The best productivity is not much more than about 300 pieces per hour and after about 500 pieces the worker needs to rest.
[0010] Another disadvantage is that this method of connecting the wire to the bracket is not very secure. Under a stress of about 50 lbs., the wire loop stretches and under a stress of about 210 lbs. the wire untwists.
[0011] Still another disadvantage is that the connection between the wire and the bracket is loose. Under normal circumstances, gravity provides tension between the wire and the bracket. However, in the case of an earthquake or a fire, the loose connection between the wire and the bracket allows vibration and movement of the fixtures supported by the wire. This can result in fixtures falling onto emergency workers and other similar hazards.
[0012] Yet another disadvantage is that if the bracket becomes damaged, the wire attached to it is usually wasted. For example, many brackets are manufactured with fasteners pre-attached so that the bracket may be installed quickly without holding both the bracket and fastener in place. If the fastener detaches from the bracket after the wire is attached but before the bracket is installed, or if the fastener fails to fasten properly, the bracket with the attached wire is typically discarded, thus wasting the wire.
[0013] It is estimated that the annual sale of brackets and wires is in excess of one hundred million. It is also estimated that the failure rate is 12-20%. The average wire length is six feet. Thus, approximately 72-120 million feet of wire goes to waste.
[0014] My first prior application, referenced above, discloses an angle bracket with a hole for a fastener and a flange for coupling a wire to the angle bracket. The flange is lanced and it is coupled to the wire by crimping. According to a first embodiment, the flange is provided with two horizontal lances. According to a second embodiment, the flange is provided with at least three alternating horizontal lances. According to a third embodiment, the flange is provided with a horizontal lance and a vertical lance. According to a fourth embodiment, the flange is provided with a vertical lance in the shape of a hook and an eyelet is provided for connecting the wire. According to a fifth embodiment, the flange is wrapped to form a slotted cylinder. The wire is inserted into the slotted cylinder which is then compressed and crimped onto the wire. According to a sixth embodiment, the angle bracket is provided with two wire connecting flanges. A seventh embodiment is similar to the sixth embodiment with features of the second embodiment. A kit is also disclosed which includes a plurality of lanced angle brackets, a plurality of pre-cut lengths of wire, and a combined crimping and testing tool.
[0015] My second prior application, referenced above, discloses an angle bracket with a hole for a fastener and a flange with a hole for receiving a wire and a wire with a deformation or attachment at one end which prevents it from passing completely through the hole in the flange of the bracket. Six embodiments of a bracket are disclosed. Eight embodiments of a wire are disclosed. The wires may be used with prior art brackets with little or no modification to the bracket. An unmodified prior art bracket is shown in conjunction with wires according to the invention and a slightly modified prior art bracket is shown with a wire according to the invention.
[0016] Although the methods and apparatus disclosed in my prior applications are improvements over the prior art, it is my intention to provide yet additional methods and apparatus which overcome disadvantages of the prior art.
SUMMARY OF THE INVENTION
[0017] It is therefore an object of the invention to provide improved methods and apparatus for suspending fixtures.
[0018] It is also an object of the invention to provide methods and apparatus for suspending fixtures which are not labor intensive.
[0019] It is another object of the invention to provide methods and apparatus for suspending fixtures which are more economical than the state of the art.
[0020] It is still another object of the invention to provide methods and apparatus for suspending fixtures which are safer and stronger than the state of the art.
[0021] It is yet another object of the invention to provide methods and apparatus for suspending fixtures which provide brackets and wires which are easily coupled and uncoupled.
[0022] In accord with these objects which will be discussed in detail below, the apparatus of the present invention includes an angle bracket with a hole for a fastener and a hole for coupling a wire to the angle bracket. Wires according to one aspect of the invention include a collar for forming a loop through the hole in the angle bracket. Three embodiments of wires with collars are disclosed. According to one embodiment, the collar is a slotted cylinder which is crimped to the wire at the time it is attached to the bracket. According to a second embodiment, the collar is crimped to the wire at the factory and has a J-shaped extension which allows the end of the wire to be engaged by the collar in a manner similar to a safety pin. According to a third embodiment, the collar is made of a loop of wire which is twisted several times at the time it is attached to the bracket. Wires according to another aspect of the invention are provided in two parts with a crimpable structure for joining the wires. According to this aspect of the invention, the length of the wire assembly can be adjusted without cutting wire. A new angle bracket according to the invention includes a tongue formed by lancing. The tongue prevents wire from escaping. Three other embodiments of wires and brackets following from my second previous application are also disclosed. According to another aspect of the invention, a wire is provided with two bends at one end which may be slipped through the wire-receiving hole of a conventional bracket and hooked upon itself.
[0023] Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIG. 1 is a schematic side elevational view, in partial section, of a state of the art apparatus for suspending fixtures;
[0025] [0025]FIG. 2 is a partially transparent schematic side elevational view of a first embodiment of the invention;
[0026] [0026]FIG. 2 a is a top plan view of the collar of the first embodiment;
[0027] [0027]FIG. 2 b is a rear side elevational view of the collar of the first embodiment;
[0028] [0028]FIG. 3 is a view similar to FIG. 2 with a slightly different loop in the wire;
[0029] [0029]FIG. 4 is a partially transparent schematic side elevational view of a second embodiment of the invention, partially assembled;
[0030] [0030]FIG. 4 a is a bottom plan view of the collar of the second embodiment;
[0031] [0031]FIG. 5 is a view similar to FIG. 4 showing the wire fully engaged by the collar;
[0032] [0032]FIG. 6 is a partially transparent schematic side elevational view of a third embodiment of the invention, partially assembled;
[0033] [0033]FIG. 6 a is a plan view of the wire used to form the collar of the third embodiment;
[0034] [0034]FIG. 7 illustrates an embodiment of a two part wire assembly according to the invention in conjunction with a bracket and a hanging structure;
[0035] [0035]FIG. 8 illustrates the two part wire assembly without the bracket and hanging structure;
[0036] [0036]FIG. 9 illustrates an embodiment of an angle bracket with a tongue;
[0037] FIGS. 10 - 12 illustrate alternate embodiments of a wire and bracket structure as described in my second parent application;
[0038] [0038]FIGS. 13 and 14 illustrate a wire similar to the wire illustrated in FIG. 6 but configured to hook onto itself without a collar;
[0039] [0039]FIGS. 15 and 16 illustrate the wire of FIG. 11 with a modified prior art bracket;
[0040] [0040]FIG. 17 illustrates an angle bracket having an extruded funnel;
[0041] [0041]FIG. 18 illustrates the angle bracket of FIG. 17 installed with a nail in a cement ceiling;
[0042] [0042]FIG. 19 illustrates a bracket similar to FIG. 17 but designed to secure a conduit or cable;
[0043] [0043]FIG. 20 illustrates an angle bracket having a tongue for engaging the loop of a wire;
[0044] [0044]FIG. 21 illustrates the looped wire used with the bracket of FIG. 20;
[0045] [0045]FIG. 22 illustrates an angle bracket having a pair of slots for engaging a hook shaped wire;
[0046] [0046]FIG. 23 illustrates one embodiment of the bracket of FIG. 22;
[0047] [0047]FIG. 24 illustrates another embodiment of the bracket of FIG. 22;
[0048] [0048]FIG. 25 illustrates an angle bracket for use with a wire having a T-shaped end;
[0049] [0049]FIG. 26 is a top view of the bracket of FIG. 25; and
[0050] [0050]FIG. 27 is a broken side elevational view of a wire with a T-shaped end.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] Referring now to FIGS. 2, 2 a , and 2 b , a first embodiment of the invention is illustrated with a conventional angle bracket fastener 100 . The angle bracket 100 has a first flange 102 and a second substantially orthogonal flange 104 . The first flange 102 has a first hole 106 for receiving a fastener such as the nail 108 . As illustrated, the nail 108 is premounted in the hole 106 and is provided with a collar 109 which facilitates aiming and firing the nail with a gun (not shown). The flange 104 is provided with a hole 110 for receiving a wire.
[0052] The wire 112 according to the invention has a first end 114 and a second end 116 . Though illustrated as a short wire, the wire 112 is typically six feet or longer. The wire 112 is preferably provided with a loop 118 so the end 114 comes adjacent to an earlier portion of the wire. According to the invention, a crimpable collar 120 is provided. The collar 120 is substantially cylindrical and is preferably a slotted cylinder as shown in FIGS. 2 a and 2 b . According to a method of the invention, after the loop 118 is formed and the end 114 is passed through the hole 110 in the flange 104 , the collar 120 is slipped over the end 114 and the adjacent portion of the wire 112 and is then crimped.
[0053] According to the first embodiment of the invention, the wire 112 is pre-formed with the loop 118 . The loop is passed through the hole 110 on-site and the collar is also applied and crimped on-site. However, the wire with the collar could be attached to the bracket at the factory if desired.
[0054] [0054]FIG. 3 shows a slightly different version of the first embodiment. Here the wire 212 has slightly different shaped loop 218 . From the foregoing described FIGS. 2 and 3, those skilled in the art will appreciate that the loop at the end of the wire need not be preformed. According to an alternate method of the invention, an on-site worker is provided with brackets, wires, collars, and a crimping tool. The on-site worker threads and loops a wire onto a bracket, slips the collar over the wire and crimps the collar to achieve a configuration similar to that shown in FIGS. 2 and/or 3 .
[0055] [0055]FIGS. 4, 4 a and 5 illustrate a second embodiment of a wire with a collar for use with a prior art angle bracket 100 . The wire 312 has a first end 314 and a second 316 . A loop 318 is formed near the end 314 and a substantially “g-shaped” collar is attached to the wire before the loop 318 . The collar has a closed portion 320 a which is crimped to the wire 312 and a substantially “J-shaped” open portion 320 b which extends outward. As shown in FIGS. 4 and 5, the end 314 is provided with a substantially 180° bend 319 . As shown in FIG. 5, a portion of the wire before the bend 319 is captured by the open portion 320 b in a manner similar to that of a safety pin. Thus, it will be appreciated that the bend 319 is optional.
[0056] According to this embodiment, the bend 318 and optionally 319 are formed in the factory where the collar 320 is crimped to the wire. The on-site worker can then insert the end 314 through the hole 110 in the clip 100 and fasten the wire by engaging the end in the open portion 320 b of the collar 320 .
[0057] [0057]FIGS. 6 and 6 a illustrate an embodiment similar to that shown in FIGS. 4 and 5 but where the collar is formed by a twisted wire. As shown in FIG. 6, the wire 412 has a first end 414 , a second end 416 and two bends 418 and 419 similar to the wire 312 . Here the area of the wore adjacent the bend 319 is secured to an area before the bend 318 by a twisted wire 420 . The wire 420 is preferably applied with a twisting device (not shown).
[0058] [0058]FIGS. 7 and 8 illustrate a two part wire assembly which can be adjusted lengthwise on-site without cutting wire. As shown in FIG. 7, a bracket 500 of the type disclosed in my second parent application includes two parallel flange 502 , 504 with a bowl-like hole 510 in the second flange 504 . A first wire 512 has a first end 514 , a second end 516 and a loop 518 formed near the first end 514 . The loop 518 prevents the wire from passing completely through the hole 510 . A second similar wire 522 is provided having a first end 524 , a second end 526 , and a loop 528 near the second end 526 . The loop 528 is used to engage a hole in a hanging structure 530 such as a frame for an acoustic tile ceiling or the like. According to this embodiment of the invention, the first wire 512 and the second wire 522 are coupled to each other by a crimpable collar 520 . As shown in FIGS. 7 and 8, the collar 520 is a sheet of metal which has been lanced in several places to provide two openings for receiving the wires. This type of lancing is shown and described in my first parent application, previously incorporated hereinabove. Those skilled in the art will appreciate that it will be advantageous to lance in one direction for one wire and in the other direction for the other wire so that the wires pass on opposite sides of the metal sheet. When the two wires are inserted into the collar 520 , they can be moved longitudinally so as to adjust the overall length of the two wire and collar assembly. According to a method of the invention, the collar 520 is crimped to the upper wire 512 and the lower wire 522 is moved through the collar. When the overall length of the wire assembly is decided, the lower wire 522 can be bent slightly as shown in FIG. 8 to maintain its position temporarily while the collar 520 is crimped to it.
[0059] [0059]FIG. 9 illustrates an angle bracket 600 having a tongue 611 . The angle bracket 600 is similar to those described in my second parent application, having an upper flange 602 and a substantially parallel lower flange 604 . The lower flange 604 is provided with a bowl-like hole 610 which receives and captures the upper loop of a wire 512 . According to this embodiment, a portion of the bracket 600 (above the lower flange) is lanced to create a tongue 611 which can be bent down on top of the loop in wire 512 to prevent the wire from escaping the bracket. Those skilled in the art will appreciate that the tongued bracket can be used with several of the different wire embodiments disclosed in my second parent application.
[0060] FIGS. 10 - 12 illustrate wires of the type discussed in my second parent application but where the deformation at the upper end of the wire is relatively small and thus requires the use of a bracket with a wire hole not too much larger than the diameter of the wire.
[0061] [0061]FIG. 10 illustrates a wire 712 in conjunction with a bracket 700 having two parallel flanges 702 , 704 similar to those described in my second parent application. The bracket 700 has a wire-receiving hole 710 in the second flange 704 . The diameter of the whole 710 is preferably only large enough to allow the wire 712 to pass through without difficulty. The wire 712 has a first end 714 and a second end 716 . The first end 714 is provided with a deformation 718 , in this case a Z-bend, which allows the first end of the wire to be passed carefully through the hole 710 but which prevents the wire from passing back out when the bracket 700 and wire 712 are in hanging relationship as shown in FIG. 10.
[0062] [0062]FIG. 11 illustrates a wire 812 in conjunction with a bracket 800 which is similar to a prior art bracket. The bracket 800 has a wire-receiving hole 810 with a diameter preferably only large enough to allow the wire 812 to pass through without difficulty. The wire 812 has a first end 814 and a second end 816 . The first end 814 is provided with a deformation 818 , in this case a Z-bend, which allows the first end of the wire to be passed carefully through the hole 810 but which prevents the wire from passing back out when the bracket 800 and wire 812 are in hanging relationship as shown in FIG. 11.
[0063] [0063]FIG. 12 illustrates a wire 912 in conjunction with a bracket 800 which is similar to a prior art bracket. The bracket 800 has a wire-receiving hole 810 with a diameter preferably only large enough to allow the wire 812 to pass through without difficulty. The wire 912 has a first end 914 and a second end 916 . The first end 914 is provided with a deformation 918 , in this case a U-bend, which allows the first end of the wire to be passed carefully through the hole 810 but which prevents the wire from passing back out when the bracket 800 and wire 912 are in hanging relationship as shown in FIG. 12.
[0064] [0064]FIGS. 13 and 14 illustrate a wire 1012 which may be used with any conventional bracket 100 . The wire 1012 has a first end 1014 and a second end 1016 . The first end of the wire is provided with two bends 1018 and 1019 . The bends are configured so that the wore may be passed through the hole 110 in a conventional bracket 100 and then hooked onto itself as illustrated in FIG. 14.
[0065] [0065]FIGS. 15 and 16 illustrate the wore 812 with a modified prior art bracket 101 . The only modification to the bracket is the diameter of the hole 111 which is made closer to the diameter of the wire 812 .
[0066] Turning now to FIGS. 17 and 18, an angle bracket 1100 according to the invention has a first end 1104 and a second end 1104 , a hole for receiving a nail 16 and a hole 1108 for receiving wire 812 . The nail receiving hole 1106 is provided with a funnel-like structure 1110 which will fill in the cavity 21 normally formed in cement 20 by the nail 16 .
[0067] [0067]FIG. 19 illustrates a bracket 1200 having a first end 1202 , a second end 1204 , a nail receiving hole 1206 and a funnel-like structure 1210 substantially the same as the funnel-like structure 1110 described above. The end 1204 of this bracket is designed to hold a conduit or cable (not shown).
[0068] [0068]FIGS. 20 and 21 illustrate a bracket 1300 and wire 1400 which are designed to engage each other in a secure manner so that little or no movement of the wire relative to the bracket is permitted. The bracket 1300 has first and second ends 1302 , 1304 , a wire receiving hole 1310 and a wire engaging tongue 1311 . The wire 1400 has a loop 1402 at one end. The loop 1402 is dimensioned to be engaged by the tongue 1311 as shown in FIG. 20. The wire 1400 is also provided with a z-bend 1404 adjacent to the loop so that the wire may pass through the hole 1310 in the bracket 1300 as shown in FIG. 20.
[0069] [0069]FIG. 22 shows a bracket 1500 designed for use with a wire 1600 having a hooked end 1602 . As shown in FIG. 22, the hooked end 1602 is formed by three ninety degree bends in the wire. The bracket 1500 has a first end 1502 , a second end 1504 , and is provided with two holes 1506 , 1508 adjacent to the second end 1504 .
[0070] According to one embodiment, shown in FIG. 23, the bottom hole 1506 is shaped like an inverted T and the top hole is a vertical slot. Those skilled in the art will appreciate that the holes and the wire are advantageously dimensioned such that it is possible to position the wire horizontally to pass through the lower horizontal par of the hole 1506 . The holes and the wire are also advantageously dimensioned such that when the wire and bracket are assembled as shown in FIG. 22, the lower horizontal par of the hook 1602 is engaged in the vertical portion of the inverted T slot 1506 . This arrangement restricts movement of the wire relative to the bracket.
[0071] According to a second embodiment, shown in FIG. 24, the bottom hole 1506 ′ is a horizontal slot and the upper hole 1508 ′ is substantially semi-circular. Those skilled in the art will appreciate that the wire can be hooked into the bracket following the same steps as the first embodiment. It will further be appreciated that the dimensions of the hole 1508 ′ may be chosen to allow rotation of the wire and the length of the slot 1506 ′ may be chosen to set the limits of rotational movement of the wire. Alternatively, by providing the wire with a substantially semi-circular cross section and properly dimensioning the hole 1508 ′, rotational movement of the wire relative to the bracket can be minimized or eliminated.
[0072] FIGS. 25 - 27 illustrate a bracket and wire combination which are easy to assemble and which limits movement of the wire relative to the bracket when assembled. The bracket 1600 has a straight flange 1602 coupled to a U-shaped flange 1604 . The flange 1602 has a nail receiving hole 1606 and a slot 1610 which extends into the U-shaped flange 1604 . As seen best in FIG. 26, the slot 1610 is T-shaped with the head of the T lying in the bottom of the U-shaped flange 1604 .
[0073] The wire 1700 has a T-shaped head 1702 which is dimensioned to fit through the slot 1610 and be rotated into the position shown in FIG. 25. As seen best in FIG. 27, the head 1702 of the wire 1700 is formed by six ninety degree bends in the wire resulting in the wire doubling against itself below the head. This double width fits into the head of the T-shaped slot 1610 when the wire is rotated into the position shown in FIG. 25. From the foregoing, those skilled in the art will appreciate that the wire and bracket are assembled by rotating the wire to the position shown in FIG. 27 and inserting it through the slot 1610 until the double width below the head 1702 clears the slot, rotating the wire ninety degrees and lowering it to the position shown in FIG. 25.
[0074] There have been described and illustrated herein several embodiments of methods and apparatus for suspending fixtures. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed. | Various systems including brackets and associated wires are disclosed for suspending fixtures from ceilings and the like. The systems improve over the prior art in several ways. Attachment of the wire to the bracket is faster and easier. The attachment can be made more rigid. Several different components can be combined to adapt to different suspension requirements. Brackets can be provided with structure to make more stable connections to cement and masonry. |
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This invention relates to the field of plumbing accessories and is particularly concerned with a drain flushing device for allowing a user to unclog a drain in either of two modes. The user is given the option to either use the device as a liquid column guide or as a pump.
BACKGROUND OF THE INVENTION
Water drains are usually clogged by a blockage of foreign matter in the trap area of the drain system. If this blockage is broken up into smaller pieces or forced through the trap, the system will again function properly. Various methods can be used to break up the blockage into smaller particles or to force it through the trap. Examples of such methods include chemical reactions with the foreign matter and force exerted on the foreign matter. One of the methods of applying force to the foreign matter is the usage of water that is usually contained in the drainage system above the clogged area. Since the water is incompressible, any pressure applied above its surface will be directly transmitted to the foreign matter. A conventional method of applying pressure to the surface of the water is the use of a force cup plunger. The force cup plunger has a resilient plunger ring fixed to a substantially elongated handle. In operation, the plunger is positioned on the opening of the clogged drain. The user then pushes down and pulls up the plunger thereby alternatively exerting a downward pressure and a siphon on the water inside the clogged drain. Water being incompressible, the pressure and siphoning effect are transmitted to the clogging matter inside the drain, thus forcing the clogging matter inside the drain and releasing the latter. Because of the relatively small size of conventional plunger rings, the force cup plunger only displaces a small volume of water, thus exerting a limited pressure on the clogging matter. Another type of device conventionally used is the so-called piston-type pump. Piston-type pumps have been inherently complex and require complex piston seals. In operation, the piston-type pump is positioned on the opening of the clogged drain. The pump either uses water that is usually contained in the drainage system above the clogged area or, through an adapter, is hydraulically linked to a source of water under pressure, such as the conventional household water line. The piston inside the pump is reciprocated up and down along the cylindrical body, exerting a pressure and a siphoning effect on water present in the pump, thus releasing the clogging matter inside the clogged drain.
A search amongst prior art has revealed a number of patents disclosing devices either of the piston-type pump or of a type using an adapter for hydraulically linking a source of water under pressure, such as the conventional household water line, to an outlet nozzle which is positioned inside the drain to be unclogged. Examples of such patents are Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger, U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi, U.S. Pat. No. 4,096,597 granted on Jun. 27, 1978 to Duse and U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo.
Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger discloses a pump for unclogging pipes. The pump comprises a cylinder, a plunger rod with an integral handle at one end and the other end threaded to receive nuts retaining a set of leather disc forming a piston for reciprocating within the cylinder. The bottom end of the cylinder is adapted to receive a flexible pipe such as a hose hydraulically linked to a domestic water line. The use of a water supply such as the domestic water line is essential to the operation of the pump, the water being the main source of pressure on the clogging matter. The handle linked to the piston is then reciprocated up and down in order to increase the pressure exerted on the clogging matter. This invention is adapted to function with running water and does not suitably function in the absence of an independent source of water.
U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi is concerned with a drain-flushing device comprising a cylinder closed at its upper end with a piston shaft support, a piston shaft passing there through with its top end connected to a handle and the bottom end connected to a piston. In operation, the user siphons up water which is inside the clogged drain by pulling up the handle and then applies a downward push on the handle, exerting a pressure on the water inside the cylinder and on the clogging matter. In the absence or insufficiency of water into the drain, the invention will not function properly.
U.S. Pat. No. 4,096,597 granted on Jun. 27, 1978 to Duse provides a drain opening device comprising telescoping cylinders sealed by a flexible plastic membrane. The bottom end of the bottom cylinder is covered with a pressure activated valve. The telescoped cylinders can be filled with water through the pressure activated valve. To unclog a drain, the top cylinder is pushed downwardly, thereby telescopingly overriding the bottom cylinder. The water inside the cylinder is thus forced through the pressure activated valve in the form of a high speed water jet. The invention has to be inverted and filled with water, which can prove unergonomical. Furthermore, the device is limited to a predetermined volume of liquid which can prove to be insufficient if the clogging matter is located at a distance from the device.
U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo provides a sanitary pump comprising a cylinder, an elastic disc attached to the bottom of the cylinder, a piston, a piston rod, a cap covering the top of the cylinder and a handle connected to the upper end of the piston rod. In operation, the invention is placed and held on the opening of the clogged drain, the handle is pulled up and pushed down several times, thereby siphoning up and pushing down drain water thus exerting pressure on the clogging matter. Situations sometimes occur when not enough water is present in the clogged drain, or is present but not accessible, to fill the cylinder of this invention. The operation of the latter is thus complicated.
The present invention proposes a device adapted to circumvent the above-mentioned disadvantages.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved drain flushing device.
Accordingly, the present invention allows the user to unclog a drain using a minimum amount of manipulations and relatively problem-free. Contrary to Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger, the present invention necessitates no running water, thus it is not exposed to the problem caused by the absence of the latter. Contrary to U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi and to U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo, the proper operation of the present invention does not depend upon the presence of accessible water inside the clogged drain. The presence of apertures on the top of the cylinder eliminates the problem of possible insufficiency or absence of water inside the clogged drain, and the problem of unavailability of running water. Water can be poured inside a cylinder, part of the invention, through a set of apertures situated adjacent the top end of the cylinder. Contrary to U.S. Pat. No. 4,096,597 granted on Jun. 27, 1978 to Duse, it is not necessary to invert the invention and to use unergonomical manipulations in order to fill it with water. Furthermore, the presence of apertures at the top of the cylinder eliminates the necessity to handle the bottom part of the cylinder, which is often soiled because of its contact with the clogged and often dirty drain.
The present invention operates in either of two ways, as a water column exerting pressure on the clogging matter inside the clogged drain, or as pump.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further understood from the following description with reference to the drawings in which:
FIG. 1, in a perspective view, illustrates a drain flushing device in accordance with a first embodiment of the present invention positioned inside a sink about to be unclogged;
FIG. 2, in a longitudinal cross-sectional view taken along arrows 2--2 of FIG. 1, illustrates the internal mechanism of a drain flushing device in accordance with a first embodiment of the present invention;
FIG. 3, in a longitudinal cross-sectional view, illustrates a drain flushing device in accordance with a first embodiment of the present invention in which water is being poured in order to form a water column; and
FIG. 4, in a longitudinal cross-sectional view, illustrates a drain flushing device in accordance with a first embodiment of the present invention with its piston being pushed in a downward motion.
FIG. 5, in a longitudinal cross-sectional view, illustrates a drain flushing device in accordance with an embodiment of the present invention with its piston being pulled upwardly.
DETAILED DESCRIPTION
Referring to FIG. 1, there is illustrated in a perspective view, a drain flushing device 10 in accordance with a first embodiment of the present invention. The drain flushing device 10 has a substantially cylindrical body 12 and a piston element 14 adapted to reciprocate inside the cylinder 12. The cylinder 12 has a lower discharge aperture 16 and an upper aperture 18 with an upper peripheral rim 24. A substantially funnel-shaped liquid guide 20 extends integrally from the cylindrical body 12 adjacent its upper aperture 18. The funnel shaped liquid guide 20 has a peripheral wall 22 which merges into the cylindrical body 12 at a peripheral junction position indicated by the reference letter P located underneath the upper peripheral rim 24 of the aperture 18. The guide 20 and the upper portion of the cylinder 12 thus define a substantially annular cavity 26 positioned peripherally around the upper portion of the cylinder 12 into which a liquid can be poured. The cylindrical body 12 is provided with a set of peripheral apertures 28 extending there through. The apertures 28 are located intermediate the upper rim 24 and the peripheral junction position P and are thus adapted to allow the liquid poured into the annular cavity 26 to flow into the cylinder 12.
The piston element 14 comprises a piston disk 30 having integrally and downwardly extending peripheral sealing flanges 32 adapted to slidably abut against the inner wall of the cylinder 12. The disk 30 is fixed to an elongated piston rod 34 by a bolt 35 extending through the disk 30 and threadaly inserted into a corresponding longitudinal threaded recess 36 provided in the lower end of the piston rod 34. A rigid spacing disk 38 is provided between the bolt 35 and the disk 30. A cover cap 40 is fittingly positioned on top of the cylinder 12. The cap 40 has a central aperture 42 extending there through. The piston rod 34 is adapted to slidably extend through the aperture 42 of the cap 40. A handle 44 is rigidly fixed to the top end of the piston rod 34 for allowing manual operation of the piston element 14.
Cushioning disks 46 and 48 made of relatively resilient material, are respectively positioned on the rod 34 adjacent the disk 30 and the handle 44 for limiting the course of the piston element 14 and preventing the disk 30 and the handle 44 from knocking on the cap 40. The disks 46 and 48 thus absorb the impact created by the reciprocation of the piston rod 34. A ring adapter 50 fittingly positioned on the lower end 16 of the cylinder 12 is provided with a recess 52. The recess 52 is adapted to slidably receive and fittingly lock a set of angled elbows configured to various sizes, shapes and configurations allowing insertion in correspondingly shaped drain apertures.
In use, the drain flushing device 10 is adapted to be used in two modes. According to one mode, as shown in FIG. 3, the user pulls up the handle 44 until the piston element 14 is positioned above the set of apertures 28, then positions the lower open end 16 of the cylinder 12 on the opening of a clogged drain 54. The user then pours water from a container, such as container 56, into the substantially funnel-shaped liquid guide 20. The water then freely flows through the set of apertures 28 substantially filling the cylinder 12 thus forming a column of water that exerts pressure on a clogging matter 58 in the drain 54, for releasing the clogging matter 58 in the drain 54. A column is thus formed using gravity, contrary to Canadian Patent No. 299,247 granted on Apr. 15, 1929 to Krieger, U.S. Pat. No. 3,934,280 granted on Jan. 27, 1976 to Tancredi, and U.S. Pat. No. 4,186,451 granted on Feb. 5, 1980 to Ruo wherein the forming of a column of water needs the use of pressure.
According to an alternative mode, as illustrated in FIG. 4, once the water has been poured into the substantially funnel-shaped liquid guide 20 and substantially fills the cylinder 12, the user holds the cylinder 12 with one hand and pushes down and pulls up the handle 44 with the other hand, thus reciprocating the piston element 14 inside the cylinder 12 and thereby alternately siphoning and exerting a downward pressure on the clogging matter 58 inside the drain 54 until the clogging matter 58 is released. With the present invention, it is also possible to siphon water that is inside the clogged drain 54, if readily accessible, instead of pouring water inside the substantially funnel-shaped liquid guide 20. | A drain flushing device for allowing a user to unclog a drain in either of two modes. The user is given the option to either use the device as a liquid column guide or as a pump. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not Applicable.
BACKGROUND OF THE INVENTION
Technical Field
[0005] The present invention relates to an odor-eliminating apparatus. More specifically, an embodiment of the present invention involves a toilet ventilation exhaust system that employs a dedicated, internal, orificial, annular vent passage integral to the upper rim of the toilet bowl. When connected to an appropriate exhaust line and vent exhaust fan, this system effectively and efficiently eliminates toilet odors. This invention functions during normal operation and offers provisions for recovery from upset conditions of condensate buildup and overflow as well as for periodic maintenance if vent exhaust path clogging ever were to occur.
[0006] Current art toilets depend on a ceiling ventilation exhaust fan to remove bathroom odors which originate in the toilet. Many of the more noxious gases are considerably heavier than air so a prolonged ventilation period using the ceiling exhaust fan method is necessary to exhaust toilet odors. This process is inefficient and ineffective as the gases must exit the toilet and enter the room air space before being exhausted. This non-direct exhaust flow path makes the odorous gases susceptible to mixing with other air and to being carried into areas outside the toilet room, thus causing the exhaust fan to operate for an extended period of time to remove all odors and often ineffectively. Since current art ceiling exhaust fans generally operate at 1.42-3.12 cubic meters per minute (50-110 cubic feet minute), literally scores of cubic meters (hundreds or thousands of cubic feet) of air are removed by prolonged operation of the fan before the toilet odors are eliminated from the toilet and surrounding air space. This air generally is conditioned (i.e., heated or cooled), and continued exhaust flow will result in pulling more outside, unconditioned air into the home or building. Sustained exhaust fan operation and the need to condition excessive replacement air cause unnecessary operation of building exhaust and heating, ventilating, and air conditioning systems, thus demanding unnecessary energy consumption when compared to the proposed invention. Additionally, the current art exhaust fans often include a light which is energized when the exhaust fan is energized using the same on/off switch. Daytime use of the light may be an additional waste of energy.
[0007] Some have attempted to address the problem by employing the use of the existing rim jet ports for gaseous odor removal. Sharing of common vent/flow ports for both noxious air exhaust and flushing water would require cycling of the exhaust fan to reestablish the exhaust flow after flushing. Otherwise, the continuing ventilation exhaust flow will establish and maintain a small standing column of water in the vent/flow ports equal in height (in millimeters or inches) to the suction pressure of the exhaust fan and will prevent subsequent exhaust air flow. During this period there will be no further exhaust flow from the toilet, and noxious odors will escape from the toilet and into the surrounding area. This cycling of exhaust fan operation to eliminate this concern makes such arrangements in a single residence inconvenient. It is impractical or unworkable for such arrangements in a larger building with multiple toilets and a common exhaust ventilation system which cannot be cycled off then on after every individual flush. Additionally, using the same rim jet holes for both water and air flows will result in cyclical wetting and drying of the small diameter ports. This ultimately will clog these ports due to normal presence of soluble solids in the water. In such cases neither the flush water flow nor exhaust air flow will be maintained without frequent maintenance to keep the rim jet ports clear. This is not a workable approach to toilet operation or odor removal. Therefore, an aspect of the present invention which provides for a separate flow path for water introduction into the toilet bowl and a separate flow path for odor removal is necessary to maintain reliable and efficient toilet operation for both flushing and odor removal.
[0008] The toilet system of U.S. Pat. No. 5,727,263 discloses two separate flow paths with two separate exhaust fans, each servicing a separate exhaust path. In the event of toilet overflow or condensate buildup in the exhaust path, the fan motors, which are below toilet bowl level, would fail due to water intake and would require replacement. There is no design provision for drainage of condensate or overflow liquid on the upstream or downstream side of each exhaust fan. There is no provision for performing maintenance which may require unclogging or removing water in the vent exhaust path or performing other required cleaning of the vent exhaust path which may occur over time. There is no specified consideration for factors of vent exhaust orifice sizing, exhaust ventilation piping size, vent exhaust flow rate, or capillary action relating to fan performance capabilities.
[0009] The toilet system of U.S. Pat. No. 5,809,581 discloses a system without toilet overflow or condensate buildup remedies. There is no recovery of the system due to overflow or condensate buildup without excavating the floor to remove the liquid filled exhaust piping which slopes downward from the toilet rim and is buried into the floor below the toilet. This resulting water column would block vent exhaust air flow, deprive the exhaust fan of air flow and cause exhaust fan failure and loss of vent exhaust flow. Consistent with the first deficiency, there is no element for draining any part of the vent exhaust path. There is no element for performing maintenance which may require unclogging of the vent exhaust path or performing other required cleaning of the exhaust pathway which may occur over time. There is no teaching of vent exhaust orifice sizing, exhaust ventilation piping size, vent exhaust flow rate, or capillary action relating to fan performance capabilities. There is no stated consideration for location of the exhaust fan with respect to concern for condensate buildup or toilet overflow condition. Drawings show the vent exhaust orifices smaller than the liquid rim jet flush orifices. While the drawings are not stated to be to scale, the air vent holes would be larger than the liquid rim jet orifices to achieve adequate air flow and avoid capillary action concerns.
[0010] U.S. Pat. No. 7,331,066 discloses a toilet system with a non-collapsible, flexible, hollow tube running throughout the upper rim duct in contrast to the wholly integrated but separate casting of the annular exhaust passage described herein. The flexible, hollow tube running throughout the upper rim duct of U.S. Pat. No. 7,331,066 would reduce the otherwise available cross-sectional area of the liquid, upper rim duct, create turbulence, and impede liquid flow through the upper rim duct. The airflow means/air exhaust mechanism disclosed in U.S. Pat. No. 7,331,066 can be any selection of suction blower, vacuum pump, or exhaust fan. Also, a high pressure suction created by a vacuum pump or suction blower would exacerbate orifice clogging, jeopardize the function of the air exhaust mechanism due to the possibility of pulling water into these mechanisms with condensate buildup or toilet overflow, and would exacerbate efforts to perform effective back flushing of the vent exhaust passageways due to high suction pressures pulling in possible contaminants into the vent exhaust orifices. Some aspects of these concerns could be mitigated by the pressure switch which would turn off the exhaust mechanism when the user leaves the toilet, but upon subsequent usage of the toilet, failure of the system to function would be likely. There is no element for maintenance back flushing or cleaning. This connection between the vent exhaust orifices and the non-collapsible, flexible, hollow tube is a very restrictive flow path to the flexible, hollow tube and makes questionable the ability to provide adequate exhaust air flow. There is no provision to accommodate condensate buildup or toilet overflow. This could result in fan (or other exhaust mechanism) failure and cessation of function of the vent exhaust system. There is no consideration of capillary action. Capillary action could be significant due to the very restrictive flow paths shown between the vent exhaust orifices and the non-collapsible, flexible, hollow tube.
[0011] All of the aforementioned systems suffer from the same deficiency of permitting condensate or overflow conditions into the vent pathway whereby the water would block the evacuation of the fumes in the pathway.
[0012] The references do not address the upset conditions of condensate buildup or of toilet overflow which subsequently may render many of the other known systems to be non-functional. An embodiment of the present invention provides for features which would allow recovery without equipment damage from toilet overflow and condensate buildup. Embodiments of the present invention also permit maintenance back flushing to clear the annular vent passage, vent exhaust orifices, annular exhaust vent line, and parent exhaust line if clogging of the exhaust ventilation flow path were to occur for any reason over the lifetime of operation.
BRIEF SUMMARY OF THE INVENTION
[0013] One embodiment of the present invention provides a toilet system comprising a toilet bowl having a rim jet annulus located circumferentially inside a portion of a rim disposed above and around the periphery of the toilet bowl wherein the rim jet annulus has a plurality of rim jet orifices for introducing water into the toilet bowl. An annular vent passage which is separate from the rim jet annulus is located circumferentially inside and concentric with the rim jet annulus of the toilet rim of the toilet bowl. The annular vent passage has a plurality of vent exhaust orifices located at the inner radius of the annular vent passage and positioned above the rim jet orifices to avoid communication of the water from the rim jet orifices into the annular vent passage via the vent exhaust orifices. According to another embodiment, the annular vent passage is predominantly located above the existing rim jet annulus. In either embodiment, the annular vent passage connects to an annular exhaust vent line at the back vertical plane of the toilet bowl to avoid interference with the rim jet annulus. The annular exhaust vent line slopes downward from the back vertical plane of the toilet bowl to a low point where there is located a low point drain line and a low point drain valve at the bottom of the low point drain line. The annular exhaust vent line continues with a constant slope upward for a distance to join with an enlarged parent exhaust line. The parent exhaust line is in communication with a bypass branch line upstream of a vent exhaust fan upstream isolation valve located upstream of a vent exhaust fan and the parent exhaust line. The annular exhaust vent line may exit the toilet bowl at a same elevation as the annular vent passage or may exit the toilet bowl below the toilet rim from inside the toilet bowl to avoid interference with the rim jet annulus flow path. For example, the vent exhaust orifices are sized in consideration for vent exhaust flow and capillary action consistent with the vent exhaust fan.
[0014] In a further embodiment, the bypass branch line tees off the parent exhaust line upstream of the vent exhaust fan upstream isolation valve and at a minimum elevation more than the sum elevations of the toilet rim plus the maximum suction pressure of the vent exhaust fan. Alternatively, the bypass branch line further comprises a branch line isolation/throttle valve which may be used for throttling of air flow or for throttling or isolating liquid flow for maintenance back flush operations. In yet another embodiment, the bypass branch line does not include a branch line isolation/throttle valve. The bypass branch line is sized to allow sufficient and continuous ventilation flow for the vent exhaust fan under normal and upset conditions to maintain exhaust flow through the vent exhaust orifices with the bypass flow and to serve as a maintenance access connection for back flushing the parent exhaust line, annular vent passage, and vent exhaust orifices.
[0015] In one embodiment, a single fan is used with a system as described herein to create a suction at the plurality of vent exhaust orifices of the annular vent passage of the toilet when one or more toilets are connected to the same parent exhaust line.
[0016] According to one embodiment, the upward slope of the annular exhaust vent line and parent exhaust line of a system as describe herein is at least 3 millimeters per 0.3 meters of piping from the low point drain line.
[0017] According to another embodiment, the low point drain line located at the low point of the annular exhaust vent line of the system described extends to a length which is greater than the height of the water column equivalent to the maximum suction pressure possible from the vent exhaust fan to ensure positive drainage under all use conditions, and the low point drain line and the low point drain valve at the end of the low point drain line have an internal diameter which is greater than the diameter of any vent exhaust orifice.
[0018] Another embodiment of a toilet system comprises a toilet bowl having a rim jet annulus located circumferentially inside a portion of a rim disposed above and around the periphery of the toilet bowl wherein the rim jet annulus has a plurality of rim jet orifices for introducing water into the toilet bowl. An annular vent passage is located through a portion of a circumference of the toilet bowl rim and is separate from the vent passage but circumferentially inside and concentric with the rim jet annulus such that the annular vent passage has a plurality of vent exhaust orifices located at the inner radius of the annular vent passage and above the outer, annular rim jet orifices to avoid communication of water from the plurality of rim jet orifices to the plurality of vent exhaust orifices. The annular vent passage exits the toilet at the back vertical plane of the toilet bowl at an annular exhaust vent line to avoid interference with a water rim jet annulus flow path. The annular exhaust vent line slopes downward from the rear vertical plane of the toilet bowl, and deliberately creates a low point drain location, having a low point drain line tee from the low point drain location of the annular exhaust vent line which extends from the low point drain location to a length which is greater than a water column equivalent to the maximum suction pressure of a vent exhaust fan to ensure positive drainage under all conditions during normal operation, recovery from toilet overflow, and upon completion of back flushing activities. The annular exhaust vent line continues on an upward slope of at least 3 millimeters per 0.3 meter of piping to the rear vertical plane of the toilet where the vent exhaust line is enlarged to continue as a parent exhaust line which is in communication with a bypass branch line upstream of a vent exhaust fan upstream isolation valve located upstream of the vent exhaust fan and the parent exhaust line. The low point drain line and the low point drain valve at the end of the low point drain line have an internal diameter which is greater than the diameter of any vent exhaust orifice. For example the vent exhaust fan of this embodiment is located in the remainder of the parent exhaust line at a minimum elevation greater than a sum elevation of the elevation of the toilet bowl rim plus the maximum suction pressure of the vent exhaust fan, and has a vent exhaust fan upstream isolation valve selected for minimum resistance to ventilation air flow and is located upstream of the vent exhaust fan and wherein the vent exhaust fan is capable of overcoming a capillary effect which may occur after water intrusion into the plurality of vent exhaust orifices, and is of sufficient suction pressure and flow capability to establish desired vent exhaust flow rate through the plurality of vent exhaust orifices even with air flow through the bypass branch line.
[0019] In one embodiment, the bypass branch line can be added at the elevation greater than the sum of the elevation of toilet rim plus the maximum suction pressure of the vent exhaust fan, and wherein the bypass branch line tees into the parent exhaust line upstream of the vent exhaust fan upstream isolation valve, and is sized to allow sufficient, continuous ventilation flow for the vent exhaust fan operation under both normal conditions and upset conditions of a toilet overflow or condensate condition blocking ventilation exhaust air flow through the annular vent passage, and is with or without an installed branch line isolation/throttle valve selected to ensure necessary air flow through the vent exhaust fan, and serves as a maintenance connection for back flushing the annular vent passage, vent exhaust orifices, annular exhaust vent line, or parent exhaust line in the event of vent path clogging.
[0020] In yet another embodiment a method of venting an odor within a toilet system is provided. An odor within a toilet bowl is vented through a plurality of exhaust orifices of an annular passage of the toilet bowl. The toilet bowl includes a rim jet annulus located circumferentially inside a portion of a rim disposed above and around the periphery of said toilet bowl wherein the rim jet annulus has a plurality of rim jet orifices for introducing water into the toilet bowl. An annular vent passage is located circumferentially inside the rim of the toilet bowl. The annular vent passage having the plurality of exhaust orifices and the annular vent passage is positioned concentric with the rim jet annulus to avoid communication of the water from the rim jet orifices into the annular vent passage via the vent exhaust orifices. The annular vent passage connects to an annular exhaust vent line at the back vertical plane of the toilet bowl to avoid interference with the rim jet annulus. The annular exhaust vent line slopes downward from the back vertical plane of the toilet bowl to a low point where there is located a low point drain line and a low point drain valve at the bottom of the low point drain line. From this point, the annular exhaust vent line continues with a constant slope upward for a distance to join with a parent exhaust line wherein the parent exhaust line is in communication with a bypass branch line and a vent exhaust fan upstream isolation valve located between a vent exhaust fan and the parent exhaust line wherein the annular exhaust vent line, the parent exhaust line, the exhaust fan upstream isolation valve and vent exhaust fan are above ground. The odor is evacuated through the annular exhaust vent line with the aid of the vent exhaust fan when the fan is creating a suction at the plurality of exhaust orifices of the annular vent passage. In another embodiment a single fan is used to create a suction at the plurality of vent exhaust orifices of the annular vent passage of the toilet when one or more toilets are connected to the same parent exhaust line.
[0021] The operation of an embodiment of the present invention under normal conditions of use will be transparent to the user, only requiring exhaust fan operation consistent with current exhaust fan control art. However, an embodiment also accommodates the condition of toilet overflow and condensate buildup anywhere in the vent exhaust path while allowing recovery without equipment damage. Further, embodiments of the invention provide for as-needed maintenance to back flush any portion of the exhaust system in the event of system clogging. The system and method may be applied to a single toilet and exhaust fan or to multiple connected toilets with interconnected vent lines to a common exhaust fan. 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.
[0022] The vent exhaust path may be considered the ventilation flow path comprising the annular vent passage, vent exhaust orifices, annular exhaust vent line, parent exhaust line, including in-line components or any part of this path not otherwise specifically designated. The ventilation flow path communicates fumes from the toilet bowl to a location other than the room where the toilet bowl is located.
[0023] Embodiments of the present invention include a toilet having an inner annular vent passage which runs through a portion of the circumference of the toilet bowl rim. The annular vent passage is separate but concentric with the current art liquid flush rim jet annulus such that the vent exhaust orifices are located inside and above the outer, annular rim jet orifices to avoid communication between the vent exhaust orifices of the upper annular vent passage and the liquid rim jet orifices. The annular vent passage is formed integral to the toilet bowl rim and is not therefore flexible. The annular exhaust vent line serves as the annular vent passage exit flow path as the line exits the toilet, and it exits the toilet bowl to avoid interference with the water rim jet annulus flow path. The annular exhaust vent line slopes downward from the toilet bowl rim and deliberately creates a low point drain location. At the low point drain location of the annular exhaust vent line, there is located a low point drain line. The low point drain line extends from this low point to a length which is greater than the water column equivalent to the maximum suction pressure of the vent exhaust fan to ensure positive drainage under all conditions. A low point drain valve is located at the end of the low point drain line and, when open, permits drainage of liquid from condensate buildup during normal operation, upon recovery from a toilet overflow, and upon completion of back flushing operations of the vent exhaust flow path. The annular exhaust vent line continues on an upward slope from the low point to the back vertical plane of the toilet where it would be enlarged to continue as the parent exhaust line.
[0024] Embodiments of the present invention include a dedicated vent exhaust fan which is located at a minimum level above the sum elevations of toilet rim plus the maximum suction pressure of the exhaust fan. Upstream of the vent exhaust fan is located a vent exhaust fan upstream isolation valve which will be a gate or ball valve to minimize resistance to flow. If the vent exhaust fan is located at an elevation that will prevent water intrusion during a back flush maintenance activity, an upstream isolation valve may not be necessary. The vent exhaust fan must be capable of overcoming any effect from capillary action which may occur after water intrusion into the annular vent passage and be capable of sufficient flow capability to provide desired vent exhaust flow rate.
[0025] An embodiment of the present invention includes a bypass branch line which is upstream of the dedicated vent exhaust fan and upstream of the vent exhaust fan upstream isolation valve (if installed). The bypass branch line must be installed at an elevation greater than the sum of the toilet rim elevation and the maximum suction pressure of the vent exhaust fan. The bypass branch line is sized to allow sufficient, continuous ventilation flow for reliable vent exhaust fan operation even with toilet overflow or condensate condition blocking ventilation exhaust air flow. The bypass branch line may have installed a branch line isolation/throttle valve (globe valve or similar to allow effective throttling) to ensure vent exhaust fan flow under all conditions. The bypass branch line serves as a maintenance connection for back flushing the vent exhaust path if clogging ever were to occur.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0026] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings:
[0027] FIG. 1A and FIG. 1B illustrate cross sectional views of the toilet rim according to embodiments of the present invention.
[0028] FIG. 2 is a top view of the toilet bowl rim according to one embodiment illustrating the relative numbers and locations of the current art rim jet orifices and the proposed vent exhaust orifices of the present invention.
[0029] FIG. 3A and FIG. 3B illustrate two different embodiments of the complete toilet/exhaust system present invention.
[0030] FIG. 4A and FIG. 4B illustrate two embodiments of the utility box configurations housing the bypass branch line and other components.
[0031] FIG. 5 is a view of the toilet exhaust system according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] As used herein “a” or “an” or “the” means one or more.
[0033] Referring now to FIGS. 1A and 1B , FIGS. 1A and 1B depict cross-section views of the toilet bowl rim 103 according to two embodiments of the present invention. In FIG. 1A the vent exhaust orifices 105 of the ventilation exhaust path are located in the inner radius of the annular vent passage 111 which is circumferentially inside the rim jet annulus 113 , and the vent exhaust orifices 105 are located above the existing rim jet orifices 107 of the rim jet annulus 113 to avoid water intrusion during normal operation. In FIG. 1B the vent exhaust orifices 105 of the ventilation exhaust path are located in the inner radius of the annular vent passage 111 which is concentric with but predominantly above the rim jet annulus 113 , and the vent exhaust orifices 105 are located above the existing rim jet orifices 107 of the rim jet annulus 113 to avoid water intrusion during normal operation. In the FIG. 1B embodiment, the outer, circumferential wall of the annular vent passage shares the toilet bowl wall with the rim jet annulus at the rim of the toilet bowl. These vent exhaust orifices 105 are in communication with the balance of the ventilation exhaust path (i.e., annular vent passage, annular exhaust vent line, and parent exhaust line). Wall thickness for each toilet bowl wall of any embodiment of this invention would continue to be similar to the current art to ensure structural integrity during normal use but is not limited thereto as the system could work with custom toilets having non-traditional toilet bowl wall thickness.
[0034] Referring now to FIG. 2 , a plan view embodiment of the toilet bowl rim 203 showing the relative number and location of the existing rim jet orifices 205 and the vent exhaust orifices 207 according to one embodiment of the present invention is illustrated. The size and number of the vent exhaust orifices may vary, depending on the suction pressure capability of the vent exhaust fan and desired vent exhaust flow rate. Cross section 1 A of the toilet bowl rim is illustrated in FIG. 1A with an alternate embodiment illustrated in FIG. 1B .
[0035] Referring now to FIGS. 3A and 3B (associated with FIGS. 1A and 1B , respectively) show side view embodiments of the toilet 300 with the location of the annular exhaust vent line 315 leading from the annular vent passage 111 upon exiting at the back vertical plane 316 of the toilet bowl 301 and molded into the toilet body and connecting to the parent exhaust line 305 . The low point drain line 307 , low point drain valve 310 , and the constant slope upward of the annular exhaust vent line from the low point to the back vertical plane 317 of the toilet are illustrated. The exhaust path is illustrated by the dotted arrows. The vent exhaust fan 313 is positioned between the parent exhaust line outlet 309 and the vent exhaust fan upstream isolation valve 314 . The vent exhaust fan upstream isolation valve is a valve which offers little head loss (e.g., ball valve or gate valve). Further upstream of the vent exhaust fan upstream isolation valve is located a bypass branch line 311 which tees off the parent exhaust line 305 at a minimum elevation greater than the sum of the elevation of the toilet rim plus the maximum suction pressure of the vent exhaust fan. In the bypass branch line is a branch line isolation/throttle valve 312 (e.g., globe valve) which may be used for throttling of air flow or for throttling or isolating liquid flow for maintenance back flush operations. The branch line isolation/throttle valve may be present in either embodiment described in FIGS. 1A and 1B . The manner in which the annular exhaust vent line exits the toilet bowl rim in the system may vary in the two embodiments. In FIG. 3A , the embodiment of the annular exhaust vent line exits the toilet bowl rim below the toilet rim from inside the bowl at position 304 . In FIG. 3B , the embodiment of the annular exhaust vent line exits the upper part of the toilet rim outside of the toilet bowl 301 and at the same elevation as the annular vent passage at position 304 A.
[0036] Referring now to FIG. 4A the installation of the vent exhaust fan 413 (with conventional on/off and/or proximity switch), the vent exhaust fan upstream isolation valve 414 , the bypass branch line 411 , and the branch line isolation/throttle valve 412 are illustrated according to one embodiment of the present invention. The bypass branch line and the branch line isolation/throttle valve exist to ensure continued vent exhaust fan flow even with toilet overflow or condensate buildup. This will prevent damage to the vent exhaust fan under upset conditions when there is no flow through the annular vent passage. FIG. 4B illustrates the installation of the vent exhaust fan at a significantly higher elevation (not to scale) than the other components, without a vent exhaust fan upstream isolation valve or a branch line isolation/throttle valve but with the bypass branch line according to another embodiment of the present invention. The utility box 403 is illustrated in FIGS. 4A and 4B . In FIG. 4A the utility box includes the vent exhaust fan 413 , bypass branch line 411 with branch line isolation/throttle valve 412 , and the vent exhaust fan upstream isolation valve 414 . In FIG. 4B the louvered utility box is in the same relative location but with the vent exhaust fan at a higher elevation, no vent exhaust fan upstream isolation valve and the bypass branch line without a branch line isolation/throttle valve.
[0037] Any combination of the embodiments depicted in FIGS. 4A and 4B may be employed, depending on the intended approach to maintenance activities.
[0038] Referring now to FIG. 5 the flow path of the ventilation exhaust from the toilet rim as it enters through the vent exhaust orifices 511 , travels through the ventilation exhaust annulus 504 , out the rear vertical plane 516 of the toilet bowl, as the annular exhaust vent line 515 to the low point drain line 507 , through the upwardly sloped portion of the annular exhaust vent line, to the enlarged connection 509 at the rear vertical plane 517 of the toilet, and up through the parent exhaust line 508 , vent exhaust fan upstream isolation valve 514 , through the vent exhaust fan 513 and to the outside according to one embodiment of the present invention. Some ventilation flow also will exist through the bypass branch line 505 during vent exhaust fan operation to protect the fan against no-flow conditions.
[0039] One embodiment of the present invention consists of a standard toilet configuration but with an annular vent passage 111 and vent exhaust orifices 511 integral to the toilet bowl rim. The annular exhaust vent line 515 exits the toilet bowl so as not to interfere with the current art liquid flushing configuration. The vent exhaust orifices 511 would be located above and radially inside the current rim jet orifices 512 . This would prevent any water intrusion into the vent exhaust orifices during the normal flushing operation of the toilet. The annular exhaust line may exit the bowl through an opening at the rear vertical plane 516 of the toilet bowl. The continuing annular exhaust vent line will unavoidably slope downward from the toilet bowl rim and, therefore, create a low point where collection of liquid would occur due to toilet overflow or condensation. This location would serve as the low point drain for the vent exhaust system. At this low point location there would be installed a tee-off low point drain line 507 from the annular exhaust vent line. To ensure positive drainage of the annular exhaust vent line and the parent exhaust line 508 under all conditions, this drain line length is greater than the height of the water column equivalent to the maximum suction pressure possible from the vent exhaust fan. The low point drain line 507 would have a petcock or other type of valve 310 installed at the bottom of the low point drain line. If exhaust ventilation flow is ever interrupted by toilet overflow or by collection of condensation, this low point drain valve may be opened to drain all liquid from the exhaust line even with continued vent exhaust fan operation. Alternatively, the low point drain valve could be left open for normal operation and closed only for vent line back flushing during maintenance as discussed further below. The low point drain valve would be closed for maintenance back flushing and open to drain the vent exhaust path upon completion of flushing operations.
[0040] From the low point drain line 507 in the annular exhaust vent line 515 , the annular exhaust vent line must continue on an upward slope to the connecting vertical portion of the parent exhaust line 508 in which will be located the vent exhaust fan upstream isolation valve 514 and the vent exhaust fan 513 . To avoid fragility and to add to the aesthetics of the toilet, it is preferred to mold the annular exhaust vent line integral with the existing body mold of the toilet for that portion of the annular exhaust vent line which is upstream the rear vertical plane 517 of the toilet. However, the annular exhaust vent line upstream the rear vertical plane 517 of the toilet may be created with materials and components that are not integral to the toilet mold. An upward slope of at least 3 millimeters per 0.3 meters of piping from the low point drain line must be maintained as the annular exhaust vent line and the parent exhaust line continue to the vent exhaust fan 513 . To ensure adequate vent exhaust flow, the size of the annular exhaust vent line 515 and the parent exhaust line 508 would need to be matched appropriately with the performance capability of the vent exhaust fan 513 . The annular exhaust vent line 515 would exit the rear vertical plane of the toilet 517 , connect with the enlarged connection 509 of the parent exhaust line 508 , and enter the wall. The enlarged connection may be made with an O-ring seal, threaded, glued fitting, hose clamp, or any other connecting type device and using either flexible or rigid piping from any of a number of material types. Enlarging the parent exhaust line would be advised to reduce the head loss in the exhaust line and increase the vent exhaust flow rate. The parent vent line would continue to the vent exhaust fan 513 and discharge to the outside or to a means to deodorize and return the air. The vent exhaust fan inlet must be located above a minimum height equal to the sum of the level of the toilet rim plus the equivalent water column expected from the maximum suction pressure of the vent exhaust fan. That is, the vent exhaust fan is not located below the toilet bowl rim.
[0041] Operation of the vent exhaust fan would be controlled with a standard on/off wall switch or a proximity switch and power source as employed in current art. An optional embodiment is to appoint the vent exhaust fan with a rheostat controller to allow adjustment of the vent exhaust fan flow rate. The rheostat control of the vent exhaust fan also is current art.
[0042] A bypass branch line 505 would be installed at a minimum elevation greater than the sum elevation of the toilet rim plus the maximum suction pressure of the vent exhaust fan 513 and installed upstream of the vent exhaust fan upstream isolation valve 514 . The bypass branch line 505 is installed to provide a bypass flow capability such that a no-flow condition for the vent exhaust fan 513 would never occur, even with toilet overflow or condensate buildup blocking flow from the upstream portion of the vent exhaust path. This bypass branch line also would serve as the maintenance connection for back flushing of the exhaust system. To ensure the bypass flow is properly matched with the fan capabilities while maintaining adequate exhaust ventilation flow, the bypass branch line 505 may or may not include a branch line isolation/throttle valve 510 .
[0043] To accommodate back flush maintenance of the vent exhaust orifices 512 , the annular vent passage 504 , the annular exhaust vent line 515 , the parent exhaust line 508 , and a vent exhaust fan upstream isolation valve 514 (one such as a gate valve or ball valve to reduce head losses) may be installed upstream of the vent exhaust fan 513 . The vent exhaust fan upstream isolation valve 514 would be open during normal operation and shut only during maintenance back flushing. The vent exhaust fan upstream isolation valve 514 would serve to prevent water intrusion into the vent exhaust fan inlet during maintenance back flushing operations.
[0044] Another embodiment would be to raise the vent exhaust fan to a higher elevation to preclude the need for a vent exhaust fan upstream isolation valve. This embodiment would be appropriate so long as the pressure source of fluid for back flush operations would not exceed the equivalent water column height to the vent exhaust fan inlet. This arrangement also would avoid water intrusion into the vent exhaust fan inlet during maintenance back flushing operations.
[0045] To avoid a potentially damaging no-flow condition for the vent exhaust fan, the vent exhaust fan would be turned OFF during back flushing activities when a single vent exhaust fan exhausts a single toilet. Turning off the vent exhaust fan may not be necessary if the vent exhaust fan exhausts multiple toilets as sufficient flow may be available from the other vent exhaust paths even as flow is completely isolated from one toilet during the back flushing operation or resulting from toilet overflow or condensate buildup in the vent exhaust system of an individual toilet.
[0046] Any combination of the arrangements described in paragraphs [0042], [0043], and [0044] may be employed, depending on the intended approach to back flush maintenance capabilities.
[0047] For convenience and accessibility, the vent exhaust fan, the vent exhaust fan upstream isolation valve (if installed), the bypass branch line, and branch line isolation/throttle valve (if installed) may be installed in a louvered connection box integral to the back wall. This connection box must be louvered to permit flow through the bypass branch line.
[0048] The phenomenon of capillary action must be considered. Capillary action would occur if water were to be introduced into the vent exhaust orifices. Capillary action results in a residual water column in each orifice even after normal drainage, the water column level dictated by the individual radius of the vent exhaust orifices. The suction pressure of the vent exhaust fan must be adequate to overcome the resulting water column so vent exhaust flow can be reestablished and maintained after the vent exhaust orifices are flooded. Therefore, proper vent exhaust orifice sizing for adequate vent exhaust flow as well as for consideration of capillary action must be determined to be compatible with the vent exhaust fan performance specifications (i.e., its fan performance curve).
[0049] Use of a positive displacement exhaust driver instead of a common exhaust fan would negate the innate features of this invention which avoid equipment damage and ensure effective vent line drainage after a toilet overflow, condensate buildup, or post maintenance back flush condition. Also, a vent exhaust fan, contrary to a positive displacement or high pressure ventilation mechanism, would have a relatively low suction pressure so that the suction force would do little to cause any debris to clog the vent exhaust orifices, annular vent passage, annular exhaust vent line, or parent exhaust line. These design attributes of this invention make it easy for the maintenance back flush operation to clear any obstructions and restore toilet exhaust ventilation.
[0050] The internal vent exhaust path according to an embodiment of the proposed invention will more effectively and more efficiently contain and remove toilet gases with less required energy and in less time than the current art. The use of a dedicated vent exhaust fan would reduce energy consumption without sacrifice to efficiency or effectiveness. A dedicated vent exhaust fan or a vent exhaust fan of shared use may be placed on a rheostat so that vent exhaust fan flow rate could be adjusted according to need. However, at all times the suction pressure of the vent exhaust fan must be adequate to meet the vent exhaust flow requirements and overcome any concerns associated with capillary action.
[0051] In a preferred embodiment of the present invention, a toilet comprises a toilet bowl with an upper rim which includes a separate, integrally-molded inner circumferential, annular vent passage with multiple vent exhaust orifices in number and size to be compatible with vent exhaust flow needs and the vent exhaust fan performance specifications. The annular vent passage connects to the annular exhaust vent line at the rear vertical plane of the toilet bowl and would be molded into the body of the toilet and would slope downward to the low point drain line as it exits the toilet bowl and then slope continuously upward from the low point drain line toward the back of the toilet. At the bottom of the low point drain line, a low point drain isolation valve is located. The low point drain line would be of adequate length to drain the parent exhaust line even during exhaust fan operation. Therefore, the length of the drain line must be greater than the maximum suction pressure capability of the vent exhaust fan. The properly sized annular exhaust vent line follows the contour of the toilet mold as it slopes upward to the rear of the toilet. At this point the annular exhaust vent line connects to the enlarged parent exhaust line. This connection would be made using any of the various means discussed previously. The parent exhaust line will continue to the vent exhaust fan which will be preceded by the vent exhaust fan inlet isolation valve (gate valve or equivalent for minimizing head loss). The vent exhaust fan upstream isolation valve for the vent exhaust fan could be excluded if the vent exhaust fan is installed at an elevation that would exceed the equivalent elevation of the head pressure from any back flushing source of fluid. Upstream of the vent exhaust fan upstream isolation valve would be connected a bypass branch line properly sized with or without an in-line branch line isolation/throttle valve to ensure reliable vent exhaust fan operation under all conditions without damaging the vent exhaust fan. The bypass branch line would be installed at a minimum elevation greater than the sum elevation of the toilet rim plus the maximum suction pressure of the vent exhaust fan and installed upstream of the vent exhaust fan upstream isolation valve (if installed). The vent exhaust fan outlet will be connected to the continuing parent exhaust line and vent to the outside.
[0052] Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art, and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference. | This invention pertains to an internally exhausted toilet bowl which employs basic principles of fluid flow to provide reliable, more efficient, and more effective removal of noxious toilet odors while reducing energy consumption when compared to current art. This is accomplished during all conditions of normal operation. In case of toilet overflow or condensate buildup, the impact on the vent exhaust path from these upset conditions can be resolved easily, and normal operation can be restored without damage to any components. Additionally, this invention includes maintenance features that would provide means for back flushing the annulus vent line and orifices if clogging ever were to occur. |
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BACKGROUND OF THE INVENTION 1. Field of the invention
The present invention relates to the trim or framing around wall mounted information display boards such as chalkboards, tackboards and dry marker boards and an improved method for installing the trim.
2. Description of the Prior Art
Wall mounted chalkboards, tackboards and dry marker boards are frequently used in classrooms to display information. Such boards exist in various sizes depending, for example, upon the size of the classroom. It is well known to provide a trim extending around the margins of the board. The trim serves at least several purposes. The trim, which is usually made of a durable material such as aluminum, serves to protect the margins of the board from being chipped or worn. Further, the trim serves as a decorative border framing board. In addition, the bottom trim portion associated with a chalkboard is provided with a tray for placement of chalk and erasers while the top trim portion of a chalkboard or tackboard is often provided with ears for holding maps or poster displays. Finally, the trim serves as a hold down means to mount the chalkboard or tackboard to the wall without having to directly mount the boards to the wall.
Present methods for installation of the trim involve the use of anchors, also known as grounds, which are bolted, screwed, or otherwise secured directly to a wall. The grounds are aligned at spaced intervals and each serves to receive a clip over which the trim segments are snapped into place. Because of the substantial labor involved in aligning and spacing grounds for mounting, continuous grounds have come into use. Continuous grounds extend the full length of the trim segment and have mounting holes for receiving the clips pre-drilled at the desired spacing intervals.
While continuous grounds save substantial labor time over use of the individual grounds, there are still disadvantages. For example, considerable time must still be spent mounting the clips onto the ground and adjusting the clips to have the proper alignment for trim mounting. Also, the snap-in mounting of the trim to the clips requires that the clips not be fastened too loosely or too tightly to the ground or additional adjustment will become necessary. In addition, when snapping on or removing trim from clips care must be taken not to apply force at the wrong location or too hard, otherwise the trim may be dimpled. Yet further, because clips may be moved when snapping in the trim, adjusting the trim miters to a proper fit can be difficult. Moreover, if clips are positioned over high spots along the wall the trim may not snap into place, or do so only with difficulty.
SUMMARY OF THE INVENTION
A trim mounting system for mounting display boards such as chalkboards, tackboards, dry marker board and the like to a wall, according to one aspect of the present invention, is characterized by a plurality of trim members and trim/mount grounds each having lengths corresponding to the side dimensions of a display board to be mounted. There is further provided a trim mounting means, associated with each of the trim members and trim-mount/grounds, for mounting the trim members directly to the trim-mount/grounds. The trim mounting means extends continuously along the length of the trim members and trim-mount/grounds.
In a further aspect of the invention, there is provided a method for installing informational display boards such as chalkboards, tackboards, dry marker boards and the like to a wall. The method is characterized by the steps of: (1) providing a plurality of trim members and trim-mount/grounds, each having lengths corresponding to the side dimensions of a display board to be mounted to a wall and having interlocking means for interlocking the trim members and trim-mount/grounds extending continuously along the length thereof, (2) fastening said trim-mount/grounds to the wall, (3) mounting the display board onto the wall in between said trim-mount/grounds, and (4) interlocking the trim members directly to the trim-mount/grounds so as to overlie the margins of the display board in abutting relationship with the display surface of the board.
In a yet further aspect, the present invention is characterized by a one-piece formed, metal trim-mount/ground adapted for mounting informational display boards such as chalkboards, tackboards, dry marker boards and the like to a wall. The trim-mount/ground has a length corresponding to one of the side dimensions of the display board to be mounted. The trim-mount/ground includes a trim mounting means for directly mounting the trim-mount/ground to a trim member and the trim mounting means extending continuously along the length of the trim-mount/ground.
Accordingly, it is an object of the present invention to provide an improved trim mounting system for mounting display boards such as chalkboards, tackboards, dry marker boards and the like to a wall.
It is a further object of the present invention to eliminate certain problems caused by the ground and clip trim mounting system by providing a single piece trim mounting member.
It is a further object of the present invention to provide an improved trim mounting system which lessens the time and skill necessary to produce a quality trim installation for display boards.
Related objects and advantages of the present invention will become more apparent by reference to the following figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 are front elevational views of a chalkboard, tackboard and combination chalk/tackboard, respectively, having trim borders of a type suitable for adaptation to the trim mounting system of the present invention.
FIG. 4 is a cross-section view taken along lines 4--4 in FIG. 1 showing a prior art trim mounting system.
FIG. 5 is a cross-section view taken along lines 5--5 in FIG. 3 showing a prior art trim mounting system.
FIG. 6 is a cross-section view taken along lines 6--6 in FIG. 1 showing the mounting of the chalktray to the wall.
FIG. 7 is a cross-section view of the combination trim-mount/ground of the present invention.
FIG. 8 is a cross-section view showing the mounting of an alternative top running trim segment to the trim-mount/ground of the present invention.
FIG. 9 is a cross-section view taken along lines 9--9 in FIG. 1 showing a side or top running trim segment mounted to the trim-mount/ground of the present invention.
FIG. 10 is a cross-section view taken along lines 10--10 in FIG. 3 showing a divider trim segment mounted to the trim-mount/ground of the present invention.
FIG. 11 is a cross-section view showing the mounting of an alternative divider trim segment to the trim-mount/ground of the present invention.
FIGS. 12-15 are cross-section views showing the trim segments depicted in FIGS. 8-11, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring now to the drawings in detail, FIGS. 1, 2, and 3 show representative examples of information display boards such as could either conventional trim mounting systems or the trim mounting system of the present invention. FIG. 1 shows a chalkboard 10 such as would typically be found in a classroom. The chalkboard 10 has a rectangular configuration and is bordered at its top and left and right sides by trim segments 11, 12, and 13, respectively, and at the bottom by a chalkboard tray 14. Although not shown, the trim segments 11-13 may be mitered at their respective junctures. FIG. 2 shows a tackboard 15 having mitered top, bottom and side trim segments 16-19, respectively. FIG. 3 shows another common exemplary display board 20. In this configuration, the display board 20 includes a lower chalkboard 21 and upper tackboard 22 divided by a trim segment 23 which is adapted for hanging thereon display maps and other like informational material. Trim segments 24-26 bound the sides and top of board 20 and a chalkboard tray 27 extends along the bottom margin. It should be understood that a dry markerboard could, for example, substitute for the chalkboard in FIGS. 1 and 3.
FIGS. 4 and 5 show examples of the use of the prior art trim mounting system with informational display boards of the type such as are exemplified in FIGS. 1-3. A detailed description of this prior art system is unnecessary as it is well known and understood to those persons skilled in the art. It should be noted that in FIGS. 4 and 5 common reference numerals are used to refer to identical elements. Referring first to FIG. 4, the trim mounting system is seen to include a ground 30, clip 31 and trim segment 11. Typically, the ground 30 will accommodate one wall mounting screw (not shown) which extends into wall 32 and a clip 31, although ground 30 is typically also a continuous strip which extends coterminously with the corresponding trim segment 11. If the ground 30 is not the type which extends coterminus with the trim segment 11, there will be a plurality of grounds 30 equally spaced apart as desired along the length of the trim segment. Clips 31 are secured to ground 30 by a screw 33. Although not shown, clip 31 is typically provided with an oblong mounting slot for receiving screw 33 which provides a lateral adjustment capability.
When in its mounted position, clip 31 overlies the margin of board 10 which is snugly received between it and lip 34. Ideally if the grounds 30 and clips 31 have been properly mounted and aligned, when trim segment 11 is snapped into position over clip 31, edge 35 will be flush against board 10 and edge 36 will be flush against the wall 32. Unfortunately, it is often very difficult and time consuming to achieve such a quality fit along the full length of the trim segments without dimpling the trim segments or otherwise marring the quality of the installation.
Referring now particularly to FIG. 5, there is shown another example of the prior art trim mounting system, here in a crossectional view taken along lines 5--5 in FIG. 3. In this example the ground 30 is shown mounted to wall 32 between chalkboard 21 and tackboard 22. It is noted that the different configuration and sizes of lips 34 and 36 serves to accommodate different standard thicknesses of boards 21 and 22. The installation of ground 30, clip 31 and trim segment 23 is the same as described in connection with FIG. 4. It is noted that the trim segment 23 shown here differs from that shown in FIG. 4 in that it includes a cork insert 41 and ears 42 and 43 which are shaped to receive corresponding standard mounting structure for hanging map displays, etc.
FIG. 6 shows a crossectional view of the chalkboard tray taken along lines 6--6 in FIG. 1. Chalk tray 14 is mounted to wall 32 by a plurality of mounting screws, bolts or tappet anchors such as shown at 46. Chalkboard 10 is supported in chalktray 14 within a recess 47. The trim installation system of the present invention may be employed with a chalktray mounted in this conventional fashion.
FIG. 7 shows a crossectional view of the one-piece, combination trim-mount/ground 50 of the present invention. Although shown in cross-section, it should be understood that trim-mount/ground 50 has an identical shape along its length and may be made by an extrusion. It should further be understood that the length of trim-mount/ground 50 will be cut or otherwise formed to correspond to the length of the trim segment to be mounted upon it. Trim-mount/ground 50 includes a central body portion 51 from which extend two lips 52a and 52b. The purpose of lips 52a and 52b is similar to the function of lip 34 of the prior art ground 30. Lip 52a is slightly shorter than lip 52b in order to facilitate the mounting of certain trim segments. Also extending from central body portion 51 is a trim mounting means for directly mounting a trim segment thereto. Surface 90 rests against the face of the display board to provide uniform fit of surface 61 to the board. The trim mounting means includes a flange 53 which extends from body portion 51 in a direction obliquely away from the display board to be mounted and functions as a hook to retain the trim segment to the trim-mount/ground 50. Towards the end thereof, the flange 53 has an abutment surface 54 for abuttingly engaging a trim segment in a manner as can seen in FIGS. 8-11. A round-shaped bead 70 extending along the length of the trim segment prevents edge 60 or leading surface 62 from being pulled away from the wall or display board surfaces, respectively. The trim mounting means further includes a bendable leg 55 extending from body portion 51 and having teeth or serrations 56 thereon. As also seen in FIGS. 8-11, the serrations 56 are adapted to interlockingly engage a resiliently flexible finger 57 which extends along the length of the variously configured trim segments which are adapted to mount to the trim-mount/ground 50.
Although not shown in FIG. 7, it should be appreciated that the trim-mount/ground 50 is provided with a plurality of pre-formed mounting holes at desired spaced intervals along the length of central body portion 51 for receiving therethrough wall fasteners such as shown in FIGS. 8-11. Preferably, these mounting holes are oblong slots which provide a degree of lateral adjustability in mounting to a wall.
The trim-mount/ground 50 of the present invention can be used with any of the various exterior configurations of trim segments commonly used with the prior art trim mounting system. FIGS. 8-11 show cross-sectional views of the improved trim mounting system of the present invention in its mounted position on a wall with various types of trim segments mounted thereon, while FIGS. 12-15 show the trim segments by themselves. Where applicable, similar reference numerals have been used to describe similar elements in these figures. Each of the FIGS. 8-11 shows the mounting of trim-mount/ground 50 to a wall, but with differently configured trim segments mounted thereon. The trim segment 58 shown in FIG. 8 is used as a top running trim segment only and has map display ears 42 and 43 similar to those shown in the prior art FIG. 5 as well as a cork insert 41. The trim segment 11' shown in FIG. 9 may be used for either the side or top borders of a display board while the trim segments 23' and 59, respectively, are divider segments for use between two display boards, such as is depicted in FIG. 3. The use of a prime after a reference numeral indicates that the element corresponds to a previously identically numbered element but is modified for use with the trim mounting system of the present invention.
It should be noted in FIGS. 8-9 that each of the trim segments has an upper leading edge 60 which abuts the wall 32 and a lower leading edge 61 on finger 57 which abuts the display board when the trim segment is properly locked into position over trim-mount/ground 50 as shown. In similar fashion, the upper leading surface 62 and lower leading edge 61 on the trim segments of FIGS. 10 and 11 abut the upper and lower display boards. This quality trim fit is more easily accomplished using the trim-mount/grounds 50 of the present invention than with using prior art grounds and clips because the interlocking relationship between the finger 57 and the multiple serrations 56 on leg 55 allows for some variability in the advancement of the trim segment over the trim-mount/ground while still maintaining a positive locked in or snapped in orientation. In contrast, the trim segments merely snap into position over the prior art clips 31 and once snapped in may be loosely fitted to the display board or wall with no possibility of further adjustment.
The installation procedure for the trim mounting system of the present invention with an exemplary display board having a chalktray may be described as follows. The wall surface is checked for flatness and the areas required for shimming are marked. The chalktray is cut to the desired length and installed at the desired mounting height from the floor. Adhesive is applied between the chalkboard and the wall and the chalkboard is seated in position on the chalktray against the wall. A trim-mount/ground 50 is mounted to the wall along the top edge of the chalkboard, leaving 1/8" clearance between the ground 50 and the chalkboard. Trim-mount/grounds 50 are then mounted vertically into the wall along the sides of the chalkboard leaving 1/8" clearance between the grounds 50 and the chalkboard. Cut the desired trim segments to the desired lengths and install trim segments over grounds 50 by snapping therefore. If trim segments are too loose, bend the bendable leg 55 on grounds 50 to make small tabs at 12"-14" intervals to snap over.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A trim mounting system for mounting display boards such as chalkboards, tackboards, dry marker boards and the like to a wall. The system includes a plurality of one-piece, extruded metal trim members and combination trim-mount/grounds each having lengths corresponding to the side dimensions of the display board. The trim members and trim-mount/grounds are provided with interlocking portions which extend continuously along their lengths, permitting simplified mounting of the trim members. |
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BACKGROUND OF THE INVENTION
It is known to use snow guards on roof structures, particularity in northern climates, where the weather conditions are such that snow and/or ice accumulates on roofs. Snow guards are used, most particularly when the roofs are steeply sloped, to provide protrusions or outwardly extending platforms that protrude outwardly and upwardly, generally perpendicular to the slope of the roof, to engage snow or ice that may accumulate on the roof, to keep sheets of snow or ice from sliding down the roof, off the roof, possibly causing damage to people, shrubs, etc.
Typically, snow guards have, in addition to the protrusion or platform, a base that is disposed between underlying and overlying shingles on the roof. It is generally known that in colder climate conditions, snow guards are installed as the roof is built up, being placed over an underlying shingle or shingles in a course, prior to installing the next-overlying shingle in its overlying course.
Most particularly, it is known that snow guards are desirable on steeply sloped roofs wherein the shingles on the roof are of natural slate or natural tile, being made of materials that are very rigid, often having outer weather-engaging surfaces that can be smooth, allowing snow or ice that accumulates on the outer surfaces of such shingles or tiles to slide downwardly along the highly sloped surface of the roof, most particularly as the snow or ice begins to thaw, with the protrusions or platforms of the snow guards engaging the snow or ice and breaking up large sheets of the same into smaller, generally harmless pieces of snow or ice not readily capable of causing damage to personnel, plants, bushes, etc.
Where a roof is made up of naturally occurring materials, such as slate, shake or tile, it is known to install snow guards as the roof is being laid up, on top of courses of such roof materials that have already been applied, prior to applying an overlying course of such rigid slate, shake, or tile shingles thereover. However, in the case of an already-installed roof of rigid natural slate, shake, or tile shingles, if snow guards are later desired to be installed, it can become necessary to remove some shingles of slate, shake, or tile construction so that the same can be lifted upwardly an amount to install snow guards therebeneath, between shingles in two underlying-overlying courses. Where such slate, shake, or tile shingles of natural materials are rigid, they can break as they are being lifted upwardly. In the absence of breaking it becomes necessary to remove the nails or fasteners for such shingles an amount sufficient to raise such shingles upwardly to enable placement of a snow guard therebeneath, and then to re-fasten such rigid naturally occurring shingles back down to the roof.
THE PRESENT INVENTION
The present invention is directed to providing snow guards for use with synthetic, generally thermoplastic materials that are either being installed on a roof, or when already-installed on a roof, such that the shingles are made so that they can be flexibly bent upwardly an amount within their elastic limit to permit insertion of snow guards under tab portions of shingles, wherein the snow guards have hooks thereon that engage behind shingles in a next-underlying course, and with the shingles that have been lifted upwardly, flexibly bent within their elastic limit, being then allowed to return to their original generally planar configuration, back down over the snow guard, leaving a protruding or platform portion of the snow guard disposed beneath the shingle, the tab portion of which had been flexibly bent upwardly.
Accordingly, it is an object of this invention to provide a roof structure comprised of a roof base, synthetic shingles of thermoplastic material, and snow guards having hooks at their upper ends and protruding portions, such as platform portions protruding outwardly at their lower ends, beyond the shingled roof in the installed condition, wherein the shingles are sufficiently resiliently flexible to allow the snow guards to be inserted between overlying and underlying shingles after the shingles have been installed on a roof, without breakage of the shingles and without requiring partial or full removal of fasteners holding such shingles to the roof.
It us a further object of this invention to provide a method of installing snow guards on a roof, consistent with the roof structure described above.
It is yet another object of this invention to provide a roof structure and a method of installing snow guards on a roof structure, wherein the resilient flexibility of the synthetic shingle is sufficient to permit installing the snow guards with their protruding platforms temporarily beneath the uplifted roof shingles, so that downwardly and rearwardly facing hooks of the snow guards can engage over upper edges of next-underlying shingles in a course, and then to slide the roof guards downwardly, parallel to the slope of the roof out beyond the lower edge of an upwardly lifted synthetic shingle, allowing the shingle to return to its original position flat against the underlying shingle or shingles on a roof, and overlying a base portion of the snow guard that connects the hook and the outwardly protruding platform portion thereof, such that the platform portion of the snow guard engages at or below the lower edge of the temporarily upwardly bent shingle after that shingle is returned to its original position.
It is another object of this invention to provide snow guards with hooks that have beveled edges, either inwardly beveled, or outwardly beveled in the hook portion.
It is yet a further object of this invention to provide snow guards for installation as described above, wherein the hooks are adapted to be resiliently or springingly engaged behind one or more shingles in a next-underlying course, when the snow guards are installed.
It is a further object of this invention that the synthetic shingles have tracks or ribs on their rear surfaces for allowing sliding movement of snow guards that are being applied, upwardly along a said track, and that after the shingles are installed, the tracks can function to inhibit lateral movement of snow guards relative to overlying shingles.
Other objects and advantages of the present invention will be readily apparent upon a reading of the following brief descriptions of the drawing figures, the detailed descriptions of the preferred embodiments, and the appended claims.
BRIEF DESCRIPTIONS OF THE DRAWING FIGURES
FIG. 1 is a plan view of a sloped roof having a plurality of courses of synthetic shingles of thermoplastic materials applied thereto, with the roof being fragmentally illustrated, and wherein snow guards are shown with their platforms disposed below lower edges of applied shingles.
FIG. 1A is an illustration similar to that of FIG. 1 , but wherein it is illustrated how snow or ice, when sliding downwardly along the highly sloped roof surface, can engage against outwardly protruding platforms of snow guards, and become broken-up into smaller, harmless pieces.
FIG. 2 is an enlarged fragmentary side elevational view of a portion of the roof of FIG. 1 , taken generally along the line III-III, showing an upwardly lifted synthetic thermoplastic shingle, that is flexibly bent upwardly an mount within its elastic limit, to permit insertion of a snow guard thereunder, with the snow guard to be slid upwardly beneath the shingle while overlying a shingle in a lower course.
FIG. 3 is an illustration similar to that of FIG. 2 , also taken generally along the line III-III of FIG. 1 , but wherein the upwardly lifted, flexibly bent overlying shingle, shown in phantom, has been allowed to return to its original flattened position against the roof, sandwiching a base portion of the snow guard therebetween, and wherein the snow guard has had its hook at its upper end slid downwardly to engage behind the upper edge of an underlying shingle, and with the snow guard then being pulled downwardly to allow complete return of the overlying shingle against the base of the snow guard, and above the outwardly protruding platform thereof.
FIG. 3A is an enlarged detailed view of a portion of FIG. 3 , showing more clearly the engagement of the hook of the snow guard beneath the upper end of a butt portion of a shingle in a next-underlying course.
FIG. 4 illustrates a pair of synthetic shingles of thermoplastic material in accordance with this invention, arranged side-by-sidle in a given course, and with a snow guard installed therebetween, between opposing side edges of butt portions of the shingle, and with a next-overlying shingle being shown in phantom thereover, such that the snow guard itself may be seen in the installed condition, with greater clarity.
FIG. 5 is an illustration of a prior art type of snow guard, having a straight upper end, to receive a fastener therein, and it is the type of a snow guard that can be used on a roof as a roof is being installed, to be fastened over a next-underlying shingle in a given course, prior to installation of a next-overlying course of shingles, wherein the shingles that are used with the type of snow guard of FIG. 5 , are generally very rigid, being constructed of naturally occurring materials such as slate, shake, or tile, that are not flexibly bendable within their elastic limit either at all, or at least not an amount sufficient to install the snow guard of FIG. 5 after the roof is installed.
FIG. 5A is a side elevational view of the shingle of FIG. 5 .
FIG. 5B is an illustration of a snow guard made in accordance with this invention, prior to bending the upper end of the snow guard into a hook formation prior to installing it with a hook behind a next-underlying shingle, in accordance with this invention.
FIG. 5C is a side elevational view of the snow guard of FIG. 5B , after the upper end of the snow guard is bent into a hook configuration, and with the hook configuration shown in engagement behind a next-underlying shingle on a roof, and wherein the next-overlying flexibly bent tab portion of the shingle is shown in phantom and in full line positions, illustrating, respectively, the upward bend of the relatively flexible portion of a shingle in accordance with this invention, and its return to its permanent position overlying the base of the snow guard.
FIGS. 5D , 5 E, 5 F, 5 G, 5 H and 5 I are fragmentary portions of upper ends of snow guards for use in accordance with the present invention, whereby various bevels, bends and constructions for facilitating engagement of the upper ends of snow guards behind upper ends of butt portions of next-underlying shingles in a course are illustrated, as will be described in more detail hereinafter.
FIG. 6 is a generally vertical section, taken through shingles and a snow guard in accordance with this invention, generally along the line VI-VI of FIG. 1 , and wherein a fragmentary portion of a roof, with shingles thereon are shown fragmentally and with a snow guard installed in a track between ribs of a next-overlying shingle in accordance with this invention, are clearly illustrated.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1 in detail, it will be see that a roof structure is illustrated, generally designated by the numeral 20 , with the structure comprising a fragmentary portion of a roof base 21 , steeply sloped as will be seen hereafter with reference to FIGS. 2 and 3 , with a plurality of courses of synthetic shingles of thermoplastic materials applied thereto, with each course such as those 22 , 23 , 24 , 25 and 26 being applied such that tab portions 27 of shingles, all generally identified by the numeral 28 in FIG. 1 , are shown in overlying relation to butt portions 30 of underlying shingles.
The thermoplastic shingles 28 are each preferably constructed of a thermoplastic resin material which may or may not have fillers therein, and which may or may not have reinforcement materials therein, such as lengths of fiber, for additional strength. The shingles 28 will also preferably be molded or shaped to simulate natural slate, tile or shake materials that are generally not flexible, although the shingles 28 , while simulating natural materials, will have sufficient flexibility that they can be upwardly, flexibly bent an amount within their elastic limit to permit insertion of snow guards therebeneath, and allow for retraction to their original, generally flattened or original configurations that existed prior to being flexibly bent upwardly, after the upward force that flexibly bends them is removed.
The synthetic shingles may, if desired have separate materials for their core and capstock (outer, weather exposed portions, if desired).
Each shingle 28 has an upper edge 31 , a lower edge 32 , a right edge 33 , and a left edge 34 . Right and left edges of adjacent shingles may be slightly spaced apart as shown at 35 , between their butt portions 30 . The shingles 28 may also have slots 36 between their right and left edges of their tab portions when the shingles 28 are disposed adjacent each other, as shown in FIG. 1 . A plurality of snow guards 40 are shown between adjacent ones of the shingles.
With reference now to FIG. 1A , it will be seen that, as snow or ice 41 accumulated on the roof 20 begins to break apart, large pieces, clumps or sheets 42 thereof may break away, falling therefrom, as shown by the arrows 43 in FIG. 1A , downwardly, to engage platform or protrusion portions 45 of the snow guards 40 as shown in FIG. 1A , whereby the pieces, clumps or sheets 42 of snow or ice are broken up into smaller pieces or particles 46 as shown, which can then fall downwardly off the lower end of the roof, without damaging people, plants or shrubs.
With respect to the enlarged fragmentary illustration of FIG. 2 , it will be noted that the roof base 21 is illustrated, as having shingles 28 in an overlying course, with their tabs portions 27 overlying butt portions of shingles 28 in an underlying course.
For ready reference, the illustrated shingle in FIG. 2 that is in an overlying course is indicated as shingle 28 ′, and the shingle in the underlying course is denominated shingle 28 ″.
As shown in FIG. 2 , the shingle 28 ′ has its tab portion lifted arcuately upwardly, being flexibly bent, as shown, in the direction of the arrow 50 , such that the tabs portion of the shingle 28 ′ is moved from the phantom line position 28 ′″ therefor, to the full line position, therefor, as shown in FIG. 2 .
With the shingle 28 ′ flexibly bent upwardly as shown in FIG. 2 , the snow guard 40 can be moved from its full line position therefor shown in FIG. 2 , to be slid upwardly beneath the flexibly upwardly bent tab portion 27 for the shingle 28 ′ such that the downwardly bent hook 51 of the upper end 52 of the snow guard 40 can be moved upwardly in the direction of the arrow 53 , overlying the butt portion of the shingle 28 ″, to engage behind the upper edges 31 of two adjacent shingles 28 ″ (as shown in FIG. 3 ). It will be noted that, in some embodiments, the amount “D” of upward bend for the shingle 28 ′ as shown in FIG. 2 in the direction of the arrow 50 is greater than the dimension D′ shown in FIG. 2 , for the outward protrusion of the platform portion 54 of the snow guard 40 , to allow for movement of the snow guard 40 upwardly in the direction of the arrow 53 an amount that the platform portion 54 of the snow guard 40 can be beneath the upwardly bent portion of the shingle 28 . The snow guard 40 has an optional protuberance 29 extending between spaced apart opposing edges of tab portions of underlying shingles, as shown, which can effectively inhibit lateral movement leftward and rightward of installed snow guards.
With reference now to FIG. 3 , it will be seen that the hook 51 of the snow guard 40 is in place, beyond and around the upper edges 31 of the butt portions of the underlying shingles 28 ″, and that the snow guard 40 , with its base 55 that connects the hook portion 51 and platform portion 54 has now been slid vertically downwardly in the direction of the arrow 56 , such that the outwardly protruding platform portion 54 is now at a sufficiently low level with the hook 51 engaged over the upper edges 31 of the shingles 28 ″, such that the upwardly flexibly bent tab portion of the overlying shingle 28 ′ that is shown in phantom in FIG. 3 can now be allowed to return downwardly into an overlying full line position therefor, shown at 57 , overlying the snow guard base 55 and overlying the butt portions of shingles 28 ″, such that, due to its inherent memory, the upwardly flexibly bent tab portion of the shingle 28 ′ also overlies the butt portions of the underlying shingles 28 ″, with the lower edge 32 of the shingle 28 ′ disposed just above the platform 54 of the snow guard 40 as shown.
In cold weather conditions, or whenever shingles 28 become somewhat brittle, an application of heat via a blow dryer or some other heating device may be helpful to make the resilient shingle more flexible, so that cracking of the shingle is avoided when the shingles are upwardly bent for installation of snow guards.
With respect to FIG. 3A , the detail enlargement shows more clearly that the hook 51 is disposed behind the upper edges 31 of the butt portions of the shingles 28 , as is the return to flattened position of tab portion 57 of the overlying shingle via inherent memory of the tab portion 57 of the overlying shingle 28 ′.
Referring to FIG. 4 in detail, it will be seen that a pair of side-by-side adjacent shingles 28 are illustrated in the same course, with the base 55 of a snow guard disposed between opposed side edges 33 , 34 of the shingles 28 , in the space 35 between those shingles, and with the snow-engaging platform portion 54 of the snow guard 40 being disposed immediately beneath and substantially adjacent to a lower edge 32 of a next-overlying shingle 28 , shown in phantom, so that it can be seen how the base 55 of the snow guard 40 extends between right and left edges of butt portions of adjacent shingles, so that the adjacent shingles 28 can inhibit lateral movement leftward and rightward, of installed snow guards, when the installed snow guards are in their installed position as shown in FIG. 4 . Alternatively, the base 55 of a snow guard can overly the butt portions of the shingles 28 , overlying the side edges 33 , 34 thereof.
With reference now with FIG. 5 and FIG. 5A , a prior art type of snow guard 63 is illustrated, with a projecting platform portion 61 , connected to an upper end 62 thereof, by a base 60 . The base 60 also carries an angular support 64 , for supporting the platform portion, as shown, as does the snow guard of the present invention.
However, at the upper end 62 of the snow guard 63 , there is shown a nail or other fastener hole 65 for fastening the snow guard 63 over an underlying course of shingles, when shingles of a very rigid type, such as natural slate, shake or tile that are being applied to a roof (not shown). In such types of installations, the base 60 overlies a shingle lying therebeneath or extends between adjacent shingles in a course, and the upper end is secured to the base roof surface by means of nails or other fasteners applied through holes 65 in the snow guard base 60 , such that the snow guard 63 , as a practical matter, can only be installed during the original installation of rigid, non-flexible shingles of such natural materials or rigid synthetic materials resembling natural materials.
With reference now to FIG. 5B , a snow guard 70 is illustrated, having a base 71 connecting the platform portion 72 thereof to the upper end 73 of the snow guard 70 , with an angular support 74 also provided. However, with the snow guard of FIG. 5B , the upper end is sufficiently long that it can be reversely bent back on itself, as shown in FIG. 5C to provide a hook 75 to be disposed over the upper end of a shingle 28 , as shown, when a tab portion 76 of a next-overlying shingle that has been resiliently upwardly bent within its elastic limit as shown in phantom in FIG. 5C , to allow the insertion of the snow guard 70 therebeneath, as is discussed above with reference to FIGS. 2 , 3 and 3 A, after which the upwardly bent portion 76 , shown in phantom, is allowed to relax into a position overlying the snow guard, as shown by the full line illustration 77 of the tab portion of the overlying shingle.
With reference now to FIGS. 5D , 5 E, 5 F, 5 G, 5 H and 5 I, a plurality of alternative embodiments for the hook portion of each of the snow guards of the present invention will now be illustrated.
In FIG. 5D , the snow guard 80 has a hook 81 that has a bevel 82 on the right end of the hook 81 of the snow guard, for facilitating and sliding of the same behind a next-underlying shingle, or plurality of shingles, in a course.
In FIG. 5E , a snow guard 84 is shown with its hook 85 also having a bevel 86 on its outer end, cut more pointedly than that shown in FIG. 5D , but otherwise functioning similarly thereto, when installed behind the upper edge of a next-underlying shingle.
In FIG. 5F , a snow guard 88 has a bevel 90 on the inside of the hook 91 , also to facilitate its disposition behind the upper end of a next-underlying shingle to facilitate sliding of the same behind a perhaps somewhat thicker shingle.
With respect to FIG. 5G , the upper end of a snow guard 93 is shown, with its hook 94 being arcuately bent, and having a lower portion 95 thereof that is at an angle “a”, as shown, to the upstanding surface 96 of the rear of the base portion of the snow guard 93 , such that the edge 97 of the hook 94 may frictionally engage behind the next-underlying shingle, over which the hook of the snow guard 93 is installed, for secure, frictionally-engaged fastening of the hook behind that shingle.
In FIG. 5H , an alternative upper end of the snow guard 100 is shown, in which the hook portion 101 thereof is arcuately bent as shown at 102 , to facilitate greater flexibility in bending a snow guard as shown in FIG. 5B , to have a hook portion thereof formed in the field from an otherwise straight base snow guard as shown in FIG. 5B , rather than having the hook formed at a site of snow guard manufacture.
In FIG. 5I , yet another alternative upper end 110 of a snow guard 111 is shown, whereby its hook 112 is formed by first bending a portion 113 of the upper end at an angle to the left surface 114 of the snow guard of FIG. 5I , whereby the angled portion 113 can more readily enable retrofitting an installation of previously applied synthetic slates or tiles on a roof, whereby the angled portion 113 can more readily slide under the next-overlying tab of a shingle. Preferably, the embodiment of FIG. 5I would be used with a shingle having a hollowed or ribbed undersurface, to be readily slid beneath the same, preferably within a track thereof, for example, between ribs of a hollowed-out structure, as will be addressed, hereinafter with respect to FIG. 6 . The sloped portion 113 , with the downwardly bent hook 112 encourages a spring-loaded lock during installation and reduces or eliminates the marring of surfaces of the shingle over or under which the snow guard is applied, minimizing the likelihood of damage due to scraping of a portion of the snow guard thereagainst.
Any of the snow guards of FIGS. 5D , 5 E, 5 F, 5 G and 5 I can have their upper ends arcuately bent like the bend 102 shown in FIG. 5H . Also, the hook portion 101 of the snow guard of FIG. 5H could be tapered or configured like any of the hook portions of any of the snow guards of FIGS. 5D , 5 E, 5 F, 5 G, and 5 I. The bending of any of the snow guards to form hooks can occur at any time, including during manufacture of the snow guard in a manufacturing installation or on site of installation of the snow guards on a roof. Also, the bending can, on some occasions, occur on site to reflect a bend that is dependent upon the height of the shingle between its upper and lower edges, especially in the situation of previously-installed shingles, where the bending would normally occur in the field, or at the site of application of the snow guards on a roof.
With reference now to FIG. 6 , it will be seen that a shingle 28 is applied to a roof base 21 , as described above, but wherein the shingle 28 has a plurality of tracks 115 in its lower surface, which tracks are formed by generally vertically disposed ribs 116 that form stand-offs between one or more underlying surfaces 120 , 121 (such as the underlying shingles 122 , 123 ) and the undersurface of the shingle 28 . By inserting the bases of the snow guards 40 in this manner, in tracks 115 after the shingles have been installed on a roof, and beneath the tab portions of shingles 28 that are flexibly bent outwardly within their elastic limits, the tracks 115 with their ribs 116 , form a guiding medium for sliding the bases 55 of snow guards upwardly from a lower edge of an overlying shingle, up over the upper edge of a next-underlying shingle, for facilitating engagement of the hook (not shown) of the snow guard 40 shown in FIG. 6 behind the rear surface of the butt portion of a next-underlying shingle.
In a case where all shingles 28 are of the same dimension, snow guards may be centered tinder the overlying course or over or within the gap between adjacent shingles of the underlying course. If the width of shingles varies then the “tracks” could help in placement of the snow guards. In a case where all shingles are the same size, tracks guide the snow guards between adjacent shingles of an underlying course, as does the gap between the shingles of the underlying course. When varying widths of shingles are employed, tracks formed from ribs of a hollowed-out structure act as guides or installation tracks to assist in placement of the snow guards. The tracks can also assist in redusing lateral movement of installed snow guards.
It will be apparent for the foregoing that various modifications may be made in the details of construction as well as in the use and operation of the components of this invention, all within the spirit and scope of the invention as defined in the appended claims. | A roof structure and a method of installing a snow guard on the base of a roof is provided, wherein the roof structure includes a plurality of synthetic shingles of thermoplastic materials, and where a snow guard is provided having an outwardly projecting snow-engaging platform and an oppositely provided hook at an upper end, wherein the hook is adapted to engage over and upper edge of a butt portion of one or more shingles in an underlying course of shingles, and wherein a tab portion of a shingle in a next-overlying course of shingles is disposed over the upper end of the snow guard, substantially covering its base, and wherein the snow-engaging platform is adapted to receive snow and ice that may slide down the roof, to intercept the same or break the snow or ice up into small harmless particles. The synthetic shingles of thermoplastic materials allow for the upward bending of the overlying tab portions of shingles a substantial amount within their elastic limit, to permit insertion of snow guards under tab portions of overlying shingles, where such tab portions of overlying shingles are already-installed on a roof, followed by a relaxation of the upwardly bent tab portions of shingles back to a flattened condition overlying the butt portions of shingles in an underlying course of shingles, and overlying the base of the snow guard between the platform and hook, due to the inherent memory of the original flattened shape of the shingles that have their tab portions flexibly upwardly bent. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Chinese Patent Application Nos. 200420020474.4, filed Feb. 27, 2004, and 200420020757.9, filed Mar. 12, 2004, each of which is incorporated herein by reference. This application also claims priority to U.S. patent application Ser. No. 10/793,369 filed Mar. 4, 2004, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The subject disclosure relates generally to shelters, and more particularly to an improved shelter that can provide additional protection when desired. Even more particularly, the subject disclosure relates to a shelter including a canopy that selectively extends.
[0004] 2. Background of the Related Art
[0005] Over the years, many tents and other shelters having collapsible frames have been introduced. Such structures are commonly used to provide shelter during camping trips, picnics, parties, military operations, and other outdoor activities. One advantageous feature of such structures is their ability to provide relief from weather elements when desired but allow removal when no longer needed.
[0006] However, prior art shelters have several problems. The shelters are unable to vary their configuration easily to suit varying demands. Some prior shelter frames also allow the overlying canopy to sag in an unsightly manner or be blown loose. Moreover, varying the configuration can be a challenging task even when multiple people are involved in the assembly. In view of these apparent shortcomings, many attempts at overcoming these difficulties have been patented, such as: U.S. Pat. Nos. 4,779,635; 5,511,572; 5,555,681; 5,632,293; 5,638,853; 5,701,923; 5,797,412; 5,813,425; and 6,173,726 (each of which is incorporated herein by reference in their entirety).
[0007] U.S. Pat. No. 5,555,681 to Cawthon discloses a building system that is modular in that a plurality of differently shaped buildings 10 , 12 may be constructed from the same basic part set. The foundation of the buildings 10 , 12 includes base plates 14 and headers 16 that are oriented horizontally. Vertical stud members 18 extend vertically between the base plates 14 and headers 16 . Connectors 22 couple the components 14 , 16 , 18 together. Rafters 20 also terminate within the connectors 22 to form a roof structure. Wall panels 24 and roof panels 26 enclose the buildings 10 , 12 and are selectively extendible from and retractable into the respective associated base plate members 14 and headers 16 . This is an essential purpose of the buildings of Cawthon to selectively store the panels 24 , 26 to allow enjoyment of ambient weather. However, once the building takes shape, major effort is required to reconfigure the space. Thus, it would be desirable to build a shelter that can quickly and easily be modified to have additional space that is protected from the elements.
SUMMARY OF THE INVENTION
[0008] The present disclosure is directed to a canopy including a frame assembly including a plurality of legs upstanding from a support surface. A resilient tarp covers the frame assembly. The resilient tarp has a main section for substantially defining a main area of protection, an auxiliary section for substantially defining an auxiliary area of protection and an overhang. A plurality of cords attach the resilient tarp to the frame assembly in a plurality of positions including: i) a set up position wherein the main section substantially covers the main area and the auxiliary section is stored; and ii) a set up position wherein the main section substantially covers the main area, the auxiliary section substantially covers the auxiliary area, and at least one of the plurality of cords extends at least partially over the auxiliary area.
[0009] Another aspect of the invention is a canopy providing shelter on a support surface. The canopy includes a frame assembly with a plurality of legs for defining a main area of protection, two auxiliary legs for defining an auxiliary area of protection adjacent the main area of protection, and a roof frame supported by the plurality of uprights. A resilient tarp secures to the frame assembly. The tarp includes a main section for substantially covering the main area, and an auxiliary section adjacent the main section, wherein the auxiliary section is (i) extendable between the plurality of legs and the at least one auxiliary leg to substantially cover the auxilary area, (ii) extendable between the plurality of legs and the support surface to provide additional cover to the main area, and (iii) storable such that only the main section substantially covers the main area.
[0010] Still another aspect of the invention is a canopy having a plurality of upright assemblies for defining a main area and an auxiliary area of protection, each upright having an interlocking male and female portion wherein the male portion includes at least one protuberance that causes at least one of the male and female portion to deform upon interlocking. A resilient tarp covering the main area and the auxilairy area whereby a plurality of cords attach the resilient tarp to the frame assembly in a plurality of positions including: i) a first position wherein the resilient tarp substantially covers the main area and the auxiliary area is exposed; and ii) a second position wherein the resilient tarp substantially covers the main area and the auxiliary area. Still another aspect of the invention is directed to a kit that allows a traditional canopy to be outfitted with an auxiliary area of protection.
[0011] It should be appreciated that the present invention can be implemented and utilized in numerous ways, including without limitation as a process, an apparatus, a system, a device, and a method for applications now known and later developed. These and other features of the system disclosed herein will become more readily apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] So that those having ordinary skill in the art to which the disclosed system appertains will more readily understand how to make and use the same, reference may be had to the following drawings.
[0013] FIG. 1 is a perspective view of an assembled collapsible shelter having one auxiliary area covered in accordance with a preferred embodiment of the subject disclosure.
[0014] FIG. 2 is a perspective view of the frame assembly of the shelter of FIG. 1 with the auxiliary portion of the tarp serving as a wall.
[0015] FIG. 3 is a perspective view of the tarp of the canopy of FIG. 1 .
[0016] FIG. 4 is a perspective view of the frame assembly of FIG. 1 .
[0017] FIG. 5 is a portion of a leg assembly of the frame assembly of FIG. 4 .
[0018] FIG. 6 is a localized view of the interconnection of a male portion and female portion of a leg assembly of the frame assembly of FIG. 4 .
[0019] FIGS. 7A-C are varying possible cross-sectional views of the interconnection of the leg assembly of FIG. 6 .
[0020] FIG. 8 is a localized view of the connection of the tarp to the frame for the canopy of FIG. 1 .
[0021] FIG. 9 is a detailed view of a preferred corner of the tarp of the canopy of FIG. 8 .
[0022] FIG. 10 is a localized view of an alternative connection of a tarp to a frame for a canopy in accordance with a preferred embodiment of the subject disclosure.
[0023] FIG. 11 is a localized view of another alternative connection of a tarp to a frame for a canopy in accordance with a preferred embodiment of the subject disclosure.
[0024] FIG. 12A is an end plan view of a clamp for a canopy in accordance with a preferred embodiment of the subject disclosure in a partially assembled state.
[0025] FIG. 12B is an end plan view of the clamp of FIG. 12A in an assembled state.
[0026] FIG. 12C is an inside plan view of the nut side of the clamp of FIG. 12A .
[0027] FIG. 12D is an inside plan view of the bolt side of the clamp of FIG. 12A .
[0028] FIG. 13 is an end plan view of another clamp for a canopy in accordance with a preferred embodiment of the subject disclosure in an assembled state.
[0029] FIG. 14A is an inside plan view of one portion of another clamp for a canopy in accordance with a preferred embodiment of the subject disclosure.
[0030] FIG. 14B is a cross-sectional view of the portion of FIG. 14A along line B-B.
[0031] FIG. 14C is a cross-sectional view of the portion of FIG. 14A along line C-C.
[0032] FIG. 15 is a perspective view of an assembled collapsible shelter having two auxiliary area covered in accordance with a preferred embodiment of the subject disclosure.
[0033] FIG. 16 is a localized view of still another alternative connection of a tarp to a frame for a canopy in accordance with a preferred embodiment of the subject disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] The present invention overcomes many of the prior art problems associated with canopies and temporary shelters. The advantages, and other features of the system disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain preferred embodiments taken in conjunction with the drawings which set forth representative embodiments of the present invention and wherein like reference numerals identify similar structural elements. For simplicity and clarity throughout this disclosure, only enough reference numerals with tag lines that are sufficient for understanding have been shown.
[0035] Referring to FIG. 1 , a canopy 100 in accordance with the present disclosure includes a frame assembly 102 for mounting a tarp 104 thereon. The canopy 100 provides shelter from the elements yet can be easily erected and modified for varying the amount and configuration of protection from weather elements. The canopy 100 is shown in the raised, unfolded or “set-up” position with the tarp 104 fully extended. As a result, two areas of protection result: i) the main section 106 ; and ii) the auxiliary section 108 . A main portion 110 of the tarp 104 covers the main section 106 and another auxiliary portion 112 covers the auxiliary section 108 . Preferably, the tarp 104 also includes a hem or overhang portion 111 . In another embodiment, the overhang portion 111 extends the full length of the tarp 104 .
[0036] Referring now to FIG. 2 , the tarp 104 is arranged so that the canopy 100 only provides protection for main section 106 . As shown, the auxiliary portion 112 of the tarp 104 that alternatively covers the auxiliary section 108 becomes a wall for the canopy 100 . When configured as a wall, the auxiliary portion 112 may attach to the frame assembly 102 by cords, attach to another portion of tarp such as an adjacent wall by a zipper and the like.
[0037] In a preferred embodiment shown in FIG. 3 , the auxiliary portion 112 of the tarp 104 is detached from the main portion 110 when not desired. As a result, the canopy 100 appears like a traditional prior art canopy. The means for detaching the auxiliary portion 112 may be a combination of hook/loop fabric, snaps, clips, straps and holes, a zipper, and the like. In other embodiments, the auxiliary portion 112 is rolled or folded at suspended from the frame assembly 102 in a substantially concealed manner. The tarp 104 may be formed of any of a number of different transparent, translucent, and/or opaque materials such as canvas, non-woven sheets or as woven fabric materials. Plastic may also be used to form the canopy, as desired, and the canopy may include a design or designs thereon (not shown), depending upon the nature of the material used for the canopy and other factors.
[0038] Referring to FIG. 4 , the frame assembly 102 includes eight leg assemblies 109 adapted to rest on a support surface to substantially define the main section 106 and support a roof assembly 114 . For example, it should be understood that the frame assembly 102 and, thereby the canopy 100 , according to the subject disclosure may include more or less than eight leg assemblies 106 to form configurations other than cubic and the like. Preferably, each of the leg assemblies 109 is the same. The roof assembly 114 includes a plurality of 3-way connectors 116 and 4-way connectors 118 for interconnecting horizontal and angled rails 120 upon the leg assemblies 109 .
[0039] Referring again to FIG. 1 , additional auxiliary leg assemblies 113 are required in order to further support the auxiliary portion 112 . Preferably, auxiliary cords 132 and anchors 134 are attached to the auxiliary leg assemblies 113 and the auxiliary portion 112 attaches to the leg assemblies 113 to further support the canopy 100 . In another embodiment, the cords 132 are only attached to the auxiliary portion 112 and in another, the cords 132 are attached to the leg assemblies 113 and the tarp 104 . It is envisioned that intermediate the leg assemblies 113 , the auxiliary portion 112 may forms a plurality of troughs for desirably channeling rainwater off the sides of the shelter 100 . Each of the frame assembly components is preferably formed of a plastic material. It has been found that polyvinyl chloride (pvc) plastics, particularly in high density configuration, are excellent for use in the manufacture of the components of the present structure because pvc plastics are impervious to corrosion and hold up well in extremes of loading, sunlight, weather, and other conditions. Other materials, such as powder coated metal tubing, may be substituted for the above pvc or other plastics, as desired.
[0040] Referring to FIGS. 5 and 6 , the leg assemblies 109 , 113 and rails 120 preferably include multiple portions 122 . Each portion 122 may terminate in a smaller neck 124 to facilitate insertion and coupling. Further, to interlock the portions 122 , protuberances 126 are formed in the inner radius of a portion 122 . It is also envisioned that the 3-way connectors 116 and 4-way connectors 118 may utilize protuberance advantageously as well. In a preferred embodiment, the protuberances form a line and are spaced half an inch apart along the line and equidistant around the circumference. In another embodiment, there is only a single line of three protuberances. In still another embodiment, only a single protuberance is required. Alternatively, the location and number of protuberances may be varied as would be appreciated by those of ordinary skill in the art based upon review of the subject disclosure.
[0041] Referring now to FIG. 7A , when the portions 122 have substantially equivalent wall thickness, the protuberances 126 cause each portion 122 to deform. The portion deformation creates tension that allows for easy assembly and disassembly of the portions. When the outer portion 122 has a thicker wall compared to the inner portion 122 mated therewith, the deformation is largely isolated to the inner portion as shown in FIG. 7B . Conversely, when the inner portion 122 has a thicker wall compared to the outer portion 122 mated therewith, the deformation is largely isolated to the outer portion as shown in FIG. 7C .
[0042] Referring to FIGS. 8 and 9 , after assembling the frame assembly 102 , the tarp 104 is secured thereto. It will be appreciated by those of ordinary skill in the art that each corner of the canopy 100 includes an arrangement as that shown in FIG. 8 . In a preferred embodiment, the tarp 104 is attached to the frame assembly 102 by a plurality of cords 128 , 130 . The cords 128 , 130 pass through a sleeve (not shown) formed in the overhang portion 111 of the tarp 104 . Cord 128 passes out of the sleeve and secures the main portion 110 to the frame assembly 102 . Means for attaching the cords 128 , 130 to the frame assembly are shown in U.S. Pat. No. 6,367,495 issued Apr. 9, 2002, U.S. patent application Ser. No. 10/282,283 filed Oct. 28, 2002 and the applications noted above, each of which is incorporated herein by reference.
[0043] As best seen in FIG. 9 , additional fabric in the comers of the overhang portion 111 is layered to provide strength and form an edge sleeves 140 . The edge sleeves 140 extend to the end of the overhang portion 111 . Although cord 128 exits the sleeve substantially above the main section 106 , cord 130 passes through an edge sleeve 140 of the main portion substantially above the auxiliary section 108 . The cord 130 is also secured to the frame assembly 102 . As a result, the tarp 104 is attractively and effectively retained against the frame assembly 102 . In another embodiment, the cords 128 , 130 are elastic and/or attach within holes formed in the frame assembly 102 . In another embodiment, the separately formed auxiliary portion 112 is directly sashed or otherwise secured to the frame assembly 102 . In the embodiment where the overhang portion 111 extends the full length of the tarp 104 , a cord secures the auxiliary section 112 to a leg assembly 113 . In still another embodiment, only cord 128 is used to secure the tarp 104 .
[0044] Referring now to FIG. 10 , an alternative method for securing a corner of the main portion 110 to the frame assembly 102 is shown. The cords 128 , 130 attach to an eye-hook 160 . However, cord 130 does not pass the entire length of the main portion 110 . Instead, cord 130 merely passes through the edge sleeve 140 so that both ends of the cord 130 attach to the eye-hook 160 . Thus, cord 130 forms a short loop through the edge sleeve 140 for securing the tarp 104 to the leg assembly 109 at the corner. In another embodiment, a single cord 128 exits normally, secures to the eye-hook 160 then passes through the edge sleeve 140 so that the short loop is accomplished with a single cord. In still another embodiment, the single cord 128 passes first through the edge sleeve 140 to the eye-hook 160 and is secured thereto. A remaining portion of the single cord 128 then is passed through the edge sleeve 140 again to further strengthen the attachment of the tarp 104 to the frame assembly 102 .
[0045] Referring to FIG. 11 , a valence 240 serves to prevent water from passing between the main portion 210 and the auxiliary portion 212 . In one embodiment, the valence 240 forms a gutter to channel water off the front and back corners of the main portion. In another embodiment, the valence 240 forms a pocket for retaining a cord for further attachment to the leg assembly 213 . Another alternative method for securing a corner of a main portion 210 to a canopy 200 is also shown in FIG. 11 . As will be appreciated by those of ordinary skill in the pertinent art, the canopy 200 utilizes the same principles of the canopy 100 described above. Accordingly, like reference numerals preceded by the numeral “2” instead of the numeral “1” are used to indicate like elements whenever possible. As shown, a clamp 250 couples the cords 228 , 230 together. In an alternative embodiment, the clamp 250 attaches directly to the main portion 210 of the tarp 204 . In both embodiment, rope 230 and clamp 250 can be used to not only secure the tarp 204 , but facilitate rerouting rope 228 during adding and removing the auxiliary portion 212 .
[0046] Referring now to FIGS. 12A-D , the clamp 250 has opposing portions 252 , 254 that form respective hollows 260 for receiving cords 228 , 230 . The opposing portions 252 , 254 are coupled together by pair of nuts 256 and bolts 258 . To attach the clamp 250 , the opposing sides 252 , 254 are loosely coupled together and cords 228 , 230 are passed through the hollows 260 as shown in FIG. 12A . The tarp 204 may or may not be included between the opposing portions 252 , 254 . Upon tightening the bolts 258 , the cords 228 , 230 are compressed and retained between the opposing portions 252 , 254 . As a result, the auxiliary portion 212 may be easily added to the main portion 210 because the cord 228 may serve the intended purpose of securing the outermost corner while the additional cord 230 secures the tarp 204 at the corner of the main portion 210 . This provides the further benefit that the auxiliary portion 212 may be added to canopy 200 not originally intended to include the auxiliary portion 212 .
[0047] The hollows 260 also include bumps or ridges 264 formed transverse to the cords 228 , 230 to increase the holding retention thereon. The ridges 264 may be formed on one or both of the opposing sides 252 , 254 . Preferably, the opposing sides 252 , 254 form a pathway 266 so that the cord 230 can centrally exit the clamp 250 . As a result, the weight carried by the clamp 250 is evenly distributed. In the embodiment shown, the hollows 260 and pathways 266 are shaped and configured to receive cords having an 8 mm. diameter. It is envisioned that the side 252 may include depressions for insertion of the nuts 256 therein. The clamp 250 is preferably constructed from a strong plastic, aluminum or the like.
[0048] Referring to FIG. 13 , another alternative clamp 350 sized for receiving 3 mm. cords is shown. As will be appreciated by those of ordinary skill in the pertinent art, the clamp 350 utilizes the same principles of the clamp 250 described above. Accordingly, like reference numerals preceded by the numeral “3” instead of the numeral “2” are used to indicate like elements whenever possible.
[0049] Referring to FIGS. 14A-C , still another alternative side 452 of a clamp is shown. As will be appreciated by those of ordinary skill in the pertinent art, the side 452 utilizes the same principles of the clamp 450 described above. Accordingly, like reference numerals preceded by the numeral “4” instead of the numeral “2” are used to indicate like elements whenever possible. The side 452 includes two pathways 466 for varying the point at which the cord 230 exits. Of course, the cord 230 may not exit via either pathway 466 as may be desired for the particular configuration.
[0050] Referring to FIG. 15 , a perspective view of an assembled collapsible shelter 200 having two auxiliary areas 208 covered in accordance with a preferred embodiment of the subject disclosure is shown. As will be appreciated by those of ordinary skill in the pertinent art, the shelter 300 utilizes the same principles of the shelter 100 described above. Accordingly, like reference numerals preceded by the numeral “3” instead of the numeral “1” are used to indicate like elements whenever possible to simplify the subject description.
[0051] The auxiliary portions 312 A, 312 B include one or more stiffening ridges 350 . The stiffening ridge 350 may be a seam sewn into the fabric, a rod inserted into a sleeve or the like. The purpose of the stiffening ridge 350 is to control the manner is which rainwater may collect on the auxiliary portion 312 . On auxiliary portion 312 A, the stiffening ridge 350 is shaped and formed to direct collected water towards the sides of the shelter 300 . Alternatively on auxiliary portion 312 B, the stiffening ridge 50 is shaped and formed to direct collected water towards the front of the shelter 300 . Dashed lines 360 indicate a manner in which the auxiliary portions 312 A, 312 B sags to collect rainwater. Preferably, the auxiliary portions 312 A, 312 B sag to a certain point at which deformation occurs. During deformation, the water is released to allow the auxiliary portions 312 A, 312 B to substantially return to shape. In another embodiment, the auxiliary sections 312 A, 312 B do not have any stiffening ridges but are allowed to sag/collect water and deform to release. In still another embodiment, the outer legs 313 are relatively shorter than the inner legs 309 . As a result, the auxiliary portions 312 A, 312 B are slanted to further increase the propensity of water to flow off to the sides of the shelter 300 .
[0052] Referring now to FIG. 16 , as will be appreciated by those of ordinary skill in the pertinent art, the canopy 400 utilizes the same principles of the canopies described above. Accordingly, like reference numerals preceded by the numeral “4” instead of the numerals “1”, “2” or “3” are used to indicate like elements whenever possible. A valence 440 serves to prevent water from passing between the main portion 410 and the auxiliary portion 412 . To assembly the auxiliary section 412 , a clamp 450 couples the cords 428 , 430 together while the cord 428 is secured to the leg 413 . Subsequently, the cord 428 can be released so that the valence 440 can be raised to rest on the auxiliary section 412 and prevent rain and wind from passing therebetween. The cord 428 may be passed onto the auxiliary section 412 as shown and, optionally coupled to the cord 428 from the opposing corner. Alternatively, the cord 428 is rolled for storage within the valence 440 . It is envisioned that a plurality of mechanisms may serve the purpose of the clamp 450 as would be appreciated by those of ordinary skill in the pertinent art based upon review of the subject disclosure. In an alternative embodiment, the valence 440 includes a hole (not shown) reinforced with a grommet at the approximate location of the leg 413 . As a result, the cord 428 can exit the valence 440 and secured the tarp to the leg 413 while the very end of the valence 440 may still be raised onto the auxiliary portion 412 .
[0053] It is envisioned that numerous variations are possible beyond those specifically described here and such would be apparent to those of ordinary skill in the art based upon review of the subject disclosure. For example, the canopy may have two auxiliary sections on opposing sides of the main section. Of course, either or both auxiliary sections may be completely detachable. For another example, the main section of the canopy may be octagonal with a plurality of auxiliary sections that are various shapes such as triangular, trapezoidal and the like.
[0054] While the invention has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the invention without departing from the spirit or scope of the invention as defined by the appended claims. | A canopy has a frame with a plurality of legs for defining a main area of protection, an auxiliary leg for defining an auxiliary area of protection adjacent the main area of protection, the auxiliary leg capable of being removed and a roof frame supported by the uprights. A tarp, secured to the frame, has a main section for covering the main area, and an auxiliary section adjacent the main section. The auxiliary section is (i) extendable between the legs and the auxiliary leg to cover the auxiliary area, (ii) extendable between the legs and the support surface to provide additional cover to the main area as a wall, and (iii) storable such that only the main section covers the main area and the at least one auxiliary leg is removed. |
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BACKGROUND OF INVENTION
This invention relates generally to window shade rollers and apparatus, and more specifically relates to a window shade roller assembly which is adapted for mounting either within the periphery of a window frame border by frictional engagement therewith, or by conventional hang-mounting upon brackets affixed to the said window frame.
In the most common form of window shade roller assemblies, a pair of mounting pintles extend from opposed ends of the roller and are received into mounting brackets, which are affixed to the window frame. Commonly, one of the said pintles is of flattened or otherwise is of other than round cross-section, and is received into a correspondingly shaped opening at one of the said brackets, whereby the axle or shaft to which such pintle is secured is restrained against rotation. The shaft associated with this pintle thus extends within the window shade roller, and is associated with a winding spring. The other pintle is commonly of rounded cross-section, whereby when it is received at the opposed bracket in a corresponding round opening, it may freely rotate. A ratchet and pawl arrangement is provided at the shaft member, and as the shade is lowered, the mentioned spring is wound, so that a biasing force is generated which will restore the shade to a desired position upon the pawl and rachet being disengaged.
It has long been recognized that window shade mounting arrangements, as aforesaid, while common and generally very acceptable, can be undesirable, in requiring the use of the aforementioned mounting brackets, which damage and deface the walls of the rooms wherein the brackets are mounted. This is particularly a problem in connection with apartment dwellings, where relatively frequent changing of occupants necessitates repeated removal and installation of brackets. Also, of course, once the said brackets are installed, they are not readily moved, which presents a problem when changes are desired, as in redecorating or so forth. Further, in many modern buildings the window frames are of steel or aluminium, making it difficult to install brackets at all. In addition, once installed in such brackets, a shade roller can easily slide from side to side and often becomes disengaged from the brackets.
The above problems have long been recognized, and from time to time proposals have been made for window shade roller assemblies which are based upon frictional mounting, including by spring-biased friction caps. A device of this type is shown in a very old patent to Wilkinson, U.S. Pat. No. 473,990.
Heretofore, however, despite the above difficulties, it has not been generally contemplated that a roller assembly could be produced which was suitable of uses in both of the aforementioned ways.
In my prior U.S. Pat. No. 3,853,170, I disclose a shade roller apparatus for use in connection with a shade roller which is partially directed to the above discussed problem. The apparatus of that said patent, in particular, is adapted to the type of alternate mounting above discussed, i.e., either by a mounting technique based upon frictional engagement within a window frame, or by being secured to conventional brackets on the outside of the window frame. In such device, the axle of the apparatus is thus biased by a spring when frictional mounting is desired. Further, in those instances where conventional bracket mounting is desired, the axle can be retracted. In order to effect this action, however, it is necessary to physically remove the assembly from the shade roller, remove a twist-lock closing member, and thereupon remove the said spring. This series of operations is cumbersome; and, indeed, generally impractical, especially for the usual consumer who desires to make use of such apparatus.
In accordance with the foregoing, it may be regarded as an object of the present invention, to provide shade roller apparatus which is adapted for mounting by either frictional engagement within a window frame periphery, or alternatively, by hang-mounting at receiving brackets on the window frame.
It is a further object of the present invention, to provide apparatus of the above character, wherein the alternate mounting described is effected by a simple externally-actuated change in the shade roller assembly, which change in configuration may be effected by unskilled personnel in rapid and simple fashion.
SUMMARY OF INVENTION
Now in accordance with the present invention, the foregoing objects, and others as will become apparent in the course of the ensuing specification, are achieved in a cylindrical window shade roller assembly which is adapted for mounting either by frictional engagement within the periphery of a window frame, or alternatively, by hang-mounting at receiving brackets on the window frame.
The assembly comprises in combination a cylindrical window shade roller having first and second axial recesses respectively at the opposed ends thereof. A projecting first shaft terminating in a first mounting pintle, is mounted in the first recess to enable rotation of the shade roller during raising and lowering of the associated shade, together with spring means which are wound during said rotation for biasing the roller to enable return to its unwound or initial position.
A two-way mounting assembly is received at the second axial recess. This mounting assembly comprises a hollow, cylindrical housing which is adapted for receipt in the second axial recess, and which terminates in a cap portion which closes the second end of the shade roller.
A second shaft extends centrally through the aforementioned cap into the cylindrical housing. The externally facing distal end of this shaft terminates in a second mounting pintle. Spring-means extend within the housing and bear against a rearward closing for same. A hollow, cylindrical link is provided within the housing between the shaft and spring-means. This link is closed at the end thereof toward the spring, and open at its other end. At such open end, the link receives the rearward portion of the second shaft. The second shaft is selectively moveable between a first longitudinal position where it is retracted within the link, and a second longitudinal position whereat the shaft is telescoped and detented at the link. The shaft is rotatable with respect to the housing at both first and second positions. At the first, i.e., retracted position, the shaft rotates within the link, at the second, i.e., telescoped position, the shaft and link rotate as a unit.
When the second shaft is within its first, or retracted position, substantially only the pintle projects through the cap, to enable hang-mounting of the window shade assembly via this pintle and the pintle provided at the end of the first shaft. When the second shaft is in its telescoped position, the window shade assembly may be frictionally secured within the window frame border by securing friction members over the pintles, positioning the friction member of the end of the first shaft in mechanical engagement with one side of the window frame, moving the second shaft inwardly to compress the spring and placing the window shade assembly within the frame, and thereupon permitting the restorative force of the spring to expand the second shaft (and thereby the friction member) against the window frame to effect frictional engagement therewith.
The aforesaid friction members are adapted for respective mounting at the pintles formed at the end of the first and second shafts. These members have outwardly facing surfaces having a high coefficient of friction to enable engagement of the window frame border when the second shaft is in its extended position, i.e., when the aforementioned spring thereupon forces the second shaft outwardly to effect the compressive engagement of the overall assembly within the frame.
The second shaft toward the rearward portion thereof, carries oppositely directed pins extending from its lateral surface. When the shaft is in its telescoped or extended position, these pins (which can be the ends of a single pin passing through the shaft) are receivable into detents cut into the wall of the cylindrical link at the edge of the open end thereof.
A pair of release slots extend longitudinally through the wall of the cylindrical link, from the said open end thereof, for a short distance. Rearward of these slots, the wall is undercut, i.e., the wall of the link is thinned. Thus, and in order to move the second shaft from its extended, detented position to its rearward or retracted positon, the operator need only effect a slight rotation of the shaft to align the pins from the detented position and align the pins with the slots, which permits the shaft to withdraw into the portion of the cylindrical link having the thinned or undercut walls. The shaft is then free to rotate. The operator need only provide a slight externally manipulated movement of the shaft to displace same from the extended to the withdrawn position. Similarly, a reversal of this action, effects movement of the said shaft to the extended position.
BRIEF DESCRIPTION OF DRAWINGS
The invention is diagrammatically illustrated, by way of example, in the drawings appended hereto, in which:
FIG. 1 is an elevational view, which is partially broken to permit foreshortening, of a window shade roller assembly in accordance with the present invention, installed in a conventional hang-mounting arrangement on brackets at a window frame;
FIG. 2 is an elevational view similar to FIG. 1, but showing the aforementioned assembly mounted via frictional engagement within the periphery of the same or a similar window frame;
FIG. 3 is a cross-sectional end view of one end of the window shade roller assembly, i.e., the end including the rewind assembly;
FIG. 4 is an exploded perspective view of the end assembly appearing in FIG. 3;
FIG. 5 is a longitudinal cross-sectional view of the two-way mounting assembly, which in accordance with the invention, is utilized at the alternate end of the window shade roller;
FIG. 6 is an exploded perspective view of the two-way assembly shown in FIG. 5;
FIG. 7 is a right-end view of the cylindrical link portion of FIG. 6;
FIG. 8 is a perspective view of the same end of the aforementioned link which appears in FIG. 7; and
FIG. 9 is a vertical cross-sectional view of the roller showing the internal end structures of the complete device.
DESCRIPTION OF PREFERRED EMBODIMENT
In FIG. 1 herein, an elevational plan view appears of a window shade roller assembly 10 in accordance with the invention. The view is broken and foreshortened in order to permit the entire showing to be made in a single Figure. In the showing of FIG. 1, assembly 10 is installed upon a window frame 12 by being hung-mounted in conventional brackets 14 and 16 which are secured to alternate sides of the window frame.
In this instance, assembly 10 is actually shown with a conventional window shade 18 is secured thereto, in order that the total arrangement of apparatus might be better appreciated. In any event, it is seen that at the left or first end 22 of the window shade roller 20, a pintle 24 projects, which as can be better seen in FIG. 4, is of flattened shape and rectangular cross-section. This pintle 24 is conventional, and is received in a corresponding opening in conventional bracket 14. The object, of course, is that once so received, it is constrained against rotation. At the opposed or second end 26 of roller 20, a further pintle 28 projects. This corresponds to the same element better seen in FIGS. 5 and 6. This pintle 28 is of simple round cross-section and in that sense is conventional, and is received at bracket 16 into either a round opening or a U-shaped channel which is rounded at the bottom. In any event, it is not constrained, but can rotate as the shade end 30 is displaced upwardly or downwardly.
In FIG. 2, the same basic apparatus as in FIG. 1 is shown, except in this instance a pair of friction members 32 and 34 have been seated upon the pintles 24 and 28. These elements are better seen in FIGS. 4 and 6. They are provided at their sides which are secured to the pintle, with openings having corresponding cross-sections to that of the respective pintle. Thus as seen in FIG. 6, a recess 38 of round cross-section is provided. A similar recess, but of rectangular cross-section is provided (but not shown) for member 32.
The outwardly facing surfaces of members 32 and 34 are covered with a layer 40 of a material having a high coefficient of friction, as, for example, a sponge rubber or the like. In use, face 35 of frame 12, and assembly 10 is pushed to the right against a spring 82 (see FIGS. 5 and 6 described below). Assembly 10 is thereupon eased within the border of frame 12, and the shaft upon which member 32 is mounted is permitted to expand (via the restorative spring) against face 33 of frame 12, to enable the frictional mounting shown in FIG. 2.
In FIGS. 3 and 4, longitudinal cross-sectional and exploded perspective views appear of the end mounting assembly 42 which is secured within an axial opening or recess provided at the left or first end of roller 20. The roller 20 is, of course, generally conventional, and may be formed of wood or other material. Assembly 42 includes a cap 44 which secures the remainder of the assembly to roller 20. Cap 44 overlies and retains in place a housing 46 through the central opening of which passes the pintle piece 48 the outward end of which is formed into the pintle 24 as aformentioned.
It is preferred in accordance with the present invention, and in contra-distinction to prior art, to utilize a bearing 52 for rotatably supporting the pintle piece 48 with respect to housing 46. The pintle piece 48, in turn, is secured by pins 53 to a metal end cap 54, which is secured to the spring guide shaft 56. A conventional winding spring 58, is mounted about the shaft 56 and secured at one end to slot 59, and at the other end, (by pins) to housing 46. In the present arrangement, the bearing 52 is important, and may constitute a roller bearing or bearing or other known type, including of self-lubricating plastic such as PFTE (e.g., "Teflon") or so forth. Such bearing is particularly significant when the present assembly is arranged as in FIG. 2, in that the high compression applied along the roller tends to generate forces which can provide a degree of sticking where conventional mounting arrangements are used for the shaft of assembly 42, i.e., in such conventional arrangements, substantially no friction-reducing bearing is provided.
The usual rachet 60 and pawls 62 (secured by pins 63) are also provided, again as known in the art, in order to enable release of the spring 58 once the latter is wound. In general, it will be appreciated that except for the use of the unusual bearing arrangement in connection with assembly 42, the function carried out by assembly 42 is conventional in prior art shade apparatus; i.e., it is intended to enable rotation of the shade roller about the shaft which can be regarded as constituted by pintle piece 24 and the extension thereof which includes cap 54 and guide shaft 56.
In FIGS. 5 and 6, cross-sectional and perspective views appear of the two-way mounting assembly 66 which is received into the axial recess which is present at the right-hand or second end 26 of roller 20.
Assembly 66 is seen to comprise a hollow, cylindrical housing 68, one end of which terminates in a cap 70 which is fitted over and closes the second end 26 of shade roller 20. The opposite, more generally open end 72 of housing 68 is seen to be internally threaded as at 74, for a longitudinal distance which can vary. The said open threaded end 72 can thus receive a correspondingly threaded plug 76, which is provided with a recess 78 of octagonal or other cross-section for receiving a wrench to enable rotation of plug 76 to achieve a given longitudinal position within housing 68. A second shaft, generally designated at 80, extends centrally through the opening 82 in cap 70. The externally facing distal end of shaft 80 terminates in the mounting pintle 28 which has previously been discussed. This pintle 28, also as has been discussed, may receive the friction member 34 if a mounting as in FIG. 2 is desired.
Spring-means 82 are seen to further extend within housing 68. The rearward end 83 of the spring means bear against the adjacent surface 75 of plug 76 which moves longitudinally within threaded portion 74 of housing 68. The longitudinal position of plug 76 can be adjusted to vary the tension on spring means 82 and also to provide a stop limiting the rearward movement of shaft 80 via link 84. Thus, as the plug moves to the right, end 85 of the link which receives rounded bearing surface 88 of the shaft moves the shaft to the right which places end 28 into the open end 72 of the housing limiting movement of the shaft. This assures clearance between housing 68 and member 34.
A hollow, cylindrical link 84 is present within housing 68, between the shaft 80 and spring-means 82. This link 84 is seen to be closed at the end 86 thereof, which is toward the spring-means 82, and is open at its other end 85. At such open end 85, the link 84 receives the rearward portion of second shaft 80.
In the showing of FIG. 5, the shaft 80 is seen to be positioned in its first or retracted position within the link 84. It is noted that in this position the rearward end of shaft 80, which is formed into a rounded bearing-like surface 88, is received at the recessed bottom 90 of link 84. Further to be noted is that a cross piece 92 passes transversely through shaft 80 and defines projecting pins 94 and 96, i.e., which project laterally at the opposed sides of shaft 80. To be noted, is that the interior of cylindrical link 84 has its wall 87 undercut at points rearward of 96, so that it will be clear that in the configuration shown in FIG. 5, the shaft 80 is free to rotate. While for clarity and full understanding, the friction number 40 is shown in FIG. 5 secured upon pintle 28, it will be apparent that the longitudinal position of shaft 80 in FIG. 5 is actually that adapted for hang-mounting; and accordingly, when shaft 80 is in this retracted position (and the assembly 10 used as in FIG. 1) the member 40 will normally not be used. Clearly, the rotation is desired in order that the roller secured thereto may freely rotate about shaft 80.
When it is desired to extend shaft 80 to its telescoped, outward position for the aforementioned frictional mounting (of FIG. 2), the shaft 80 is moved to the right (in the sense of the drawing) with respect to housing 68. Referring to the end view of FIG. 7, shaft 80 is slightly rotated so that the pin portions 94 and 96 may pass through the release slots 98 and 100 (FIG. 7) which are provided through the end portion 102 of link 84. The shaft 80, i.e., once the pins are passed through the slots, is then slightly rotated and the shaft is then seated via the pin portions 94 and 96 being received in the detents which are provided by grooves 104 and 106 at the end face 108 of link 84. These grooves 104 and 106 are also seen in the perspective view of FIG. 8.
Thus, it will be clear that with the shaft 80 now extended and reseated in its detented position, the shaft is telescoped with respect to link 84. When pressure is subsequently applied to the end of the shaft, as via member 34 being pushed inwardly, such pressure acting through the link 80 will bear against a bearing block 109 in turn seated within the central opening of spring means 82. Thus the spring means will act to provide a restorative force tending to return the shaft to its extended position after same is depressed inwardly.
At the same time, it will be clear that the rounded projection 112 is seated within the facing opening 114 of bearing block 109, so that once again the shaft 80 is free to rotate with respect to the housing 68, i.e., in this telescoped configuration, shaft 80 and link 84 rotate as a unit. Housing 68 is, of course, secured to the roller 20 via suitable fastening means, provided between such roller and cap 70.
While the present invention has been particularly set forth in terms of specific embodiments thereof, it will be understood in view of the present teaching, that numerous variations upon the invention are now enabled to those skilled in the art, which variations yet reside within the scope of the instant teaching. Accordingly, the invention is to be broadly construed, and limited only by the scope and spirit of the claims now appended hereto. | A window shade roller adapted for mounting by frictional engagement within the periphery of a window frame, or alternatively, by hang-mounting at receiving brackets on the window frame. The roller has one shaft projecting from a recess in one end that terminates in a spring-loaded pintle to enable raising and lowering the shade, and a spring-loaded second shaft extending through a cap closing a recess in the other end of the roller also terminating in a mounting pintle. The second shaft is selectively movable between a first retracted position so that only the pintle projects through the cap enabling hang-mounting of the shade, and a second telescoped position in which the roller may be frictionally secured within the window frame by placing friction members over the pintles. |
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CROSS-REFERENCES TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to mechanisms that are used to break or intermittently interrupt the flow of overburden that is cast off the end of a plow blade. Specifically, the instant plow invention, consisting of a plow blade adapted with an adjunctive, folding foreblade and supporting electrical and/or hydraulic blade drive systems, is an articulated blade apparatus.
2. Description of Related Art
Removal of debris, particularly snow, from paved roadways is done most often by plow. A snow removal problem that has received much attention in the past two or three decades is the creation of roadway and driveway blockage by the overburden pouring off the trailing edge of the plow blade. There have been numerous attempts to solve the problem by use of devices that intermittently impede formation of the continuous windrow that is normally formed by the trailing overburden. These devices consist mostly of an apparatus attached to the trailing edge of the plow blade, the function of which is to project a plate or smaller blade forward of the plow blade at an angle to it of from about 65 to about 80 degrees. The manner by which the plate or smaller blade is intruded into the debris flow exemplifies the greater quantity of creativity in this part of the art, because little is done in the way of altering the plow blade itself. Most of the plates are either translated from aft of the blade into the forward, acute angular relationship that is required to block the flow, or they (the blocking plates) are rotated downward and forward of the plow blade into that operating relationship. An example of the latter is produced by the ROOT SPRING SCRAPER CO. of Kalamazoo, Mich. and is advertized in the July 1998 issue of Public Works magazine. Both translating and dropping (or "chopping") interrupter plates appear to function well enough, but are subject to a great deal of side stress resulting from the acute projection of these devices into the flow stream.
In June 1998, U.S. Pat. No. 5,758,728 was issued, to me, for my invention that interrupts the windrow and, in which a plow blade includes two oppositely pivoted/hinged blade sections that emulate a trailing end of the blade by their alternating interpositioning. The sections are called "gates" and are connected so that one moves in the same general (fore-aft) direction as the other. Hingedly, but oppositely connected to the blade proper, one gate moves aft, bringing the second into coextensive alignment with the main blade portion. When the one blade swings forward, into a coextensive alignment with the main portion, the second moves into an acute angular relationship with that portion and blocks the debris flow. During the transition to operative (blocking) posture, debris/snow flow diminishes rapidly, but not with the acute termination of the older prior art that places undue side stress on the interrupter.
3. Incorporation by Reference
U.S. Pat. No. 5,758,728 is hereby incorporated by reference for its teaching of the use and motivation of an articulated blade and attachment to a pushing vehicle. It is also included to serve as a reference document for the various examples of prior art, as described above, including terms and definitions.
4. Definitions and Terminology
The following terms, not readily found in the incorporated reference(s), shall have the indicated meanings:
conterminous(ly) means sharing a common boundry (broadest sense);
driver is a mechanism that motivates (motivator) a device or an apparatus;
thrust bearing is a point, device or article which receives the force output from a driver/motivator; and
to pilot is to guide.
BRIEF SUMMARY OF THE INVENTION
I have avoided the common deficit experienced in most of the prior art by devising an articulative blade adjunct which effects the desired windrow interruption without suffering the undue acute side stresses on the operative interrupter member. This invention can lead to cost savings by lengthening the life of such windrow-interrupting plowing equipment.
On the face of a conventional main plow blade, of the type often attached to a dump truck or pickup, but not limited thereto, there is placed a nearly center-hinged, double section, secondary blade that covers about one-quarter to about one-third of the main plow blade from its trailing edge. The shorter secondary blade is hingedly mounted to the main proximate the trailing edge. When the leading edge of the secondary blade, i.e., the edge closer to the main blade's leading edge, is motivated towards the common trailing edge, while guidedly constrained, by a conterminous track, along the main blade, the leading edge section (LES), by virtue of the center hinge which joins it to the trailing edge section (TES), will fold pleatwise against the TES. The resulting, pleated secondary blade cannot move beyond an acute angle with respect to the main blade because the travel of the shorter LES (of the secondary blade) is limited. I prefer to employ a shorter LES because placing a limitation on its travel allows variations in its length to control the angular relationship between the pleating elements (folding sections) and the main blade. Others, using my invention will find this feature most useful.
Movement (translation) of the LES is had by hydraulic actuator which is an ideal motivator for the rapid, forceful and positive action desired in this apparatus. Motivational driving force is applied to a pilot-thrust bearing assembly that is pivotally connected to the LES outer edge. Thrust may be applied centrally or proximate both leading corners of the LES, which is then guided along and by tracks (rails/grooves) situated behind/along the top and bottom margins of the main blade.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Of the Drawings:
FIG. 1 is a plan view of the invention in non-interruptive mode;
FIG. 2 is a plan view of the invention in transitional mode;
FIG. 3 is a plan view of the invention in fully operative, pleat-extended, interruptive mode;
FIGS. 4 and 5 are frontal elevations of the invention with partial cut-away views; and
FIGS. 6 and 7 show, in cut-away plan view, a detail of the thrust-bearing hinge on the leading edge portion of the LES.
DETAILED DESCRIPTION OF THE INVENTION
Consistent with the art, the instant improvements employ a coventional superstructure or frame to join the plow mechanism to the pusher vehicle. In order to maintain clarity and brevity, I have omitted any vehicular apparatus and shown, in phantom, such a typical superstructure in FIGS. 1-3.
Referring particularly to FIG. 1, there is shown, in a plan view, the invention 10, consisting principally of the blade 12 which is overlain by the auxiliary or adjunct blade 14. The auxiliary/adjunct, which folds or pleats vertically at hinge 16, is pivotally mounted 18 proximate the trailing edge/end TE of the main blade 12. At the end opposite its TE mounting, the auxiliary (hereinafter, "folding") blade 14 is held pivotally or hingedly captive by pilot bearings 20 which are movably, i.e., slidably captured in upper (not shown) and lower 38L guide tracks. The guide track mechanism 38U,38L is more clearly defined in FIG. 5.! A blade frame or bracket 24 is used to connect the main blade 12 to the superstructure that, as aforesaid, attaches the blade assembly to a vehicle; see incorporated reference, U.S. Pat. No. 5,758,728 ('728). The bracket 24 also serves as a mount for a hydraulic actuator 26. The actuator, via its output shaft, thrust bearing 22 and link 25, provides motivating force to translate the folding blade's 14 centermost edge (on bearings 20) away from the leading edge LE and towards the TE of the blade assembly. By its designed over-center disposition, hinge 16 will actuate the instant the centermost edge is forced from its "home" position; an action more clearly defined in FIG. 2-3. Continuing with a description of remaining apparatus shown in FIG. 1, I have shown the transitional mounting apparatus which may be used to attach the invention 10 to a vehicle (not shown). I use, as a base, a triangular bracket/framework 28 that connects to a vehicle by thrust mount fixtures 30 and, to the blade assembly, by apex connector/pivot 36. A D-ring 34 is connected at its base to a central part of the blade bracket 24, but the arcuate portion is allowed to slide through the tri-bracket 28 as the full blade assembly pivots on the apex connector 36. Thus, as the side actuators 32, disposed on the left and right between tri-bracket 28 and blade bracket 24, impart a yawing motion to the blade assembly, the D-ring constrains it from undesired pitching (up and down) motion, thereby avoiding damage to either blades or working surfaces. Control of the desired lifting and lowering of the blade assembly is accomplished by equipment and superstructure not considered germane to the invention and therefore not shown herein.
FIG. 2 shows the FIG. 1 apparatus in operational transition as folding blade 14 is motivated by actuator force 40 in the direction shown. The link 25 remains rigid while the folding blade pivots on the hinging and thrust-bearing mechanisms (at 16,18 and 22). The translating end of the folding blade, held slidingly captive by pivot bearings 20, rides in the upper and lower tracks 38U,38L (only lower, 38L, shown). The embodiment shown here employs a folding blade having tapered T thickness towards hinge 16. This is done because the blades I have chosen to use have arcuate faces (seen more clearly in FIG. 5) which, if used to the extreme shown herein, could prevent the full pleating effect desired and shown at FIG. 3, where the folding blade 14 is illustrated in full pleated posture with both sections abutting, back-to-back. Reference being had to FIG. 3, the interrupting effect is demonstrated. All parts of my invention being designated as above, the newly shown items are the (increasing) overburden 42 and interrupted windrow 43.
FIGS. 4 and 5 depict just the blades 12,14 and main actuator 26 (in phantom) in the FIGS. 1 and 3 postures, respectively. The facial curvature is somewhat exaggerated, but such is typically a designer's choice; and, on some blades, is placed only at the upper extreme, thus obviating the need for taper T, as seen in FIG. 3. Both upper and lower tracks 38U,38L are shown, as well as link slot 44, a through-groove which allows link 25 to connect with thrust bearing 22. Link 25 is thereby guided through its travel towards the TE of the assembly. FIG. 4, as in FIG. 1, also displays the auxiliary blade 14 in what I term "home" position or the "overlay" posture. I also point out that, if one were to use a flatter blade (or one curved only near the top), it is not only possible, but practical, to combine the thrust bearing 22-link 25 assembly with the pilot bearings 20 by hinging the link 25 to a vertical shaft, the end extensions of which would occupy the pilot bearing 20 positions. This modification is intuitive to those of ordinary skill and commands little more that these remarks.
Final to this disclosure is the detail cross-section of FIGS. 6 and 7. The section is taken through the thrust-bearing 22 just above the link 25. When motivational force 40 is applied to the link, as shown in FIG. 6, the translation of folding blade 14 commences (as in FIG. 2) with an ensuing rotation of the pivotal end of the link 25 about the bearing 22. In reality, the blade 14 edge rotates with respect to the bearing, terminating in the posture shown in FIG. 7, as well as in FIGS. 3 and 5. Whether the bearing consists of a small hinge, as shown, or one having a more extensive length, terminating in two pilot bearings (as suggested above), is more a matter of designer's choice than manufacturing or operational necessity.
Many other minor design choices may be conceived and used to attain this invention's objective without departing from the basic concept disclosed or the spirit of the invention. The following claims compose the reasonable limits placed on such choices. | Plow windrow interruption by use of a folding auxiliary blade that is designed to overlay a portion of the plow main blade. The auxiliary blade is motivated to fold vertically pleatwise and, by alternating projection of the folded auxiliary forward of the trailing edge of the main blade, and a return to the overlying posture, respectively stop and reestablish the debris windrow. |
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BACKGROUND OF THE INVENTION
The invention relates to freight elevator landing doors and, in particular, to a device for stopping a vertically operating door in the event its suspension fails.
PRIOR ART
Freight elevator doors are typically arranged to slide vertically to open and close the opening to a hoistway and an elevator car. A common arrangement for such a door comprises a pair of bi-parting panels, an upper panel and a lower panel, that move vertically towards one another to close and vertically away from one another to open. Other vertically sliding door panel arrangements include slide up to open single or double panels, for example, and slide down to open panels. Ordinarily, each door panel is suspended by a chain, cable or other flexible strand-like element adjacent its vertical edges. The suspension chains and related components can fail through undetected wear and/or accidental damage, for example. Where a chain breaks, the door panel has the potential to fall and cause personal injury and/or property damage to objects below the panel as well as to the panel itself. In such a circumstance, it is desirable to provide a safety stop or brake that will automatically deploy upon failure of a chain and prevent the door panel from falling. U.S. Pat. No. 4,696,375 proposes an elevator door check that is activated when a suspension chain breaks. The device shown in this patent involves a wedge block that must be mounted in such a way as to permit movement relative to the door panel. The inertia of the block can slow its reaction time and any resistance on the surfaces constraining its movement can lead to a malfunction. This patent does not disclose an arrangement that can be used with a lower panel of a bi-parting door unit. From the foregoing, it is apparent that there exists a need for a door panel brake responsive to failure of the suspension chain that is reliable, simple to install and adjust and that can be readily utilized on both the upper and lower panels of a bi-parting door.
SUMMARY OF THE INVENTION
The invention provides a safety brake for vertically sliding freight elevator doors that is responsive to the failure of a suspension chain. The brake is readily adapted to conventional door panels and combinations of panels such as found in bi-parting door types, raise to open types, and lower to open types. The brake of the invention comprises a caliper housing or block fixed to the door panel and a roller cam in the caliper that work in conjunction with a door guide rail. The roller cam is released from an inactive position when a chain breaks, thereby enabling it to wedge lock the caliper to the guide rail. The caliper block and roller cam are preferably configured to enable to the roller cam to be retained in the inactive position, against a bias spring by a cable. The cable restraint feature enables the same basic brake caliper and roller cam components to be used on both upper and lower door panels with only limited variation in hardware to accommodate differences in the locations of a suspension chain relative to the associated door panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a freight elevator landing door having the safety brake device of the invention installed thereon;
FIG. 2 is a side elevational view of a safety brake device associated with an upper door panel taken along the line 2 — 2 in FIG. 1 in a normal condition;
FIG. 3 is a sectional view of the safety brake device of FIG. 2 taken in the staggered plane 3 — 3 in FIG. 2 ;
FIG. 4 is a side elevational view similar to FIG. 2 , but with an associated section of chain missing to represent breakage thereof and with the device in a door panel braking position;
FIG. 5 is a view of the braking device taken in the staggered plane 5 — 5 in FIG. 4 ;
FIG. 6 is a side elevational view of a safety brake device associated with a lower door panel taken in the plane 6 — 6 in FIG. 1 in a normal condition;
FIG. 7 is a sectional view of the safety brake device of FIG. 6 taken in the staggered plane 7 — 7 in FIG. 6 ;
FIG. 8 is a side elevational view similar to FIG. 6 , but with an associated section of chain broken and with the device in a door panel braking position; and
FIG. 9 is a view of the braking device taken in the staggered plane 9 — 9 in FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, in particular to FIG. 1 , there is shown a freight elevator landing door 10 from the hoistway or shaft side of the door. The illustrated door 10 is a bi-parting type having upper and lower vertically sliding panels 11 and 12 . In a conventional manner, the door panels 11 , 12 , move in opposite directions-toward one another to close and away from one another to open. Typically, the panels 11 , 12 are fabricated of sheet steel and structural steel elements such as angles and channels. The panels 11 , 12 are guided for vertical movement on parallel vertical guide rails 16 , one adjacent each vertical edge 17 , 18 of the panels 11 , 12 , respectively. The guide rails 16 are fixed to the building or other static structure by bolting, welding, or other appropriate technique. The guide rails have a U-shape or J-shaped shape cross-section; one of the flanges of each rail is fixed to the static structure as described and the opposite flange, designated 21 in the figures, serves to guide the respective edges 17 , 18 of the panels 11 and 12 for vertical movement. Replaceable guide shoes 22 , two pair per panel 11 , 12 , are bolted to angles 23 at the vertical panel edges 17 , 18 . The guide shoes 22 are slotted to permit them to receive the guide rail flange 21 of the adjacent guide rail 16 . This arrangement, which is generally conventional, assures that the panels 11 , 12 to which the guide shoes 22 are fixed, move vertically in alignment along the guide rails 16 .
In a conventional manner, the weight of each door panel 11 , 12 is used to counterbalance the weight of the other door panel. This is accomplished with roller chains 26 trained over rotatable pulleys 27 fixed in the hoistway at points generally overlying the vertical edges 17 , 18 of the door panels 11 , 12 . Weights can be added to one of the door panels to balance the other, as necessary.
Safety brake devices 31 , 32 , constructed in accordance with the invention, are mounted on the door panels 11 , 12 , respectively and, in response to breakage of the chain 26 are effective to stop or check downward free-fall movement of the respective panel. The safety brake devices 31 , 32 are symmetrical with one another from one vertical edge 17 to the other 18 . FIGS. 2–5 depict a safety device 31 employed on the upper panel 11 . The device 31 includes a caliper housing or block 33 , a roller cam 34 , and an actuating spring 36 of the compression type. The caliper block 33 is preferably made of steel or other suitable high-strength material and can be cast, forged, machined, or otherwise formed into the illustrated configuration. The caliper block 33 can be made of an integral body or can be assembled from two or more parts. The block 31 is bolted to the panel vertical edge angle 23 by bolts assembled through a set of three holes 37 extending through the block. In its installed orientation, the block 33 has a vertical slot 38 that is adapted to receive the flange 21 of the adjacent guide rail 16 . The slot 38 is bounded on opposite sides by a vertical surface 39 and a wedging surface 41 tilting from the vertical and converging towards the opposed surface 39 such that it is closer to the vertical surface with increasing elevation or distance upwards along the slot 38 . In the illustrated construction, the surfaces 39 , 41 are planar and are aligned such that an imaginary horizontal plane passing through these surfaces will intercept each surface at a line which is parallel to the line at the other surface.
A lower end of the wedging surface 41 merges with a more or less semi-cylindrical surface 42 having a radius preferably at least slightly larger than the outer surface 43 of the roller cam 34 , which is preferably cylindrical. As shown in FIG. 2 , the roller cam 34 is adapted to be received in a cavity bounded by the cylindrical surface 42 and wedging surface 41 . When in this cavity, the roller cam 34 does not contact the guide rail flange 21 . The roller cam 34 is held or restrained in this cavity in normal conditions by a cable 46 wrapped around it and received in a peripheral groove formed in the outer surface 43 at its mid-section. The groove is of sufficient depth and width to fully receive the diameter of the cable 46 such that the cable is radially inward of the outer cylindrical surface 43 . The adjacent end of the cable 46 is crimped onto the cable in a known manner to form a loop into which the roller cam is assembled and which is loose enough to enable the roller cam to rotate in the loop. The compression spring 36 is received in a cylindrical hole 49 drilled or otherwise formed in the caliper block and communicating with the cavity. A bracket 51 fixed on a lower end of the block 33 with bolts 50 retains the compression spring 36 in the hole 49 . The bracket 51 has a depending clevis portion 52 that carries a pin 53 on which a bell crank lever 54 pivots. The cable 46 is assembled through the center of the spring 36 , a hole in the bracket 51 and has its end remote from the roller cam 34 secured at a hole in an upper arm 57 of the lever 54 by a crimped collar 58 .
An extension 59 on a lower arm 61 of the bell crank lever 54 bears against the chain 26 normally carrying the weight of the upper panel 11 as well as the lower panel 12 . Tension in the chain 26 allows each panel 11 , 12 to balance the weight of the other panel. The chain 26 is attached to the upper panel 11 with a chain rod 71 assembled through and anchored to a bracket 72 bolted to the upper panel 11 . Tension in the chain 26 , due to the weight of the door panels 11 , 12 , ordinarily prevents counterclockwise rotation of the bell crank lever 54 (as viewed in FIG. 3 ). The length of the cable 46 is arranged to control and keep the roller cam 34 in the cylindrical portion of the cavity when the chain 26 maintains the bell crank 54 in the position illustrated in FIGS. 2 and 3 . Inspection of FIG. 2 reveals that the caliper housing or block 33 , rigidly fixed to the door panel 11 , is ordinarily arranged to slide freely along the door guide rail flange 21 .
In the event that the chain 26 supporting the door panel 11 breaks or otherwise suffers a loss of tension, the bell crank lever 54 is released. The bell crank 54 is thereby enabled to pivot counter-clockwise under a bias force developed by the compression spring 36 and transmitted by tension in the cable 46 . Tension in the cable 46 is released when the bell crank 54 is freed by loss of tension in the chain 26 to pivot counter-clockwise and, in turn, the cable releases the compression spring 36 from the compressed condition of FIGS. 2 and 3 . The spring 36 forces the roller cam 34 upwardly out of the cavity or seat area into contact with the guide rail flange 21 and the wedging surface 41 . The outer cylindrical surface 43 of the roller cam 34 can be knurled to increase its friction with the guide rail flange 21 and caliper block surface 41 . While the roller cam 34 is being raised relative to the caliper block 33 by the spring 36 , the associated upper door panel 11 and the caliper block fixed to it have a tendency to begin to free fall. The roller cam 34 , as a result of its upward movement in the caliper block 33 and any initial downward movement of the caliper block relative to the guide rail flange 21 , is very quickly wedged tightly between the guide rail flange and the wedging surface 41 . This action causes the caliper block 33 to be frictionally locked to the guide rail flange 21 and the door panel 11 is thereby immediately braked against further downward movement. More specifically, because of the wedging action by the wedging surface 41 against the roller cam, the vertical surface 39 forming one side of the slot 38 is tightly frictionally locked against the guide rail flange 21 . From the foregoing discussion, it will be evident that the caliper block 33 is frictionally locked to the guide rail 16 and the door panel 11 is thereby braked against further downward movement.
The lower door panel 12 at each vertical edge 18 is suspended by a length of the chain 26 secured to a chain rod 71 . The chain rod 71 is assembled with a slip fit through bores in a bracket 72 fixed to the lower door panel. Jam nuts 73 threaded on a lower end of the chain rod 71 adjustably locate the chain rod relative to the door panel 12 . Assembled on the rod 71 above the nuts 73 is a tension plate 74 . From this description, it will be understood that the chain rod 71 and, of course, the chain 26 , bears the weight of the lower door panel 12 at the respective end or vertical edge 18 of the panel. The safety brake device or assembly 32 , like the device or assembly 31 described above in connection with the upper panel 11 is fixed to each vertical edge or end 18 of the panel 12 . Like the safety brake devices 31 associated with the upper panel, the lower panel safety brake devices 32 are symmetrical from one vertical edge 18 to the other. The safety brake device 32 mounted on the right vertical edge 18 of the lower panel 12 in FIG. 1 is shown in greater detail in FIGS. 6–9 . The brake device or assembly 32 includes a caliper block 33 , roller cam 34 , and compression spring 36 that can, as shown, be identical to that described in FIGS. 2–5 for the upper panel 11 . As with the upper door panel, the caliper block 33 is rigidly fixed to the vertical structural angle 23 with three bolts assembled through holes 37 in the block and the slot 38 is arranged to receive and normally slide along the vertical guide rail flange 21 .
A J-shaped bracket 76 is secured to the bottom of the caliper block 33 with bolts 50 . The bracket 76 has a pair of holes in vertical alignment with the axis of the spring receiving bore or hole 49 . A cable 77 having one end looped around and locked into the peripheral groove in the roller cam 34 is threaded through the bracket holes 78 , 79 . The cable 77 is routed over a lower face 81 of a flange 82 of the bracket 76 and vertically over an outer face of a web 83 of the bracket. An end of the cable 77 remote from the roller cam 34 is anchored in a threaded bolt 84 . The bolt 84 is received in a hole or slot in the tension plate 74 associated with the chain rod 71 . A threaded nut 86 on the bolt 84 permits the bolt to be axially adjusted in the vertical direction in the plate 74 so that when the various parts are assembled, the cable 77 can be properly tensioned to control and hold the roller cam 34 in the recess or cavity and out of contact with the guide rail flange 21 .
In the event that the suspension chain 26 breaks or some other mishap occurs where the chain supporting the weight of the respective end of the lower panel 12 loses tension, the chain rod 71 is enabled to drop in the bracket 72 and move downwards relative to the door panel 12 . Relative motion between the chain rod 71 and tension plate 74 releases tension on the cable 77 so as to allow the compression spring 36 to extend and force the roller cam into a wedging action between the wedging surface 41 and guide rail flange 21 . In a manner like that described in connection with the upper panel 11 and the associated safety brake device 31 , the lower safety brake device 32 very quickly stops any tendency of the lower panel to free fall by frictionally locking the device relative to the guide rail 16 .
It will be seen that the devices 31 , 32 share common parts so as to minimize cost and inventory. The control of the roller cam 34 through simple cables 46 and 77 enables the devices 31 , 32 to be constructed without close dimensional tolerances and with minimal inertia so as to assure a quick response in release of the roller cam 34 . It will be understood that the safety brake devices 31 , 32 at each end or vertical edge of a panel are symmetrical with the devices on the opposite panel end.
While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention. | A vertically sliding freight elevator landing door with a safety brake that deploys when a chain suspending the door breaks. The safety brake is adapted for use on both panels that slide up to open or that slide down to open. The brake, which is simple in construction and installation, comprises, principally, a caliber block fixed to the door and a roller cam assembled in the block. A spring biases the roller cam towards a wedge lock position while a cable normally holds the roller cam in an inactive position. The cable and, therefore, the roller cam are released when the associated door suspension chain breaks. The roller cam, operating between a tilted internal surface in the caliper block and a door guide rail quickly frictionally brakes the door on the guard rail. |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a slip forming process and to the monolithic, reinforced concrete structures produced in accordance with this slip forming process of this invention. More specifically, this invention relates to a process for slip forming reinforced concrete road structures, wherein the resulting slip formed structures have exposed reinforcing bars (“rebars”), which are partially embedded in and extend from within a slip formed, reinforced concrete structure. in one of the preferred embodiment of this invention, this slip forming process utilizes a “tunnel mold assembly” for forming a coping for bridge construction, wherein the coping is preferably formed concurrent with a slip formed concrete road bed pad. In this preferred embodiment of the invention, this slip formed coping includes both rebars embedded therein and exposed reinforcing bars extending from within the formed/finished coping. These exposed reinforcing bars are suitable for subsequent reinforcement and integration with additional in situ cast concrete structures. so as to further integrate such additional in situ cast concrete structures with the reinforced concrete road structures produced by this process.
2. Description of The Prior Art
Slip forming of concrete structures is a well-known technique for preparation of structural concrete elements for various industrial and public works (road, conduit, etc.) projects. Slip forming is a construction method in which concrete is poured into a continuously moving form. Slip forming is used for tall structures (such as bridges, towers, buildings, and dams), as well as horizontal structures, such as roadways. Slip forming enables continuous, non-interrupted, cast-in-place “flawless”, (i.e. no joints), concrete structures which have superior performance characteristics to piecewise construction, using discretely formed elements. Slip forming relies on the quick-setting properties of concrete, and requires a balance between quick-setting capacity and workability, Concrete needs to be workable enough to be placed into the form and consolidated. (via vibration), yet quick-setting enough to emerge from the form with strength (also “self supporting strength” or “green strength”). This green strength is needed because the freshly set concrete must not only permit the form to “slip” upwards/forward. but also support the freshly poured concrete above it (“vertical slip forming”) and/or the freshly poured concrete in front of it (“horizontal slip forming”).
in vertical slip forming, the concrete on may be surrounded by a platform on which workers stand. placing steel reinforcing rods into the concrete and ensuring a smooth pour. Together. the concrete form and working platform are raised by means of hydraulic jacks. Generally, the slip-form rises at a rate which permits the concrete to harden (develop green strength) by the time it emerges from the bottom of the form. In horizontal slip forming for pavement and traffic separation walls. concrete is laid down, vibrated, worked, and settled in place, while the form itself slowly moves ahead. This method was initially devised and utilized in Interstate Highway construction initiated by the Eisenhower administration during the 1950s.
The following is a representative (and not exhaustive) review of the prior art in this field:
U.S. Pat. No. 3,792,133 (to Goughnour issued Feb. 12, 1974) describes a method and an apparatus for concrete slip forming a highway barrier wall of varying transverse cross-sectional configuration for accommodating different grade levels on opposite sides of the wall, and wherein variations in the wail cross-sectional configuration may be readily accomplished during wail formation without requiring stopping, realignment or other interruptions in the screed movement during wall forming.
U.S. Pat. No. 4,266,917 (to Godbersen issued Mar. 12, 1981) describes a method for the efficient slip forming of highway median barrier wails of differing, size (adjustable height) and shape having any arrangement of linear and curved sections and while the machine is being advanced in a single direction. The lateral adjustability of opposite side walls of the form, relative to the top wall, permits the use of the side walls with top wails of varying widths. The relative vertical adjustment of the top wall and side walls provides for a wide variation in the vertical height of a barrier will particularly where a glare shield is to be formed on the barrier wall top surface. The slip forming of the glare shield takes place simultaneously and continuously with the slip forming of the barrier wall and over any selected portion of the wail while the machine is being advanced in a single direction. At any adjusted position of the slip form, the skirt member associated with each side wall is adjustable to prevent any flow of concrete from between the ground or highway surface and the form.
U.S. Pat. No. 4,084,948 (to Petersik issued Apr. 18, 1978) describes an improved barrier forming apparatus and method whereby a barrier is formed continuously over a surface, the barrier having continuous reinforcing rods extending the length of the barrier and having cagereinforced standard supports at predetermined intervals along the length of the barrier. The Petersik improved barrier forming assembly comprising a concrete forming member having a form cavity extending there through; a concrete passing member having a concrete delivery opening for passing concrete or the like to the fibrin cavity; and a positioning assembly comprising a support shaft and a door Member pivotally supported at a forward end of the concrete forming member, the barrier being extrudable continuously via the form cavity forom a rearward end of the concrete forming member. The door member selectively is positionable to partially seal the form cavity at the forward end of the concrete forming member and has rod clearance channels through which the reinforcing rods pass through the door member into the harm cavity when the door member is so positioned to seal the form cavity. The rod clearance channels permit ie door member to clearingly pass the reinforcing rods to open the form cavity at the forward end of the concrete forming member to allow the free passage of the barrier forming assembly over the cage reinforced standard supports.
U.S. Pat. No. 5,290,492 (to Belarde, issued May 1, 1994) describes a system for continuously forming a concrete Structure (a) having a predetermined cross-sectional configuration, (b) which extends along an elongate path, and (c) includes art outer surface haying a textured pattern comprising concave or convex portions which extend other than just parallel to the elongate path. The system includes a frame, a first form assembly, a second form assembly, a drive system, and a support assembly.
As is evident from the above, there are number of alternatives for the slip forming of structures for use in road and bridge construction, The numerous alternative systems have their proponents and their detractors. In the context of selection of the more appropriate and efficient system, for example, for construction of retainer/barrier walls and/or glare shield concrete structures, time is money and often is reflected in the bidding process. More specifically, the bid letting on highway construction projects routinely include both penalty provisions for tardy completion and/or bonus payments thr early completion. Accordingly, efficiencies Which advance project completion, generally translate into cost saving. Thus, there is continuing efforts to automate, where possible, the fabrication of structural concrete components in highway construction; and, to standardize the process for the fabrication of roadway components and thereby simplify the bid letting on such proiects, particularly federally funded highway construction projects,
As is evident from the foregoing, and need not be belabored, the slip forming of structural concrete structures, including, concrete structures for highway construction, is well-known, Invariably, such slip formed highway structures are integrated into roadbeds, used as dividers for road beds and as components for bridges or overpasses for such road beds. The specifications for these concrete structures have and continue to become more uniform and/or have basic specifications in common, because of the advancements in construction methods, and the use of federal funds for such highway construction projects. For example, the specification for a concrete bridge coping must include exposed rehars for the integration into both the road bed, or with a barrier wall, which is to be erected thereupon, and integrated therewith.
Up to now, the standard or generally accepted techniques for the fabrication of bridge coping for an overpass on the highway, have required either the use of a pre-cast coping element (fabricated off-site),, and/or the manual casting of a coping on-site, utilizing traditional forms and concrete casting techniques. In the case of a pre-cast concrete coping element, the road bed of the overpass requires special preparation since the pre-cast element does not readily conform to the angle of incline or grade of a ramp or overpass and, therefore, imperfectly abut one another upon placement on the incline of the bridge overpass. Accordingly, additional installation expense is required to insure the connection of abutting pre-cast copings to one another to insure the formation of a unitary coherent structure.
Alternatively, the casting of an overpass/bridge coping, using the a manual process for forming the coping, specifically, traditional forms and concrete casting techniques, is preferably to the pre-cast coping, because the resulting coping is structurally continuous, and better conforms to the incline/grade of the ramp or overpass. Notwithstanding, the on-site casting, of a bridge coping, by traditional concrete casting technique, is very labor intensive and does not. without an inordinate amount of man power, lend itself to rapid fabrication and accelerated completion schedules. In each of the foregoing alternatives, the coping is formed with extending rebars for the later integration of the coping into a road bed pad and/or the attachment to a retaining wall. which can be later formed on the top of the coping.
Accordingly, there continues to exist the need to both simplify the on-site fabrication of a bridge coping, minimize the manual labor requirements, permit/accommodate accelerated construction schedules, and yet produces a structure which is both coherent (e.g. monolithic structure), and faithfully conforms to the angle of incline or grade of a road overpass, without additional extensive on-site preparation.
OBJECTIVES OF THIS INVENTION
It is the object of this invention to remedy the above, as well as related deficiencies, in the prior art.
More specifically, it is the principle object of this invention to provide a process for slip forming a monolithic, concrete structure having both partially embedded, rebar reinforcement and partially exposed (extending). rebar.
It is another object of this invention to provide a process ter slip forming a monolithic, reinforced concrete structure, which includes a formed. bridge coping, having exposed rebars.
it is yet another object of this invention to provide a process for the slip forming of a monolithic, reinforced concrete structure, which includes a formed road bed pad and a formed bridge coping having exposed rebars
It is still yet another of object of this invention to provide a process, which utilizes a tunnel mold assembly, for slip forming a. monolithic, reinforced concrete structure, which includes a formed bridge coping having both partially embedded and partially exposed (extending) exposed rebars.
Additional objects of this invention include a tunnel mold assembly equipped slip forming machine for slip forming a monolithic concrete structure with exposed rebars; and, a tunnel mold for use in the slip forming of a monolithic concrete structure with exposed rebars.
SUMMARY OF THE INVENTION
The above and related objects are achieved by providing a process for the on-site slip forming of a monolithic concrete structure having both partially embedded and partially exposed (extending) rebars. This process is particularly well-suited for the on-site fabrication of a monolithic concrete structure on uneven terrain (ramp) and/or an overpass/bridge grade. This process utilizes an improved slip forming process, in combination with equipment designed specifically for use in this improved slip forming process. In brief, this process combines slip forming with a unique tunnel mold assembly, which is adapted to produce a monolithic, rebar reinforced concrete structure having both partially embedded and partially exposed rebars. These exposed rebars, which extend from within the slip formed, concrete coping, produced in accord with this invention, enable the further integration and union of the slip formed coping, with a concrete retaining wall or other (preferable) concrete structure, or with a guard rail assembly.
The slip forming machinery which is used in the process of the invention includes the traditional concrete handling conveyances, and a unique tunnel mold assembly for forming a reinforced concrete structure with exposed rebars. This tunnel mold assembly includes:
(a) a tunnel mold having at least one channel therein which permits the passage of a rebar through the mold without being encased in concrete.
(b) auger means for essentially uniform distribution of unset concrete within the mold cavity of the tunnel mold and
(c) a plurality of vibration means, strategically positioned within the mold cavity of the tunnel mold, for consolidating the unset concrete within the mold cavity and thereby eliminating any voids or lack of continuity within the resultant slip formed structure.
This tunnel mold of this assembly is unique in that it is provided with one or more passages, or channels, which extend through the mold cavity, from the leading/front mold surface to the trailing/rear mold surface of the mold. The dimensions of these channels within the mold cavity is sufficient to accommodate the width and height of exposed rebars, during the in situ fabrication of a slip formed, reinforced concrete structure, such as a the slip formed bridge coping. More specifically, the dimensions of such channels within the mold cavity mold, permits the slip forming of a rebar, reinforced concrete coping, wherein a only a portion of the reinforcing rebars are partially embedded within a slip formed concrete coping, and a portion of the reinforcing rebars remain exposed, (free of concrete), and extend front the slip formed bridge coping, for later integration into a companion structure. The size and number of passages or channels of this tunnel mold is limited, to some extent, by practical constraints—the shape/dimensions of the coping—and engineering factors which dictate the thickness of the concrete which occupies the formed structure which surrounds these exposed rebars.
In the preferred embodiments of this invention, these passages or channels within the tunnel mold, are open at the base of the mold, and correspond in the placement and the extension of the rebars, which are only partially embedded within the slip formed coping. The relative viscosity/rheological properties of the concrete fed into the mold cavity of the tunnel mold (a) limits the configuration of the channels within the mold cavity, and (b) controls/limits the extent to which the concrete can flow from within the mold cavity into these channels. The tunnel mold of the slip forming assembly effectively restricts the extent to which concrete can flow from the mold cavity into these channels, and thereby such channels are maintained essentially concrete free, to accommodate passa rebars through the tunnel mold and remain concrete free.
In another of the preferred embodiments of this invention, the improved process is suitable for concurrent slip forming of multiple structural concrete components, as a monolithic structure. in this preferred embodiment of this invention, the process can be used to concurrently slip form both a bridge coping and a road bed pad, in a single pass of the slip forming equipment, thus, further minimizing the steps and time required for completion of a highway construction project.
In yet an of the preferred embodiments of this invention, the bridge coping, (which is formed in accordance with invention), is further modified, as appropriate, with additional rebar reinforcement, and a slip formed concrete structure, (e,g. noise wall, visual barrier, wall cap, etc.), formed on the top thereof, so as to integrate a latter formed concrete with the slip formed bridge coping, Insofar as the exposed rehar extending from the coping is also thereby integrated into this latter slip formed concrete structure, this latter concrete structure becomes integral with the bridge coping.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a perspective view of an inclined road bed, which has yet to be prepared for the addition of a concrete coping or concrete road pad.
FIG. 2 depicts a perspective view of the custom fabricated forms used in the on-site framing of a coping and road bed pad preliminary to the manual casting of a coping and road bed pad by traditional concrete casting techniques,
FIG. 3(A) depicts a perspective view of the iron work array on an inclined road bed, prior to the concurrent slip forming of a bridge coping and road bed pad.
FIG. 3(B) depicts a perspective view of the tunnel mold assembly of this invention. in relation to the iron work array of FIG. 3(A) .
FIG. 3(C) depicts slip forming machinery of this invention in relation to an iron work array Fig, 3 (A),
FIG. 4(A) depicts an enlarged view, oot a tunnel mold assembly of this invention, when viewed from above.
FIG. 4(B) depicts an enlarged view, in partial section, of a tunnel mold assembly of this invention of FIG. 4(A) , when viewed from the rear.
FIG. 4(C) depicts art enlarged view in partial section, of a tunnel mold assembly of this invention of FIG. 4(B) .
FIG. 5(A) depicts a perspective view of a tunnel mold assembly and slip formed bridge coping and road bed pad, when viewed from the rear of the tunnel mold.
FIG. 5(B) depicts a perspective view of a slip formed bridge coping and road bed pad. when viewed from side of an MSE retaining wall.
FIG. 6(A) depicts a perspective view of a slip formed bridge coping and road bed pad wherein the extended rebars are physically joined to additional rebars.
FIG. 6(B) is an enlarged view the extended rebars, from a slip formed bridge coping, physically joined to additional rebars
DESCRIPTION OF THE INVENTION
INCLUDING PREFERRED EMBODIMENTS
As understood within the context of this invention, the following terms and phrases are intended to have the following meaning unless otherwise indicated.
The phrase “slip forming”, or “horizontal slip forming”, is intended, and used herein, to describe a construction method in which concrete is poured into a continuously moving form. Slip forming is used for tall structures (such as bridges, towers, buildings, and dams), as well as horizontal structures, such as roadways. Slip forming enables continuous, non-interrupted, cast-in-place “flawless” (i.e. no joints) concrete structures, which have superior performance characteristics to piecewise construction using discrete form elements. Slip forming relies on the quick-setting properties of concrete, and requires a balance between quick-setting capacity and workability. Concrete needs to be workable enough to be placed into the form and consolidated (via vibration), yet quick-setting enough to emerge from the form with strength, (also “green strength”), sufficient to be self- supporting because the freshly set concrete must not only permit the form to “slip” forward but also support the freshly poured concrete which now abuts it, as the form continues to move forward.
The term “coping” or “bridge coping” is intended, and used herein, to describe and connote the structural element which is affixed and preferably integral with the top of a retaining wall of an elevated roadway. Within the context of this invention, “coping” and “bridge coping” are fabricated by the improved process of this invention, and have rebars extending from within and partially embedded within the slip formed coping, The slip formed coping prepared in accordance with the process of this invention is thus unique in terms of its fabrication history.
The phrase “road pad” is intended, and used herein, to describe a slip formed concrete slab, which is preferably formed concurrent with the bridge coping. The road pad is used to delineate the lateral margins of the road bed, and is subsequently integral with the road bed. The phrase “tunnel mold” is intended, and used herein, to describe a slip forming compatible assembly, having a one or more channels or passages through the mold cavity and extending from the front (leading edge) to back (trailing edge) of the mold. Each of these channels or passages also have an open end along the base of the mold, which opening extends from the front (leading edge) to back (trailing edge) of the mold, and is of a sufficient height to accommodate the passage of extending rebars, as the they pass through these passages or tunnels, from the front to the back of the tunnel mold, and yet remain concrete-free, as the mold advances forward in the process of slip forming a reinforced concrete structure. The structure which emerges from the tunnel mold has both embedded rebars and concrete free rebars, which extend from rebars embedded in slip formed concrete structure.
The term “rebar” (short for “reinforcing bar”), is intended, and used herein, to describe a steel bar that, is commonly used as a tension device in reinforced concrete, and in reinforced masonry structures, to strengthen and hold the concrete in compression. It is usually in the form of carbon steel bars or wires, and the surfaces may be deformed for a better bond with the concrete.
The abbreviation “MSE” is intended, and used herein, to describe Mechanically Stabilized Earth, constructed with artificial reinforcing MSE walls stabilize unstable slopes and retain the soil on steep slopes and under crest loads. The wall face is often of precast, segmental blocks, panels or geocells, that can tolerate some differential movement. The walls are in-filled with granular soil, with or without reinforcement, while retaining the backfill soil. Reinforced walls utilize horizontal layers typically geogrids The reinforced soil mass, along with the facing, forms the wall. in many types of MSE's, each vertical fascia row is inset, thereby providing individual cells that can be in-filled with topsoil and planted with vegetation to create a green wall.
In the description of the preferred embodiments of this invention, as illustrated in accompanying patent drawings, where an element or feature in one or more Figures is common to more than one of the accompanying patent drawings. it is assigned the same reference numeral for ease of understanding and simplicity of expression.
FIG. 1 is a perspective view of an inclined road bed ( 2 ) for an overpass. As is evident from this illustration, the angle of incline, and decline, of the road bed can vary with the grade, and, thus, the preferred method for the fabrication of structural components associated with such inclined road bed are best resolved with on-site fabrication of the structural bridge and road elements. Within the context of this invention, the focus is upon the integration of the structural components for a roadway by means which minimize labor intensive manual labor, and provide for the sequential formation of bridge and overpass components by means of slip forming. The road bed ( 2 ) shown in this FIG. 2 has an which has been stabilized by MSE retaining wall ( 4 ). The MSF retaining wall ( 4 ) shown in FIG. 2 has an unfinished top edge ( 6 ), which needs to be integrated into the road bed ( 2 ). This integration typically requires the formation of a coping or a comparable structural element, along the unfinished top edge ( 6 ) of the MSE retaining wall ( 4 ), which, in turn, is further integrated into the finish road bed (not shown).
FIG. 2 is a perspective view of the traditional, manual on-site preparation for casting of a bridge coping and road pad onto a road bed ( 2 ) by conventional concrete casting techniques. In the manual on-site casting of a bridge coping and road pad, extensive manual preparation is required to initially frame a series of forms ( 14 ). These forms ( 14 ) are used to confine a concrete pour onto an array of iron work reinforcing steel ( 16 ). After the cast concrete sets up, the worker thereafter breakdown the forms; and, this manual process repeated for an additional length of coping, until the job is completed. In a typical road construction environment, this process is labor intensive, time consuming, inefficient and very slow because the typical road crew can only fabricate about 40 to 50 feet of traditionally cast product per day. Obviously, the employment of additional manpower on the job will advance the construction schedule somewhat, but be prohibitively expensive and uncompetitive.
FIG. 3(A) depicts a perspective view of the layout of the iron work array ( 16 ) for the slip forming of coping and road bed pad on a similar inclined road bed ( 2 ) as in FIG. 2 , As is evident, the preparation for the slip farming of a coping a road bed pad does not require the use of the tradition series of forms ( 14 ). It is emphasized, that the placement of the ironwork array ( 16 ) is arrange along the road bed ( 2 ) proximate to the MSE retaining wall ( 4 ) without structure defining elements (forms). The ironwork array ( 16 ) can, and is often fabricated on-site; and, its placement determined by a series of surveyor/reference lines (not shown).
FIG. 3(B) depicts placement of a tunnel mold ( 18 ) preliminary to the slip forming of a coping and road bed pad upon the ironwork array ( 16 ) of FIG. 3A . FIG. (B) shows the iron work array ( 16 ), in respect to the MSE retaining wall ( 4 ), and a platform ( 20 ) which has been erected along the outside (exposed side) of MSE retaining wall ( 4 ) to allow for worker oversight of the slip funning process, and to provide a support ( 22 ) for a coping along the top of the MSE retaining wall ( 4 ), it is noted that the platform ( 20 ) is positioned, relative to the iron work array ( 16 ), and to the top of tile MSE retaining wall ( 4 ), so as to provide a base for a coping, which is to extend over the top of the MSE retaining wall ( 4 ), in this FIG. 3(B) , the tunnel mold ( 18 ) is shown to have an open form cavity ( 23 ) and an auger ( 24 ).
FIG. 3(C) depicts the tunnel mold ( 18 ) in combination with slip forming support assembly ( 19 ) typically associated therewith. In FIG. 3(C) , ready mix concrete is conveyed from a cement mixer to a slip forming support assembly ( 19 ), A workman is shown dispensing the relatively fluid concrete mix into the form cavity ( 23 ) of the tunnel mold ( 18 ). The assembly includes both well-know means for guidance of the assembly relative to the iron work arrays: and, for modulation of the speed of the assembly.
FIG. 4 (A) is an isolated and enlarged view of the tunnel mold ( 18 ) of FIGS. 3(B) & (C). In FIG. 4(A) , the auger ( 24 ) is disposed within the form cavity ( 23 ) of the tunnel mold ( 18 ) along with a series of vibrators ( 26 ). Upon the dispensing of a ready mix concrete into the form cavity ( 23 ) of the tunnel mold ( 18 ), it gradually fills the form cavity ( 23 ) until it completely covers the auger ( 24 ). The auger ( 24 ) is driven by a drive motor (not shown), which rotates an auger drive shaft ( 27 ), and thereby effects rotation of the auger and distribution of the concrete across the width of form cavity ( 23 ). in practice and operation of the slip forming process, the tunnel mold ( 18 ) is progressively advanced over ironwork array ( 16 ) of FIG. 3A (from left to right), as a slip formed, concrete coping and a road bed pad are formed upon the iron work array ( 16 ), A series of vibrators ( 26 ) within the form cavity ( 23 ) of tunnel mold assembly ( 18 ) effectively consolidates the unset concrete within the form cavity ( 23 ), and thereby eliminate any voids or lack of continuity within the resultant slip formed structure. This consolidation of the concrete is essential to the green strength of the formed structure and the continuous forward movement (slipping) of the tunnel mold assembly over the iron work array.
FIG. 4(B) is an isolated and enlarged view of the tunnel mold ( 18 ) of FIGS. 3(B) & (C).), when viewed from the rear. in FIG. 4(B) , the tunnel mold ( 18 ) is shown to have two open slots or channels ( 28 , 29 ), for accommodating the passage a pair of rebars ( 30 , 31 ), through the tunnel mold ( 18 ), without embedding rebars ( 30 , 31 ) in the concrete, which is dispensed into the form cavity ( 23 ) of the tunnel mold ( 18 ). Each of channels ( 28 , 29 ) are further provided with fins ( 32 , 33 ), which extend from the tunnel mold ( 18 ), into the concrete corresponding to the coping ( 10 ), to provent/minimizing the flow of unset concrete from the area of the tunnel mold ( 18 ), corresponding to coping ( 10 ), into channes ( 28 , 29 ), and thereby permitting the formation of a coping ( 10 ) with exposed rebars ( 30 , 31 ). and within the define a hollow insert-like member, which projects into the tunnel mold ( 18 ), which extend from the ironwork array ( 16 ).
FIG. 4(C) depicts a partial cutaway of the tunnel mold ( 18 ) of FIG. 4(B) . The fins ( 32 , 33 ) are preferably asymmetrical, having greater/deeper extension into the concrete of a formed coping at the forward or leading portion of the tunnel mold ( 18 ), and tapering gradually toward the rear of the mold cavity, ultimately withdrawing from the concrete of the formed coping as the tunnel mold ( 18 ) progressively moves forward over ironwork array ( 16 ) of FIGS. 3A & 3B .
FIG. 5(A) depicts a coping ( 10 ) and road pad ( 12 ), which have been formed with the tunnel mold ( 10 ) of FIG. 3(A) to FIG. 3 (F), in accordance the slip forming process of this invention. As is evident in FIG. 5(A) , the coping ( 10 ) and road pad. ( 12 ) have been slip harmed as a monolithic structure; and, the coping ( 10 ) fully engages the top of the MSE retaining wall ( 4 ), so as to mechanically couple the MSE retaining wall ( 4 ) to the road (road pad ( 12 )). The coping ( 10 ) includes extending rebars ( 30 , 31 ) which can be used to further integrate the coping ( 10 ) with other structural road elements.
FIG. 5(B) depicts a slip formed coping, ( 10 ) and road pad ( 12 ), when viewed from the side of the MSE retaining wall ( 4 ). In FIG. 5(B) , the coping ( 10 ) extends over the top and down the outside of the MSE retaining wall ( 4 ), to the platform., which had been constructed along the side of the MSE retaining wall ( 4 ). In this FIG. 5(B) , the platform ( 20 ) is Shown to have served as a support/form for the base of vertical extension ( 11 ) of coping ( 10 ), and thereby, the position of the platform ( 20 ) relative to the top of the MSE retaning wall ( 4 ), defines the length of the vertical extension ( 11 ) of the coping ( 10 ) proximate to MSE retaining wall ( 4 ).
FIG. 6A depicts a perspective view of the layout of an iron work array ( 50 ) for a retaining wall/barrier wall which has been placed on top of the slip formed bridge coping illustrated in FIG. 5(A) and FIG. 5(B) The extending rebars ( 30 , 31 ) from the slip formed coping ( 10 ) and road pad ( 12 ), having which have been physically connected to iron work array ( 50 ) for retaining wall/barrier wall. FIG 6 B is an enlarged view of the extending rebars ( 30 , 31 ) which have been physically connected to additional reinforcing steel rods. In order to accommodate their physical connection, rebar ( 31 ) has been bent prior to the connection to additional reinforcing steel rods. Accordingly, upon Slip, forming of retaining wall/barrier, it shall be structurally reinforced with both exposed rebars ( 30 , 31 ) from the coping ( 10 ), and the iron work array ( 50 ) intended for its reinforcement. Thus, the retaining wail/barrier wall, once formed, shall be integrated into the slip formed coping ( 10 ).
the foregoing invention has been described m reference to a number of the preferred embodiments of this process for use in the in situ fabrication of concrete structures for highway and bridge construction; and, the resultant concrete structures formed in this process. Both time and space does not permit inclusion all of the potential applications of this process for the formation of monolithic reinforced structures, nor is the invention limited to the concrete and/or rebar reinforcement, Clearly, this process has potential application to the slip formation of reinforced structural shapes having both an embedded reinforcing member and an exposed component Of such reinforcing member. Thus, the scope of this invention is not limited by what has been explicated illustrated and described, but rather defined in the following claims. | A process for slip forming of concrete structures, specifically, concrete structural components, for road and bridge construction. This process has particular application for slip forming of monolithic structures having multiple component/functional parts, wherein the resultant slip formed monolithic, structure has exposed rebars bar the later integration with additional concrete structures arid/or mechanical structural elements, c,g. noise walls, barricades, guard rails and the like. This invention also includes a system adapted for the formation of these unique, monolithic slip formed structures with exposed rebars, including the tunnel mold assembly, which is utilized in this slip forming process; and, the resultant to slip molded monolithic structural component with exposed rebus. |
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of my copending patent application Ser. No. 143,595, filed Apr. 25, 1980 and entitled "Scaffold" and now U.S. Pat. No. 4,300,657.
BACKGROUND OF THE INVENTION
This invention relates in general to scaffolding for building construction and for repair, and in particular to means for supporting the scaffolding with the building.
In my copending patent application, Ser. No. 143,595, filed Apr. 25, 1980, I described a lightweight scaffolding that is easy to erect and convenient to use. This scaffolding has telescoping legs and a horizontal rail extending between the legs. A worker's platform depends from the rail. Rollers engage the rail to make the platform easy to roll along the length of the scaffolding. This scaffolding requires only two legs, and is supported by a standoff device that contacts the wall of the building, and supports the scaffolding in a leaning position.
While this scaffolding is successful, there are occasions in which a vertical scaffolding is preferred instead of one that leans toward the building. The only vertical scaffolding known to to applicant that is presently available is a stand-alone type. It has end frames that are from about 21/2 to 5 feet wide. These are secured together by braces and a walk board about six feet long. This type of scaffolding is heavy and time consuming to erect, normally requiring more than one person.
SUMMARY OF THE INVENTION
In this invention, a vertical scaffolding is provided that requires only two legs, and is supported vertically by the building. The scaffolding is supported at the top by support means that engages a depending portion of the roof, such as an exposed rafter, a fascia board, or a gable end. Each leg has telescoping means to vary the length. A rail interconnects the legs. A worker's platform depends downwardly from the rail, with rollers at the rail to facilitate moving the platform along the length of the scaffold. The support means for supporting the scaffolding vertically by engaging the roof structure includes a channel for fitting under a depending portion of the roof and spring means for urging the channel upwardly into contact with the depending member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating an embodiment of the scaffold of this invention.
FIG. 2 is an enlarged perspective view of the support means of the scaffold of FIG. 1.
FIG. 3 is a vertical sectional view of the scaffold of FIG. 1 taken along the line III--III.
FIG. 4 is an enlarged perspective view of the pipe clamp used to vary the length of the legs of the scaffold of FIG. 1.
FIG. 5 is an enlarged side view, partially broken away, of the support means of the scaffold of FIG. 1.
FIG. 6 is another embodiment of the support means for the scaffold of this invention, shown engaging an inclined fascia board.
FIG. 7 is a perspective view of another embodiment of a support means for the scaffold of this invention, shown engaging a gable end.
FIG. 8 is an enlarged side view of the gable end support means of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a building 11 is shown of the type having a pitched roof 13 with overhanging eaves 15. Eaves 15 comprise depending members, which in this case are exposed ends of sloping rafters 17. The eaves 15 extend outwardly past the vertical wall 19 a short distance, normally from about 1 to 3 feet. Building 11 also has a gable end 21 that extends past a vertical wall 23 a short distance. Gable end 21 inclines upwardly to a gable or peak in the roof, while eaves 15 normally extend horizontally.
Scaffold 25 includes a pair of vertical legs 27 that are parallel to each other. Each leg 27 includes an outer member or tube 29 that receives an inner tube or rod 31 for serving as telescoping means for varying the length of the leg. The length of the inner rod 31 is greater than the length of tube 29.
Locking means for locking the rod 31 to tube 29, shown also in FIG. 4, consists of a conventional pipe clamp 33, such as used for clamping furniture members together while gluing. Referring to FIG. 4, pipe clamp 33 has an inner bore 35 that slidingly receives the inner rod 31. Gripping means allows the rod 31 to slide downwardly with respect to pipe clamp 33, but prevents upward movement, unless released. In the pipe clamp shown in FIG. 4, the gripping means includes a plurality of plates 37, each having an aperture for receiving rod 31. The apertures in the plates 37 are slightly larger than the diameter of rod 31, and wedge rod 31 against movement in the upward direction with respect to pipe clamp 33. Plates 37 will release rod 31 for upward movement with respect to clamp 33 by pressing the ends of the plates 37 upward, to align the plates perpendicular to rod 31, and thus release the wedging action. The upper surface of pipe clamp 33 bears against the lower edge of tube 29, the tube having an outer diameter that is greater than the inner diameter of bore 35 of pipe clamp 33.
A rail bracket 39 is welded to tube 29 near its top. Referring to FIG. 3, rail bracket 39 has a socket that consists of a rectangular aperture 41 with a slot 43 in its bottom. Rail bracket 39 is adapted to receive a rail 45 in its aperture 41. Rail 45 is a rectangular tube having a slot 47 on its bottom. Each end of rail 45 will slide within the rail brackets 39, with the rail slot 47 aligning with the rail bracket slot 43. Each end of rail 45 and rail brackets 39 is open.
Referring to FIGS. 1 and 3, two tandem sets of rollers 49 are adapted to be carried in the rail 45. Each set of rollers 49 has four wheels; two wheels for engaging the rail surface or track located on one side of rail slot 47, and two wheels for engaging the track located on the other side of rail slot 47. Each set of rollers 49 has two axles, which support one end of a tubular depending frame 51. Frame 51 is bent into a "U" shape, with a lower horizontal base 53. The ends of frame 51 depend in a vertical plane, parallel with the legs 27 and building wall 19. The lengths of the ends of frame 51 are equal and about three feet, or slightly more than about one half the average height of a worker. Frame 51 includes two horizontal braces 53 that extend between the ends of frame 51, parallel and spaced above base 52.
A plate 55 has hooks 57 for slipping over one of the horizontal braces 53. Plate 55 extends horizontally outward from its hooks 57. As shown by the phantom lines, plate 55 can be placed on either the inner side or the outer side of scaffold 25. Plate 55 and frame 51 combine to define a platform for the worker to sit or stand.
A brace 61 extends between the legs 27 at a point about three feet below rail 45. As shown also in FIG. 4, brace 61 has depending pins 63 on each end for insertion within apertures drilled in the pipe clamps 33.
A tab 65 extends outwardly from the base 52 of frame 51. Tab 65 has a pair of depending and spaced-apart pins 67. Pins 67 have rotatable sleeves and are spaced-apart to insert loosely over brace 61 to serve as a retaining means for preventing plate 55 from swinging toward and away from building 11. Pins 67 allow the platform to be moved along the length of rail 45. Each leg 27 is supported by a rectangular plate 69, as shown in FIG. 1. Each plate 69 has a socket 71 that receives the lower end of one of the rods 31.
Referring to FIG. 1, a support means for supporting the legs 27 vertically includes a tube 73 that receives the upper end of rod 31 and rests on the top of tube 29. As shown also in FIG. 2, tube 73 is adapted to receive a collar 75 inside its bore. Collar 75 is pinned rigidly to tube 73 by a pin 77 that extends through an aperture 79 in tube 73. Collar 75 thus provides an upwardly facing shoulder. A coil spring 81 (FIG. 2), rests on top of the collar 75 inside tube 73. A tubular support member 83 is slidably carried inside tube 73 on top of coil spring 81. Support member 83 has threads 85 on its upper end and has an aperture through it for receiving a pin 87. Pin 87 extends laterally outwardly through an elongated slot 89 formed in the sidewall of tube 73. Pin 87 and slot 89 define an upper and lower limit of travel for the support member 83, and serve as a stop means for preventing the support member from disengagement with tube 73.
The upper end of support member 83 is adapted to receive one of several adapters for engaging a part of the roof 13. The adapter 91 shown in FIG. 1 is for use with exposed, depending rafters 17. It comprises a threaded socket 93 for engaging threads 85 of support member 83. A channel 95 faces upwardly and is secured to the top of socket 93. Channel 95 has two spaced-apart vertical sidewalls 97 and a horizontal base 99, that is normal to the axis of support member 83. The distance between sidewalls 97 is selected so that a conventional rafter 17 will be loosely received within the channel 95. A protruberance or pin 101, shown also in FIG. 5, is located in the base 99. Pin 101 is preferably conical and has a sharp peak or apex for embedding into the lower surface of a rafter 17.
In the operation of the embodiment shown in FIGS. 1-5, to erect the scaffold 25, each leg 27 will be positioned apart from the other and extended in length. Rod 31 will slide downwardly in tube 29 to provide the proper length. The channel 95 is placed near the outer end of a rafter 17. Pin 101, (FIG. 2) will embed into the lower surface of a rafter 17, being urged upward by spring 81. Once the legs are tightly in place, rail 45 is inserted into the rail brackets 39. Brace 61 is placed between the pipe clamps 33. The rollers 49 are inserted into the rail 45, with the frame 51 depending downwardly and the tab pins 67 inserted over the brace 61. Plate 55 is suspended on one of the braces 53, on either the inner or outer side, as desired.
While working from the scaffold 25 in this position, as shown in FIG. 5, the scaffold is prevented from falling inward by the pins 101. Also, if plate 55 is located on the outer side of scaffold 25, this will provide counterbalancing to prevent inward movement of the scaffold. Outward movement of the scaffold is prevented by pin 101 and also by the wedging action by the base 99 of the channel against the lower side of the rafter 17. The base 99, being horizontal will wedge against the inclined rafter 17 and thus be prevented from falling outward.
In FIG. 6, the rafters 17' do not have exposed outer ends. Instead, a fascia board 103 is secured across the outer ends of rafters 17'. In the embodiment of FIG. 6, fascia board 103 inclines with respect to the vertical at the angle at which the outer ends of rafters 17' have been cut. Often, a sheet 105 of plywood will extend from the fascia board 103 to the wall of the building, covering the rafters 17'. Also, often a small strip 107, such as a 1"×2" board, will be secured across the top of fascia board 103 and extend longitudinally.
For the roof structure of FIG. 6, an adapter 109 that differs from adapter 91 is used. The remaining portions of the supporting means are the same, but are indicated by prime symbols to differentiate the arrangement in FIG. 6 from the arrangement in FIGS. 1-5. Adapter 109 has a socket that is secured to the support member 83' inside tube 73'. An upwardly facing but inclined channel 111 is secured on top of adapter 109. Channel 111 has two parallel sidewalls 113 and 115 separated by a base 117. Base 117 does not contain a pin similar to pin 87 (FIG. 5). Sidewalls 113 and 115 incline at the same angle of inclination as fascia board 103, with respect to vertical. The axis of tube 73' intersects the planes containing sidewalls 113 and 115 at an acute angle. The inner sidewall 113 is of less height than the outer sidewall 115 so as to not interfere with cover 105.
In the operation of the embodiment of FIG. 6, the legs are secured vertically by extending them upwardly to insert channel 111 under fascia board 103. This places sidewall 111 parallel with fascia board 103 and on the outside, while sidewall 113 will be on the inside. The legs are extended until the coil spring inside tube 73' is compressed to some extent. If the fascia board 103 is vertical instead of inclined, an adapter similar to adapter 109, but oriented vertically, would normally be used.
Another embodiment is shown in FIGS. 7 and 8, this one being for use with the gable end 21'. Gable end 21' includes a fascia board 119 that depends downwardly in a vertical plane, and also slopes upwardly to a peak (not shown) of the roof. Often, a 1"×2" strip 121 will be located on the top and outer side of fascia board 119. The structure of FIG. 1 will be used for this arrangement, but for an adapter 123 that differs from the adapters 91 and 109 (FIG. 6). Adapter 123 has a threaded socket that is secured to the same support member 83" located in tube 73". Referring to FIG. 8, a channel 125 is located on the upper side. Channel 125 has an inner wall 127 and an outer wall 129 separated by a horizontal base 131 that is normal to the axis of support member 83". Outer wall 129 extends upwardly in a vertical plane, parallel with inner wall 127 for a selected distance. Then, to clear the strip 121, outer wall 129 inclines outwardly. At the top, outer wall 129 is bent at an angle to define an overhanging projection 133 that is located in a horizontal plane over and parallel with the base 131.
In the operation of the embodiment of FIGS. 7 and 8, the legs of the scaffold are extended until the channel 131 receives the fascia board 119 and compresses the spring in the support member 83" a certain extent. Projection 133 will be located above the roof 13'. The projection 133 prevents the legs from falling laterally toward each other before the rail 45 (FIG. 1) and brace 61 (FIG. 1) are inserted in place.
The invention has significant advantages. A light, easy to erect, vertical scaffold is provided. But for the platform plate, which will be located on the inner or outer side, the scaffold is essentially in a single plane and requires only two legs. The platform easily locks itself to any type of building with an overhanging roof, merely by changing the adapter at the top to accommodate exposed rafters, covered rafters, inclined fascia boards, vertical fascia boards, and gable ends. The positive connection to the roof provides a safe scaffold that will not overturn. If one leg embeds into the earth more than the other when in use, the spring in the support member will keep the lower leg in engagement with the roof.
While the invention has been shown in only three of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes and modifications without departing from the spirit of the invention. | A scaffold has features that allow it to be supported vertically by connecting it to a building. The scaffold includes a pair of legs. Each leg will telescope to vary the length of the leg. A rail interconnects the legs. A worker's platform is carried by the rail below the rail. Rollers connected with the platform allow the platform to roll along the length of the rail. An adapter mounted to the top of each leg will insert under a depending member of the building roof to hold the legs vertically. The adapter is urged upward by a spring to maintain engagement. |
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of copending application Ser. No. 214,250, filed Dec. 8, 1980.
BACKGROUND OF THE INVENTION
The present invention relates to a supporting grid system for suspended ceilings and, more particularly, to an improvement in the construction of the ceiling tile supporting members which coact to define the suspended ceiling supporting network.
The use of suspended ceilings in building construction is well known. One mode of construction provides a metal framework with longitudinal runners and lateral cross members or runners disposed at right-angles thereto and fitted together in a lattice or grid network to thereby define plurality of modular openings. The framework is supported by hangers from overhead structure and functions to support ceiling tiles or panels, fluorescent light fixtures, ventilation fixtures, and the like.
The runners and cross runners are usually of inverted T-shape with a pair of horizontally disposed flanges on opposite sides of a central upstanding, vertically disposed web section. The flanges are relatively wide in order to support the ceiling tiles while permitting sufficient clearance or tolerance between the edges of the tiles and the web sections. Architects frequently object to the appearance presented by such exposed flanges, and seek alternatives.
Various prior constructions have been proposed in an attempt to present a pleasing, thin outline for the exposed portions of the suspended ceiling tiles. One such construction incorporates a relatively wide tile supporting flange but attempts to hide the same from view by employing L-shaped lips extending below the tile supporting flange and directed inwardly toward the upstanding web of the inverted T main runner or cross runner. In this construction, rabbet-edged ceiling tiles are employed to rest on the flange and depend downwardly therefrom, substantially flush with the L-shaped lip.
Another known construction, also employing rabbet-edged tiles, provides extruded metal runners and cross runners; each having inverted U-shaped tile supporting flanges, with the metal thicknesses of the legs thereof serving as the exposed outline for the suspended ceiling.
SUMMARY OF THE INVENTION
The foregoing problems of prior art constructions, as well as others not specifically mentioned, are overcome according to the teachings of the present invention which provides a framework or grid for suspended ceilings wherein the tile supporting flanges of the main runners and the cross runners are relatively thin in width to provide an aesthetically pleasing appearance: while, at the same time, functioning to firmly and uniformly support the ceiling tiles in such a manner that the same are automatically centered within the modular opening. The use of standard-sized, straight-edged tiles is permitted, if desired, without any need to provide sufficient clearance to avoid lateral shifting and possible fall-through of the tiles. Further, the structure of the present invention precludes the necessity of, and saves the added cost of, providing additional structure to hide from view the wide flanges of prior constructions.
The invention also incorporates in the main runners and/or the cross runners relatively simple and inexpensive structure to permit lighting fixtures and the like to be easily and effectively hung therefrom, without the need for providing specially designed, costly adapters as typified by prior art constructions.
It is a further feature of this invention to provide an efficient and effective arrangement for splicing or joining main runners in abutting end to end relationship, and for securely locking the cross runners to each other in intersecting relation to the main runners.
More specifically, the main runners and the cross a pair of resilient webs depending downwardly and outwardly from an upper tubular bulb portion to a horizontally disposed, reduced-width, tile supporting flange portion at the lower extremity of each web. The flange portions are resiliently biased in an outward direction by the webs such that supporting forces are exerted on the ceiling tiles to thereby automatically center the same and uniformly support the same in their assembled position. In this manner, thin-line, exposed flanges are observable to present a pleasing appearance without any sacrifice in the tile supporting requirements of the flanges. The interior space between the webs may be prepainted with the same color as the exposed flanges or with a contrasting color. In either case, from an observer's point of view an aesthetically pleasing grid network is presented.
The interior walls of the webs may be provided with screw-fastener guide means to permit easy installation of lighting fixtures and the like. Such guide means may preferably comprise a plurality of relatively short curved recesses in the interior facing walls of each of the webs and extending downwardly and outwardly therewith to provide a composite tubular opening sufficient to receive and guide the screw-fastener into position.
A clip member engageable with the runner members is provided to underlie the areas of interconnection of the runner members and the cross members to thereby give the appearance of an uninterrupted recess in the cross members. The clip includes a flat portion, an inverted, upwardly extending substantially U-shaped portion in the flat portion, and an upwardly extending arm at each of the outer ends of the flat portion. The arms include inwardly directed gripping means to engage the outer edge of the legs of a runner member, and the U-shaped portion engages the inner surfaces of the legs of the runner members.
Other characterizing features and advantages of the present invention will become apparent as the detailed description thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is an enlarged side elevational view of a main runner section constructed in accordance with the invention, with parts thereof broken away for ease of illustration;
FIG. 2 is an end elevational view of the runner looking in the direction of line 2--2 of FIG. 1;
FIG. 3 is a side elevational view, with parts thereof broken away, depicting a splice or connection between two main runners, each of which is characterized by the runner depicted in FIG. 1;
FIG. 4 is a cross-sectional view taken substantially along line 4--4 of FIG. 3;
FIG. 5 is an enlarged side elevational view of a cross runner constructed in accordance with the invention, with parts thereof broken away for ease of illustration;
FIG. 6 is an end elevational view of the cross runner looking in the direction of line 6--6 of FIG. 5;
FIG. 7 is a partial fragmentary view of the main runner of FIG. 1 depicting one of a plurality of spaced slots in the webs thereof for receipt of adjacent cross runner
FIG. 8 is a fragmentary elevational view of adjacent cross runners in operative engagement with each other and with their intersecting main runner;
FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 8;
FIG. 10 is a fragmentary side elevational view of a main runner or a cross runner depicting the application thereto of means for guiding fixture-holding fasteners;
FIG. 11 is a vertical cross-sectional view of one of the main runners or one of the cross runners depicting the manner in which a fixture is affixed thereto;
FIG. 12 is a fragmentary view of the assembled adjacent cross runner sections depicting the application of a clip means for blocking from view the coupling structure which locks each of such cross runners together:
FIG. 13 is a bottom fragmentary view looking in the direction of line 13--13 of FIG. 12:
FIG. 14 is a fragmentary cross-sectional view of one of the main runners or cross runners depicting support of a standard size square-edged ceiling tile and a slightly modified flange construction;
FIG. 15 is a view similar to FIG. 14 but depicting optional support of a rabbet-edged ceiling tile;
FIG. 16 is a fragmentary cross-sectional view of the assembled adjacent cross runner sections depicting the application of an alternative structure for a clip means for blocking from view the coupling structure which locks each of the cross runners together;
FIG. 17 is a bottom fragmentary view looking in the direction of line 17--17 of FIG. 16;
FIG. 18 is a fragmentary side view, partially in section, looking in the direction of line 18--18 of FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail and, more particularly, to FIGS. 1-4, a main supporting runner, generally depicted at 10, is formed to provide an upper tubular reinforcing bulb 12 of substantially circular cross-section (although other cross-sectional shapes would suffice), a pair of resilient webs 14 depending downwardly and outwardly from bulb 12 in substantial inverted V fashion, and horizontally disposed tile supporting flanges 16 integrally connecting to the lower extremities of each of webs 14 and extending outwardly therefrom. Main runner 10 can be fabricated from any single piece of any suitable material, such as thin gauge steel; however, the same is preferably rolled, folded and stamped from soft steel or the like. Alternatively, other well known methods of fabrication may be employed. The webs are inherently spring biased with a "memory" that causes them to normally maintain their spread apart position and, as such, they will offer an outward biasing force in response to inward movements.
At their opposite longitudinal ends each web 14 is integrally provided with suitable splicing or clip means to permit adjacent main runners to be rigidly joined in abutting and aligned relationship, while effectively preventing any relative twisting therebetween. To this end, one pair of web ends 18 are provided with suitable locking projection tabs or stabs 20 slightly pressed from the plane of its respective web in one lateral direction and projecting outwardly therefrom to define an upper edge surface 22, a reduced length lower surface 24, and a forward edge surface 26 upwardly and outwardly directed from lower edge surface 24 to upper surface 22 via an outwardly curved guiding edge surface 28. An elongated central reinforcing rib 30 is pressed slightly out of the plane of stab 20 in said one lateral direction and contains at its end adjacent outer edge surface 26 a laterally curved, planar edged locking element 32 protruding from the plane of stab 20 in an opposite lateral direction to thereby define an abutment or stop 34.
Each stab 20 further includes a tongue 35 pressed out of the plane thereof in one lateral direction leaving an abutment edge 36 that is substantially aligned with the projecting leading edge surfaces of the stab and is spaced inwardly of stop 34.
The opposite pair of web ends 38 are each provided with similar locking projection tabs or stabs 20a, except that the same (including projecting edge surfaces 22a, 22a, 26a and 28a reinforcing rib 30a, locking element 32a, stop 34a and tongue 35a) are slightly offset in lateral directions that are opposite to that of their corresponding structure on web ends 18. As depicted in FIGS. 3 and 4, the arrangement is such that when adjacent main runner sections are brought together, the stabs on one pair of web ends 18 are guided through the tongues on the other pair of web ends 38 whereby the abutments 34 snap into locking engagement with the abutment edges 36a and the stabs on the other pair of web ends 38 are guided through the tongues on the other pair of web ends 18 whereby the abutments 34a snap into locking engagement with the abutment edges 36, thereby providing a main runner splice.
Referring to FIGS. 5 and 6, the cross runners, generally depicted at 40, are provided with a reinforcing tubular bulb 42, a pair of resilient webs 44 and horizontally disposed tile supporting flanges 46 which are all formed in a manner similar to that of main runner 10; therefore, no further description of these elements is deemed necessary. At opposite longitudinal ends thereof each of the webs 44 are provided with suitable locking connectors, generally designated at 48, 48a, which, respectively project outwardly from their respective ends and are formed integral therewith. It should be noted that connectors 48, 48a at opposite ends of each cross runner 40 are slightly offset from the plane of their respective webs 44 in opposite lateral directions and are provided with substantially hook-shaped tabs defined by a leading curved edge 50, 50a; a flat bottom edge 52, 52a; and a web-gripping edge 53, 53a which, respectively, connects edges 50, 50a to edges 52, 52a. It should be noted that edges 53, 53a are inclined to follow the inclination angles of each of the main runner webs 14, as will become apparent hereinbelow. Each connector 48, 48a further includes transverse through openings 54, 54a located adjacent their respective curved edges 50, 50a. Also provided are catches 56, 56a aligned with and inwardly spaced from their respective openings 54, 54a. Catches 56 at one end of cross runners 40 may be suitably pressed out of the plane of each of the connectors 48 in one lateral direction, whereas catches 56a at the other end of cross runners 40 may be suitably pressed out of the plane of each of the connectors 48a in the opposite lateral direction. Such lateral offsetting of the catches 56, 56a provide the same with curved abutment edges 58, 58a, respectively.
Turning to FIGS. 7-9, each main runner web 14 is provided with a plurality of longitudinally spaced cross runner slots 60 (only one of which being illustrated); the slots on one web being disposed for alignment with their corresponding slots on the other web. Each slot 60 is formed with a pair of curved side edges 62, a flat upper edge 64 and a notched lower edge 66 to thereby define substantially the profile of an inverted bottle. The spacing between top edge 64 and the bottom of lower edge 66 substantially corresponds to the vertical extent of the leading curved edges 50, 50a of the connectors 48, 48a.
Adjacent cross runners 40 may be rigidly coupled to each other through slot 60 in locking engagement therewith to define the intersecting grid structure for supporting the ceiling tiles. Alternatively, only one cross runner may be locked through the slot 60, if desired or required. More specifically, as adjacent cross runners are joined together through slots 60 adjacent aligned connectors 48, 48a on each are snap-locked together by engagement of openings 54, 54a with their respective abutment edges 58a, 58 of catches 56a, 56, respectively, as clearly indicated in FIG. 9.
As the curved leading edges 50 and the curved leading edges 50a of their respective connectors are brought into contact with their respective slots 60 the same are engaged by the side edges 62 which cause connectors to compress to the width of the bottom notch 66. When each connector edge surface 53, 53a passes through both aligned slots, the connectors are free to expand to their normal position with the top edges 52, 52a thereof resting on slot side edges 62 above notch 66 and with edge surfaces 53, 53a gripping their respective main runner webs along a surface of the webs on each side of slot edges 62 adjacent notch 66. In this manner, opposite pull through of the cross runners is prevented unless the webs are deliberately compressed to permit the connectors to pass through notch 66 of the slot. Thus, the relationship between the connectors and the slots is such as to permit automatic straight-through insertion without the necessity of any manual squeezing of the cross runner webs. In their assembled position the cross runner flanges 46 are maintained substantially coplanar or flush with the main runner flanges 16 by means of an offset or relieved portion 68 on the ends of cross runner flanges 46.
As illustrated in FIG. 7, each main runner web 14 may be provided with a plurality of longitudinally spaced openings 70. Suitable hangers H may pass through selected openings 70 for suspending the main runners from overhead support structure, as is conventional.
It should be apparent, from the structure of the present invention as thus far described, that the tile supporting flanges on the main runners and the cross runners are substantially narrower (in a lateral sense) than would be required in constructions employing conventional inverted T-shaped members. Whereas in a conventional inverted T construction the flanges on each side of the web must be sized to permit sufficient tolerance within the modular grid for adequate support of the tile, the flanges of the present invention need only be of a size sufficient for the actual support of the tile and not any larger to provide for such tolerances as typified by prior art constructions. It should be understood that the spring action of the resilient webs, on the main runners and the cross runners, provides or permits automatic centering and support of the tiles without any need for greater flange widths. Moreover, no additional structure is required to hide the actual supporting flanges from view to give the appearance of a narrower grid network. Further, in the event of slight tile shrinkage due to fire or other sources of high heat, the resilient webs will expand to permit the flanges to move outwardly for continued tile support.
It is a further feature of the present invention to provide a simple and effective means for permitting lighting fixtures and the like to be supported from either the main runners or the cross runners without any need for special adaptors or the like.
Prior to a discussion of such means as depicted in FIGS. 10 and 11 and to such other features or arrangements as depicted in FIGS. 14 and 15, it should be noted that these Figures depict main runner and/or cross runner structure. Therefore, generic designation shall be employed to indicate various parts of such structure that are clearly common to both main runners and cross runners.
Thus, turning to FIGS. 10 and 11, the web W of either a main runner or a cross runner may be provided with a plurality of adjacent recesses or serrations 72. Each recess 72 is preferably formed integral with its respective web and pressed out of the inner surfaces thereof adjacent the bulb portion B to extend downwardly and outwardly therefrom to a point between the upper and lower extremities of the webs. Recesses 72 on each web W are disposed for alignment with corresponding recesses on the opposite web to thereby define composite channels or tubular openings for guiding and receiving suitable fasteners or metal screws 74. As depicted in FIG. 11, the arrangement is such that a fixture or a support S for a partition head channel or the like may be brought into engagement with ceiling tiles T and affixed to runner bulbs B by means of the sheet metal screw or the like 74 which is guided through the composite openings defined by the facing recesses 72 and secured through the bulb portion B.
As depicted in FIGS. 12 and 13, the present invention further contemplates the employment of a suitable means to maintain the thin-line, exposed grid appearance in the locations where the cross runners intersect the main runners. To this end, a clip, generally designated at 76, is provided to substantially span the gap between the flanges 46 of adjacent connected cross runners 40. More specifically, clip 76 is fabricated of a suitable resilient, spring-like material and has a pair of upwardly and outwardly directed snap fingers 78 connecting to a pair of substantially planar horizontally disposed sections 80 which, in turn, connect to an upwardly directed and centrally located substantially inverted U-shaped portion 82 extending upwardly into the space between main runner webs 14. The arrangement is such that spring fingers 78 removably snap onto the outer edges of main runner flanges 16 to permit clip 76 to bridge the space between adjacent connecting cross runners 40 whereby the connecting or coupling structure thereof is hidden from view. Thus, the continuity of the outline of the grid network is preserved as normally seen from an observer's point of view. Inverted U-shaped portion 82 functions to simulate the appearance of the shadow space formed between the inner surfaces of oppositely inclined main runner webs 14.
As noted earlier, the exposed surfaces of flanges 16 and 46 may be prepainted or coated prior to forming with a color contrasting to that of the space between their respective webs 14 and 44. In which case, the main runners and the cross runners would have their flanges folded in such a manner as to reverse the surfaces thereof to enable one color to appear between the webs and the contrasting color exposed on the flanges. This folding arrangement has been disclosed throughout the drawings but is highlighted at F in FIG. 15. However, if it were desired to expose the same colors between the webs and on the exposed portions of the flanges, then the flanges could be folded opposite to the folds of FIG. 15 as depicted at F' in FIG. 14.
FIG. 15 also illustrates the optional employment of rabbet-edged ceiling tiles T' for support by the main runner flanges and the cross runner flanges.
Another embodiment of a clip structure suitable for use in connection with the present invention is shown in FIGS. 16, 17, and 18. The clip member 76 there shown is somewhat similar to the clip member illustrated in FIGS. 12 and 13, except that the former includes a differently configured, upwardly directed, centrally located substantially inverted U-shaped portion 82. In this embodiment U-shaped portion 82 has a greater width than the corresponding portion of the earlier embodiment, and it is adapted to contact the inner surfaces of the webs 14 to thereby define a minimum separation angle for the webs. This particular feature is advantageous in situations where the webs do not diverge outwardly sufficiently because of a loss of spring in reinforcing bulb 12 of runner member 10, and the combination of the U-shaped portion 82 with the upwardly and outwardly directed snap fingers 78 defines a pair of spaced openings to receive supporting flanges 16 of webs 14 and thereby space them at a predetermined distance. As in the embodiment of FIGS. 12 and 13, each of planar, horizontally disposed sections 80 interconnects one of snap fingers 78 with U-shaped portion 82.
As best seen in FIG. 17, when clip 76 is in position on runner 10, it preferably is in alignment with the longitudinal axis of cross runner 40, which also has an upwardly directed recess defined by cross runner flanges 46. The recesses provided in the runner and cross members are for decorative purposes in that they provide a contrasting linear element which adds to the visual appeal of the grid structure. The discontinuity in the cross member recess at the point where the cross members intersect the runner members is masked by providing clip 76 of a generally dark color to correspond with the color in the longitudinal recesses. When so colored, clip 76 appears from a distance to be a part of the recess and renders the appearance of the cross member recess essentially continuous. In addition to serving to impart visual continuity to the cross member recess, clip 76 preferably also is of such a width as to define a minimum spacing between the webs of the adjacent cross runner members. Thus clip 76 establishes the minimum lateral spacing between tile supporting flanges 16 of runner member 10 and between tile supporting flanges 46 of cross runners 40 and thereby maintains a consistent and uniform spacing therebetween to provide a more visually appealing grid structure.
Referring now to FIG. 18, snap fingers 78 each include an inwardly recessed portion in the side edges thereof in order to provide a space to accommodate inwardly directed wrinkles which may develop in the course of the manufacture of the cross members adjacent the intersection of the web members and the outwardly directed flanges. Preferably, the recessed portions define inwardly bowed areas and are positioned between the upper and lower edges of fingers 78.
Although preferred embodiments of the present invention have been disclosed and described in detail, changes will obviously occur to those skilled in the art. It is, therefore, intended that the present invention is to be limited only by the scope of the appended claims. | A clip member is disclosed for underlying the areas of interconnection of main and cross runner members of a grid system for suspended ceilings. The runner members include downwardly opening recesses between their respective tile supporting flanges, and the clip member provides the appearance of an uninterrupted recess in the cross members at the areas of interconnection. |
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a continuation of and claims priority of U.S. application Ser. No. 12/694,730 filed Jan. 27, 2010 which is a continuation of and claims priority of U.S. application Ser. No. 11/191,251 filed Jul. 26, 2005, which claims the benefit of the six provisional patent applications identified below. This Application also claims the benefit of these six provisional patent applications identified below, and incorporates herein by reference the entire contents and teachings of the six provisional patent applications identified below and the entire contents and teachings of application Ser. Nos. 11/191,251 and 12/694,730. The six provisional patent applications are:
[0002] U.S. Application No. 60/591,018 for Foundation module for anti-ram devices where subsurface clearances are minimal, by Richard Steven Adler and John Crawford, filed Jul. 26, 2004.
[0003] U.S. Application No. 60/600,955 for Anti-ram foundation pad, by Richard Steven Adler and John Crawford, filed Aug. 12, 2004.
[0004] U.S. Application No. 60/605,959 for RSA/K&C anti-ram foundation pad, by Richard Steven Adler and John Crawford, filed Aug. 30, 2004.
[0005] U.S. Application No. 60/622,385 for RSA/K&C anti-ram foundation pad with attached surface elements, by Richard Steven Adler and John Crawford, filed Oct. 26, 2004.
[0006] U.S. Application No. 60/674,965 for RSA/K&C anti ram bollards and RSA/K&C anti-ram headknocker, by Richard Steven Adler and John Crawford, filed Apr. 25, 2005.
[0007] U.S. Application No. 60/679,547 for RSA/K&C anti-ram bollard pad extension sleeves with integral structural integrity, by Richard Steven Adler, John Crawford and George Heyward, filed May 9, 2005.
FIELD OF THE INVENTION
[0008] The present invention relates to the assembly and installation of bollard systems for use in protecting building and other structures from being rammed by vehicles. It also relates to the adaption of bollard systems to varying installation requirements, and the disguising of the bollards to make them appear to be part of a normal landscape around a building or structure.
BACKGROUND OF THE INVENTION
[0009] A well know activity of terrorists is to crash a vehicle loaded with explosives or incendiary material into a building or other structure, so as to inflict damage to the building or other structure, and to harm the people in the building or structure. Various bollard constructions and methods of installation have been proposed and utilized in the past. Typically these bollard installations required rather deep excavations, several feet or more, to receive the base for a group of bollards. Alternatively, individual bollards were anchored by boring deep holes to receive the lower end of the bollard.
[0010] With the increased threat of terrorism, it has become desirable, and to some extend even necessary, to provide bollard protection to existing buildings in a well developed urban or commercial area. Typically it is desirable to locate the bollards between the building or other structure and the adjacent streets or roadways. Quite often buried below the surface of the space between a building or other structure and the street are utilities such as gas, water, electric, and telephone or other communication lines and related components. Thus, to provide a deep excavation for the base of a bollard system is difficult if not impossible. While the underground utilities, could be moved to make way for the deep excavation for the base of a bollard system, to do so would be quite costly, and considerable construction time would be required. Such construction would not only most likely result in disruption of the utility services, but more so disrupts travel on the street and pedestrian traffic on the sidewalk between the building and the street.
[0011] It would therefore be desirable to provide a bollard system which would require very little or no excavation for the base of the bollard system, and which bollard system could be partially or completely preassembled and readily delivered to the installation site for placement and final assembly. It would be further desirable that the bollard system be readily adaptable to different terrain and installation requirements. For instance, it should be adaptable to installation on slopes, around corners, and in other none straight line applications. Further, it should meet installation requirements such as allowing for vents and access to underground vaults, and accommodating fire hydrants and street lighting poles. Further, it should provide for ramps for handicap access to the building or structure, and even for removal of one or more bollards to provide vehicle access to the building when occasionally needed.
SUMMARY OF THE INVENTION
[0012] In accordance with this invention, a bollard system is provided which requires very little or no excavation for the base of the bollard system, and which can be partially or fully assembled prior to bringing it to the installation site. The bollard system of this invention includes one or more bollards secured to a shallow mounting pad or base. The shallow mounting pad or base of the bollard system of this invention may be formed or constructed in various ways and of various materials. In all cases, the shallow mounting pad or base is designed to made of heavy materials, so as to have considerable mass.
[0013] The major benefit in the physics of the bollard system of this invention, is that the striking forces from the crash vehicle are transmitted from the bollard down to the shallow mount pad (5″ to 14″ in depth) in a way that is different from standard deep trench foundations (4′ to 6′). The shallow mount pad is pushed down onto the soil (horizontal force backwards) instead of into the soil (vertical force downwards) as in the case of deep trench foundations.
[0014] The shallow base system makes for a much more effective and efficient load transfer into the soil which reduces the overall volume of displacement of soil by the base, as compared to the standard deep trench foundation systems. The shallow base system of this invention also provides a more efficient foundational system.
[0015] One of the issues with the deep trench system is that the lateral compliance at the top of the trench is quite low: If there is no strong resistive force at the top of the trench, then there is a greater chance of more rotation of the bollard which would permit the crash vehicle to breach the system, thereby obviating the crash control device. In the shallow mount bollard system of this invention, the resistive forces are all at the base of the bollard (at the top of the trench) and therefore reduce the likelihood of the bollard rotating and vehicle breaching the security system.
[0016] The bollard system of this invention works as the crash vehicle strikes the bollard near its top edge translating the forces from that impact to the base of the bollard. The forces at the base of the bollard are transmitted to the foundation pad or base, and from there into the soil or concrete depending on what the unit is seated on. The resistance force is of the reverse order stated above.
[0017] The bollard system of this invention is able to become more shallow (14″ to 6.5″ to 3″) by controlling the compliance supplied by the foundation to resist the rotation at the base of the bollard. Specifically the bollard system of this invention can utilize a more shallow trench by more efficiently transmitting the loads to the support media (soil or concrete). The more efficient transfer of the impact load is also accomplished by the addition of either one, a group or all of the following enhancements: 1) a wider base; 2) a heavier base; 3) longer base (laterally and tying adjacent units together); 4) increasing the efficiency of the grillage; 5) stiffer base; 6) ability to place bollard in different locations in the base (for example placing the bollard at the back of the base makes the system weaker), 7) the addition of internal stiffeners both inside the tubes forming the base and inside the pipe forming the bollard, and 8) others.
[0018] While in the preferred embodiment of this invention the base or pad is rectangular, other shapes can be used, such as angled and curved bases, zigzags, and indented, so as to go around an appurtenance.
[0019] In the preferred embodiment of this invention the frame or grill of the base and the bollards are formed of structural steel members. The amount of weldment required to assemble the frame or grill of the base and the bollards is dependant upon the availability of stock or over the counter materials. If more stock or over the counter materials are usable and available then less weldment is required to connect pieces and create a stronger base grillage.
[0020] Another major benefit of the shallow trench system of this invention is realized in its accommodation of site constraints (such as not interfering with underground utilities, able to install at sites where there is limited access to underground excavation (presence of vaults, basements), not interfering with vegetation, etc.
[0021] The base or pad in a preferred embodiment or the bollard system of this invention is constructed using a series of structural tubes to form a grillage (ie. pipes, tubes, channels and sometimes angles) to produce rigidity of the pad or base against upheaval and torsion forces. The grillage is a framework for supporting the load imparted by the bollard. The framework means the tubes (or other structural steel elements) tied together to form the grillage. The base or pad is completed on site, by filling the shallow excavation and grillage with concrete to form a finished foundation unit. It is preferred that the concrete be in contact with the soil or existing concrete at the base of the excavation in order to improve the resistance of the lateral motion of the pad. The top surface of the pad is to be formed in such a way to support the materials forming the final finished appearance (non-structural stone pavers or tiles, etc.).
[0022] The shallow base or pad concept of this invention differs from the standard deep trench system because it only requires a simple replacement of area near the surface, thereby significantly reducing the interference with any existing underground objects at the site. Unlike a deep trench footing, detailed inspection of pre-existing underground conditions, are not required. With the standard trench, personnel inspectors and multiple tools are required to hold the trench open, issues also arise with rain water or other media spilling into the trench.
[0023] The physics of the interaction of the base or pad of the bollard system of this invention with supporting media (soil or concrete) is different than that of the deep trench system, in that the forces imparted by the pad or base are much less than the forces imparted by the deep trench foundation. This is partly due to the large support area of the pad as compared to the deep trench foundation--the vertical forces being carried by the bottom edge of the trench foundation and the horizontal forces being carried by the top few inches of the trench foundation in a deep trench foundation, as compared to the horizontal forces being provided by the frictional forces being between the pad and media over the entire area of the pad and the vertical forces between the pad and media being carried over the entire area of the pad. The area of the pad or base in the bollard system of this invention may be reduced by the addition of engineered stiffeners, tying adjacent pads together, larger section modulus parts, larger welds, etc.
[0024] Restated, the area of a deep trench foundation interacting with the media is significantly smaller than the area of the pad interaction with the media in the system of this invention, thus the forces transferred to the media are far less than the forces transferred by the trench footing to the media. The pad or base of this invention spreads the forces out while the deep trench footing concentrates the forces which require the trench footing to be massive and deep. The deep trench footing for comparable performance will always have to be more massive than the pad or base of this invention.
[0025] The pad or base of the bollard system of this invention is superior in design because it transmits the load more efficiently to the foundation (ground) than a deep trench design, thus allowing a smaller device to absorb the same or greater amount of energy than a more onerous design.
[0026] The shallow pad or base of the bollard system of this invention supports the development of corner units with inherent advantages over a deep trench foundation. The shallow base of the system of this invention allows for complex geometry at corners, thereby facilitating ADA access and foot traffic by allowing bollards to be placed in an optimal pattern for pedestrian traffic without regard to the excavation needed to support the bollards. This is achieved by taking advantage of the flexibility in bollard placement offered by the grillage concept that allows the bollards to be placed anywhere in the grillage. Whereas with deep trench footing, the bollards necessarily need to be lined up with the trench itself In order for the deep trench to support out of line placement of bollards, it would have to be the full width of the bollard pattern whereas only an excavation of the shape of that pad needs to be made in accordance with this invention.
[0027] The flexibility of the bollard system of this invention permits the extension of a pad in any one direction for any unique situation for the bollard to be supported by the pad, but not beyond the pad. This is achieved by extending a tube connected to the grillage in any desired direction and placing (anchoring) a bollard in the tube.
[0028] In certain situations, site encumbrances may not allow a pad or base to be used where it is desirable to place one or more bollards. Extending one or more horizontal connector tubes between spaced pads achieves the necessary anti-ram capability without requiring additional excavation for the pad itself. In a specific embodiment, a connector tube, either above or below ground, can be secured at its ends to the grillage of two adjacent pads with the ends of one or more bollards placed in vertical holes formed in the connector tube. The physics behind this inventive concept is that the torsional rigidity of the connector tube is being used to resist the motion of the bollard, instead of upheaval or moment resistance of the tube used in the standard pad design. That is, when a vehicle strikes the bollard in the conventional design the tube supporting the bollard on axis with the impact is the tube that resists the motion of the bollard using its moment capacity, while in this alternate construction, the tube resists the motion of the bollard with its torsional capacity, bending not twisting.
[0029] Another variation of this invention provides removable units in which the bollard is temporarily removed for access through the on-center spacing and then replaced for its anti-ram purpose. The method to achieve this without a fixed bottom weld is the addition of an extra thick steel sleeve connected to the base of the grillage, with the bollard being slipped into and out of the sleeve. Additional bolts or a variation of locking mechanisms provide security to prevent unauthorized personnel from removing the removable bollard.
[0030] When using the shallow base of pad system of this invention, it may be necessary to place the pad over an air vent or access open to an underground space. To accommodate this need, the grillage is formed to provide an open space located over the air vent or access opening. A form is provided around the open space, such that when concrete is introduced into the grillage, it does not enter the open space. Once the base of the pad system is completed, the usual grate or grill can be placed over the opening.
[0031] While it is desirable in accordance with this invention to have the pad extend further in the direction of expected impact, that is on the opposite side of the bollard from the side of impact, than on the side of impact, some applications may require a reversal of the extension. For instance, if it becomes necessary to move the bollards farther away from the road, that is closer to the building being protected, a bollard unit in accordance with this invention may be lifted, rotated 180 degrees and replaced. This rotation will place the bollards closer to the building and farther away from the road. The bollard system of this invention also makes possible the temporary removal of the bollards and the supporting base. For instance, if it becomes desirable to access something under the bollards, the bollards and connected base may be lifted and temporarily removed. This would not be feasible with a deep trench bollard system.
[0032] The bollard system of this invention does not lend itself to the installation of a single bollard, since without an extended base or pad, there is not sufficient resistance to stop the rotation of the pipe bollard. However, a feature of this invention is to provide a single bollard with a supporting pad, such that if a single bollard is damaged in a row of bollards, the damaged bollard and its supporting pad may be cut out of the row of bollards and the supporting pad of the single replacement bollard secured to supporting pads of the adjacent bollards.
[0033] In its most basic form the bollard system of this invention would have its base or pad formed of a continuous flat piece of steel with holes cut out for the bollards. The plate would need a minimum depth 5″ to qualify as a DOS rated system. The cross pieces are inherent in the continuous plate. Still another basic configuration of the bollard system of this invention is to bolt separate thick pieces of steel to continuous cross plates, and to have the bollard set inside that construction. Again, 5″ thick steel would be required to have two plates 5″ apart.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a perspective view of the anti-ram system of this invention installed alongside the edge of a sidewalk, prior to the pad being covered with a landscaping surface;
[0035] FIG. 2 is a perspective view of the anti-ram system of this invention as shown in FIG. 1 , with a landscaping surface applied over the pad, and with the bollards covered by ornamental and functional items;
[0036] FIG. 3 shows an embodiment of this invention with four bollards mounted on the framework for the pad or base of the anti-ram system;
[0037] FIG. 4 , shows the embodiment of this invention shown in FIG. 3 , with a rebar cage surrounding the framework for the pad or base;
[0038] FIG. 5 is a top plan view of the steel layout for the base of a set of three bollards in accordance with a preferred embodiment of this invention;
[0039] FIG. 6 is a side elevation view of the steel layout of FIG. 5 ;
[0040] FIG. 7 is a top plan view of the steel layout shown in FIG. 5 , showing in addition the layout of rebars forming a grill or cage around the rebars;
[0041] FIG. 8 is a side elevation view of the steel and rebar layout shown in FIG. 7 ;
[0042] FIG. 9 is an end elevation view of the steel and rebar layout shown in FIG. 7 ;
[0043] FIG. 10 is an end elevation view of the steel layout of FIG. 5 ;
[0044] FIG. 11 is an end plate detail of the steel layout of FIG. 5 ;
[0045] FIG. 12 is a cover strip shown encircling the bollards in FIGS. 6 and 8 - 10 ;
[0046] FIG. 13 is a top plan view of the steel layout for the base of a set of three bollards in accordance with a second preferred embodiment of this invention;
[0047] FIG. 14 is a detailed top plan view of the steel layout encircled by the line A-A in FIG. 13 ;
[0048] FIG. 15 is a typical section view of the steel layout shown in FIG. 12 ;
[0049] FIG. 16 is a top elevation view similar to FIG. 13 . Showing the steel and rebar layout;
[0050] FIG. 17 is a typical elevation view of the steel and rebar layout shown in FIG. 16 ;
[0051] FIG. 18 is a cross-sectional view of the longitudinal tubular member located adjacent to the bollards in FIG. 13 ;
[0052] FIG. 19 is a cross-sectional view of the longitudinal channel member located at the rear end of the transversely extending members in FIG. 13 ;
[0053] FIG. 20 is a detail of a front stiffener as used in the transversely extending member shown in FIG. 13 ;
[0054] FIG. 21 is a detail of a rear stiffener as used in the transversely extending member shown in FIG. 13 ;
[0055] FIG. 22 is a cross-sectional view of the support arrangement for the bollard tube, including a solid circular steel bar in the center of the tube;
[0056] FIG. 23 is a top elevation view showing the layout of the steel members for forming the framework for a pad designed to support bollards at a corner;
[0057] FIG. 24 is a side elevation view of the corner pad and bollards shown in FIG. 23 ;
[0058] FIG. 25 is a top elevation similar to FIG. 23 showing the location of rebars used in the corner;
[0059] FIG. 26 is a side elevation view of the corner pad and rebars as shown in FIG. 25 ;
[0060] FIG. 27 is a cross-section view showing a stiffener place in the end of the transversely extending members shown in FIG. 23 ;
[0061] FIG. 28 is a cross-sectional view of the support arrangement for a bollard in the framework shown in FIG. 23 ;
[0062] FIG. 29 is a detailed top plan view of the steel frame layout for a pad in accordance with this invention wherein the bollards are removable so as to provide access to the protected structure;
[0063] FIG. 30 is a side elevation view of the steel frame shown in FIG. 29 , showing the reinforced steel socket provided for receiving the lower end of a bollard;
[0064] FIG. 31 is a detailed top plan view similar to FIG. 29 showing the placement of the rebars on the steel frame;
[0065] FIG. 32 is side sectional view of the steel frame and bollard shown in FIG. 29 ;
[0066] FIG. 33 is an end view of the steel frame and bollard shown in FIG. 29 ;
[0067] FIG. 34 is an end sectional view of the frame reinforce steel socket and bollard as shown in FIG. 29 :
[0068] FIG. 35 is a cross-section view showing a stiffener place in the end of the transversely extending members shown in FIG. 29 ;
[0069] FIG. 36 show an arrangement including a bolt for securing a bollard in a socket as shown in FIG. 29 ;
[0070] FIG. 37 is a cross-sectional view of a typical end section of the steel frame shown in FIG. 29 ;
[0071] FIG. 38 is an detailed cross-sectional view of the socket and locking or securing arrangement for a bollard mounted in the steel frame shown in FIG. 29 ;
[0072] FIG. 39 is a cross-sectional view shown the enclosure provide for the locking or securing arrangement shown in FIG. 36 ;
[0073] FIG. 40 is a perspective view of still another embodiment of this invention;
[0074] FIG. 41 shows still another embodiment of this invention, wherein the pad or base is surface mounted;
[0075] FIG. 42 is a perspective view of a corner or curved bollard system in accordance with this invention wherein the base is formed with a ramp for handicap access;
[0076] FIG. 43 is a perspective view of a steel frame formed for the base of a bollard system of this invention which is intended for placement on a slope; and
[0077] FIG. 44 is a perspective view of an embodiment of this invention wherein an opening is left is the base of the bollard system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0078] FIG. 1 shows an embodiment of the anti-ram system of this invention installed in a shallow trench alongside a sidewalk. The top surface 10 of the base or pad of the anti-ram system is shown recessed below the desired grade level. As shown in FIG. 2 , a landscaping surface, such as grass 12 is placed over the top surface 10 of the base or pad. As further shown in FIG. 2 , ornamental or functional objects are placed over the bollards 14 shown in FIG. 1 . Such objects include lamp posts 16 , waste container 18 , ornaments 20 , and a seat and shelter 22 . The ornamental and functional items disguise the presence of the bollards of the anti-ram system.
[0079] FIG. 3 shows an embodiment of this invention with four bollards 14 , mounted on the steel framework 23 for the pad of the anti-ram system. The framework 23 includes transversely extending tubular members 24 , longitudinally extending tubular members 26 , and longitudinally extending angle members 28 . In a preferred embodiment of this invention, the tubular members 24 and 26 have a rectangular cross-section, such that they form a generally planar upper and lower surface for the pad. The longitudinally extending tubular members 26 are welded to the sides of the transversely extending tubular members 24 . Depending on the strength requirements of a particular anti-ram system, the welds can be fillet welds or full penetration welds on all four sides of the tubular members 26 . Similarly, the longitudinally extending angle members 28 are welded to the sides of the tubular members 24 by either full penetration or fillet welds. Alternatively, angular notches can be cut in the transversely extending tubular members 24 for the longitudinally extending angle member to pass through, in which case the angle member may be formed as one continuous piece. Holes are provided in the transversely extending tubular members 24 to receive the cylindrical bollards 14 . Again, the cylindrical bollards are secured to the tubular members 24 by fillet or full penetrations welds at both the upper and lower surfaces of the tubular members 24 . Apertures 30 are provided in both tubular members 24 and 26 , such that they may be filled with a material such as concrete, to add strength and weight to the base or pad.
[0080] FIG. 4 , which is similar to FIG. 3 , shows a rebar cage, or grillage 30 placed around the steel framework 23 . The rebar cage includes an upper portion on top of the tubular members 24 and 26 and a lower portion under the tubular members 24 and 26 . The rebars forming the cage 30 , are welded to the tubular member 24 and 26 .
[0081] FIG. 5 shows a top plan view of a framework for a typical set of three bollards, and FIG. 6 shows a side elevation of the same framework constructed in accordance with this invention. FIG. 7 shows an elevation view of a rebar cage or grillage secured to the framework shown in FIG. 5 . FIG. 8 is a typical side section view of the rebar cage and framework shown in FIG. 7 , and FIG. 9 is a typical front end section view, while FIG. 10 is a typical rear end section view. FIG. 11 is a cross-sectional detailed view of an end plate secured in the tubular member 24 . A gap is provided in the end plate to provide for the filling of the tubular member with a material such as concrete. FIG. 12 is a detailed cross-section of one of the cover strips 32 provided on the bollards 14 . FIGS. 5-12 are representative of a base or pad system in accordance with this invention which requires the provision of an excavation approximately 14 inches deep. The steel framework has a height of approximately 10 inches, the rebar cage adding approximately ½ inch to the height, and the encapsulating concrete adding another 1 and ½ inch, for a total of 12 inches.
[0082] FIGS. 13-22 are similar to FIGS. 5-12 in showing details of a second preferred embodiment of this invention. In this embodiment the base or pad is considerable thinner than that shown in FIGS. 5-12 . In this embodiment the overall height of the pad could be only 6 and ½ inches, the steel frame having a height of 5 inches, with the rebar being located mid-height in the steel frame, rather that on the top and the bottom. The concrete adds 1 and ½ inches to the height of the pad.
[0083] Referring to FIGS. 23-28 , it can be seen that by forming triangles with the transversely and longitudinally extending tubular members, it is possible to form a curved line of bollards.
[0084] Referring to FIG. 40 , two bollard pads 32 , are shown spaced apart by a gap. Before the pads are filed with concrete, a pair of pipes are placed within the pads, such that post tensioning members can be passed through the pipes to secure the two bollard pads 32 to each other. Of course, any number of pads could be placed in alignment and secured by the post tensioning members.
[0085] Referring to FIG. 41 , the bollard system of this invention may be formed as a unit to be place on a surface for temporary bollard protection. The bottom surface is formed as a high friction surface, so as to resist sliding when an impact is received by the bollards.
[0086] Referring to FIG. 43 a perspective view of a steel frame formed for the base of a bollard system of this invention is shown, which is intended for placement on a slope. The bollards are secured to the base at an angle, such that when the base is placed on a slope, the bollards will be vertical.
[0087] FIG. 44 shows an embodiment of this invention wherein an opening is left in the base of the bollard system to provide for an opening, such that when a grate is installed over the opening, an open space below the base is ventilated through the opening.
[0088] While only one embodiment of the invention has been shown, it should be apparent to those skilled in the art that what has been described is considered at present to be a preferred embodiment of the anti-ram system and method of installation of this invention. In accordance with the Patent Statute, changes may be made in the anti-ram system and method of installation of this invention without actually departing from the true spirit and scope of this invention. The appended claims are intended to cover all such changes and modifications which fall in the true spirit and scope of this invention. | An anti-ram system and method of construction having a shallow mounted base pad from which extend a plurality of bollards. Very little or only a shallow excavation is required for the base of the bollard system, which can be partially or fully assembled prior to bringing it to the installation site. The shallow mounting pad or base of the bollard system of this invention may be formed or constructed in various ways and of various materials, and in various configurations. The shallow mounting pad or base is constructed so as to have considerable mass. |
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REFERENCE TO RELATED CASES
[0001] This application claims the benefits of U.S. Provisional application Ser. No. 61/238,675, filed Aug. 31, 2009.
BACKGROUND OF THE INVENTION
[0002] When it rains on a construction site with exposed soil, rain water can cause the soil to erode and be carried into receiving waters, contaminating them with sediment loads and rapidly deteriorating them.
[0003] Heavy contaminates and light oils can be separated from a fluid stream by drawing from the center of a fluid stream. Fine, suspended particles are the most difficult sediment particles to remove, because they require very long settling times and low turbulence in the fluid stream to settle out. It is also most often these fine particles (mainly clay particles) that contribute the most to turbidity (increased opacity) in the water.
[0004] There are a number of methods and technologies used to remove sediments prior to discharge with varying degrees of efficacy. One method of expediting the removal of these fine suspended contaminants is with the introduction of flocculation agent(s) which are used to cause the fine particles to coagulate and settle more quickly. Most of these have an ionic charge which is opposite that of the particles to be settled. As the sediment particles attach to the flocculation agent particles the aggregate particles become larger and larger and settle more quickly. The disadvantage associated with the use of flocculation agents is that in some cases they may involve the addition of something that may be considered a pollutant, and for waters with fish in them, higher concentrations of flocculation agent can cause an occlusion of the fish gills as the gills function with a charge opposite of the flocculation agent causing the agent to accumulate on the gills which could suffocate the fish and kill them.
[0005] While fish are typically not a concern within sediment basins (ponds) at a construction site, where the flocculation agent is introduced and the fine particles are aggregated and settled out of the rain water runoff, fish are a concern in down stream receiving waters. Therefore, it is important to introduce a proper amount of flocculation agent into the rainwater runoff stream, sufficient to remove fine suspended sediment without excess. For example, a minimum of 0.5 ppm of flocculation agent may be sufficient to remove the sediment particles in a particular rainwater runoff, and a dose above 15 ppm may be toxic to some fish species. Therefore it is critical that the proper amount of flocculation agent be introduced into the rainwater runoff to be certain that there is no chance of the floc being overdosed and discharged into the downstream receiving waters.
[0006] One method utilized to avoid the use of excess flocking agents uses a highly controlled, pump and metering system to carefully meter the water and dose the flocculation agent. The water is then retained in a settling tank for a sufficient period of time to allow the settling of the fine sediments to settle. The water is tested for the presence of residual flocking agent and then discharged into the receiving body of water only if the residual presence of flocking agents is below a minimal value. This, although safe and effective, is very expensive.
[0007] Flocking agents can also be administered by placing the flocking agent into a cloth or semi-porous material sock. This sock is then placed into a gravity flow pipe or pump discharge pipe and, as the water flows through the sock, the flocking agent is slowly released. This is a very crude and risky means of inducing the flocking into the water stream, because dosing rates are virtually impossible to control with any level of precision and an overdose could easily occur.
SUMMARY OF THE INVENTION
[0008] This invention treats runoff water which is laden with fine particulate sediment prior to discharge into downstream waters. The invention incorporates a treatment train with a dosing system for introducing a flocking agent and a settling means to allow settling of resultant aggregations of particulate material, followed by filtration of the remaining water through a filter to remove any residual flocking agent as well as particulate matter. Water thus treated is sufficiently clean to discharge into downstream receiving waters, in an effective and efficient manner, and is sufficiently free of flocking agent to avoid being a hazard to aquatic life.
[0009] A series of components are utilized in a treatment train that will clean runoff water. First the required dose is activated by a rain gauge located on a dosing station near the inlet of the sedimentation pond. As the rain occurs, the rain gauge meters the amount of rainfall and sends that data to a microprocessor. The microprocessor will get a signal for each interval of rain (typically 0.01″). The microprocessor can then determine the dose by taking into consideration any number of parameters: antecedent dry period from last rain event, minimum rainfall before dosing will occur, site conditions that will contribute to the runoff, intensity of the rainfall (interval between signals of at least 0.01″), drainage area to the system, time of year, temperature, time to concentration of the runoff, soil types, effluent targets, and target dose concentration. This data will then be evaluated by the microprocessor to determine the precise amount of floc agent to be dispersed. The dosing station is preferably one that uses a finely ground powdered floc agent such as chitosan, metered using an auger with controlled rotation, however any number of feed metering methods may be employed including for example feeding a liquid floc agent by metering with a peristaltic pump. The preferred method of dosing the floc agent is at or near the inlet of the sediment basin so the floc mixes with the turbid influent. As the turbid runoff water enters the pond, mixed with the floc agent, flocculation and subsequent settlement will occur.
[0010] When the pond reaches a certain level, water is skimmed from the storage chamber and diverted by gravity or pump to a filtration vault. The filtration vault will have filters preferably of a polypropylene felt that will remove any unsettled and/or floc'd particles as well as residual floc.
[0011] This system controls the dose of floc agent to a level that the risk of overdosing is minimized, and by the filtration method incorporated any residual floc is removed prior to discharge. The present invention achieves an efficient means for cleaning very fine (typically clay) particles from runoff water, typically the reduction of the clay content of the water to a negligible level. The present invention is capable of removal of 99% of the clay particles in a stream of water with less than 10 minutes of residence time in the filter vault.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a diagram of the overall system for capture and treatment of runoff from a job site.
[0013] FIG. 2 is a detail diagram of the rain gauge controlled floc agent dosing station.
[0014] FIG. 3 Shows the system with the filtration vault located within the sedimentation basin
[0015] FIG. 4 shows the system with the filtration vault located Outside of the sedimentation basin (opposite a weir wall).
[0016] FIG. 5 shows the system utilizing a lift pump to pump the water to the filtration vault located outside of the sedimentation basin.
[0017] FIG. 6 shows the siphon feature associated with the skimmer and filter vault.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] An exemplary embodiment of the present invention is illustrated as implemented on a construction job site, which can typically introduce a large quantity of fine particulate sediment into the rainwater runoff water. Although the present invention is illustrated in connection with a construction site, the invention is applicable in any situation where fine particulate material is introduced into a water flow and requires removal, whether or not the introduction of the material is the result of soil erosion.
[0019] Prior to start of construction the job site FIG. 1 topography is analyzed to determine the water runoff flow for the limits of the construction site 8 . The analysis will determine how rain water and/or ground water drains from the site. Typically a site is divided into drainage areas, such as drainage areas 1 , 2 and 3 illustrated in FIG. 1 , which are separated by drainage divides 6 . An analysis is also made to determine the surface area in a particular drainage area to determine the volume of rain that will fall on that area for each increment of rainfall. As an example, a sedimentation basin 30 will be constructed at the low point of the drainage area 3 . The drainage divides 6 and diversion berms 4 will divert all runoff water to an influent location 7 of sedimentation basin 30 . At preferably the most concentrated inlet location 7 to the sedimentation basin 30 , is a floc dosing station 33 . Inside of the sedimentation basin 30 is a floating skimmer 31 , a filter vault 32 , and an effluent pipe 34 . Ideally the sedimentation basin may contain a high flow bypass means (not shown) to safely convey extreme storms beyond the flow capacity of the filter vault.
[0020] FIG. 2 shows the core components of the dosing station 33 . This is typically a self contained modular unit which is capable of operating remotely with a battery and solar operated battery charger. The dosing station 33 has a rain metering means (rain gauge) 20 . Each increment of rain (typically at least 0.01″) sends a signal to a microprocessor 21 , which collects this data. The microprocessor will have any number of variables programmed into it which, combined with each increment of rain data, will be used to determine the appropriate volume of floc agent to disperse. The microprocessor will then use programmed variables such as expected runoff for the geographic conditions, rainfall intensity (interval between increments), drainage area, dry period from last storm event, target effluent concentrations, time of year, temperature, and other variables determined to target the best dosage.
[0021] The quantity of flocking agent dosed into the water can be dependant on the quantity of rain as a one dimensional variable or can also include the rate of rainfall over time as a second dimension variable to adjust the dosage of flocking agent. For example the same total quantity of rain falling over a shorter period of time may require a greater quantity of flocking agent than the same total quantity of rain falling over a longer period of time. Also, the same periodic quantity of rainfall with greater or less separation between periods of rainfall may require differentiated treatment dosages. With the incremental rainfall data, the microprocessor then determines the timing and volume of floc agent to disperse. This can be done using either a standard dose of for example 1 gram and sending a signal to dose 1 gram at a time or it can be done by determining the exact amount and controlling the rotation of the auger to meter that precise amount. There are many means of taking this computed data and metering the appropriate dose, including for example using a liquid floc agent and a peristaltic pump to meter the volume. In the preferred example provided, the rain gauge 20 located on the dosing station 33 trips a tipping bucket 26 for each increment of rain. This sends a signal to the microprocessor 21 which uses that signal to process, in conjunction with the other variables, and determines the appropriate dose of floc agent 29 to disperse into the influent water 25 . The microprocessor 21 having computed the volume of floc agent 27 and time to disperse, converts this volume to degrees of rotation of the dosing auger 23 and sends a signal to the motor 24 to rotate the dosing auger 23 by that amount thereby sending the precise dose of floc 29 into the influent stream 25 .
[0022] Locating the dosing station at the most turbid input location is ideal in that it will enable the greatest mixing of the floc agent and the influent stream. The flocked water then enters the sedimentation basin 30 and begins to settle the fine solids and flocked clay particles. As the water level rises in the sedimentation basin 30 , it will raise to the point that the skimmer 31 will begin to flow water into the filter vault 32 . The water that flows into the filter vault 32 has been skimmed from just below the surface so that it has had the maximum settling time and is the cleanest. This water will still contain some solids and floc. The water enters the filter vault 32 and flows through the filters 38 which remove the remaining turbidity causing contaminants, any remaining flocked solids, as well as the residual floc agent. From there the water is released through the effluent pipe 34 to the downstream receiving waters.
[0023] The filters 38 are preferably polypropylene felt and of a spiral wrapped design, to optimize surface area. However the filters can be of many different combinations including sand, fabrics or other media.
[0024] FIGS. 3 , 4 , and 5 illustrate alternative locations of the filtration vault 32 relative to the sedimentation basin 30 . FIG. 3 shows the filtration vault 32 inside of sedimentation basin 30 . FIG. 4 shows the filtration vault 32 is located outside of the sedimentation basin 30 , just opposite of a weir wall 35 . The weir wall 35 could also be simply an embankment.
[0025] FIG. 5 illustrates the filtration vault 32 located outside of the sedimentation basin 30 , at a height which prevents the water from flowing into the filtration vault 32 by gravity. When the filtration vault 32 is located above the level of the water in the sedimentation basin, water can be pumped directly from the skimmer pipe 39 or alternatively, a sump basin 37 can be located within the sedimentation basin 30 and the skimmer pipe 39 can discharge into the sump basin 30 . As the water enters the sump pump basin 37 it is pumped by a lift pump 36 to the filtration vault 32 .
[0026] The present invention enables a calculated and precise dose of floc agent, followed by sedimentation, and then a final filtration step which removes remaining sediments, remaining partially flocked clays, as well as residual floc agent. Thereby insuring that only clean water free of any floc agent is discharged into receiving waters.
[0027] A system designed to implement the present invention can be altered or optimized to address the particular needs, requirements and/or design choices and considerations of the particular installation. For example, increasing the settling time will reduce the load on the filter and increase its life expectancy. Decreasing the settling time will allow a smaller pond to process a greater quantity of rainwater in a given amount of time but will decrease the useful life of the filters because they will be able to process a smaller quantity of water before replacement.
[0028] In another exemplary embodiment, a second skimmer 31 is added to the filtration vault 32 which operates only when the sedimentation basin 30 reaches a certain increased level. This will decrease the load on the filters during most storms yet be able to still treat the higher volume/intensity storms, thereby optimizing the filter life between change outs.
[0029] In further exemplary embodiment, a float controlled metering valve can be installed on the filter effluent pipe 34 , inside the filtration vault 32 , which is float activated thereby increasing the flow of the filters at higher levels of water in the filtration vault.
[0030] In an additional exemplary embodiment, FIG. 6 , shows the floating skimmer 31 adapted with a one way air release valve 41 . As the water level rises in the sedimentation basin 30 , it will displace the air under the hood of the skimmer 31 through the air release valve 41 . The water will flow through the skimmer pipe 39 into the filtration vault 32 . There is a turned down elbow 42 located on the skimmer pipe 39 inside of the filtration vault 32 . Once the water has achieved an elevation above the top of the skimmer pipe 39 where it enters the filtration vault 32 there will be a sealed (air free) water chamber. Then as the storm event subsides, a siphon occurs until the water level in the filtration vault is below the bottom of the elbow 42 and at that point air will enter and break the siphon. This achieves an increased settling time and capacity between storm events, further reducing load on the filters and further increasing their life cycle.
[0000] Treatment train above | A treatment system for removal of contaminates includes the introduction of a flocking agent and the settling of resultant aggregations of particulate material, followed by filtration of the remaining water to remove residual flocking agent and particulate matter. Water thus treated is sufficiently clean to discharge into downstream receiving waters, in an effective and efficient manner, and is sufficiently free of flocking agent to avoid being a hazard to aquatic life. The required dose is activated by a rain gauge which meters rainfall over an appropriate time period and evaluated by the microprocessor. |
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FIELD OF THE INVENTION
The present invention concerns a safety apparatus and method used in a gate security system to prevent injury to a user of the system. More particularly it relates to a method and apparatus that automatically shuts off power to the gate security system when a user of the system manually opens or closes the gate.
BACKGROUND OF THE INVENTION
Systems that control and limit access to a secure area are very common in our current day and age. They have wide spread use in gated communities, apartment complexes and single-family residences. These security systems consist of enclosing the selected secure area with some type of barrier and limiting access to the secure area to selected entry-exit points where those wishing to enter or leave can be screened to determine if they meet the criteria of those who can have access to the secure area. Typically, the entry-exit points have a movable barrier controlled by a guard or an automated system to allow entry or exit from the secure area.
In systems manned by a guard, upon the arrival at the barrier the person desiring entry will provide some proof to the guard that they are authorized to enter. Upon determining that the individual is authorized to enter the guard will open the gate, generally by pressing a gate open button so the gate motor can open the gate or alternatively when the individual either on foot or in a vehicle approaches the gate a sensor triggers the opening and then subsequent closing of the gate when the individual or vehicle passes into the secure area.
In an automated system without a guard the individual seeking entry will initiate the opening of the gate by a variety of means, these can include use of a transponder that transmits a coded signal to the gate opening mechanism or entering a code on a key pad to initiate opening of the gate. Other automated gate entry systems provide for calling on a communication device provided at the gate to another individual at a different location that has authority to open the gate with some type of remote control device.
Gate entry systems are used in a wide variety of circumstances including systems for allowing individuals or motor vehicles to have ingress or egress to the secure area. However, since all of these systems are automated to one extent or another, including motors to open and close the gate or barrier, they are all subject to malfunction or failure at one time or another. Often the system is located in a remote location. Thus, they have back up mechanisms or other alternative means to assure that the system can still function and allow them to be used even in the event of failure. One of the alternative means provided in many of these gated security systems, in particular those that rely on a motor to open and close the gate, is a mode of manually opening and closing of the gate. One means is to provide some type of release mechanism that detaches the gate from the automated system. Once detached the gate can than slide or swing freely depending on whether it is a sliding or swinging gate. The trouble with this alternative is that once the gate is detached from the system and allowed to swing or slide freely all of the safety and security systems have been overridden. In order to put the systems back on line the gate must be serviced. This typically requires a service call by a technician to assure the gate is properly reconnected to the system.
An alternative that does not require the detaching of the gate from the automated system involves manually opening the gate with the systems gate opening and closing mechanism. This typically involves cranking the gate open or closed by inserting a shaft of a hand or power crank into a crank shaft receptacle located on a pulley or other rotary member used to transfer power from the gate motor to the gate to move the gate. With this alternative the gate operating mechanism remains unaltered and if the problem causing the failure of the system is transitory, i.e. the result of a local power failure, there is no need for a service call to reset the gate mechanism. However, this alternative has a serious problem in that if the automatic system starts to function while the gate is being manually cranked open or closed, such as the gate motor starts, the individual operating the crank might be injured, perhaps seriously or the system itself might be damaged.
Thus, what is needed is a system and method for manually opening and closing a security that does not require detaching the gate form the automated systems but which allows the safe injury free opening and closing of the gate.
SUMMARY
It is an object of the present invention to provide a method and apparatus that will allow an individual to safety manually open or close a security gate that forms part of an automated security gate system. It is another object of the present invention to provide a failsafe safety system that automatically shuts down an automated gate control system while the gate is being manually opened or closed. It is an additional object of the invention to provide a method and apparatus that does not require the system to be reset after it is manually opened or closed. It is yet another object of the present invention to provide a safety system that functions while the gate is being manually opened or closed, that is efficient and easy to manufacture and integrate into new or existing automatic gated security systems.
The invention accomplishes the above and other purposes by providing an automated security gate with a safety mechanism having: a security gate movable between a closed and an open position to thereby deny or allow access to a secure area; a security gate controller which controls the opening and closing of said gate in response to an open or close signal; a motor mechanically connected to said gate which opens or closes said gate upon receipt of an appropriate signal from said gate controller; a mechanism for manually opening and closing the gate when necessary; and a power shut off device which shuts off power to said gate motor when said gate is being manually opened or closed.
In a variation of present invention the power shut off device is a switch response to a crank shaft being inserted in a crank shaft receptacle on the end of the rotating shaft of the motor wherein when the crank shaft is inserted into the receptacle and turned manually opens or closes the gate depending on the direction the crank is turned.
In yet another variation of the present invention the power shut off device is a leaf responsive to a crank shaft being inserted in a crank shaft receptacle on the end of the rotating shaft of the motor wherein when the crank shaft is inserted into the receptacle and turned manually opens or closes said gate depending on the direction the crank is turned, the leaf being retractably pushed out of a path of the crank shaft and thereby engaging a power shut off switch of the motor.
In another aspect of the invention it provides a method for providing a user safe system for manually opening or closing a security gate in which the automatic opening and closing apparatus has malfunctioned including the steps of: manually opening or closing a security gate when it fails to open or close do to a malfunction of the system; shutting of the power to the automatic gate opening system as soon as the step of manually opening or closing the gate commences; and turning the power back on as soon as soon as the step of manually opening or closing the gate ceases.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by an examination of the following description, together with the accompanying drawings, in which:
FIG. 1 depicts the housing of a security gate system with a hand crank inserted therein to open an adjacent gate;
FIG. 1 depicts a portion of the drive mechanism located in the gate housing depicted in FIG. 1;
FIG. 2 is another view of the gate housing with a power crank inserted therein to manually open an adjacent gate;
FIG. 3 is a view of a gate motor and part of the drive mechanism Located in the gate housing depicted in FIGS. 1 and 2;
FIG. 3A is a review view of a gear box hosing located within the housing of FIGS. 1 and 2;
FIG. 4 is a schematic block diagram of the invention and some of the function components it would work with;
FIG. 5 is a view of the gate motor with the present invention implemented;
FIG. 5A is a perspective side view of a preferred embodiment of the safety plate;
FIG. 6 is a rear view of the safety plate with a first version of the present invention;
FIG. 7 is a rear view of the safety plate with a second version of the present invention;
FIG. 8 is a rear view of the safety plate with a third version of the present invention;
FIG. 9A is a side view of the safety plate with a fourth version of the present invention;
FIG. 9B is a rear view of the safety plate with the leaves of the fourth version of the invention closed over the opening in the plate;
FIG. 9C is a rear view of the safety plate with the Leaves of the fourth version of the invention in the open position and the shaft of a crank protruding through the opening;
FIG. 10A is a rear view of the safety plate with the leaves of the fifth version of the invention closed over the opening in the plate; and
FIG. 10B is a rear view of the safety plate with the leaves of the fifth version of the invention in the open position and the shaft of a crank protruding through the opening.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows some of the basic parts of a typical security gate system. Enclosure 21 houses the gate motor, gate controller and mechanism for transferring the power of the motor to the gate to thereby move the gate 23 . If a failure occurs due to a power failure, malfunctioning of the gate controller which controls the opening or closing of the gate or for some other reason an individual that wants to open or close the gate need only insert a crank 25 into a crank shaft receptacle 26 on the end of drive shaft 39 of motor 36 and crank the gate open or closed. FIG. 1 provides a blow up view of the opening 27 in the housing through the crank is inserted into the crank receptacle 29 . Crank 25 is then rotated to open the gate 23 . A belt 31 , part of which can be seen, forms part of the mechanism for transfer power from the motor 36 to the gate to open the gate. The person using crank 25 thus uses the same mechanical system to open gate 23 as the gate motor 36 . FIG. 2 depicts use of a power crank 34 to open the gate.
FIG. 3 provides a view of gate motor 36 , crank 25 , and crankshaft receptacle 29 used in current security gate systems with the cover removed. Drive shaft 39 of motor 36 has pulley 41 at its end that transfers power to belt 31 . Also, crankshaft receptacle 29 is located on the side of pulley 41 opposite drive shaft 39 of motor 36 . Belt 31 transfers power from pulley 39 to pulley 43 . Pulley 43 connects to gate drive shaft 45 . Gate drive shaft 45 transfers the power to a gear box 47 FIG. 3A, which in turn transfers the power to move the gate. Gear box 47 (FIG. 3A) in turn transfers the power to drive pulley 49 . In turn drive pulley 49 , in concert with positioning pulleys 51 and 52 , moves chain 55 to thus move gate 23 (FIG. 1) back and forth. As noted, the proceeding only describes one system, any number of different types of mechanical systems, not shown, can be used to make the final transfer of power and thus move the gate. The system also has limiting switches or sensors that tell the system when the gate is fully open or closed. The preceding description and drawings only depict one type of security gate set up. Those of ordinary skilled in the art once having read and understood the concepts set forth will readily see that the invention to be disclosed herein has wide application with a variety of security gate systems.
As previously discussed one of the problems with all security gate systems that allow the manual opening or closing of the gate in an emergency is the possibility of injury to the person opening the gate or damage to the mechanism if the security gate system were to start operating when the gate is manually being opened or closed. If a person is manually opening the gate with a crank and the power was to suddenly come on serious injuring could result such as a broken arm or some similar injury. The motor turns at multiple revolutions per seconds much faster than a person might be able to crank it. The person turning the crank would feet a sudden jolt as the motor inadvertently kicks on. If the person opening the gate manually were to be using a power crank 34 (FIG. 2) not only might he or she be injured when it kicks back if the motor were to inadvertently start the system or the power crank could be damaged.
FIG. 4 provides a schematic block type diagram of the major functional components of the invention and the system with which the invention would be used. A security gate 38 operating under normal parameters would be opened and closed by power provided by gate motor 40 . Gate controller 42 would control the operation of gate motor 40 . The invention herein adds manual “gate” operation sensor 44 and power shut off mechanism 46 . The present invention operates such that whenever someone is attempting to open or close gate 38 sensor 44 would note this fact and generate a gate manual operation signal. Power shut off mechanism 46 would receive the gate manual operation signal and accordingly either directly shut off power to gate motor 40 or send a signal to gate controller 42 which in turn would shut off power to motor 40 for so long as the gate manual operation signal was generated by sensor 44 . As will be noted in more detail below sensor 44 and power shut off mechanism can be separate entities or a single unity device. In it simplest form sensor 44 and power shut off mechanism 46 would be a single switch activated by the insertion of a crankshaft into a crankshaft receptacle for manually opening or closing gate 38 . The single switch would shut off gate motor 40 directly. More sophisticated systems would have a separate sensor 44 and power shut off mechanism 46 as will be explained in more detail below.
The above description only provides a basic description of a security gate system using a preferred embodiment of the present invention. Such systems can be much more sophisticated and include sensors embedded in the roadway leading into and through the gate for detection of vehicles. The gate controller can have many different functional features all controlled by its own computer system with memory with security codes it identifies as belonging to persons or vehicles authorized to enter the restricted area. Many of these features are well known to those of ordinary skill in the art and will not be discussed at length herein since they are not necessary for a complete description of the invention herein and an understanding of the invention herein.
FIG. 5 depicts the present invention implemented in the above-described system. A safety plate 61 is positioned between the interior side of the gate system housing 21 (depicted in partial cut away view) and pulley 41 . Safety plate 61 in the embodiment depicted attaches by bolts 62 to motor stand 63 . Safety plate 61 has an opening 65 positioned at point between crank receptacle 29 and opening 27 in housing 21 . Thus, when shaft 25 A of crank 25 is inserted into opening 27 on housing 21 to position the end of the crankshaft in the crankshaft receptacle 29 it passes through opening 65 of safety plate 61 . When shaft 25 A of crank 25 passes through opening 65 it trips or activates a sensing device or switching device that automatically turns off the power to the motor or to the entire gate security system and the power remains off for so Long as the shaft is inserted through opening 65 . This thereby prevents the power to the motor from inadvertently coming on when the gate is manually being opened or closed. This type of safety shut off mechanism works automatically without the need of the person opening or closing the gate having to take the extra step of shutting the system power off, a step that one could easily forget. Additionally, it is the least intrusive means for implementing a safety shut off feature since the act of manually opening the gate automatically implements the system but does not otherwise disturb or reset the system. Thus, if the problem is a transient or passing one, such as a Local power failure, once local power is restored there is no need for any further action on the system in order to assure it is properly functioning.
A variety of sensor or switching systems can be used as part of the present invention. They can range from electromechanical switches to infrared or light sensitive sensors such as those activated by the breaking of the path of a beam of light.
FIG. 5A provides a perspective view of safety plate 61 with a first version of the shut off device of the present invention. Plate 61 has a front 61 A, a rear or back surface 61 B and a base 61 C. In FIG. 5A a portion of two sliding doors or leaves 67 cover opening 65 . FIG. 6 provides a view of the rear 61 B of safety plate 61 on which the mounting of leaves 67 can be view. Upon insertion of the shaft of a crank leaves 67 would slide out and make contact with switches 69 . When doors 67 are pushed out they depress buttons 71 on each of the switches. Wire bundle 72 would connect switches 69 to the electrical system of the security gate system. Upon insertion of the shaft of the crank and activation of the switches the power to at least the gate motor is turned off. The power remains off while the shaft of the crank remains in the crank receptacle. Thus, while the crank is being turned to open or close the gate the power remains shut off.
Only one switch and leave could be used and the system would still operate properly. As depicted in FIG. 7 a single door or leaf 74 partially covers opening 65 . When the shaft of a crank is inserted into opening 65 it forces up leaf 74 , which slides up on slides 77 . When leaf 74 slides up it depresses button 79 of switch 81 . Switch 81 is connected to the electrical system of the security gate system by wire 83 . This in effect shuts off the power to the motor and or entire gate security system for so long as the shaft remains inserted in opening 65 . When the shaft is removed from opening 65 gravity forces leaf 74 back down. This in turn causes button 79 to extend out of switch 81 caused by insertion of a crankshaft.
FIG. 8 provides another variation of the system in which the shaft of the crank when inserted through opening 65 interrupts passage of a beam of light 85 between a Light source 87 and a light receptor 89 . The system detects the interruption of the beam over line 91 and thereby shuts off the power of the system so long as the shaft remains in opening 65 and keeps the power off. Any suitable light source and receptor can be used including a laser light source and receptor.
FIGS. 9A to 9 C depict another variation of the present invention. In FIG. 9A two leaves 93 cover opening 65 . The fronts of leaves 93 form a indented or depressed funnel shape 95 to facilitate the parting of the leaves 93 when a shaft is inserted into opening 65 . FIG. 9B provides a rear view of safety plate 61 with leaves 93 closed over opening 65 which appears in outline from. Leaves 93 are attached to safety plate 61 each by single hinge 95 . Switches 97 are positioned adjacent to leaves 93 within the swing range of leaves 93 . As depicted in FIG. 9C when a shaft 99 of a crank is inserted into opening 65 leaves 93 each swing back out of the way and make contact with buttons 101 of each of the switches 97 . Switches 97 connect to the electrical system of the security gate system over tines 103 to thereby signal the system to shut down power while shaft 99 remains in opening 65 .
FIGS. 10A and 10B provide another version of the invention in which two swinging leaves or doors 107 cover opening 65 . Leaves 107 are retained in the closed position over opening 65 by springs 109 , which pull leaves 107 closed. Adjacent to each of the leaves 107 is contact point or switch 110 which connect to the electrical system of the security gate system by line 112 . When a shaft 99 of a crank is inserted into opening 65 this forces leaves 107 back which pivot on hinges 115 . As both leaves 107 pivot out they make are forced against contact surface of switch 110 . Upon making contact a signal is sent to the electrical system of the security gate system, which initiates a shut off of the power to the gate motor and or system. This shut off condition remains until shaft 99 is removed from opening 65 . Device 110 can be either a sensing contact surface or switch for this version of the invention or any of the other versions of the invention. A sensing contact surface
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be made to it without departing from the spirit and scope of the invention. | An apparatus for shutting off power to a gate motor is disclosed when the gate to which the gate motor is connected is opened or closed manually. In a preferred embodiment a sensor is activated that immediately shuts off power to the gate motor upon insertion of a crank into a receptacle on a pulley of the power driven gate movement system to commence manual opening or closing of the gate with the crank. Rotation of the crank in the appropriate direction either opens or closes the gate. Power is restored to the gate motor when the sensor determines that the crank has been withdrawn from the pulley. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of Provisional Patent Application Ser. No. 60-555,497, filed on Mar. 22, 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a screeding device for uncured concrete floors and surfaces and more particularly to a lightweight self leveling automatic screed apparatus which may be easily transported, easily knocked down and reassembled, and used by one person or a small crew. The lightweight screeding device of the present invention is particularly suited for over ground sites as well as any site requiring portability of the screed apparatus such as elevated or basement floors, driveways, or slabs to be placed by small crews and/or minimally experienced personnel.
BACKGROUND OF THE INVENTION
[0003] Concrete screeds are used by personnel in the building industry to place and level uncured concrete to form a slab or floor. In its most simplistic form, a straightedge such as wooden 2″×4″ is pulled back and forth across the uncured concrete by one or more persons to level the concrete to a predetermined grade which has been previously determined and set using such methods as stakes, wet pads or metal tubing on supports. This manual screeding method requires skilled, physically capable personnel to achieve a quality floor or slab.
[0004] More recently different types of sophisticated screeds have been developed to obtain a more consistently level concrete surface using lasers to meet stricter standards of today's building industry. Large, self propelled, laser screeds such as developed by Somero et al., U.S. Pat. No. 4,655,633, are useful for placing huge easily accessible floors, but are not easily portable or useful on smaller floors. Similarly, truss screeds such as Morrison's U.S. Pat. No. 4,806,047, are more adaptable to use on very large jobs.
[0005] At the other end of the modern screed continuum are the hand held vibratory screeds, such as U.S. Pat. No. 5,676,489, and U.S. Pat. No. 5,540,519 which work well on smaller jobs and are readily portable, but rely on operator skill to achieve consistency of the finished product, even when grade is laser established. By simply tilting the screed apparatus during placement of the concrete, the result may be deflections and variations in the levelness of the concrete both horizontally and vertically to the operator.
[0006] In light of the prior art, a need still exists for a relatively inexpensive, lightweight, easily portable screed, which does not rely on operator experience and skill to achieve an on grade level floor.
BRIEF SUMMARY OF THE INVENTION
[0007] It is the object of this invention to provide an apparatus for screeding/striking off concrete with laser accuracy, automatic mechanical means and ease of portability, in which the entire concrete screed process is performed automatically and accurately with minimal assistance from the operator.
[0008] The present invention establishes grade from a laser plane, employs a tri-pod supported framework, which adjusts for grade by means of linear actuators and strikes the concrete off using a screed member directed by a programmed control circuit, and controlled mechanically by attachment arms connected to a fore and aft movable carriage operating under the tri-pod frame means which has been placed into the freshly poured concrete, and is movable on the job using tires with which it may be placed into the concrete. The tires may then be stowed during the actual screeding until they are once again unstowed for moving to the next area. The screed apparatus may be knocked down and reassembled for further ease of transport in the bed of a pick-up or small trailer.
[0009] The tripod stance of the present invention provides a lightweight frame which may easily be placed into the fresh concrete, providing a platform from which the screed means may operate to strike off the concrete, with minimal obstruction of the work area, unlike prior art which typically is screeded with the screed means at least partially supported on the fresh concrete. In the present invention the screed means is supported entirely by it's tripod framework, placed into and over the uncured freshly placed concrete.
[0010] Further, the at least three actuator legs, of the present invention, in a triangular stance, advantageously permit maximum access for workers tending the concrete in the work area. The singular rear actuator, provides minimal structural obstruction.
[0011] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
[0012] In accordance with a preferred embodiment of the invention, there is disclosed a Lightweight Self-leveling Automatic Screed Apparatus comprising: an automatic height adjustable framework means, employing actuator means in three corresponding legs as the preferred embodiment, responding to a controller predetermined preprogrammed manner to planar establishment means, screeding automatically and repeating the method means until grade is achieved upon which apparatus shuts down, when the controller is satisfied. Further, an advantageous mode of transit consisting of two rotatably stowable wheels may be employed to manually transport the apparatus to its next screed area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
DRAWING KEY
[0000]
1 . Side Plan View
2 . Side Plan View Transport
3 . Top Plan View
4 . Block Diagram of Screeding Method
5 . Electronic Controller
6 . Control Box
7 . Diagram of Screed Leveling
Drawing Key Index
10 . Screed Entity
12 . Fore and Aft Extending Beam
18 . Cross Bars
20 . Frame
21 , 24 Front Leveling Actuators
27 . Rear Leveling Actuator
30 . Screed Tool Member
33 . Tubular Beam
36 . Screed Tool Pivotal Arm Assembly
39 . Screed Tool Carriage
42 . Pivot Rotational Shaft
45 , 48 Carriage Brackets
51 . Carriage Engagement Elastomeric Rollers
54 . Screed Tool Elevation Actuator
57 . Screed Actuator Motor
60 . Sprocket
63 . Chain
65 . Chain Attachment Point Front Cross Bar
67 . Chain Attachment Point Rear Cross Bar
70 . Electronic Controller
73 . Controller Housing
76 . Batteries and Battery Box
81 . Mercury Switches
84 . Photo Electric Cells
87 . Receiver Mast
89 . Laser Receivers
92 . Laser Receiver Lights
95 . Concrete
98 . Upper Concrete Surface
100 . Chain
102 . Gas Shock
230 . Position Sensor
235 . Safety Position Sensor
263 . Transport Wheel Assembly
280 . Transport Handles
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0057] Turning now to the drawings, as discussed above, embodiments of the present invention relate to a portable automatic screed. FIG. 1 is a side plan view of the portable automatic screed 10 in accordance with the present invention. As shown the portable automatic screed 10 has at least one fore and aft track formed of one or more fore and aft extending beams 12 . The fore and aft extending beams 12 are connected to each other in a front thereby a cross bar 15 , and in the rear thereof a rear cross bar beam or channel 18 . The front aft rear cross bars 15 , 18 and the fore and aft beams 12 are supported by at least three leveling actuators 21 , 24 , and 27 , in the preferred embodiment being linear actuators. As shown, the front leveling actuators 21 and 24 are canted slightly forwardly and downwardly and the rear leveling actuator 27 is canted slightly rearward and downwardly. This configuration advantageously provides greater stability and permits a screed tool to have a greater range of motion for the screed means as described below.
[0058] As may be appreciated, the leveling actuators 21 , 24 , and 27 and the fore and aft beams 12 provide a tripod frame on which the screed tool 30 may be movably supported. As shown in FIG. 1 , the screed tool 30 may comprise a hollow tubular beam 33 supported by a pivotal arm assembly 36 and a carriage 39 by a rotational shaft 42 , for example. While the screed tool is shown extending longitudinally perpendicular to the fore and aft direction, other transversely extending configurations are also considered to be within the spirit and scope of the present invention. The carriage, in turn is supported on the for and aft extending beams 12 by a plurality of brackets 45 , 48 . These brackets adjustably support elastomeric rollers 51 that rollably engage a plurality of sides of the fore and aft extending beams 12 . Thus the brackets 45 , 48 , the carriage 39 , the arm assembly 36 and the screed tool 30 are movably supported on the fore and aft extending beams 12 for movement in the fore and aft direction along the beams 12 . Furthermore, a screed tool elevation actuator 54 provides for movement of the arm assembly; 36 in a generally up and down direction, albeit in an arc about the pivot shaft 42 .
[0059] As shown in FIG. 1 , a fore and aft screeding actuator 57 may be mounted on the carriage 39 . As shown in FIG. 1 , the screeding actuator 57 is provided in the form of an electric motor mounted to an upper surface if the carriage 39 . This motor may be a stepping motor that is capable of precise control such as by pulse width modulation, for example. Alternatively, other motors could be used or other actuators could be incorporated, which may include without limitation linear actuators, lead screw driven actuators, hydraulic actuators, pneumatic actuators or actuators mounted to control attached wheels. Furthermore it is understood that the actuator 57 could be mounted on the frame that comprises the front and rear crossbars 15 and 18 without departing from the spirit and scope of the invention. However, as shown in FIG. 1 , the actuator 57 may have a sprocket 60 that engages a chain 63 having a front end 65 fixed to the front cross bar 15 and the rear end 67 fixed to the rear cross bar 18 . Thus, when the actuator 57 is activated, the sprocket 60 turns and holds the carriage 39 along the fore and aft extending beam 12 in either a forward or a rearward direction.
[0060] As shown in FIG. 1 and 3 , an electronic controller 70 is supported on the rear cross bar 18 . The electronic controller 70 has several switches on the exterior of a housing 73 . The switches may include those shown and described with regard to FIG. 1,3 , and 5 . Each of the actuators shown and described above and the electronic controller 70 are powered by the one or more batteries 76 . These batteries may be two twelve volt gel cell batteries connected in a series, for example. Alternatively or additionally, the electrical components of the portable automatic screed may be powered by an alternating current source. Such an arrangement could include a transformer to convert the alternating current to direct current for example. As may be appreciated from FIG. 1 , during operation, the electronic controller 70 receives signals from any number of sensors. These sensors may include but are not limited to, mercury switches 81 and photo electric cells 84 . As shown, the sensors 84 are mounted on the height adjustable masts 87 that are mounted to the screed tool 30 . As may be appreciated, the photo electric cells sensors 84 are part of at least two laser receivers 89 mounted on respective height adjustable masts 87 . The receivers 89 detect a position at which the laser beam strikes the receiver 89 and indicates a needed adjustment by way of lights 92 . This enables the user to manually adjust the height of the receivers 89 and to level the screed tool 30 . Once the screed tool 30 has been leveled and the receivers 89 have been positioned at equal heights, the receivers 89 can be reset to a null value. Thereafter, a signal indicating any variation from the null value is sent back to the electronic controller 70 . The electronic controller is configured to process this signal and in turn actuate any or all of the actuators to automatically provide the originally selected level. Thus, when the ground varies in elevation, or when one of the leveling actuators sinks into the soft ground the screed tool may still be kept at the preselected height and grade based on the independent standard of the laser. It is to be understood that the present invention advantageously levels the frame based on feedback from the laser. This ensures that the screed tool 30 is urged downwardly to the preselected height and grade. advantageously if the screed moves to a position below grade, the fore and aft screeding actuator is turned off by the controller, until the below grade situation is corrected and the leveling actuators cause the screed to come back to the preselected height and grade, unlike prior art which relies on its operator to determine that the screed may be below grade.
[0061] It is understood that the screed tool could be set at a level having a predetermined slope with the laser receivers 89 still indicating a null. In this way a user can selectively vary grade of concrete 95 for all or part of a slab or floor to be poured and finished. Similarly, in another embodiment mercury switches 81 can be operatively connected to the electronic controller 70 to provide feedback as to whether the frame is level or not. In the embodiment shown in FIG. 1 , the photo electronic sensors 84 detect variation in a side to side direction while the mercury switches 81 detect variation in the level in the fore and aft direction. However, in another embodiment both side to side and fore and aft leveling means could be provided by mercury switches or by providing an additional laser receiver spaced rearwardly from those shown in FIG. 1 , a fore and aft level could be detected and transmitted purely by photo electric sensors 84 .
[0062] The electronic controller 70 is configured to either automatically or in response to manual activation of particular switches, activate each of the actuators 21 , 24 , 27 , 54 , and 57 . The manner in which this actuation occurs automatically or by active input will be described in greater detail below. However, it should be noted here that the portable automatic screed of the present invention advantageously, automatically pulls the screed tool 30 across a bed of freshly poured concrete 95 in a work area that underlies the frame 20 . Access to the work area is improved over prior art by having only a single leveling actuator 27 at the rear of the screed 10 . The screed 10 performs and repeats this action for any number of runs needed to bring the upper surface 98 of the concrete 95 to the initially set level on grade condition. As may be appreciated, there are cases in which the poured concrete will be stacked higher than can be leveled in a single run. Therefore it is necessary to permit the arm assembly 36 to be looped upwardly without backdriving the linear actuator 54 . To this end a flexible connection such as chain 100 may be provided between the linear actuator 54 and the arm assembly 36 . Furthermore, gas shock 102 may be provided to bias the screed tool 30 in a downward direction. The stiffness of the gas shock 102 may be selected to be less than the combination of weight and actuation forces that will be experienced at the connection point on the arm assembly 36 . Thus, if the concrete 95 is too stiff, or is stacked too high for the screed 10 to bring the upper surface 98 to the predetermined level, then additional passes may be automatically provided to compensate.
[0063] With regard to FIG. 6 , a rear panel 200 of the electronic controller 70 is shown. Several exemplary switches are shown including a manual/automatic mode switch 205 . It is to be understood, that this switch 205 may be a three position switch, having an “off” position intermediate the manual position and automatic position. Alternatively a separate on/off switch 210 may be provided. Leveling actuator switches 212 , 214 , and 216 may be provided for activating each of the leveling actuators in “up” and “down” directions. These switches may also have a stationary center position. A fore and aft screeding switch 218 may be activated to move the carriage arm assembly and screed tool forwardly and rearwardly. Similarly, a screed tool elevation switch 220 may be activated to move the screed tool and arm assembly up and down. Additionally, a speed control switch 225 may be provided. The switch 225 may be in the form of a rheostat that modulates pulse width, for example.
[0064] FIG. 5 is a schematic diagram showing various elements of the portable automatic screed that have electrical components operatively connected to and/or controlled by the electronic controller 70 . Some of the elements of the screed that are connected to the electronic controller 70 simply provide feedback. For example, position sensors 230 may be positioned along the fore and aft beams 12 to sense and relay a signal to the controller 70 regarding a position of the carriage along the track. These position sensors may be any of a variety of switches including reed switches, micro switches, photo electric cells, or sonic sensors. A corresponding physical characteristic would need to be provided on the carriage for sensing by means of sensors 230 . For example, with reed sensors, a magnet may be located in the carriage or bracket supporting the wheels so that when the carriage approaches a respective sensor, the sensor is activated. Some or all of the position sensors 230 may be eliminated when the screeding actuator is a stepping motor that counts revolutions, for example. With this arrangement, the exact position of the carriage would be indicated by the number of revolutions, for example. Another element that is not controlled by electronic controller is a safety stop switch or sensor 235 . The switch or sensor 235 may be of the type described above with regard to position sensors 230 . However the safety stop switch or sensor 235 is positioned to stop the carriage, arm assembly and screed tool before they engage other components of the portable automatic screed 10 . For example. if the arm assembly 36 were to contact the safety arm shown in FIG. 1 , the safety stop switch or sensor 235 would be automatically activated. In response a signal would be sent to the electronic controller 70 and the motor 57 would be stopped. Slowing and stopping the motor may be accomplished in accordance with a predetermined pattern by the electronic controller. This may be achieved by pulse width modulation of the motor for example. As described above, power 240 may be supplied to the electronic controller 70 by two twelve volt gel cell batteries 76 , for example. Power may be supplied to the various elements of the screed via the electronic controller and/or directly to components. Alternatively, a power cord could be extended from the screed to a 120 volt power source.
[0065] As shown in FIG. 5 , the leveling actuators 21 , 24 , and 27 are connected to the electronic controller 70 . Likewise the screed tool elevation actuator 54 is also connected to the electronic controller 70 . The screeding actuator 57 is also connected to the electronic controller. One or more mercury switches 81 may be connected to the electronic controller. Laser receivers 89 may be connected to the electronic controller as described above. Thus the electronic controller provides an integrated system that may be operated in an automatic mode, or actively controlled via switches as described above, in the manual mode.
[0066] While the present invention has been shown and described with regard to specific embodiments above, it is to be understood that a similar automatic screed could be provided with only two automatic leveling actuators in cases where the ground is substantially level. That is with two automatic leveling actuators and a third non-automatic leg, both side to side and fore and aft leveling could be effectuated under the control of an electronic controller. On the other hand, three automatic leveling actuators as described above advantageously enables a more sophisticated leveling protocol by way of example, and not by way of limitation. The tri-pod stance also uniquely and advantageously provides unobstructed work area for the placement workers.
[0067] FIG. 7 shows a diagrammatic view of an area generally corresponding to that which is swept out in a run by the screed tool of the present invention. Elements 250 correspond generally to the placement of the forward leveling actuators 15 in FIGS. 1 through 3 .
[0068] Elements 253 corresponds generally to the placement of the rear leveling actuator 18 . The run area 256 is depicted by a rectangle. As shown, the left front and right front actuators are run at a maximum speed when the carriage and screed tool is in a forward position. The speed of the front leveling actuators is reduced generally proportional to a distance traveled in the rearward direction by the carriage and screed tool. As shown the left and right front leveling actuators are run at approximately 25 percent of its maximum speed when the carriage reaches a generally central position in the fore and aft direction along the tracks. At the same time, the rear leveling actuator is run at approximately 75 percent of its maximum speed when the carriage is at the central position. When the carriage is approximately 3/4 of the fore and aft distance of a complete run back from the forward position, the front leveling actuators are run at approximately 10 percent of the maximum speed while the rear leveling actuator is run at 90 percent of its maximum speed. Alternatively, a protocol may be devised in which the percentages shown in FIG. 7 represent the extent to which the front and rear leveling actuator account for leveling when the carriage and screed tool are at respective fore and aft positions. The speed variations may be provided by pulse width modulation under electronic control for example. This kind of dynamic control is extremely advantageous in a system in which the force dynamics are constantly changing. Furthermore, actuating the leveling actuators nearest the screed tool at higher percentages will provide a more direct response in vertical movement. With this kind of dynamic control greater precision in leveling concrete is made possible even with a relatively light weight portable automatic screed.
[0069] It is to be understood that while the invention has been shown and described as having three leveling actuators or legs, it is possible to provide the present invention with four or more such leveling actuator components. However, the complexity of such a device would increase with each added leveling actuator. On the other hand, replacing the single rear leveling actuator 18 by a pair of leveling actuators is well with in the spirit and scope of the present invention, especially if the pair of rear leveling actuators are placed close together.
[0070] As shown in FIGS. 1, 2 , and 3 , the leveling actuators 21 , 24 , and 27 are canted outwardly and downwardly from the frame 20 in the fore and aft direction. The angle at which the leveling actuators 21 , 24 , and 27 are canted in the fore and aft direction may be approximately one hundred ten degrees relative to the fore and aft extending beam 12 . This angle may be varied without departing form the spirit and scope of the invention. In particular, this angle is intended to approximately match the angle at which the screed tool beam 33 will be disposed during screeding. Thus, the canted angle of the leveling actuators 21 and 24 advantageously reduces the tendency for the screed tool 30 to contact and/or damage the front leveling actuators 21 and 24 . Furthermore, the canted angle provides greater stability to the portable automatic screed 10 . The front leveling actuators 21 and 24 are also canted outwardly and downwardly in a side to side direction for greater stability. Canting the leveling actuators outwardly and downwardly has the added advantage of dampening of vibration during the operation of the screed.
[0071] When the screed tool is caused to move rearwardly in a sweep that engages poured concrete, the reactive forces tend to push the frame and leveling actuators 21 , 24 , and 27 forwardly. However, the canted angle of the leveling actuators 21 , 24 , and 27 tend to cause the lower ends of the leveling actuators to pierce the subgrade instead of sliding horizontally. Furthermore, lower ends may be provided with cleat structure to frictionally grip the ground, when the subgrade is hard.
[0072] As shown in FIG. 1 , the screed tool beam 33 may be angled at approximately one hundred and ten degrees. Providing the screed tool beam 33 at this angle has the advantage of engaging the concrete 95 more aggressively. However, screeding with the screed tool beam 33 alone disposed at such an angle also tends to leave rocks exposed on the surface 98 of the screeded concrete 95 . In order to avoid this problem while implementing the more aggressive engagement, a trowel plate 260 may be provided as part of the tool. The trowel plate 260 is fixed to or integral with the screed tool 33 , and extends under and rearwardly of the screed tool 33 in a generally horizontal direction. Thus the trowel plate 260 is disposed generally at one hundred and ten degrees relative to a rear face of the screed tool 30 . Another advantage of the trowel plate is that it extends the working reach of the screed tool 30 in a forward direction. For example, the trowel plate 260 of the screed tool 30 can be made to nearly engage the front leveling actuators 21 and 24 . Alternatively, the trowel plate 260 could be notched to generally surround the front leveling actuators 21 and 24 in a forward most position at the beginning of a run. Thus, the portable automatic screed of the present invention may screed substantially to a wall disposed in front of screed 10 .
[0073] Another advantage of the portable automatic screed of the present invention is that after the screed has been wheeled to the position of a run, the wheels 263 and the wheel arms 266 are rotated up and out of the work area by a manual wheel handle, for example. Thus, the wheels 263 and the wheel arms 266 , are out of the way of the workers tending to the concrete and operating screed 10 .
[0074] As shown in FIG. 1 and 2 , the elastomeric rollers 51 advantageously surround and engage the fore and aft extending beam 12 to provide rolling movement of the carriage 39 and the screed tool 30 there along. As shown in FIG. 1 , the upper brackets 45 and the lower brackets 48 support the elastomeric rollers 51 in a surrounding relation with respect to the fore and aft extending beam 12 . The rollers may be supported on the brackets 45 , 48 by respective eccentrics, thus, the position of the rollers may be adjusted until the rollers 51 engage the fore and aft extending beam 12 , at which position, the eccentrics may be tightened. FIG. 1 shows lower portions of bracket 48 extending upwardly from the carriage 39 and having eccentrics and axles supporting elastomeric rollers 51 .
[0075] The elastomeric rollers 51 may advantageously comprise a resilient material surrounding a ball bearing or other friction reducing device. The material of the elastomeric rollers 51 may include rubber, polyurethane,nylon, or a composite material. Wheels similar to roller blade wheels provide a dampening advantage in which the side to side and up and down vibrations are reduced. Furthermore, having a pair of wheels supported on each flange of the bracket 45 / 48 also enhances the dampening effect. The result is that the vibrations experienced by the laser receiver 89 is lessened. Wheels of such make-up and in this configuration also provide the advantage of enabling rolling travel of the elastomeric rollers 51 over contaminated surfaces of the for and aft extending beam 12 without significant decreases in performance in most cases. In lieu of the wheeled movement of the carriage, linear slides might be employed within the spirit and scope of the present invention.
[0076] The present invention may include vibration of all or part of the screed to improve finishing characteristics of the concrete 95 , for example. Furthermore, if any of the actuators are implemented as hydraulic actuators, providing vibration in the system may improve functionality in starting and stopping actuation.
[0077] The frame of the screed is constructed so that the transport tire and wheels 263 are only slightly rearward of a center of gravity for the overall screed 10 when the carriage is in a rearmost position. Thus an operator need only apply a small downward force as indicated by 277 on the transport handles 280 , which are fixed to the rear cross bar 18 , in order to lift a front end of the frame 20 as shown in FIG. 1 . Continuing to apply the small downward force, the operator can move the screed 10 supported on the transport wheels 263 in a deployed position shown in dashed lines in FIG. 1 . Continuing to apply the small downward force, the operator can move the screed 10 supported on the transport wheels 263 in a deployed position shown dashed lines in FIG. 1 . Moving the screed 10 may require similar force and be approximately as simple as would be moving a wheel barrow, for example. Thus, moving the screed into and out of a position for striking of a screed section is relatively easy. Furthermore, moving the screed over wet concrete is also possible, when necessary. The lightweight, easily moveable screeding apparatus of this invention, with its stowable wheels, is an improvement over prior art in that the apparatus may be moved easily by one person without the aid of heavy motor means, or the aid of heavy transportation means, which in prior art are seen obstructing the work area.
[0078] The screed of the present invention may be made to have any number of dimensions. However, in one particular embodiment of the invention, the frame 20 may be located approximately thirty-six inches above the ground or subbase. The frame may have a width of approximately thirty-six inches, a fore and aft length of approximately seventy-two inches and may be formed of a tubular material such as aluminum or composites to reduce weight. The fore and aft screeding actuator means 57 , may be a one-third horse power motor at approximately two hundred seventy pounds of pulling capacity at the radius of the output sprocket. The leveling actuators 21 , 2 and 27 and the screed tool elevation actuator 57 may be provided as linear actuators that employ a lead screw that is turned at at high rate of speed to move one portion of the actuator relative to another and thus lengthen or shorten the actuator. The frame 20 , arm assembly 36 , and the actuators 21 , 24 , 27 can be easily dismantled and stored or hauled in a pickup truck for example, Furthermore, the screed 10 can be easily carried through doorways in a disassembled state and put back together inside a building in which concrete is to be poured and finished. The frame members may be separately connected to each other by way of sockets and inserts on respective members, for example. Thus even the frame can be knocked down into separate components for storage and/or transport, by separating frame, carriage, and transport wheel assembly.
[0079] A method of using a portable automatic screed in accordance with the present invention includes the following steps. Initially, a laser is positioned in accordance with a step 110 of FIG. 4 . This laser may be of a type that sends out a laser beam in a level non-level plane in an arc of 360 degrees, for example. A non-level plane may be used for screeding a sloped surface. Lasers that send a beam in a shorter or a longer arc may also be implemented in accordance with the present invention. Typically, a laser would be mounted on a wall or supported on a tripod for a stable motionless condition. Next the portable automatic screed is raised and/or lowered to an appropriate level and grade as indicated at 115 . With the screed tool at the appropriate level and grade, the laser receivers are adjusted to indicate level, as indicated at 120 . Concrete is poured out on the subgrade to be covered as indicated at 125 . Then the portable automatic screed is rolled into position for a screed run as indicated at 130 . Steps 125 and 130 may be interchanged, depending on the availability of the machine and the concrete, as well as other logistical considerations. The portable screed of the present invention has the advantage of providing a center of gravity that is very; near a vertical plane through the travel wheels in their deployed position, Therefore, only minimal force by a user is required in order to keep the screed balanced during the movement from one run position to another. As may be appreciated, the portable screed may be transported similarly to moving a wheel barrow, for example. Furthermore the transport wheels and overall configuration of the portable screed facilitate traversal of soft soil or poured concrete, when needed. With the portable automatic screed in position, a user then switches the machine on and begins its operation as indicated at 135 FIG. 4 .
[0080] In the automatic mode the portable automatic screed raises the screed tool and moves it to a forward position. The portable automatic screed then lowers the screed under electronic control, as indicated at 140 . The screed the makes a path by moving the screed tool to the rear as indicated at 145 . At the end of the path, the screed checks to see if the screed tool is on grade at the preselected level for the complete path as indicated at 150 . If the screed tool was not on grade for the entire path, then the screed returns to the step indicated at 140 and prepares for and makes another pass. After the screed tool remains on grade at the predetermined level for the entire pass, the screed automatically goes into the park condition by raising the screed tool to a fully raised position and shutting off the controller as indicated at 155 in FIG. 3 . At this point, the portable automatic screed has completed screeding for the work area under the frame 20 . In accordance with the present invention, steps 125 through 155 may be repeated as many times as desired as indicated by loop shown in FIG. 4 . If the portable automatic screed is to be used in a completely different site, or if a different level or grade is desired, then stops 110 , 115 , and 120 will be repeated as well.
[0081] With the electronic controller turned off, the operator manually rotates the tires from the stowed position into a deployed position, “park” position contacting the ground. By forcing the tires slightly past a vertical center, the wheel support arms will rotate into a locked position, as indicated at 126 . In the park condition, the center of mass for the portable screed 10 is very near the center of the wheels. With the wheels in the “park” position, the operator can raise the rear leveling actuator in the manual mode, as indicated at 127 . It is to be noted that the manual switches of the controller 70 can be made to override the automatic mode so that a user can adjust a level or turn off the screed at any time. With the tires in the locked position and the rear leveling actuator raised, the user applies minor downward force on the transport handles 280 to raise the front end of the portable automatic screed, as indicated at 128 . Only minor force is required because the screed is configured to have its center of mass only slightly forward of transport wheels. Then the screed can be easily wheeled to the location of the next run while applying the downward force. In another embodiment of the present invention, the wheels might be self propelled.
[0082] Once the screed is in position for the next run, the operator rotates the tires out of the work area, as indicated at 133 in FIG. 4 . It is to be noted that the screed self levels after each run and after each time the machine is moved to a new run area. In particular, when the rear leveling actuator has been raised, the screed self-actuates the rear leveling actuator until a mercury switch, for example indicates a level condition. Then the screed moves the screed tool to the forward position and begins striking in the repeat sequence described above.
[0083] It is to be noted that the portable automatic screed of the present invention could alternatively be configured to have the center of gravity located rearward of the center of the transport wheels when the screed is in the park condition. In this case a user would have to apply an upward force to the transport handles 280 to balance the screed and to keep it from tipping rearwardly during the transport from one location to another. In this case, instead of the rear leveling actuator being retracted, the front leveling actuators would need to be retracted and the self leveling would be primarily effectuated by actuation of the front leveling actuators. It is to be understood that with a center of mass located rearwardly of the center of the transport wheels, the portable screed would handle much more like a wheel barrow during transport. However this configuration may also require the user to support the screed for a period before the carriage reaches a rearmost position. Alternatively, the rear leveling actuator may be positioned so that it is always rearward of the center of gravity so that the user only needs to apply upward force when the rear leveling actuator is manually retracted. In any case, it is to be understood that only a minor force will be required to keep the screed balanced in the “park” position so that movement of the screed may be easily performed and is facilitated by rolling of the transport wheels.
[0084] The embodiments and examples set forth herein are presented in order to best explain the present invention and its practical application and to thereby enable those of ordinary skill in the art to make and use the invention. However, those of ordinary skill in the art will recognize that the foregoing description and examples have been presented for the purpose of illustration and example only. The description as set forth se not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the teachings above without departing from the spirit and scope of the invention.
[0085] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. | A lightweight one man screed apparatus to automatically strike off and level uncured concrete flatwork, includes a tri-pod framework beneath which a cutting/leveling member operates. The apparatus is controlled by two grade setting devices, adjustably mounted to the screed tool, which may be adjusted relative to a laser plane generating system. Physical control of the screed member may be provided by at least one screed tool pivotal arm assembly moved for and aft by a carriage operated under the tri-pod framework within a fore and aft footprint. The screed tool is adjusted to grade by being raised or lowered by at least one linear actuators responding to an electronic controller. When moving the framework and screed assembly into freshly poured concrete, an operator is assisted by retractable wheels. The wheels are rotationally stowable or used deployed as part of the tripod/transport system facilitating mobility. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 62/059,348 (“the '348 application”), filed on Oct. 3, 2014 and entitled “Trimless Door Frame.” The '348 application is hereby incorporated in its entirety by this reference.
FIELD OF THE INVENTION
[0002] Embodiments of the invention relate to door frames having energy absorbing door stops.
BACKGROUND
[0003] Door openings are generally surrounded about their perimeters or “trimmed” with heavy framing to absorb the forces and vibrations associated with repeatedly opening and closing a door mounted within a door opening. Heavy framing is necessary to withstand the day-to-day usage of a door without producing cracks in the surrounding wall due to stress or fatigue. However, door frames are visible and can prevent construction of doors with a smooth, modern appearance with no visible framing.
SUMMARY
[0004] Aspects of the present disclosure relate to door frames that incorporate an energy absorbing door stop to distribute the forces and vibrations associated with opening and closing a door. The energy absorbing door stop helps to absorb and distribute the forces so that lower levels of force are transferred into the surrounding wall and thus obviates the need for a traditional door frame or trim. Decreased levels of force applied to the surrounding wall reduces the likelihood of cracking the surrounding wall due to stress or fatigue over many opening or closing cycles of the door.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of a trimless door frame installed in a wall according to certain embodiments of the present invention.
[0006] FIG. 2 is a perspective view a trimless door frame in isolation.
[0007] FIG. 3 is a front elevation view of the trimless door frame of FIG. 2 .
[0008] FIG. 4 is schematic end view of a trimless door frame.
[0009] FIG. 5 is a schematic end view of a flush mount plate.
[0010] FIG. 6 is a schematic end view of a door stop frame.
[0011] FIG. 7 is a schematic end view of a support plate.
[0012] FIG. 8 is a sectional end view of a hinge side trimless door frame with a traditional hinge.
[0013] FIG. 9 is a sectional end view of a hinge side trimless door frame with a concealed hinge.
[0014] FIG. 10 is a sectional end view of a hinge side trimless door frame with a flush mount plate.
[0015] FIG. 11 is a sectional end view of a strike plate side trimless door frame with a strike plate.
[0016] FIG. 12A is an assembly view of a hinge side trimless door frame.
[0017] FIG. 12B is an assembly view of a top side trimless door frame.
[0018] FIG. 12C is an assembly view of a plate side trimless door frame.
[0019] FIG. 13A is an assembly view of a trimless door frame with concealed hinges.
[0020] FIG. 13B is a detail perspective view of a support plate for a concealed hinge.
[0021] FIG. 14 is a perspective view of a hinge side trimless door frame assembly.
[0022] FIG. 15 is a perspective view of a plate side trimless door frame assembly.
[0023] FIG. 16 is a perspective view of an assembled trimless door frame.
DETAILED DESCRIPTION
[0024] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
[0025] The described embodiments of the invention provide a trimless door frame assembly with an energy absorbing door stop. While the energy absorbing door stops are discussed for use with trimless door frames, they are by no means so limited. Rather, embodiments of the energy absorbing door stop may be used in any door including, but not limited to, fully framed or trimmed doors.
[0026] With reference to FIG. 1 , embodiments of the invention relate to a trimless door frame assembly 100 . The illustrated door frame is “trimless” in that it does not include the traditional exposed trim on the wall around the door opening that visibly frames the door positioned within the opening. As described in more detail below, the trimless door frame assembly 100 includes a door stop that absorbs shock and/or vibration from the door 500 opening and closing, which may prevent or reduce the amount of shock transferred to adjacent wall 600 (which may be constructed of drywall or any other suitable building materials). The trimless door frame assembly 100 may thus be installed around the perimeter of the door opening within or adjacent the wall 600 without the need for exposed trim on the wall 600 surrounding the door 500 .
[0027] FIGS. 2 and 3 are perspective and elevation views of a trimless door frame assembly 100 with a door 500 installed within it. As shown, the trimless door frame assembly 100 may be constructed such that the door 500 may be substantially flush with one side of the trimless door frame assembly 100 , and, consequently, the door 500 may be substantially flush with the wall or drywall when the trimless door frame assembly 100 is installed adjacent to the wall or drywall. In some embodiments, the trimless door frame assembly 100 may be used in conjunction with a door closer. The trimless door frame assembly 100 is compatible with both surface mounted and concealed door closing mechanisms.
[0028] FIGS. 4-7 are schematic end views of constituent components of a trimless door frame assembly 100 that, with other optional components, may be combined to form a trimless door frame assembly 100 . One embodiment of a trimless door frame assembly 100 includes a door frame 150 (formed of a top frame side 150 a , a hinge frame side 150 b , and a strike plate frame side 150 c ), flush mount plate 200 , floating door stop 250 , and support plate 300 , among other hardware or parts.
[0029] The door frame 150 , flush mount plate 200 , floating door stop 250 , and support plate 300 may be individual components that are assembled together as described below. In some embodiments, the door frame 150 , flush mount plate 200 , floating door stop 250 , and/or support plate 300 may be combined and/or formed from a single piece of material. Any of the below described parts may be constructed from metals, such as aluminum, steel, or other alloys, polymers, composites, or any other material selected for its ease of manufacturing, cost, durability in use, and resistance to corrosion or other environmental conditions. Furthermore, the parts may be produced by machining, casting, stamping, extrusion, any other applicable forming method, or any combination thereof.
[0030] FIG. 16 is a perspective view of an exemplary door frame 150 formed by a top frame side 150 a , a hinge frame side 150 b , and a strike plate frame side 150 c . In use, the door frame 150 is positioned around the perimeter of a door opening provided in a wall 600 .
[0031] The frames sides 150 a - c of door frame 150 may have different cross-sectional profiles tailored to their position within the door frame 150 . However, in other embodiments, the frame sides 150 a - c have the identical profile, an example of which is shown in FIG. 4 . In such embodiments, a single frame member bearing the profile may be formed and then cut to the desired length to serve as the top frame side 150 a , hinge frame side 150 b , and/or strike plate frame side 150 c . The door frame 150 may have a rear side 155 that is adjacent the wall or drywall 600 when the trimless door frame assembly 100 is installed and flanges 156 that wrap around or about the wall or drywall 600 . The door frame 150 may also include a hardware recess 160 with associated clearance gap 165 , an assembly recess 152 , and a door stop recess 170 with associated projections 175 . The various recesses and features of the door frame 150 are configured to accept or receive the flush mount plate 200 , floating door stop 250 , support plate 300 , and any additional parts or hardware as described below.
[0032] FIG. 5 is a schematic end view of a flush mount plate 200 with arms 210 . The arms 210 of the flush mount plate 200 are configured to mate with the hardware recess 160 of the frame sides 150 a - c so that the face surface 201 of the flush mount plate provides a level surface with other components or hardware that are installed in or near the hardware recess 160 . In certain embodiments, the flush mount plate 200 may be used as a spacer or stacking component in the construction of a trimless door frame assembly 100 , as described in more detail below.
[0033] FIG. 6 is a schematic end view of the door stop frame 252 of a floating door stop 250 , which may include a silencer recess 255 configured to receive a door silencer 260 (shown in FIGS. 8-12 , 14 , and 15 ), an optional hollow 275 for lightness, reduction in material usage, and/or ease of manufacturing, one or more absorber recesses 265 configured to receive absorbers 270 (shown in FIGS. 8-12 , 14 , and 15 ), and one or more locator arms 280 with optional extensions 281 . The door stop frame 252 may also include a strike face 251 as the region of contact between a door and the floating door stop 250 . The absorber recesses 265 are configured to receive an absorber (not shown) that forms the point of contact and connection between the floating door stop 250 and door frame 150 . The locator arms 280 and/or extensions 281 are adapted to mate with the door stop recess 170 of the door frame 150 , and the width W is sufficiently small to allow for clearance and lateral movement of the floating door stop 250 with respect to the door stop recess 170 of the door frame 150 .
[0034] FIG. 7 is a schematic end view of a support plate 300 that may comprise one or more protrusions 310 . The support plate 300 and its associated protrusions 310 are configured to mate with the contours of the hardware recess 160 of the door frame 150 . In certain embodiments, the trimless door frame assembly 100 may not include structural supports for hinges, strike plates, and other door hardware as with traditional door frames. The support plate 300 may be installed on the door frame 150 to provide hard mounting points for hinges, strike plates, or other door hardware. Similar to the flush mount plate 200 , the support plate 300 may be used alone or in conjunction with the flush mount plate 200 to stack components in the hardware recess 160 during construction of a trimless door frame assembly 100 .
[0035] FIGS. 8-11 are sectional end views of a hinge frame side 150 b and strike plate frame side 150 c with flush mount plates 200 , floating door stops 250 , support plates 300 , and additional hardware as typically installed to a hinge side stud 151 b and plate side stud 151 c , respectively. The frame side 150 b , 150 c may be affixed or otherwise attached to a stud 151 b , 151 c with drywall screws 153 that pass through the flanges 156 and wall or drywall 600 into the studs 151 b , 151 c . The flanges 156 may overlap the wall or drywall 600 to varying degrees to adjust the amount of spacing between the rear side 155 of the frame side 150 b , 150 c . The spacing between the rear side 155 of the frame side 150 b , 150 c may be used to compensate for variations in the size or trueness of the wall opening. The frame side 150 b , 150 c may then be adjusted to be plumb with respect to the ground and adjacent frame sides 150 a - c . In certain embodiments, the flanges may be left exposed, painted, anodized, or covered with mud, sanded, and painted to match the drywall to provide a smooth and clean appearance. In some embodiments, a decorative reveal 180 may be included in the frame side 150 b , 150 c.
[0036] A floating door stop 250 may be positioned along the length of each frame side 150 a - c and more particularly is positioned within the door stop recess 170 on each frame side 150 a - c and retained therein via locator arms 280 . The floating door stop 250 may include a door silencer 260 positioned within silencer recess 255 on the strike face 251 of the door stop frame 252 . The door silencer 260 may be formed of a gasket material, such as a rubber or other elastomeric material. One exemplary gasket material for the door silencer is a thermoplastic vulcanizate (TPV) material. The door silencer 260 acts to seal the door 500 (not shown) against the floating door stop 250 and silences the door 500 as it closes against the floating door stop 250 . The locator arms 280 may interact with the projections 175 of the door stop recess 170 to allow a loose-fit between the floating door stop 250 and door stop recess 170 . As shown, the locator arms 280 have clearance around their ends to allow the floating door stop 250 to move laterally relative to the door stop recess 170 . In certain embodiments, the locator arms 280 may have different end configurations to allow for additional degrees of freedom. For example, as shown in FIGS. 8-11 , the locator arms 280 allow for relative movement between the floating door stop 250 and door stop recess 170 , and subsequently the frame side 150 b , 150 c , in the direction perpendicular to the strike face 251 of the floating door stop 250 . However, the locator arms 280 have extensions 281 that restrict relative movement between the floating door stop 250 and door stop recess 170 in a direction parallel to the strike face 251 of the floating door stop 250 . In some embodiments, the locator arms 280 may not have the extensions 281 or otherwise be designed to allow for relative movement between the floating door stop 250 and door stop recess 170 in a direction parallel to the strike face 251 of the floating door stop 250 . Certain embodiments of the floating door stop 250 , locator arms 280 , extensions 281 , door stop recess 170 , and/or projections 175 may be configured to allow for relative movement between the floating door stop 250 and door stop recess 170 in one, two, or three dimensions, including rotation about any given axis.
[0037] The floating door stop 250 may also include one or more absorbers 270 positioned within or proximate to the door stop frame 252 and more particularly within the absorber recesses 265 of the door stop frame 252 . The absorbers 270 may be a spring or a component made from rubber, an elastomer, cellular material, a polymer, a thermoplastic vulcanizate, or any other material selected for its ability to deflect, compress, or elongate and regain its shape to absorb and distribute forces. The absorbers 270 function to stabilize the floating door stop 250 in an aligned position within door stop recess 170 of a frame side 150 a - c . When the floating door stop 250 encounters a force, such as when a door is closed against the strike face 251 of the door stop frame 252 , the floating door stop 250 will be laterally displaced relative to the door stop recess 170 , which compresses the absorber 270 distal the strike face 251 into a projection 175 of the door stop recess 170 such that the absorber 270 absorbs the energy of the door closure instead of the surrounding wall. More specifically, the motion and/or displacement of the floating door stop 250 distributes the impact of a door closure or other applied force over a larger amount of time as the absorber 270 deflects and extends the range of motion of the floating door stop 250 . The impact energy applied through the floating door stop 250 extends over a larger time with a correspondingly lower peak force. Also, the internal friction and deflection of the absorber 270 , along with any frictional losses due to the movement of the floating door stop 250 relative to any other parts of the frame side 150 b , 150 c may absorb and dissipate impact energy. The resulting force transferred through a trimless door frame assembly 100 to the studs 151 b , 151 c and wall or drywall 600 has a much lower peak magnitude relative to solidly mounted door stops. These lower peak forces greatly reduce the chances of cracking or fatigue, particularly of the wall or drywall 600 at or around the frame sides 150 a - c and/or drywall screws 153 , even through repeated cycles of opening and closing the door. While the floating door stop is shown equipped with two absorbers 270 , it is certainly contemplated to use a single absorber 270 or more than two absorbers 270 .
[0038] The floating door stop 250 may include any number of modifications or alterations to suit a particular application. For example, as shown in FIGS. 9-11 , an auxiliary absorber 271 may be included in the door stop recess 170 to support or otherwise cushion one or more of the locator arms 280 or extensions 281 . As shown, the auxiliary absorber 271 is disposed between the locator arm 280 and the door stop recess 170 on the opposite side of the floating door stop 250 as the strike face 251 . This auxiliary absorber 271 may be particularly beneficial for absorbing the forces associated with closing of a door. Furthermore, absorbers 270 and/or auxiliary absorbers 271 may be positioned in any orientation or relation between the floating door stop 250 , locator arms 280 , and or extensions 281 and the door stop recess 170 , projections 175 , and/or frame sides 150 a - c.
[0039] In order to adjust or optimize the amount of force absorption for a particular application, the floating door stop 250 (with absorber(s) 270 and optional auxiliary absorbers 271 ) may take on different materials, geometries, or characteristics. For example, the absorbers 270 or auxiliary absorbers 271 may be hollow or solid, and may be made from any material that is suitable for its characteristics to compress, deflect, or elongate in response to an applied load over a large number of loading cycles. In some embodiments, the absorber 270 and/or auxiliary absorber 271 may be cast or otherwise molded in place within the absorber recesses 265 or between the floating door stop 250 , locator arms 280 , extensions 281 , door stop recess 170 , and/or projections 175 . In certain embodiments, the absorbers 270 and/or auxiliary absorbers 271 may be asymmetrical so as to better adapt to differing levels of force applied in different directions. The absorber 270 and/or auxiliary absorber 271 may also be affixed or otherwise attached to the floating door stop 250 , locator arms 280 , extensions 281 , door stop recess 170 , and/or projections 175 by adhesives, directly molding the absorbers 270 and/or auxiliary absorbers 271 to a surface, or forming the absorbers 270 and/or auxiliary absorbers 271 in such a shape as to allow them to accept tensile loads between the floating door stop, locator arms, and/or extensions 281 and the door stop recess 170 and/or projections 175 in addition to compressive loads.
[0040] Referring to FIG. 8 , a hinge frame side 150 b may also include a hinge 320 coupled to a support plate 300 . The support plate 300 is installed in the hardware recess 160 of the hinge frame side 150 b . In certain embodiments, the support plate 300 may be slid along the length of the hinge frame side 150 b to the appropriate location for mounting the hinge 320 . As shown, the hinge 320 may be attached to a support plate 300 with standard fasteners 305 . In certain embodiments, the fasteners 305 may be sufficiently long that they extend into the clearance gap 165 .
[0041] FIGS. 9 and 10 are sectional views of a hinge frame side 150 b adapted for use with concealed hinges 321 taken above and below the concealed hinge 321 , respectively. Concealed hinges 321 may be substantially larger than traditional hinges, and may extend farther into the hinge frame side 150 b such that they impinge upon the hinge side stud 151 b and/or wall or drywall 600 . Notches or other clearance apertures (not shown) must be cut into the hinge frame side 150 b , hinge side stud 151 b , and/or wall or drywall 600 to provide adequate clearance and space for the concealed hinge 321 . In some embodiments, the weakening of the wall or drywall 600 , hinge side stud 151 b , and/or frame side 150 b may require the use of a secondary hinge side stud 322 affixed to the primary hinge side stud 151 b with an optional stud screw 154 . The concealed hinge 321 may be affixed or otherwise attached to a concealed hinge support plate 301 with bolts 306 or other fasteners. The concealed hinge support plate 301 mates with hardware recess 160 . The vertical positioning of the concealed hinge support plate 301 , and consequently the concealed hinge 321 , may be adjusted by stacking the concealed hinge support plate 301 in the hardware recess 160 with different lengths of flush mount plates 200 . The flush mount plates 200 , which may interact with the hardware recess 160 through arms 210 , may provide vertical support to the concealed hinge support plate 301 , and, as shown in FIG. 10 , provide a flush, aesthetically pleasing surface when face surface 201 is coplanar with one or more other portions or features of the hinge frame side 150 b and/or any other adjacent hardware. In certain embodiments, the flush mount plates 200 may be notched or cut to conform to the edge contours of a standard hinge 320 , concealed hinge 321 , or any other hardware that may impinge on the flush mount plates 200 .
[0042] FIG. 11 is a sectional end view of a strike plate frame side 150 c as installed with a strike plate 340 . The strike plate 340 is attached to a support plate 300 by one or more fasteners 305 . The support plate 300 is disposed within the hardware recess 160 of strike plate frame side 150 c . The vertical location of the support plate 300 , and the attached strike plate 340 , may be adjusted by stacking the support plate 300 in the hardware recess 160 with differing lengths of flush mount plates 200 (not shown). The flush mount plates 200 may be notched or otherwise cut or shaped to fit the contours of the strike plate 340 or any other hardware that may be in the vicinity of the flush mount plates 200 .
[0043] FIGS. 12A-C are assembly views of exemplary embodiments of the hinge frame side 150 b , top frame side 150 a , and strike plate frame side 150 c . The frame sides 150 a - c may be provided with a series of flush mount plates 200 interspersed with one or more support plates 300 . Each frame side 150 a - c may also include a door stop frame 252 with a door silencer 260 and absorber 270 . One exemplary method of installing the flush mount plates 200 , support plates 300 , door stop frames 252 , door silencers 260 , and/or absorbers 270 comprises sliding the individual parts into their respective recesses or channels of the frame side 150 a - c by aligning the part at the end of a recess and simply feeding it through.
[0044] As shown in FIG. 12B , the flush mount plate 200 and door stop frame 252 (with door silencer 260 and/or absorber 270 ) may be the same length as the top frame side 150 c so that only one component of each is required to span the length of the top of the door frame 150 . However, the flush mount plate 200 and door stop frame 252 (with door silencer 260 and/or absorber 270 ) may also be provided in multiple sections or pieces to facilitate installation, or to interact with other components of the trimless door frame assembly 100 . For example, the hinge frame side 150 b may require one or more support plates 300 to provide mounting points for one or more hinges 320 . The flush mount plates 200 and support plates 300 may be installed in series such that the flush mount plates 200 establish the vertical location and/or support for the support plates 300 . The positioning of the support plates 300 may be adjusted or otherwise altered by cutting the flush mount plates 200 to length and stacking the flush mount plates 200 and support plates 300 in order in the hardware recess 160 of the hinge frame side 150 b . The hinges 320 may then be affixed or otherwise attached to the support plates 300 in any vertical position as necessary for a particular application.
[0045] Similarly, the strike plate frame side 150 c may include a strike plate 340 affixed or otherwise attached to a support plate 300 . The flush mount plates 200 may be cut to length and stacked in the hardware recess 160 of the strike plate frame side 150 c along with the support plate 300 to vertically locate the support plate 300 and strike plate 340 . In certain embodiments, the flush mount plates 200 may be notched, cut, or otherwise shaped to conform to the peripheral contours of a hinge 320 , strike plate 340 , or any other hardware that may be in contact with the flush mount plates 200 .
[0046] Once the required components have been installed into individual frame sides 150 a - c , the frame sides 150 a - c may be connected with angle brackets 350 to form the door frame 150 . The angle brackets 350 may be installed into assembly recesses 152 to connect the top frame side 150 a with the hinge frame side 150 b and strike plate frame side 150 c on either side, respectively.
[0047] To further describe the operation and interaction of the flush mount plate 200 , support plate 300 , hinges 320 , and/or strike plate 340 , an exemplary installation method of strike plate frame side 150 c is described. A first flush mount plate 200 is first inserted longitudinally into the hardware recess 160 (not shown) and slid along strike plate frame side 150 c until the bottom of the flush mount plate 200 rests against the floor. As shown in FIG. 12C , the upper edge of the flush mount plate 200 towards the bottom of the figure may be notched such that it conforms to the strike plate 340 . This notch, and others, would typically be made prior to taking the strike plate frame side 150 c to the installation location, but they may also be made on-site. In other words, the flush mount plate 200 pieces are typically, but do not have to be, pre-cut. Next, a support plate 300 is inserted longitudinally into the hardware recess 160 and slid along the strike plate frame side 150 c until it abuts the first flush mount plate 200 , which prevents further translation of the support plate 300 within hardware recess 160 and locks support plate 300 in position. This position is where the strike plate 340 will be located. A second flush mount plate 200 is then inserted into hardware recess 160 and slide along strike plate frame side 150 c as described above until it abuts the support plate 300 . The strike plate 340 can then be secured (e.g., screwed) into the support plate 300 . A similar assembly method is performed for the hinge frame side 150 b , although this side may involve the installation of more flush mount plates 200 and support plates 300 depending on the number of hinges 320 used. The assembly of the top frame side 150 a may be simpler, as there may not be hinges 320 or strike plates 340 , and only a single flush mount plate 200 having substantially the same length as the top frame side 150 a need be inserted into hardware recess 160 . In much the same way, the floating door stop 250 may be installed into the frame sides 150 a - c by aligning the floating door stop 250 with the end of the door stop recess 170 . The floating door stop 250 may then be slid along the door stop recess 170 until it is fully installed within the frame side 150 a - c.
[0048] FIG. 13A is an assembly view of a hinge frame side 150 b and strike plate frame side 150 c with concealed hinges 321 . The assembly of the strike plate frame side 150 c may be similar to that described above, with a strike plate 340 mounted to a support plate 300 , which is located by flush mount plates 200 . The assembly of hinge frame side 150 b may be altered or changed to support the use of concealed hinges 321 that are considerably larger and bulkier than traditional hinges. To accommodate concealed hinges 321 , the hinge frame side 150 b may include hardware apertures 162 . The concealed hinge support plates 301 , as shown in FIG. 13B , may include protrusions 311 for aligning and/or locating the concealed hinge support plate 301 in the hinge frame side 150 b , a cavity 312 , hinge aperture 314 , and fastener holes 316 . The cavity 312 and hinge aperture 314 may be configured to accept the concealed hinge 321 so that it may be affixed or otherwise mounted to the concealed hinge support plate 301 via fastener holes 316 . Similarly, flush mount plate 200 may also include apertures 215 to provide clearance for the concealed hinges 321 . As shown, the flush mount plate 200 may be a single piece or may be separate pieces as described above. A single piece flush mount plate 200 may be installed by sliding it into the hardware recess 160 , before or after the installation of the concealed hinge support plates 301 .
[0049] Referring to FIGS. 12A-C and 13 A, the trimless door frame assembly 100 may take on a number of variations or alternative embodiments. For example, trimless door frame assemblies 100 may be fully or partially assembled in a factory or other production facility, including any necessary trimming or shaping of the flush mount plates 200 or any other parts, and installed on site. Alternatively, trimless door frames assemblies 100 may be provided as kits, as individual components cut to length, individual components provided in stock lengths and cut on site, or as bulk lengths of stock material to be cut into individual components on site. In any embodiment, features such as, but not limited to, hardware apertures 162 , apertures 215 , length, notches, or the like may be cut or formed either in a manufacturing facility or on site during door installation. Furthermore, components such as the flush mount plates 200 , door stop frames 252 , door silencers 260 , absorbers 270 , support plates 300 , 301 or the like may be installed by snapping them into place, retaining them with fasteners or adhesives, or sliding them into the applicable recesses as described above. Certain embodiments of the trimless door frame assembly 100 may include the floating door stop 250 and its associated hardware on only the top frame side 150 a , hinge frame side 150 b , strike plate frame side 150 c , or any combination thereof.
[0050] FIGS. 14 and 15 are perspective views of the hinge frame side 150 b and strike plate frame side 150 c . The frame sides 150 b , 150 c include a floating door stop 250 with door stop frame 252 , door silencer 260 , and absorbers 270 . The hinge frame side 150 b has a hinge 320 disposed on mounting plate 300 and between two flush mount plates 200 . Similarly, the strike plate frame side 150 c has a strike plate 340 installed on mounting plate 300 and between two flush mount plates 200 . As shown, the flush mount plates 200 have a face surface 201 that is coplanar with the hinge 320 and/or strike plate 340 . The flush mount plates 200 may also be notched or otherwise shaped to mate with the contours of the hinge and/or strike plate 340 to provide a relatively flat visible surface.
[0051] FIG. 16 is a perspective view of the trimless door frame assembly 100 as assembled from a top frame side 150 a , hinge frame side 150 b , and strike plate frame side 150 c . The flush mount plates 200 and hinges 320 are visible on the hinge frame side 150 b . The frame sides 150 a - c have been assembled by inserting angle brackets 350 into the assembly recesses 152 (not shown). The frame sides 150 a - c may be assembled into a trimless door frame assembly 100 in a wall or wall frame, or they may be assembled and then installed into a wall or wall frame.
[0052] Any of the above described components, parts, or embodiments may take on a range of shapes, sizes, or materials as necessary for a particular application of the described invention. The components, parts, or mechanisms of the described invention may be made of any materials selected for the suitability in use, cost, or ease of manufacturing. Materials including, but not limited to aluminum, stainless steel, fiber reinforced plastics, rubber, elastomers, carbon fiber, composites, polycarbonate, polypropylene, other metallic materials, or other polymers may be used to form any of the above described components.
[0053] Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below. | Described are trimless door frames and energy absorbing door stops. The energy absorbing door stop allows for relative movement between the door stop and the surrounding door frame. The relative movement of the energy absorbing door stop helps to distribute and dissipate forces and vibrations from opening and closing a door, reducing the levels of force transferred into the surrounding wall. The reduction in forces applied to the wall allows for the elimination of heavy door framing and trim. Since door trim is no longer necessary, trimless door frames may be installed with a smooth appearance without cracks appearing in the surrounding wall due to stress or fatigue. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the priority of U.S. Provisional Patent Application Ser. No. 61/337186, filed Feb. 1, 2010, entitled “EMERGENCY SHELTER.”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not Applicable
[0003] REFERENCE TO SEQUENCE LISTING, A TABLE, OR COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to emergency shelters and specifically to emergency shelters provided to relieve suffering as a result of large scale disasters where many people are displaced from their homes. More specifically, the present invention discloses construction of short term sleeping quarters using pre-formed plastic panels enabling displaced persons to survive more safely and comfortably than they would if they were using more conventional facilities.
[0007] 2. Description of the Prior Art
[0008] Typically, relief agencies and governments turn to tent erection as the primary solution to short term housing even though the limitations and shortcomings of tents and tent-like shelters are well known. Tents of the kind provided to refugees offer little protection from temperature extremes in cold or very hot climates. The internal support structure of a tent can be difficult for ordinary, unskilled persons to assemble properly without training. Tents usually have dirt floors which can be wet and unsanitary and a haven for vermin, insects and even unwanted reptiles. Tents can also be expensive to manufacture depending upon the fabric used and the complexity of the mechanical structure needed to keep them up. Therefore many shelters and alternative dwelling units have been invented or proposed but have not been successfully commercialized. Cost is a major consideration and there is reluctance on the part of decision makers to depart from tents as a well known palliative. Some examples of more recent prior art follows beginning with the earliest chronologically.
[0009] A first example is U.S. Pat. No. 4,621,467, issued to Golden, which describes a system for constructing buildings using plastic panels to make emergency structures of unusual shape—rhombic triacontahedral buildings—featuring special hollow edge connectors. The hollow connectors have extruded profiles which fit along the edge of each panel connecting one to another. The instant invention uses a different means of fastening panels altogether as each panel is joined directly to an adjacent panel to form a simple rectangular structure.
[0010] A second example, more akin in appearance to the instant invention, is U.S. Pat. No. 5,083,410 to Watson, for a “System for Construction of Emergency Housing”. Watson's rectangular construction is made of metal and uses a number of different preformed metal channels and common fastening components. Watson envisions an emergency shelter which can be converted into a permanent habitation. Except for initial appearance, the Watson structure is quite different in scope and manufacture from that offered here as an inventive solution.
[0011] U.S. Pat. No. 5,184,436 issued to Sadler discloses a portable utility structure which, in its preferred form, comprises two specially fabricated boards. One board can be folded down along hinged axes to form the top and sides of the shed and the second board can be folded up forming front and back panels. Interlocking tabs connect the top board structure to the bottom part. This appears analogous to various constructions of cardboard boxes and differs markedly from the instant invention which uses primarily plastic panels and entirely different connecting devices.
[0012] U.S. Pat. No. 5,319,904 awarded to Pascoe describes a prefabricated modular building formed from plastic interlocking panels. The panels are configured to form a cone-like structure which helps it resist extreme climatic wind forces and other harsh environmental hazards. It is a much more costly and sturdy structure than the current invention as it is intended to last much longer as a habitation, and even, as inventor Pascoe suggests, function as a hazardous waste storage facility.
[0013] U.S. Pat. No. 5,447,000 to Larsen discloses a system which uses plastic panels to partition the interior of standard intermodal freight containers. These containers are commonly used throughout the world and could be converted to emergency housing relatively quickly using pre-fabricated panels and cam-based connectors. While such an idea may have merit for longer term use as habitations for displaced people, they would be impractical to use in many disaster situations as the cost, availability and difficulties associated with converting great numbers of units and then transporting such large structures to remote areas poses huge logistical problems. The present invention addresses the more immediate need for fast and inexpensively manufactured habitations.
[0014] U.S. Pat. No. 5,771,639 issued to Wood discloses a polygonal structure put together with panels hinged to one another. Pulling on ropes or tensioning lines from opposite sides allows the structure to change from a group of stacked panels into a three dimensional polygonal structure. The present invention is delivered as a group of stacked panels, however, the method of assembly and the design of the shelter are, as will be shown herein, plainly a departure from the Wood disclosure.
[0015] Helin, WIPO Patent Application WO/2000/066846, discloses a house for temporary erection comprised of a plurality of plastic panel elements that are arranged in three layers. This design emphasizes the greater volume of inside space created by having an additional layer of ceiling panels. Of necessity, more panel elements are required in Helin's survival house than the simpler design employed in the present invention.
[0016] Linares, in U.S. Patent Application 2007/0074462 A1, discloses a modularizable and assembleable housing structure that emphasizes the use of powder impression molded construction. While some embodiments appear similar to the instant invention, the structure of Linares is different in manufacture, more costly and complicated and is intended to serve as permanent as opposed to temporary housing.
[0017] Similarly, Day, in U.S. Patent Application 2008/0263968, shows a structure built from a “kit” containing all the requisite components including toilet facilities, air conditioning and apparatus suitable for a housing unit in a society with a developed infrastructure. The instant invention, however, is only intended for temporary use in places where there is little or no functioning water or electricity infrastructure.
[0018] Finally, Esposito, in two U.S. Pat. Applications 2009/0223143 and 2009/0223144, discloses new variations on the use of intermodal containers for housing. These containers are designed for long term habitation unlike the present invention which is intended only for temporary use, at most, perhaps, a six month duration.
[0019] While there have been many prior attempts to address the need for better emergency shelters, the present invention removes the principal impediments to adoption of a newer design, namely, by providing a design that has lower manufacturing costs, lower costs of transportation and extreme ease of assembly. It is exceedingly important that emergency shelters be easy to assemble on site wherever they may be needed by people who may be under a great deal of stress. Accordingly, an object of this invention is to provide an emergency shelter which is lightweight, easily transported using conventional means, and can be erected quickly and easily without tools. Another object of this invention is to provide an emergency shelter which is more durable, safe and comfortable than conventional tents which are usually supplied as a first response to calls for emergency shelters.
[0020] A further object of this invention is to provide an emergency shelter capable of shielding displaced persons from the debilitating effects of exposure to the natural elements and can serve as a temporary replacement dwelling for two persons though capable of being extended modularly into a larger habitat.
[0021] A further object of the invention is to provide a shelter which is constructed primarily of plastic panels, securely packaged and capable of being air-dropped by parachute to remote locations. Still another object of this invention, in an advanced embodiment, is to provide a fully operable emergency shelter equipped with uni-directional heating apparatus (as described in U.S. Pat. No. 4,922,084) located within the floor panel and solar generating power means normally supplied and located in the roof.
[0022] A still further object of this invention is to provide an emergency shelter composed of easily recyclable materials.
SUMMARY OF THE PRESENT INVENTION
[0023] The present invention discloses a novel and non-obvious assembly for use as an emergency shelter. In one embodiment, the inventive shelter is assembled from eight (8) plastic composite hollow-filled panels as sub-assemblies. Six (6) hollow-filled panel sub-assemblies form an exterior structure and two (2) bed platform panel sub-assemblies form interior components. Each component or sub-assembly is comprised mainly of a plastic polymerized panel shell with a hollow interior. At least a portion of the interior shell of each panel is filled with cellular or composite material. The panels, referred to herein also as sub-assemblies, or, panel sub-assemblies, have been pre-formed with holes or apertures and relieved portions for very fast assembly in the field by untrained people without the benefit of hand tools or power tools. Four (4) exterior panels or sub-assemblies are raised into an upright position to form the walls of the structure, and one wall panel contains a window and a doorway with a door hingedly affixed. A floor panel sub-assembly and a roof panel sub-assembly together with four wall sub-assemblies form the completed exterior structure. The inventive emergency shelter is portable and assembleable on the site where it is needed. It is delivered to the site in pre-assembled form. Normally, the panel sub-assemblies are stacked on a pallet in “knocked down” form. Very fast assembly of the emergency shelter structure from the pre-assembled form to a fully assembled three dimensional form is accomplished using “push anchors”. Push anchors are fasteners that can be inserted manually and pushed into pre-existing holes in the panels joining adjacent panels together permanently. Panel fastening means incorporating wall or “push” anchors of the type shown in U.S. Pat. No. 4,633,640 and in U.S. Pat. Nos. 4,963,051 and 5,088,851 permit very rapid assembly of adjacent panels. Push anchors of this type have pivotable, triangular-shaped gripping members which will engage the internal foam or other composite medium inside the panel sub-assemblies. Holes are pre-formed or drilled in the panels to accept the insertion of the push anchors. It has been demonstrated that the entire emergency shelter can be erected by two people in 10 minutes or less after opening the packaging on the pallet containing the panel sub-assemblies. In more advanced embodiments, not illustrated in the accompanying drawings, the roof panel carries arrays of solar cells for converting radiant energy into electricity. In other embodiments, floor heating apparatus are embedded into the floor panel. Additionally, packaging used to contain a shelter assembly while it is being transported can be used to anchor it more firmly in its fully assembled location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Drawings are provided which illustrate and clarify inventive aspects of the emergency shelter as described in the Detailed Description which follows. Reference numerals in the drawings which refer to similar parts throughout the various views have similar numbers. It should be understood, however, that the invention is not limited to the embodiments illustrated by these Figures. The drawings, briefly described, are as follows:
[0025] FIG. 1 is a perspective view from a front corner of the embodiment of an assembled emergency shelter unit.
[0026] FIG. 2 is a perspective line drawing of the emergency shelter of FIG. 1 as if the roof and front and near sidewalls were removed illustrating interior features.
[0027] FIG. 3 is a elevation detail in cross-section of a wall panel connected to the roof panel assembly by means of a fully inserted push anchor.
[0028] FIG. 4 is an elevation detail in cross-section showing how a vertical panel is connected to the floor platform by means of a fully inserted push anchor.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] Referring to FIGS. 1 and 2 , a housing unit assembled for use as an emergency shelter is illustrated generally at 10 in the present invention. The shelter is comprised of a front wall panel 18 , two sidewall panels 14 and 16 respectively, a back wall panel 22 , a roof panel 20 , two bed platform panels 24 and a lower platform panel 12 which serves as the interior floor. In a preferred embodiment, the floor panel 12 also serves as the top surface of a rugged pallet for transporting the other panel sub-assemblies. The platform panel 12 of this preferred embodiment has a horizontal upper surface and lower skid-like projections, or risers, 40 , which extend laterally along the underside of floor panel 12 . The ends of three lateral risers 40 are visible in FIGS. 1 and 2 . The lateral risers 40 are useful as a pallet for the sub-assemblies and also serve to keep the emergency shelter above the ground and free from flowing water.
[0030] Each panel sub-assembly is manufactured from plasticized polymeric panels of dual wall construction. Essentially these are plastic panels of dual wall construction having a hollow area contained within an outer plastic shell. In some constructions, the shell can have multiple layers. The hollow region between the outer shell(s) is filled with insulation or other composite material. Insulation such as cellular foam is sandwiched between the external polymeric shells to limit the effects of climatic temperature extremes. The rigid foam or other internally contained composite material acts as the medium to accept secure engagement with the aforementioned push anchors 50 . The shelter illustrated in these FIGS. is approximately 2 meters (7 feet) wide, side wall 14 to side wall 16 , and 1.6 meters (5 feet) deep measured from the front door panel 18 to the back wall panel 22 . It is designed with a minimum inside ceiling height of approximately 1930 mm (6 ft. 4″) and increases to more than 2200 mm (more than 7 feet) in the center of the structure. Thus it is able to provide comfortable accommodation to the vast majority of humans regardless of physical stature.
[0031] The front wall panel 18 contains within it a conventional door for ingress and egress and a window, suitably insulated, to supply light and ventilation which makes the inventive shelter more user-friendly and secure than tents commonly provided to refugees. A series of clearance holes 52 are molded into the panel to accommodate push anchors 50 . The holes 52 project perpendicularly through the thickness of the panel and are located near the edge of the front surface, or face, of panel 18 . Each hole 52 is slightly inset from the perimeter of panel 18 as they are designed to align with holes 54 in the edge faces of panels abutting the back surface of front panel 18 . Hole 52 , as mentioned, is a clearance hole for a push anchor whereas hole 54 is an acceptance hole for a push anchor. As such, hole 54 is a cavity within material designed to engage the pivoting members of the push anchor 50 as taught in U.S. Pat. Nos. 4,963,051 and 5,088,851. To simplify the assembly of the emergency shelter, all the push anchor 50 fasteners should be of the same size, in both diameter and length.
[0032] The back wall panel 22 supports two horizontal cleats 26 which provide partial support for the bed or sleeping platforms 24 . Two such platforms 24 , an upper and a lower, are provided with each shelter. A novel aspect of the inventive shelter is the structural support provided by the sleeping platforms 24 as they are fixed in position using push anchors 50 on outwardly molded cleats, or projections, 30 from each interior sidewall 14 and 16 . The platforms 24 span the entire width of the shelter and therefore, as a person reclines on a horizontal platform 24 , the down force imparted by his or her weight is transferred directly to the sidewalls 14 and 16 increasing the rigidity of the lightweight structure and thus enhancing its stability. The back wall panel 22 , like front panel 18 , has holes 52 to accommodate push anchors 50 located linearly around the surface of the panel near its perimeter. Alternatively, the bed or sleeping platforms 24 , if extended in length, could be inset into the sidewalls 14 , 16 if a relief is provided in the sidewall to accept the additional length. Push anchors 50 can still be used to maintain the bed platforms fixedly against the sidewalls and back wall.
[0033] Each sidewall panel, as shown by numerals 14 and 16 in the various Figures, contains a surface projection 30 designed as a cleat or support for the end of a bed platform 24 . These cleats contain a hole 54 suitably sized for acceptance and engagement of a push anchor 50 . In addition, the sidewall panels 14 and 16 , like the front panel 18 and back panel 22 , have thru holes 52 to accommodate push anchors 50 located linearly around the surface of each respective panel near each of the panel perimeters.
[0034] Each bed platform 24 has one or more thru holes 52 on each end perpendicular to its top horizontal surface, suitably located to align with the push anchor acceptance holes 54 in the cleats 30 located on the sidewall panels 14 , 16 .
[0035] A roof panel 20 is delivered with the other sub-assemblies as a flat rectangular panel (not shown as flat) with protruding flanges 44 approximately 3″ (7.6 cm.) high and 2″ (5 cm.) in thickness. A view of a part of one protruding flange 44 is shown in FIG. 3 . A relieved midline bend line 48 is molded into the plastic roof panel 20 allowing it to bend downward. As a result, the roof can rest on the top edges of the four vertical walls 14 , 16 , 18 , 22 bringing holes 54 in line with holes 52 . Holes 54 are located in a line in flanges 44 which protrude from the underside of the roof 20 ; holes 52 are located in a line near the top edges of the vertical wall panels 14 , 16 , 18 , 22 as disclosed previously. The rapid assembly of the inventive emergency shelter 10 is possible because the parts are lightweight and capable of being assembled using a single size of push anchor 50 . The method of rapid assembly is as follows: The sub-assemblies are delivered to the shelter erection site stacked on the floor platform 12 which is placed in a desired location. The back panel assembly 22 is removed from the stack and tilted into a vertical position along a longer side of the floor platform 12 . The floor platform 12 has a horizontally relieved surface 34 along its perimeter; in this example, the width of the relieved surface 34 is the thickness of a vertical panel—3″ (7.6 cm.). The depth of the relief is 2″ (5 cm.). As a result, there is a secondary horizontal surface 34 3″ wide adjacent a 1″ (2.54 cm) high vertical face 38 along the entire perimeter of the floor platform 12 . Locating pins 28 project vertically up from this secondary horizontal surface 34 . These pins 28 are designed to mate with holes (not shown) in the bottom edge of each panel as each is raised and tilted into vertical position along the floor platform 12 . When the back panel 22 is located on the pins 28 and held vertically, all the holes 52 along that side align with all the holes 54 in the vertical face 38 of the floor platform 12 . Push anchors 50 are inserted passing through holes 52 into holes 54 and are pressed in permanently, locking the back panel 22 against the floor panel 12 . Then, sequentially, a first sidewall panel, 14 or 16 , is mounted on its respective locating pins 28 and tilted into vertical position and fastened in place. It is mated with the adjacent back wall panel along its vertical edge in the same manner as previously described by lining up holes 52 and 54 and inserting and fully depressing the push anchors 50 . Then the second sidewall panel is erected and fastened in place. Then, with two sidewalls and the back wall fixed in place, the bed platforms 24 are mounted on cleats 30 and fastened to the inside wall panels using push anchors 50 . Next, the front wall panel 18 is tilted into vertical position and fastened to the floor panel 12 and both sidewalls 14 , 16 . Finally, the roof panel 20 is lifted into position over the tops of the vertical panels and fastened to each vertical panel 14 , 16 , 18 , 22 using push anchors 50 . The push anchors are inserted through holes 52 in the vertical panels. The shank of the push anchor passes through holes 52 into holes 54 in the flanges 44 as shown in FIG. 3 which project downward from the underside of the roof panel 20 .
[0036] Another embodiment of the emergency shelter provides the additional feature of solar cells in arrays on the roof panel 20 (not specifically illustrated in Figures provided) for harvesting solar energy for use directly or indirectly to supply electrical current for lighting or to augment current required for floor heating apparatus. These arrays of solar cells supply electricity where none is available or increase the available supply of electricity to occupants of the shelter when the supply is limited.
[0037] A further embodiment of the emergency shelter for use where colder temperatures are prevalent provides heating means embedded in the lower platform panel 12 preferably in the floor immediately below and in front of the bed platforms 24 . An appropriate heating apparatus is shown in U.S. Pat. 4,922,084 which discloses a uni-directional device which would efficiently direct heat upwards into the interior of the emergency shelter. This device would also work in conjunction with the solar cells already mentioned.
[0038] The emergency shelter invention described is meant to be useful for a limited time, perhaps six months at most. As such it is desirable that it be made from fully recyclable materials.
[0039] In instances where wind or stormy weather will impart lateral forces against the paneled structure, the use of rope tethers or a weighted fabric skirt fastened to the outer panels will inhibit wind damage and keep the structure firmly in place. The embodiment illustrated in FIGS. 1 and 2 can use risers 40 manufactured of formed plastic which are hollow. Water can be injected to provide ballast and further retard movement by wind forces.
[0040] The emergency shelter as described weighs approximately 150 kg and thus can be easily air-dropped singly or in multiples. In a further embodiment, an air bladder is provided to act as a drop cushion fastened to the package containing the emergency shelters. As it exits the plane, the bladder is expanded to cushion the impact of the package as it hits the ground. The bladder, in collapsed form, can then be removed, fastened to the side panels or lower platform of the emergency shelter to act as the skirt noted above.
[0041] While the present invention has been disclosed and described herein with reference to certain embodiments, variations and modifications may be made which will fall into the true spirit and scope of the invention as defined in the following claims: | An emergency shelter structure is disclosed for use where people are displaced from their homes as the result of some catastrophe. The inventive shelter can be erected entirely without hand tools or power tools in less than 20 minutes. It is comprised of plastic panels which are joined together using push anchors, fasteners which permit rapid and permanent engagement of adjoining panels. Bed platforms are included as part of the assembly. In advanced embodiments, solar arrays are provided for harvesting solar energy for use as electricity and uni-directional heating apparatus is molded into the floor panel. |
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Continuation-in-Part of U.S. patent application Ser. No. 09/794,964 filed on Feb. 27, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to drilling fluid telemetry systems and, more particularly, to a telemetry system incorporating an oscillating shear valve for modulating the pressure of a drilling fluid circulating in a drill string within a well bore.
[0004] 2. Description of the Related Art
[0005] Drilling fluid telemetry systems, generally referred to as mud pulse systems, are particularly adapted for telemetry of information from the bottom of a borehole to the surface of the earth during oil well drilling operations. The information telemetered often includes, but is not limited to, parameters of pressure, temperature, direction and deviation of the well bore. Other parameter include logging data such as resistivity of the various layers, sonic density, porosity, induction, self potential and pressure gradients. This information is critical to efficiency in the drilling operation.
[0006] Mud pulse valves must operate under extremely high static downhole pressures, high temperatures, high flow rates and various erosive flow types. At these conditions, the valve must be able to create pressure pulses of around 100-300 psi.
[0007] Different types of valve systems are used to generate downhole pressure pulses. Valves that open and close a bypass from the inside of the drill string to the wellbore annulus create negative pressure pulses, for example see U.S. Pat. No. 4,953,595. Valves that use a controlled restriction placed in the circulating mud stream are commonly referred to as positive pulse systems, for example see U.S. Pat. No. 3,958,217.
[0008] The oil drilling industries need is to effectively increase mud pulse data transmission rates to accomodate the ever increasing amount of measured downhole data. The major disadvantage of available mud pulse valves is the low data transmission rate. Increasing the data rate with available valve types leads to unacceptably large power consumption, unacceptable pulse distortion, or may be physically impractical due to erosion, washing, and abrasive wear. Because of their low activation speed, nearly all existing mud pulse valves are only capable of generating discrete pulses. To effectively use carrier waves to send frequency shift (FSK) or phase shift (PSK) coded signals to the surface, the actuation speed must be increased and fully controlled.
[0009] Another example for a negative pulsing valve is illustrated in U.S. Pat. No. 4,351,037. This technology includes a downhole valve for venting a portion of the circulating fluid from the interior of the drill string to the annular space between the pipe string and the borehole wall. Drilling fluids are circulated down the inside of the drill string, out through the drill bit and up the annular space to surface. By momentarily venting a portion of the fluid flow out a lateral port, an instantaneous pressure drop is produced and is detectable at the surface to provide an indication of the downhole venting. A downhole instrument is arranged to generate a signal or mechanical action upon the occurrence of a downhole detected event to produce the above described venting. The downhole valve disclosed is defined in part by a valve seat having an inlet and outlet and a valve stem movable to and away from the inlet end of the valve seat in a linear path with the drill string.
[0010] All negative pulsing valves need a certain high differential pressure below the valve to create sufficient pressure drop when the valve is open. Because of this high differential pressure, negative pulse valves are more prone to washing. In general, it is not desirable to bypass flow above the bit into the annulus. Therefore it must be ensured, that the valve is able to completely close the bypass. With each actuation, the valve hits against the valve seat. Because of this impact, negative pulsing valves are more prone to mechanical and abrasive wear than positive pulsing valves.
[0011] Positive pulsing valves might, but do not need to, fully close the flow path for operation. Positive poppet type valves are less prone to wear out the valve seat. The main forces acting on positive poppet valves are hydraulic forces, because the valves open or close axially against the flow stream. To reduce the actuation power some poppet valves are hydraulically powered as shown in U.S. Pat. No. 3,958,217. Hereby the main valve is indirectly operated by a pilot valve. The low power consumption pilot valve closes a flow restriction, which activates the main valve to create the pressure drop. The power consumption of this kind of valve is very small. The disadvantage of this valve is the passive operated main valve. With high actuation rates the passive main valve is not able to follow the active operated pilot valve. The pulse signal generated is highly distorted and hardly detectable at the surface.
[0012] Rotating disc valves open and close flow channels perpendicular to the flow stream. Hydraulic forces acting against the valve are smaller than for poppet type valves. With increasing actuation speed, dynamic forces of inertia are the main power consuming forces. U.S. Pat. No. 3,764,968 describes a rotating valve for the purpose to transmit frequency shift key (FSK) or phase shift key (PSK) coded signals. The valve uses a rotating disc and a non-rotating stator with a number of corresponding slots. The rotor is continuously driven by an electrical motor. Depending on the motor speed, a certain frequency of pressure pulses are created in the flow as the rotor intermittently interrupts the fluid flow. Motor speed changes are required to change the pressure pulse frequency to allow FSK or PSK type signals. There are several pulses per rotor revolution, corresponding to the number of slots in the rotor and stator. To change the phase or frequency requires the rotor to increase or decrease in speed. This may take a rotor revolution to overcome the rotational inertia and to achieve the new phase or frequency, thereby requiring several pulse cycles to make the transition. Amplitude coding of the signal is inherently not possible with this kind of continuously rotating device. In order to change the frequency or phase, large moments of inertia, associated with the motor, must be overcome, requiring a substantial amount of power. When continuously rotated at a certain speed, a turbine might be used or a gear might be included to reduce power consumption of the system. On the other hand, both options dramatically increase the inertia and power consumption of the system when changing from one to another speed for signal coding. Another advantage of the oscillating shear valve is the option to use more sophisticated coding schemes than just binary coding. With the fast switching speed and large bandwidth of the oscillating shear valve, multivalent codes are possible (e.g. three different conditions to encode the signal). The large bandwidth also enables the operator to use chirps and sweeps to encode signals.
[0013] The aforesaid examples illustrate some of the critical considerations that exist in the application of a fast acting valve for generating a pressure pulse. Other considerations in the use of these systems for borehole operations involve the extreme impact forces, dynamic (vibrational) energies, existing in a moving drill string. The result is excessive wear, fatigue, and failure in operating parts of the system. The particular difficulties encountered in a drill string environment, including the requirement for a long lasting system to prevent premature malfunction and replacement of parts, require a robust and reliable valve system.
[0014] The methods and apparatus of the present invention overcome the foregoing disadvantages of the prior art by providing a novel mud pulse telemetry system utilizing a rotational oscillating shear valve.
SUMMARY OF THE INVENTION
[0015] The present invention contemplates a mud pulse telemetry system utilizing an oscillating shear valve system for generating pressure pulses in the drilling fluid circulating in a drill string in a well bore. In one aspect of the invention, a mud pulse telemetry system comprises a drillstring having a drilling fluid flowing therein, where the drill string extends in a borehole from a drilling rig to a downhole location. A non-rotating stator is disposed in the flowing drilling fluid, the stator having a plurality of flow passages to channel the drilling fluid. A rotor is disposed in the flowing drilling fluid proximate the stator, the rotor having a plurality of flow passages. A motor driven gear system is adapted to drive the rotor in a rotationally oscillating manner for generating pressure fluctuations in the drilling fluid.
[0016] In another aspect, a method for providing a high data rate in a mud pulse telemetry system by generating a fast transition in a mud pulse telemetry multivalent encoding scheme, wherein the combination of an amplitude shift key encoding (ASK) scheme and a frequency shift key encoding scheme (FSK) comprises driving a rotor in an oscillatory periodic motion through at least one first predetermined rotational angle at at least one first frequency generating at least one first pulse amplitude at the at least one first frequency. A drive signal is changed to drive the rotor in an oscillatory periodic motion through at least one second predetermined rotational angle at at least one second predetermined frequency according to the multivalent encoding scheme. At least one second pulse amplitude at the at least one second frequency is attained in no more than one rotor oscillatory period.
[0017] Examples of the more important features of the invention thus have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For detailed understanding of the present invention, references should be made to the following detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, in which like elements have been given like numerals, wherein:
[0019] [0019]FIG. 1 is a schematic diagram showing a drilling rig engaged in drilling operations;
[0020] [0020]FIG. 2 is a schematic of an oscillating shear valve according to one embodiment of the present invention;
[0021] [0021]FIG. 3 a is a schematic of a typical torque signature acting on an oscillating shear valve according to one embodiment of the present invention;
[0022] [0022]FIG. 3 b is a schematic of a magnetic spring assembly according to one embodiment of the present invention;
[0023] [0023]FIG. 3 c is a cross section view of the magnetic spring assembly of FIG. 3 b;
[0024] [0024]FIG. 3 d is a schematic of a shaped torque profile according to one embodiment of the present invention;
[0025] [0025]FIG. 4 is schematic which describes Phase Shift Key encoding using an oscillating shear valve according to one embodiment of the present invention;
[0026] [0026]FIG. 5 is a schematic which describes Frequency Shift Key encoding using an oscillating shear valve according to one embodiment of the present invention;
[0027] [0027]FIG. 6 a illustrates a continuously rotating shear valve;
[0028] [0028]FIG. 6 b illustrates an oscillating shear valve according to one embodiment of the present invention;
[0029] [0029]FIG. 6 c illustrates the jamming tendency of a continuously rotating shear valve;
[0030] [0030]FIG. 6 d illustrates the anti-jamming feature of an oscillating shear valve according to one embodiment of the present invention;
[0031] [0031]FIG. 7 is a schematic which describes a combination of a Frequency Shift Key and an Amplitude Shift Key encoding using an oscillating shear valve according to one embodiment of the present invention;
[0032] [0032]FIG. 8A is a schematic of an oscillating shear valve incorporating a motor-gear system combination for oscillating the shear valve rotor according to one preferred embodiment of the present invention;
[0033] [0033]FIG. 8B is a section view through the gear system of FIG. 8A;
[0034] [0034]FIG. 8C is a schematic showing the torque limits for a motor driven—versus a motor-gear driven system;
[0035] [0035]FIG. 9A is a schematic of an oscillating shear valve incorporating a motor-cam shaft gear combination according to one preferred embodiment of the present invention;
[0036] [0036]FIG. 9B is a section view through the gear system section of FIG. 9A;
[0037] [0037]FIG. 9C shows a mechanism to change the eccentricity and therefore the resulting oscillation angle of the gear system according to one preferred embodiment of the present invention;
[0038] [0038]FIG. 9D shows an example of a cam shaft gear torque vs. speed ratio according to one preferred embodiment of the present invention;
[0039] [0039]FIG. 10 shows an example of multivalent coding according to one preferred embodiment of the present invention;
[0040] [0040]FIG. 11 shows an example of using chirps to encode a signal according to one preferred embodiment of the present invention;
[0041] [0041]FIG. 12 shows an example of a measured, time-varying frequency signal at the location of a receiver according to one preferred embodiment of the present invention;
[0042] [0042]FIG. 13 shows another example of a measured time varying frequency signal at the location of a receiver at another location different from that of FIG. 12 according to one preferred embodiment of the present invention; and
[0043] [0043]FIG. 14 shows discrete signals of different shapes according to one preferred embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0044] [0044]FIG. 1 is a schematic diagram showing a drilling rig 1 engaged in drilling operations. Drilling fluid 31 , also called drilling mud, is circulated by pump 12 through the drill string 9 down through the bottom hole assembly (BHA) 10 , through the drill bit 11 and back to the surface through the annulus 15 between the drill string 9 and the borehole wall 16 . The BHA 10 may comprise any of a number of sensor modules 17 , 20 , 22 which may include formation evaluation sensors and directional sensors. These sensors are well known in the art and are not described further. The BHA 10 also contains a pulser assembly 19 which induces pressure fluctuations in the mud flow. The pressure fluctuations, or pulses, propagate to the surface through the mud flow in the drill string 9 and are detected at the surface by a sensor 18 and a control unit 24 . The sensor 18 is connected to the flow line 13 and may be a pressure transducer, or alternatively, may be a flow transducer.
[0045] [0045]FIG. 2 a is a schematic view of the pulser, also called an oscillating shear valve, assembly 19 , for mud pulse telemetry. The pulser assembly 19 is located in the inner bore of the tool housing 101 . The housing 101 may be a bored drill collar in the bottom hole assembly 10 , or, alternatively, a separate housing adapted to fit into a drill collar bore. The drilling fluid 31 flows through the stator 102 and rotor 103 and passes through the annulus between the pulser housing 108 and the inner diameter of the tool housing 101 .
[0046] The stator 102 , see FIGS. 2 a and 2 b , is fixed with respect to the tool housing 101 and to the pulser housing 108 and has multiple lengthwise flow passages 120 . The rotor 103 , see FIGS. 2 a and 2 c , is disk shaped with notched blades 130 creating flow passages 125 similar in size and shape to the flow passages 120 in the stator 102 . Alternatively, the flow passages 120 and 125 may be holes through the stator 102 and the rotor 103 , respectively. The rotor passages 125 are adapted such that they can be aligned, at one angular position with the stator passages 120 to create a straight through flow path. The rotor 103 is positioned in close proximity to the stator 102 and is adapted to rotationally oscillate. An angular displacement of the rotor 103 with respect to the stator 102 changes the effective flow area creating pressure fluctuations in the circulated mud column. To achieve one pressure cycle it is necessary to open and close the flow channel by changing the angular positioning of the rotor blades 130 with respect to the stator flow passage 120 . This can be done with an oscillating movement of the rotor 103 . Rotor blades 130 are rotated in a first direction until the flow area is fully or partly restricted. This creates a pressure increase. They are then rotated in the opposite direction to open the flow path again. This creates a pressure decrease. The required angular displacement depends on the design of the rotor 103 and stator 102 . The more flow paths the rotor 103 incorporates, the less the angular displacement required to create a pressure fluctuation is. A small actuation angle to create the pressure drop is desirable. The power required to accelerate the rotor 103 is proportional to the angular displacement. The lower the angular displacement is, the lower the required actuation power to accelerate or decelerate the rotor 103 is. As an example, with eight flow openings on the rotor 103 and on the stator 102 , an angular displacement of approximately 22.5° is used to create the pressure drop. This keeps the actuation energy relatively small at high pulse frequencies. Note that it is not necessary to completely block the flow to create a pressure pulse and therefore different amounts of blockage, or angular rotation, create different pulse amplitudes .
[0047] The rotor 103 is attached to shaft 106 . Shaft 106 passes through a flexible bellows 107 and fits through bearings 109 which fix the shaft in radial and axial location with respect to housing 108 . The shaft is connected to a electrical motor 104 , which may be a reversible brushless DC motor, a servomotor, or a stepper motor. The motor 104 is electronically controlled, by circuitry in the electronics module 135 , to allow the rotor 103 to be precisely driven in either direction. The precise control of the rotor 103 position provides for specific shaping of the generated pressure pulse. Such motors are commercially available and are not discussed further. The electronics module 135 may contain a programmable processor which can be preprogrammed to transmit data utilizing any of a number of encoding schemes which include, but are not limited to, Amplitude Shift Keying (ASK), Frequency Shift Keying (FSK), or Phase Shift Keying (PSK) or the combination of these techniques.
[0048] In one preferred embodiment, the tool housing 101 has pressure sensors, not shown, mounted in locations above and below the pulser assembly, with the sensing surface exposed to the fluid in the drill string bore. These sensors are powered by the electronics module 135 and can be for receiving surface transmitted pressure pulses. The processor in the electronics module 135 may be programmed to alter the data encoding parameters based on surface transmitted pulses. The encoding parameters can include type of encoding scheme, baseline pulse amplitude, baseline frequency, or other parameters affecting the encoding of data.
[0049] The entire pulser housing 108 is filled with appropriate lubricant 111 to lubricate the bearings 109 and to pressure compensate the internal pulser housing 108 pressure with the downhole pressure of the drilling mud 31 . The bearings 109 are typical anti-friction bearings known in the art and are not described further. In a preferred embodiment, the seal 107 is a flexible bellows seal directly coupled to the shaft 106 and the pulser housing 108 and hermetically seals the oil filled pulser housing 108 . The angular movement of the shaft 106 causes the flexible material of the bellows seal 107 to twist thereby accommodating the angular motion. The flexible bellows material may be an elastomeric material or, alternatively, a fiber reinforced elastomeric material. It is necessary to keep the angular rotation relatively small so that the bellows material will not be overstressed by the twisting motion. In an alternate preferred embodiment, the seal 107 may be an elastomeric rotating shaft seal or a mechanical face seal.
[0050] In a preferred embodiment, the motor 104 is adapted with a double ended shaft or alternatively a hollow shaft. One end of the motor shaft is attached to shaft 106 and the other end of the motor shaft is attached to torsion spring 105 . The other end of torsion spring 105 is anchored to end cap 115 . The torsion spring 105 along with the shaft 106 and the rotor 103 comprise a mechanical spring-mass system. The torsion spring 105 is designed such that this spring-mass system is at its natural frequency at, or near, the desired oscillating pulse frequency of the pulser. The methodology for designing a resonant torsion spring-mass system is well known in the mechanical arts and is not described here. The advantage of a resonant system is that once the system is at resonance, the motor only has to provide power to overcome external forces and system dampening, while the rotational inertia forces are balanced out by the resonating system.
[0051] [0051]FIG. 3 a shows a typical torque signature acting on an oscillating shear valve. The torque acting on the rotating disc is subdivided into three main parts, the torque due to the fluid force 310 , the dynamic torque caused by the inertia and acceleration 315 , and the counterbalancing spring torque 320 (example is taken for 40 Hz). If the dynamic torque 315 and the spring torque 320 are added, the spring torque 320 will cancell out most of the dynamic torque 315 and essentially only the fluidic torque 310 remains.
[0052] In an alternative prefered embodiment, the spring, that is primarily designed to cancell out the dynamic torque at high oscillating frequencies, is also used to cancel a portion of the fluidic torque at low oscillating frequencies. FIG. 3 c shows another example of a the hydraulic torque 330 acting on the valve. In this case the valve is designed in a way that results in a hydraulic torque, that can be compensated with a spring. As shown, the shaped hydraulic valve torque 330 is partly compensated 331 by the spring torque 332 . The maxima 333 of the compensated curve 331 are smaller than the maxima 334 of the orignal hydraulic torque 330 . The spring can therefore serve to balance the inertia forces at higher frequencies and to compensate hydraulic forces at low frequencies.
[0053] In an alternative preferred embodiment, the spring used in the spring-mass system is a magnetic spring assembly 300 , as shown in FIG. 3 b . The magnetic spring assembly 300 comprises an inner magnet carrier 303 being rigidly coupled to the shaft 106 , inner magnets 301 fixed to the inner magnet carrier 303 , and an outer magnet carrier 304 , carrying the outer magnets 302 . The outer magnet carrier 304 is mounted to the pulser housing 108 . The outer magnet carrier 304 is adapted to be moved in the axial direction with respect to the tool axes, while remaining in a constant angular position with respect to the pulser housing 108 . The magnetic spring assembly 300 creates a magnetic torque when the inner magnet carrier 303 is rotated with respect to the outer magnet carrier 304 . Using an appropriate number of poles (number of magnet pairs) it is possible to create a magnetic spring torque which counterbalances the dynamic torques of the rotor 103 , the shaft 106 , the bearings 108 , the inner magnet carrier 303 , and the motor 104 . With axial displacement of the outer magnet carrier 304 with respect to the inner magnet carrier 303 , the magnetic spring rate and, therefore, the spring-mass natural frequency can be adjusted such that this spring-mass system is at its natural frequency at, or near, the desired oscillating pulse frequency of the pulser.
[0054] The above described rotor drive system provides precise control of the angular position of the rotor 103 with respect to the position of the stator 102 . Such precise control allows the improved use of several encoding schemes common to the art of mud pulse telemetry.
[0055] In contrast to an axial reciprocating flow restrictor, the torque to drive a flow shear valve is not as dependent on the pressure drop being created. Hence the power to drive a shear valve at the same frequency and the same pressure drop is lower. Commonly used rotational shear valves that rotate at a constant speed consume relatively low power when operating at a constant frequency. A high power peak is required when those devices switch from one frequency to a second frequency, for example in an FSK system. With the oscillating spring mass system, the encoding or switching between phase/frequency/amplitude does not require a high actuation power, because the speed is always zero when the valve is fully closed or open. Starting from the zero speed level a phase/frequency/amplitude change does not substantially affect the overall power consumption. In a preferred embodiment of the shear valve, the main power is used to drive the system at a high frequency level. Once it is capable of creating a high frequency it can switch to another one almost immediately. This quick change gives a very high degree of freedom for encoding of telemetry data. The characteristic used for the encoding (frequency, phase or amplitude change) can be switched from one state to a second state, thereby transmitting information, within one period or less. No transition zone is needed between the different levels of encoded information. Hence there will be more information content per time frame in the pressure pulse signal of the oscillating shear valve than with a conventional shear valve system.
[0056] In another embodiment, the encoding characteristic change is initiated at any rotor position, with the new state of phase, frequency, or amplitude still achieved within one oscillating period.
[0057] [0057]FIG. 4 displays a graph which shows Phase Shift Key encoding of the oscillating shear valve as compared to a continuously rotating shear valve. The continuous phase shift signal 400 requires 1½ signal periods of the reference signal 405 to achieve a fill 180° phase shift. In the transition time between 0.5 s and 0.9 s the information of the continuous phase shift signal 400 can not be used because it contains multiple frequencies. With the oscillating shear valve, the DC motor allows the rotor to be started at essentially any time thereby effectively providing an essentially instant phase shift. As shown in FIG. 4, the oscillating shear valve phase shift signal 410 starts at 0.5 s already in the proper phase shifted relationship with the reference signal 400 such that the following signal period can already be used for encoding purposes. Thus, there is more information per time frame with a phase shift keying signal generated with an angular oscillating shear valve than with a continuously rotating shear valve.
[0058] [0058]FIG. 5 displays a graph showing a Frequency Shift Keying signal of the angular oscillating shear valve compared to a signal of a continuously rotating shear valves using the same encoding scheme. This example shows a frequency shift from 40 Hz to 20 Hz and back to 40 Hz. At 0.10 s the frequency is shifted from 40 Hz to 20 Hz, with the signal 500 from the continuously rotating shear valve, shifting only one full amplitude 500 a of the low frequency at 0.16 s before it must shift back to the high frequency signal at 500 b . Only the peaks at 500 a and 500 b are suitable for encoding information. The transition periods before and after the frequency shift contain multiple frequencies which can not be used for coding purposes. With the signal 505 from the angular oscillating shear valve, there are still two fully usable amplitudes 505 a and 505 b at the lower frequency and two usable peaks at the higher frequency 505 c and 505 d . As with phase shift keying, there is more information content per time frame with the angular oscillating shear valve than with a continuously rotating shear valve. This can provide higher detection reliability by providing more cycles to lock onto, or alternatively the frequency changes can be more rapid, thereby increasing the data rate, or a combination of these.
[0059] An Amplitude Shift Key (ASK) signal can be easily generated with the oscillating shear valve of the present invention. The signal amplitude is proportional to the amount of flow restriction and thus is proportional to the amount of angular rotation of the rotor 103 . The rotor rotation angle can be continuously controlled and, therefore, the amplitude of each cycle can be different as the motor 104 can accurately rotate the rotor 103 through a different angular rotation on each cycle according to programmed control from the electronics module 135 .
[0060] In addition, because the rotor can be continuously and accurately controlled, combinations of ASK and FSK or ASK and PSK may be used to encode and transmit multiple signals at the same time, greatly increasing the effective data rate. FIG. 7 is a schematic showing one scheme for combining an ASK and an FSK encoded signal. Both signals are carried out in a constant phase relationship with an amplitude shift from A 1 to A 2 or from A 2 to A 1 representing data bits of a first encoded signal and the frequency shifts from F 1 to F 2 or from F 2 to F 1 representing data bits of a second encoded signal. This type of signal is generated by changing both the oscillating frequency of the rotor and simultaneously changing the rotor oscillation angle, as previously described. Similarly, a signal combining ASK and PSK encoding (not shown) can be generated by changing the phase relationship of a constant frequency signal while simultaneously changing the amplitude by changing the rotor oscillation angle. Here, the amplitude shifts represent a first encoded signal and the phase shifts represent a second encoded signal.
[0061] One problem for rotating valves used in a drill string is plugging the valve during operation, for example, with either lost circulation materials or foreign bodies in the flow stream. FIG. 6 a - 6 d illustrates the anti-plugging feature of the angular oscillating shear valve as contrasted to a continuously rotating shear valve. FIG. 6 a and 6 b show a continuously rotating shear valve and an oscillating shear valve, respectively. A rotor 603 rotates below a stator 602 . Rotor 603 and stator 602 have a plurality of openings 607 and 606 , respectively serving as a flow channels. Because of the rotor rotation, the flow channel is open when the flow channels 606 and 607 are aligned and the flow channel is closed when the both flow channels 606 and 607 are not aligned. A continuously rotating shear valve opens and closes the flow passage only in one rotational direction as seen in FIG. 6 a . An angular oscillating valve opens and closes the flow passage by alternating the rotational direction as illustrated in FIG. 6 b . A foreign body 605 enters and traverses a flow passage in both the stator 602 and the rotor 603 . FIG. 6 c demonstrates that the continuously rotating shear valve jams the foreign body between the rotor 603 and the stator 602 , and fails to continue to rotate, possibly requiring the downhole tool to be retrieved to the surface for maintenance. However, an oscillating shear valve, as illustrated in FIG. 6 d , opens the valve again in the opposite direction during its standard operation. The flow channel recovers to its full cross section area and the foreign body 605 is freed, and the valve continues to operate.
[0062] [0062]FIGS. 8A, B show another preferred embodiment, similar to that of FIG. 2 but incorporating a commonly known type of gear system 210 between the shaft 206 and the motor 204 . Preferably the gear system 210 is a planetary gear arrangement. The motor 204 is connected to the sun wheel 219 (high speed) of the gear system 210 . The shaft 206 is connected to multiple satellite wheels 217 (low speed) of the gear system 210 . The torsion spring 205 is connected to shaft 206 and end cap (not shown). Alternatively, the torsion spring 205 may be connected to motor 204 . If the spring 205 is connected to shaft 206 , smaller spring torsion angles are required than connecting the spring to the motor 204 . Depending on the selected gear ratio, the high speed—and low speed driven side can also be reversed. The annular gear 218 of the gear system 210 is fixed to the pulser housing 208 .
[0063] [0063]FIG. 8B is a section view through the gear system 210 of FIG. 8A, showing a planetary gear arrangement with 4 satellites 217 . It is obvious to one skilled in the art, that also other gear systems arrangements are possible. The gear ratio of such a planetary gear arrangement is given by
Speed rotor =Speed Motor /1(Radius Annulargear /Radius Sungear )
[0064] where the rotor 203 is directly coupled to the shaft 206 . The gear system 210 allows more precise control of rotor 203 rotation. The motor shaft rotates more than the rotor 203 as determined by the gear ratio. By controlling the motor shaft angular position, the rotor 203 position can be controlled to a higher precision as related by the gear ratio. To keep the power demands of the pulser as small as possible, the gear ratio is optimized in regards to the spring-mass system and the inertias of the drive—and load side.
[0065] [0065]FIG. 8C shows a 3-dimensional plot based on a spring-mass system driven by a motor/gear combination. The plot is based on keeping the natural frequency of the spring-mass system constant for all shown combinations. Gear inertia and friction are neglected to simplify the model and to ease understanding. The plot shows the relation β=T M /T MO (motor torque with gear/motor torque without gear) versus gear ratio “n” (motor speed/rotor speed) and inertia ratio α=J M /J L (motor inertia to load inertia). The line, which separates the dark—and bright gray areas, is the line of equal motor torque. Using a gear above this line (dark grey area) will result in an unfavorably large motor torque, when the spring-mass system is oscillating. The plot shows, that for the given system only a certain gear ratio is advantageous. An example is shown by following the arrow on the chart. If the load-inertia is three times bigger than the motor-inertia, the gear ratio should not exceed 3 to avoid higher power consumption of the pulser due to using a gear system as compared to a pulser without the gear system.
[0066] [0066]FIG. 9A shows another preferred embodiment similar to that described in FIG. 8A incorporating a cam, or crank, shaft system 220 between the shaft 206 and the motor 204 . Two preferred operating modes are possible with such a system. In one preferred embodiment, the gear system transmits oscillating(rotating back and forth) motor 204 movements into oscillating rotor 203 movements. Alternatively, continuous motor 204 rotation may be converted into oscillating rotor 203 movements.
[0067] The system 220 features two gears 229 , 231 and crank shaft 226 . Crank shaft 226 is fixed to shaft 206 . Drive gear 229 is positioned on motor shaft 204 and drives the secondary gear 231 fixed on drive shaft 230 . Bearings (not shown) to keep the drive shaft 230 in position are incorporated into support plate 228 . Support plate 228 is fixed to pulser housing 208 . Drive shaft 230 features on it's opposite end an eccentric displaced drive pin 227 . Drive pin 227 reaches into a slot of crank shaft 226 .
[0068] [0068]FIG. 9B shows an example of the crank shaft gear system 220 movement. Driven by the electrical motor 204 , drive shaft 230 and drive pin 227 are continuously rotated. Drive pin 227 rotates eccentrically around the axes of drive shaft 230 . Due to the eccentric movement of drive pin 227 , crank shaft 226 is forced to the left and to the right hand side, oscillating around the axes of shaft 206 . The oscillation angle of shaft 206 is related to the eccentricity and diameter of drive pin 227 and the distance between the axes of drive shaft 230 and shaft 206 . Alternatively, for an oscillating motor 204 movement (instead of rotating motor movement), the oscillation angle of shaft 206 is, in addition to above mentioned geometrical parameters, also related to the oscillation angle of motor 204 . While the system is moving, the effective gear ratio is continuously changing depending on selected drive pin eccentricity, distance between axes of shaft 206 to drive pin 226 , and the gear ratio between drive gear 229 and secondary gear 231 . Practically a gear ratio of 1 to 6 may be realized in the design space of a common tool size. It is obvious to someone skilled in the art that other common cam shaft gears or crank shaft gears might be used to transmit a continuous motor rotation into an oscillating rotor movement.
[0069] [0069]FIG. 9C serves as an example to show how to adjust the eccentricity of drive pin 227 . Drive shaft 230 has an bore, placed eccentric from its axes. Adjustment shaft 235 is placed inside the bore of drive shaft 230 . Drive pin 227 is eccentrically fixed onto adjustment shaft 235 . The eccentricity 231 of drive pin 227 to the axes of adjustment shaft 235 is the same as the eccentricity of adjustment shaft 235 to axes of drive shaft 230 . To change the resulting eccentricity 237 of drive pin 227 to drive shaft 230 , the adjustment pin 235 must be turned. Between a 0-180° turn, the resulting eccentricity 237 changes from zero to the maximum eccentricity, which equals two times the original eccentricity.
[0070] [0070]FIG. 9D shows an example of the gear ratio across the oscillation angle of motor 204 . The abscissa 401 shows the motor oscillation angle from 0-360°. The ordinate 403 shows the torque ratio and ordinate 402 shows the speed ratio (the reverse of the torque ratio). At position 407 and 406 , the rotor 203 reaches it maximum displacement and reverses the direction of movement. If hydraulic disturbances or loads are acting on the rotor shaft 206 the resulting torque at the motor shaft 204 is zero. Close to these positions, extremely large loads of valve shaft 206 can easily be supported by the motor 204 .
[0071] [0071]FIG. 10 shows an example of multivalent coding. Instead of using a binary code with only two different conditions (on/off condition) advanced coding schemes can be used with the novel shear valve pulser of the present invention. In one preferred embodiment, in FIG. 10, three different frequencies f 1 , f 2 , f 3 are used to explain multivalent coding. Using the change from one frequency into another one, six different conditions can be defined by using three frequencies. Changing from f 1 to f 2 is one condition 501 . Other conditions are f 2 -f 1 502 , f 1 -f 3 503 , f 3 -f 1 504 , f 3 -f 2 505 , f 2 -f 3 (not shown). Instead of frequency changes, phase shift changes, amplitude shift changes, or combinations thereof can be used for multivalent coding.
[0072] [0072]FIG. 11 shows an example how a chirp, or sweep (means a time dependent change in frequency), can be used to encode signals. Advantage of using a chirp is the larger bandwidth of the signal. Signal distortion and attenuation, due to e.g. reflections, is less critical than in a signal using just one—(e.g. Phase shift keying) or two frequencies to modulate/encode the data. In a binary code (on/off), as shown in FIG. 11, the presence of a chirp pattern signifies an “on” 601 , and absence of a chirp pattern signifies an “off” 602 . The bandwidth and the chirp pattern may be adjusted according to operational conditions.
[0073] The envelope curve of the chirp can also be considered as a discrete signal or discrete pulse. The chirp or any other frequency pattern inside the envelope curve gives an additional information to enhance detection of a single pulse at a receiver station.
[0074] [0074]FIG. 12 shows the measured signal of different frequencies at the location of a receiver. Due to reflections and interactions of the signal with the system boundaries, commonly used frequencies may be substantially attenuated. With the oscillating shear valve it is possible to choose frequencies exhibiting low attenuation to send and encode signals. As an example given in FIG. 12, for a frequency dependent binary code, the optimum frequencies might be the strong signal at 25 Hz 702 which is easy to detect and the weak signal at 20 Hz 701 which is nearly fully attenuated. Other frequencies of interest might be two low attenuated frequencies 703 , 704 at 30 Hz and 35 Hz.
[0075] [0075]FIG. 13 shows, that in a different application, the frequency transmission characteristics may change and other frequencies might be better suited to send a binary signal. In FIG. 13, 20 Hz 802 and 35 Hz 804 could be selected for a binary coding scheme.
[0076] [0076]FIG. 14 shows two different shapes of a discrete square type signal. Both signals are generated by using the same rotor shape. Signal 901 features a sinusoidal increase in signal amplitude, followed by a plateau and a sinusoidal decrease in amplitude. Signal 902 is a true square signal. To generate signal 901 requires substantially less power, because less acceleration and deceleration of rotor masses is required to create the signal. Signal 902 requires very fast acceleration and deceleration of the rotor masses. Further more, the high frequency content of the sharp edges of signal 902 will suffer strong attenuation. At a far receiver station both signals will therefore look the same.
[0077] The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to one skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention. It is intended that the following claims be interpreted to embrace all such modifications and changes. | An oscillating shear valve system for generating pressure fluctuations in a flowing drilling fluid comprising a stationary stator and an oscillating rotor, both with axial flow passages. The rotor oscillates in close proximity to the stator, at least partially blocking the flow through the stator and generating oscillating pressure pulses. The rotor passes through two zero speed positions during each cycle, facilitating rapid changes in signal phase, frequency, and/or amplitude facilitating enhanced, multivalent data encoding. The rotor is driven by a motorized gear drive. In one embodiment, a torsional spring is attached to the motor and the resulting spring mass system is designed to be near resonance at the desired pulse frequency. The system enables the use of multivalent encoding schemes for increasing data rates. |
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